Manual Izadora Pipecat PC-5-47

OPERATION and
MAINTENANCE MANUAL
IDEAL RIG 131-135/137/139
PC-5-47 PipeCatTM LAYDOWN SYSTEM

55°C HIGH AMBIENT
Serial No.: DPH-092/DPH-093/DPH-094/

DPH-095/DPH096/DPH-104/
DPH-105
Job No.: C27217 to C27266, C27628 to C27647
Project No.: E2378/E2379/E2380/E2381/
E2382/E2434/E2435
P.O. No.: GPK1000518/19/20/21/22/
GPK1000827/28
ADDITIONAL INFORMATION
This document contains proprietary and confidential DRECO ENERGY SERVICES ULC
information of National Oilwell Varco. Reproduction NATIONAL OILWELL VARCO
or use of this design or distribution of information by
others is permissible only if expressly authorized in 6415-75 Street
writing by National Oilwell Varco. Edmonton, AB T6E 0T3
Canada
Copyright National Oilwell Varco Ph. (780) 944-3800
DOCUMENT NO. Rev.
D231005044-MAN-001 01
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Copyrighted as an unpublished work.
All RIGHTS RESERVED

© COPYRIGHT 2012 by National Oilwell Varco
This work contains the CONFIDENTIAL AND PROPRIETARY INFORMATION of National Oilwell Varco. Neither
this document nor any information disclosed herein, shall be reproduced in any form, used, or disclosed to others
for any purpose including manufacturing without express written permission from National Oilwell Varco.
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Document No. D231005044-MAN-001
Page 1
REVISION HISTORY
01 12.05.2012 Final Documentation MSH BMR/CJK IC

Rev Date Change Description Prepared Checked Approved
(mm.dd.yyyy)
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TABLE OF CONTENTS
1. INTRODUCTION 5
1.1 MANUAL OVERVIEW AND SCOPE ...................................................................................... 5
1.2 WARRANTY INFORMATION ................................................................................................ 6
1.3 WARRANTY LIMITATIONS ................................................................................................. 7
1.4 EQUIPMENT SERVICE LIFE ............................................................................................... 7
1.5 CONTENT AND ACCURACY OF INFORMATION ..................................................................... 8
2. SAFETY SUMMARY 9
2.1 SAFETY TERMS AND CONVENTIONS .................................................................................. 9
2.2 BASIC SAFETY PRECAUTIONS .......................................................................................... 9
3. STORAGE AND PRESERVATION 11

3.1 STORAGE AND PRESERVATION ....................................................................................... 11
4. EQUIPMENT OVERVIEW 12
4.1 GENERAL INFORMATION ................................................................................................ 12
4.2 TECHNICAL SPECIFICATION ............................................................................................ 13
5. MAJOR COMPONENTS 15
5.1 MAJOR COMPONENTS OVERVIEW ................................................................................... 15
5.2 COMPUTER CONTROL SYSTEM (CCS)/ LOCAL CONTROL STATION (LCS) ........................ 16
5.3 POWER CONTROL CABINET (PCC) ................................................................................. 16
5.4 WIRELESS RADIO CONTROL (WRC) ............................................................................... 17
5.5 CATWALK ..................................................................................................................... 17
5.5.1 Safety Curtain .......................................................................................................... 17
5.5.2 Pipe Racks .............................................................................................................. 17
5.5.3 Indexers ................................................................................................................... 18
5.6 HPU POWER PACK ....................................................................................................... 19
5.7 V-DOOR RAMP .............................................................................................................. 20
5.8 TROUGH LIFT WINCH ..................................................................................................... 21
5.9 TROUGH ....................................................................................................................... 21
5.9.1 Wire Tensioner Assembly ........................................................................................ 22
5.9.2 Lifting Leg ................................................................................................................ 23
5.9.3 Safety Pins .............................................................................................................. 24
5.9.4 Kickers ..................................................................................................................... 25
5.10 SKATE .......................................................................................................................... 26
5.10.1 Skate Drive .............................................................................................................. 26
5.10.2 Skate Chain Tensioner ............................................................................................ 27
6. RIG UP/RIG DOWN 28

6.1 RIG UP PROCEDURE ...................................................................................................... 28
6.2 RIG DOWN PROCEDURE ................................................................................................. 30
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7. START UP/POWER DOWN PROCEDURES 31

7.1 WIRELESS RADIO CONTROL (WRC) START UP PROCEDURE ........................................... 31
7.2 LOCAL CONTROL STATION (LCS) START UP PROCEDURE ............................................... 32
7.3 POWER DOWN PROCEDURE ........................................................................................... 33
8. OPERATING INSTRUCTIONS 34
8.1 LOADING TUBULARS TO THE DRILL FLOOR ..................................................................... 34
8.2 UNLOADING TUBULARS FROM THE DRILL FLOOR ............................................................ 35
9. CONTROL LAYOUTS AND DESCRIPTIONS 37

9.1 LOCAL CONTROL STATION (LCS) CONTROLS ................................................................. 37
9.1.1 Normal Operation Mode ........................................................................................... 38
9.1.2 Pipe Rack Setup Mode ............................................................................................ 42
9.2 WIRELESS RADIO CONTROL (WRC) CONSOLE CONTROLS .............................................. 43
9.2.1 Normal Operation Mode ........................................................................................... 44
9.2.2 Pipe Rack Setup Mode ............................................................................................ 47
9.3 OWNERSHIP TAKE/RELEASE FUNCTION .......................................................................... 48
10. MAINTENANCE AND LUBRICATION 49

10.1 GENERAL INSTRUCTIONS ............................................................................................... 49
10.2 MAINTENANCE CHARTS ................................................................................................. 50
10.3 RECOMMENDED OILS AND LUBRICANTS .......................................................................... 52
10.4 STORAGE LUBRICATION ................................................................................................. 53
10.5 SKATE CHAIN TENSIONING PROCEDURE ......................................................................... 53
11. GENERAL ROLLER CHAIN MAINTENANCE 55

11.1 ROLLER CHAIN MAINTENANCE ....................................................................................... 55
11.2 CHAIN AND CONNECTING LINK INSTALLATION ................................................................. 55
11.3 RETAINING DEVICES ...................................................................................................... 56
11.4 LUBRICATION OF ROLLER CHAINS .................................................................................. 58
11.5 METHODS OF LUBRICATION............................................................................................ 59
11.6 DRIVE GUARDING .......................................................................................................... 60
12. TROUBLESHOOTING 63
12.1 OVERVIEW .................................................................................................................... 63
12.2 MANUAL HYDRAULIC VALVE ACTUATION ........................................................................ 63
12.3 EMERGENCY TROUGH LOWERING PROCEDURE ............................................................... 64
12.4 MACHINE INTERLOCKS INDICATOR .................................................................................. 65
12.5 STATUS AND INFORMATION SCREEN ............................................................................... 65
12.5.1 Location of the SBC Ethernet Ports ......................................................................... 66
12.5.2 Laptop Setup ........................................................................................................... 66
13. TIGHTENING TORQUE GUIDE 68

13.1 BOLT TORQUE CHARTS ................................................................................................. 68
13.2 SOCKET HEAD CAPSCREW TENSILE REQUIREMENTS ...................................................... 70
13.3 TURN-OF-NUT TIGHTENING ............................................................................................ 71
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14. SENSOR INFORMATION 72

14.1 SOLENOID CHART.......................................................................................................... 72
14.2 SENSOR CHART ............................................................................................................ 73
15. SPARE PARTS 74

15.1 GENERAL SPARE PARTS LISTING ................................................................................... 74
15.2 CONTROL SPARE PARTS LISTING ................................................................................... 75
15.2.1 Ideal Rig 131............................................................................................................ 75
15.2.2 Ideal Rig 132............................................................................................................ 79
15.2.3 Ideal Rig 133............................................................................................................ 83
15.2.4 Ideal Rig 134............................................................................................................ 87
15.2.5 Ideal Rig 135............................................................................................................ 91
15.2.6 Ideal Rig 137............................................................................................................ 95
15.2.7 Ideal Rig 139............................................................................................................ 99
16. DRAWINGS 103

16.1 OVERALL DRAWING LIST ............................................................................................. 103
16.2 ELECTRICAL DRAWING LIST ......................................................................................... 105
17. VENDOR INFORMATION 107

17.1 VENDOR LISTING ......................................................................................................... 107
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1. INTRODUCTION
1.1 Manual Overview and Scope
1.2 Warranty Information
1.3 Warranty Limitations
1.4 Equipment Service Life
1.5 Content and Accuracy of Information
1.1 Manual Overview and Scope
This operation and maintenance manual provides instruction on the PC-5-47 PipeCatTM
laydown system. The mechanical components discussed here are engineered and
selected for the most reliable and cost-effective operation; however, correct preventive
maintenance should be considered an investment, as it minimizes equipment wear,
failures, and downtime. New parts can be installed at less expense when the equipment
is in the shop for repairs or strip-down than when the equipment requires emergency
servicing.
The scope of this manual includes only equipment supplied by National Oilwell Varco
and does not pertain to equipment supplied by the Customer or others. The Vendor
Information, Section 17, provides information pertaining to the equipment supplied, but
not manufactured, by National Oilwell Varco. If there is any overlapping information
between this manual and a manual from a vendor, the vendor’s manual shall take
precedence unless otherwise noted.
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1.2 Warranty Information
1. All National Oilwell Varco equipment built in National Oilwell Varco’s plant is
guaranteed to be free from defects in workmanship for a period of 12 months from
the date of delivery to the original customer or as specified in the contract.
2. In the event of any failure on which a warranty claim may be presented the owner
must notify National Oilwell Varco and follow National Oilwell Varco’s instructions
relative to the inspection or disposition of the defective part or parts and to the
repairing and/or replacement thereof.
3. The foregoing warranty is contingent on the proper application of equipment and

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

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

necessitate changes in this project over time. National Oilwell Varco reserves the right
to make these design changes without incurring any obligation for the equipment
previously delivered.
1.4 Equipment Service Life
National Oilwell Varco equipment that is properly maintained and operated within rated
loads has a long service life. The service life of the equipment is dependent on the
operator’s operating practices and the codes under which the country is regulated. The
operator will test and maintain the equipment at intervals as per his or her set program.
In order to prolong the life of their equipment, operators should compile and retain
accurate and clear maintenance records. These maintenance records should include
the following information:
• Inspector/Mechanic
• Date of Inspection
• Records of Performance
• Preventive Maintenance
• Repair/Replacement History
Operators should prepare specific operating procedures that have been modified to
account for specific operating goals and conditions. These should include selecting
suitable lubricants and other fluids for the range of operating and temperature
conditions. The procedures should consider the desired method in addition to choosing
a maintenance schedule that allows for optimum performance, minimum equipment
wear, failures, and downtime.
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1.5 Content and Accuracy of Information
This manual is not intended as a textbook on mechanics, electronics, or hydraulics. The

purpose of this manual is to guide the operators and maintenance personnel in the
proper use of the equipment. Sufficient descriptive material and illustrations are
included to aid the understanding of basic construction, theory of operation, and
maintenance of the equipment.
Operators, maintenance personnel, and service technicians should study the

appropriate sections of this manual that pertain to their particular duties to familiarize
themselves with the components, parts, or subassemblies of the equipment.
Every effort has been made to provide all the critical operation and maintenance
information in a timely manner. All of the information in this manual is based on the
latest production information available at the time of publication release.
The content and the accuracy of the information in this manual have been checked and
approved for release within the confines of human error. If for any reason, its contents
or the accuracy of its information is in question, contact National Oilwell Varco.
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2. SAFETY SUMMARY
2.1 Safety Terms and Conventions
2.2 Basic Safety Precautions
2.1 Safety Terms and Conventions

This manual uses the following standard safety terms and conventions that span all
areas of the industry:
WARNING: A Warning provides a specific procedure or additional

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

information which must be followed while completing the
procedure at hand. Failure to comply with a caution will result in
damage to the assembly/equipment being worked on.
NOTE: A Note provides information necessary to complete the procedure
properly or information that will make the procedure easier to
understand.
2.2 Basic Safety Precautions

Only qualified personnel should be allowed to operate and maintain the equipment.
Personnel should not operate the unit unless they have read the equipment manual and
are thoroughly familiar with all unit operating controls and functions.
The PipeCatTM laydown system is designed to minimize mechanical dangers.

Nevertheless, operating and maintenance personnel should wear suitable protective
clothing and equipment. Keep hands, hair, clothing, jewelry, rags, tools, etc. away from
all moving parts during operation.
Do not attempt equipment operation with inadequate visibility.
Promote good safety measures, including training, at all times around the equipment
and throughout all operating phases. It is the equipment owner's/operator's
responsibility to establish safety measures as well as to enforce them.
Equipment used when lifting and moving the unit must be sufficiently rated to handle the
weights involved.
Ensure the v-door ramp turnbuckles are securely attached to the substructure eyelets
before operating the PipeCatTM laydown system.
Ensure the emergency stop button has been properly employed and the breaker has
been properly locked out when servicing the equipment.
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Maintain a safe distance away from both the PipeCatTM laydown system and the pipe
racks during operation. Always stay clear of the indexers, kickers, skate, winch, or
trough when equipment is in use.
Use only the lift points that have been provided when lowering and/or transporting the
PipeCatTM laydown system. Never attempt to use the trough to lower the top drives.
Ensure the unit has been bled to zero pressure before performing maintenance on the
equipment or disconnecting any high-pressure piping or hoses. Observe a similar
procedure for electrical connections; ensure electrical power is locked out before
attempting maintenance.
WARNING: Do not breathe cleaning solvent vapors. The toxic effect of some
solvents is cumulative. Continued inhalation can lead to
permanent disability or death. When using flammable cleaning
solvents, take all appropriate fire protection precautions to
prevent injury to personnel and damage to equipment.
WARNING: Do not direct compressed air against any part of the body. High
pressure air can cause injuries. Do not rotate ball or roller
bearings with compressed air. Do not direct compressed air
against a fire. Tag controls and depressurize hydraulic system
before disconnecting or removing any part of the hydraulic
piping. Ensure all tanks, lines, and equipment are depressurized
by slowly releasing pressure through approved means.
WARNING: Use adequate hoisting equipment. Observe all safety precautions.

Ensure that hydraulic systems are depressurized and controls are
tagged “DANGER – DO NOT OPERATE – EQUIPMENT BEING
REPAIRED” before attempting adjustment and repair procedures
on the equipment.
WARNING: When working on a system, disconnect electrical power supply

and tag controls to prevent accidental operation. Serious injury or
death could result. Use mechanical shut-off when available.
WARNING: Set up an exclusion zone to keep all personnel a safe distance

away from the v-door and catwalk at all times to avoid any risk of
injury and/or death due to uncontrolled tubular falling from the
tubular shuttle. Failure to comply with this warning could result
in personal injury and/or death.
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3. STORAGE AND PRESERVATION

3.1 Storage and Preservation
3.1 Storage and Preservation

Proper storage and preservation measures help ensure maximum design life for the
PipeCatTM laydown system. Protect all accessory items, spare parts, etc. in accordance
with the guidelines.
• Ensure the equipment has been cleaned of all foreign matter and thoroughly dried
before preservation.
• Protect all machined surfaces with a rust inhibitor (i.e. Denso Tape or Tecteel spray
or equivalent) where applicable.
• Place rubber gaskets and metal blanks over all interface connections. Interface
surfaces, which are not corrosion resistant, should be protected with a corrosion
inhibitor before sealing.
• Ensure all grease points are well-greased.
• Indoor storage is preferred for the equipment because condensation and corrosion
can be minimized in a controlled environment.
• Remove mud, adhering dirt, and other foreign matter able to hold moisture. If
cleaning is done with steam or a solvent, avoid washing lubricating oil or grease
from unpainted surfaces or close-fitting elements. Touch up the paint if necessary.
• The equipment should be elevated high enough from the ground to avoid water
accumulation. A drained location is preferable. Remove any accumulated moisture
on or near equipment.
• Sufficient support must be provided to ensure equipment stability.
• If the equipment must be stored outdoors, prevent moisture from contacting the
equipment. Crate all equipment or pack with heat-shrunk plastic or tarpaulin of at
least 0.15 mm thickness.
• Where storage temperature is not stable, sufficient sealing of the equipment with
tape and plastic sheet is recommended along with use of desiccant. Cable ends are
to be preserved with sealing tape or blanks. Desiccant bags are used inside all
enclosed areas such as instrument cabinets and junction boxes. Renew desiccant
and sealing tape as necessary.
• Place packing around valve panels (if applicable) to protect against shock and
impact.
• All applicable reservoirs should be shipped with sufficient oil in order to minimize the
exposure to condensation and prevent corrosion.
NOTE: Preservation done by National Oilwell Varco at the time of shipping is

only valid for a period of three months unless otherwise noted in the
contract. It is required for the customer to inspect the product and
upgrade preservation for any storage period longer than three months.
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4. EQUIPMENT OVERVIEW
4.1 General Information
4.2 Technical Specification
4.1 General Information
The function of the PipeCatTM laydown system is to provide delivery of drilling rig
tubulars to and from the catwalk and the drill floor. The PipeCatTM laydown system
positions the box end of the tubular approximately 3’ (914 mm) above the mousehole to
allow the elevators to be manually latched. The PipeCatTM laydown system is close
enough to well centre to allow heavy tubulars to be manually pushed off well centre
when lying down.
The system consists of the catwalk, v-door ramp, and trough assemblies which include
a series of positioning and monitoring sensors. These sensors are integrated with a
hydraulic power pack mounted on the catwalk assembly. The operator controls the
laydown system movement using either a wireless radio control (WRC) or a local control
station (LCS) – both of which have been integrated with a computer control system
(CCS) processor to allow finite tubular position control.
The hydraulic power unit (HPU) has two independent electrically driven pumps and an
electrically driven air cooler designed for 131°F (55°C) operation. The v-door ramp
functionality is also maintained if the PipeCatTM laydown system is not working.
TM
Illustration: PC-5-47 PipeCat Laydown System
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4.2 Technical Specification
General Specifications
Ideal Rig 131 Serial Number: DPH-092
Model: PC-5-47
Safe Working Load: 10,000 lbs (4,536 kg)
(Single Joint of 11” (279 mm) DC)
Supply Voltage: 460 VAC
Drill Floor Height: 25’ (7,620 mm)
Control System
Control Type: High Ambient Amphion System
Maximum Ambient Temperature: 131°F (55°C)
HPU
Pumps: 2 Independent Electric Driven
Air Cooler: Electric Driven
Maximum Ambient Temperature: 131°F (55°C)
Overall Transportation Dimensions
Length: 61’ – 0 5/8” (18,609 mm)
Width: 10’ – 1” (3,073 mm)
Height: 10’ – 2 11/16” (3,116 mm)
Overall Working Dimensions
Length: 84’ – 10 5/16” (25,865 mm)
Width: 29’ – 2” (8,890 mm)
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Technical Specification (Continued)
Tubular Specifications
Ranges: Range II & Range III
2 3/8” to 6 5/8” (60 to 168 mm) DP and Tubing
(Range II and Range III)
3 ½ to 11” (89 to 279 mm) DC (Range II)
(maximum weight 10,000 lbs/4,536 kg)
Range III Casing up to Ø 24” (610 mm)
Maximum Length: 47’ (14,326 mm)
Diameter Allowances: 2 3/8” to 24” (60 mm to 610 mm)
Approximate Total Weight: 73,182 lbs (33,195 kg)
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5. MAJOR COMPONENTS
5.1 Major Components Overview
5.2 Computer Control System (CCS)/Local Control Station (LCS)
5.3 Power Control Cabinet (PCC)
5.4 Wireless Radio Control (WRC)
5.5 Catwalk
5.6 HPU Power Pack
5.7 V-Door Ramp
5.8 Trough Lift Winch
5.9 Trough
5.1 Major Components Overview
The major components of the catwalk assembly consist of the following equipment:
• Computer Control System (CCS)/ • HPU Power Pack

Local Control Station (LCS) • V-Door Ramp
• Power Control Cabinet • Trough Lift Winch
• Wireless Radio Control (WRC) • Trough
• Catwalk
Refer to Figure #1 for further information.
Figure #1
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5.2 Computer Control System (CCS)/ Local Control Station (LCS)
The computer control system (CCS) is used to control and monitor all functions of the
PipeCatTM laydown system. The CCS consists of a remote computer system which is
interfaced with a local CCS cabinet on the PipeCatTM laydown system via a fiber optic
connection. The local CCS cabinet is installed on the catwalk near the HPU.
The local CCS cabinet contains the input/output modules that interface with the HPU,
local controls, wireless radio control (WRC), winch encoder, and all other
sensors/switches/solenoids on the PipeCatTM laydown system.
A local control station (LCS) is integrated into the top of the CCS to provide backup
operator controls for the PipeCatTM laydown system. A wing walk is provided to allow
easy access to the LCS. Refer to the Local Control Station (LCS) Controls, Section 9.1,
for a detailed description of the LCS controls.
An air conditioner is mounted on the CCS to maintain a safe operating temperature for
the enclosed electrical components. The air conditioner is initially set up with the
following temperature set points:
• Alarm Hi – 100°F (38°C)
• Temp Hi – 77°F (25°C)
• Temp Lo – 32°F (0°C)
• Alarm Lo – 23°F (-5°C)
The air conditioner is set up using its integral control panel. Refer to the Ice Qube –
Intelligent Electronic Enclosure Thermal Management Systems Manual in Vendor
Information, Section 17, for further information.
5.3 Power Control Cabinet (PCC)
The power control cabinet (PCC) distributes power to the PipeCatTM laydown system.
The PCC contains the main breakers for switching the power. An air conditioner is
mounted on the PCC to maintain a safe operating temperature for the enclosed
electrical components. The air conditioner is initially set up with the following
temperature set points:
• Alarm Hi – 100°F (38°C)
• Temp Hi – 77°F (25°C)
• Temp Lo – 32°F (0°C)
• Alarm Lo – 23°F (-5°C)
The air conditioner is set up using its integral control panel. Refer to the Ice Qube –
Intelligent Electronic Enclosure Thermal Management Systems Manual in Vendor
Information, Section 17, for further information.
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5.4 Wireless Radio Control (WRC)
The wireless radio control is the primary operator control for the PipeCatTM laydown
system. The WRC communicates with a wireless radio mounted in the local CCS
cabinet.
Refer to the Wireless Radio Control (WRC) Console Controls, Section 9.2, for a detailed
description of the WRC controls.
5.5 Catwalk
The PipeCatTM laydown system catwalk is the main body that supports and contains all
of the system components. During installation, the catwalk is positioned perpendicular
to the drill floor and in-line with well centre. The catwalk must be completely level and
well supported to ensure safe operation. Optional stairs are attached to the catwalk to
allow easy access to the catwalk.
5.5.1 Safety Curtain
A safety curtain consisting of through-beam sensors is installed on the PipeCatTM

laydown system catwalk to detect the presence of personnel on the frame during
operation. There is one transmitter and receiver pair installed on each side of the frame.
NOTE: All PipeCatTM laydown system movements will stop when a beam is
broken.
Hinged covers protect the through-beam sensors. Ensure all four covers are open
before starting the PipeCatTM laydown system and are closed when the PipeCatTM
laydown system is not in use.
5.5.2 Pipe Racks

Refer to the Pipe Rack Assembly, drawing 9800A071, and the "PipeCat™" Operational
Layout – Pipe Racks/Kickers/Indexers, drawing 9800L015.
The pipe racks are used to hold tubulars, which are loaded/unloaded by the indexers.
There are six pipe racks attached to the catwalk – three on the driller side and three on
the off driller side. On the outer end of each pipe rack is an anti-rollback pin that can be
installed to keep tubulars from rolling off the pipe rack.
The elevation of the outer end of each pipe rack is independently adjustable. The speed
of the pipe rack adjustment is limited by needle valves located within the driller side of
the catwalk. The needle valves are pre-set and normally do not need to be adjusted.
The pipe racks are independently adjustable after setting the pipe rack mode of the LCS
or WRC. When not in pipe rack mode, the two groups of three pipe racks, move
simultaneously.
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CAUTION: Always ensure all personnel maintain a safe distance from the
pipe racks as they are adjusted. Do NOT rely solely on the anti-
rollback or indexer pins to protect personnel from rolling tubulars.
CAUTION: Always ensure the pipe racks are properly pinned to their shipping
mounts before transporting the PipeCatTM laydown system.
5.5.3 Indexers
Refer to the “PipeCatTM” Operational Layout ~ Pipe Racks/Kickers/Indexers, drawing

9800L015, and the Indexer Assembly, drawing 9800A072.
Indexers
The indexers are used to move tubulars
from the pipe racks onto the trough or from
the catwalk onto the pipe racks.
There are two sets of indexers contained

within the catwalk – one set of three on the
driller side and one set of three on the off
driller side. Each set of indexers is actuated
simultaneously and with their movement
synchronized by hydraulic flow dividers. The
speed of the indexers is mechanically limited
and is not adjustable.
Photo: Skate and Indexers
Beside each indexer is an indexer pin which is used only when loading tubulars from the
pipe racks onto the trough. The position of the indexer pins needs to be adjusted to
ensure only a single tubular is lifted from the pipe racks. Refer to “PipeCat” Operational
Layout ~ Pipe Racks/Kickers/Indexers, drawing 9800L015 for proper indexer pin
positions. The indexer pins need to be removed when unloading tubulars from the
catwalk onto the pipe racks.
NOTE: The indexer pins are adjustable or removable and are not permanently
attached to the catwalk. It is the responsibility of the operator to ensure
the pins are not misplaced when they are removed.
The indexer can be controlled with the WRC or the LCS using the driller side and the off
driller side indexer in/out controls.
NOTE: The indexers will not function when the trough is raised out of the
catwalk or while the skate is moving.
CAUTION: Move the skate to a safe position, clear of any tubulars before
operating the indexers. The CCS cannot prevent the indexers from
sending a tubular into the side of the skate – this is the
responsibility of the operator.
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5.6 HPU Power Pack
Refer to HPU Assembly – High Ambient/460V, drawing M231006892-ASM-001 and

HPU Schematic, drawing M231007689-SCH-001.
The HPU power pack is controlled by the CCS and provides hydraulic power for all
PipeCatTM laydown system movements/functions. The unit consists of a hydraulic tank
assembly, two hydraulic pump assemblies, and unitized oil cooler.
The HPU power pack is located on the end of the catwalk furthest from the drill floor. It
is designed to be removed easily with electrical and hydraulic connections at the HPU.
The major components of the hydraulic tank assembly consist of:

• 300 US gallon (1,136 L) tank.
• Filters for all return lines.
• A fluid level switch to enable the CCS
to detect a low hydraulic fluid level.
• Hydraulic tank RTD temperature
sensor to enable the CCS to monitor
hydraulic oil temperature.
• Visual fluid level gauge.
• Visual temperature gauge.
• Operational Strobe light.
• Two receptacle boards with 10 receptacles. Photo: HPU Power Pack
The major components of each hydraulic pump assembly consist of:

• A 50 HP electric motor that receives power from the PCC.
• Horsepower limited variable displacement pump that is oversized to the motor to
allow higher flows at reduced pressure.
• Filter and check valve mounted on the pump case drain.
• Pressure transmitter to enable the CCS to monitor hydraulic pressure.
• Check valve, noise suppressor, relief valve with pressure gauge, and high pressure
ball valve on each pump discharge.
• High pressure hydraulic filter on the pump outlet circuit with a differential pressure
switch to enable the CCS to detect a plugged filter.
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The unitized oil cooler consists of a heat exchanger, fan, electric motor, hydraulic pump,
and a relief valve. The electric motor receives power from the PCC and drives both the
cooling fan and a small hydraulic pump which circulates oil from the hydraulic tank.
The CCS controls the oil cooler based upon the following criteria:
• PipeCatTM laydown system operation allowed when oil temperature exceeds 32°F
(0°C).
• Oil cooler started when oil temperature exceeds 120°F (49°C).
• Oil cooler stopped when oil temperature drops below 110°F (43°C).
• PipeCatTM laydown system operation disabled when oil temperature exceeds 170°F
(77°C).
NOTE: The PipeCatTM laydown system operation will be disabled if the oil
temperature is below 32°F (0°C).
5.7 V-Door Ramp

Refer to the PipeCat V-Door Assembly, drawing M231005513-ASM-001.
The PipeCatTM laydown system v-door ramp provides a track and roller to support and
guide the trough as it moves. The v-door ramp is mounted on the end of the catwalk
with a hinged connection to allow the v-door ramp to fold onto the catwalk for
transportation.
Figure #2
With the trough kept lowered into the catwalk, the v-door ramp can be used as a
standard v-door ramp to raise and lower the equipment that exceeds the rated
capacity of the trough. The winch cables are contained in tracks on the v-door ramp
and are protected from damage.
An optional set of stairs may be attached to the v-door ramp to allow personnel to move
safely between the catwalk and the drill floor.
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5.8 Trough Lift Winch
The trough winch is mounted on the v-door ramp near the hinged connection to the
catwalk. The winch raises and lowers the trough using two winch cables for improved
safety. For more winch information, refer to the Lantec LHS Series Installation and
Maintenance Manual in Vendor Information, Section 17.
The major components of the winch assembly include:

• A drum with two opposing wire grooves.
• Tandem hydraulic drive motor.
• Integral planetary gearbox.
• Integral hydraulically released brake.
• Absolute encoder to enable the CCS to
monitor the winch position and movement.
• Pressure switch to enable the CCS to monitor
hydraulic pressure for integral brake.
• Pressure transmitter to enable the CCS to
monitor the hydraulic pressure and detect a Photo: Trough Lift Winch
winch overload.
The winch can be controlled using the WRC, or the LCS using the trough lift up/trough
lift down control. The control is fully proportional in both directions with the speed limited
and intelligently controlled by the CCS.
When the winch is stopped, it is automatically locked in

place with the integral brake. A pressure switch monitors
the hydraulic pressure supplied to the brake and if the
pressure is less than 50 psi (345 kPa), the brake will not
release and the CCS will disable the control. A hydraulic
connection is provided near the winch for emergency
brake release (refer to the Emergency Trough Lowering
Procedure, Section 12.3).
Photo: Trough Lift Winch
5.9 Trough
Refer to the Trough Assembly, drawing M231007009-ASM-001.
The primary moving component of the PipeCatTM laydown system is the trough. It is
used to transport tubulars and tools between the catwalk and the drill floor. The trough
travels in a track contained within the v-door ramp. It is retracted flush inside the catwalk
for loading and unloading to and from the pipe racks. The trough is raised to the drill
floor for loading and unloading to and from the elevators/drill floor.
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The CCS controls automatically limit the winch speed to provide smooth transitions in all
stages of trough movement.
The CCS automatically resets the trough to the home position when the trough is fully
lowered into the catwalk.
WARNING: Never exceed the rated load of the trough. Failure to comply with
this warning could result in personal injury and/or damage to the
equipment.
WARNING: Personnel are to remain clear of the trough when it is raised.

NEVER work or pass under a raised trough. Ensure the trough is
safely supported before working nearby.
The major components of the trough assembly are the:

• Wire Tensioner Assembly
• Lifting Leg
• Safety Pins
• Kickers
• Skate
• Skate Drive
• Skate Chain Tensioner
5.9.1 Wire Tensioner Assembly
Refer to the Pipe Handler Trough Wire Tensioner Assembly, drawing M231005807-
ASM-001.
The wire tensioner assembly, located within the trough, is only needed to
match/balance the tension in the two trough lift cables. The actual wire tension for the
winch cables is a function of the rotational position of the winch and the load/position of
the trough.
Adjustments should always be made with the trough empty. For an improved view of the
relative cable tensions, adjustments can be made with the trough empty and raised a
short distance up the v-door ramp.

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It is not possible to over-tighten the cables – if a cable is pulled too tight, the trough will
travel a short distance up the v-door ramp. The trough home position will automatically
reset when it is lowered into the catwalk.
If both sides of the tensioner reach opposite adjustment limits without

matching/balancing the cable tensions, relax both sides of the tensioner completely.
Next, shorten the longer cable at the winch end. Then, retry to balance the cable
tensioner. When replacing the cables it may take several attempts, depending on the
accuracy of the cable lengths.
WARNING: Always ensure the nuts on the tensioner assembly are properly
tightened.
WARNING: Always ensure there are a minimum of five dead wraps on the
winch drum at all times.
5.9.2 Lifting Leg
Refer to the Pipe Handler Lifting Leg Assembly, drawing M231002290-ASM-001.
The lifting leg controls the height of the HPU end of the trough as it moves along the
v-door ramp.
One end of the lifting leg is attached to the underside of the trough with a pivot shaft.
The other end of the lifting leg travels along the track contained within the catwalk.
When this end is locked into the leg stop at the end of the track, it will hold/lift the HPU
end of the trough out of the catwalk.
WARNING: Keep the inside of the catwalk and the leg stop clear of mud,
snow, ice, or other debris at all times. Failure to comply with this
warning could result in personal injury and/or damage to the
equipment.
Refer to Figures #4 and #5.
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Figure #4
Figure #5
5.9.3 Safety Pins
Refer to the Trough Kicker and Safety Pin Assembly, drawing M231002471-ASM-001.
The safety pins are used to keep the tubulars

safely contained in the trough and to aid in loading
the tubulars into the trough from the pipe racks.
There are two sets of safety pins contained within

the trough – one set of three on the driller side and
one set of three on the off driller side. Each set of
safety pins is actuated simultaneously. The speed
of the safety pins is mechanically limited and is not Illustration: Safety Pin
adjustable.
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The primary function of the safety pins is to ensure the tubulars remain safely contained
on the trough when it is raised. The CCS automatically operates the safety pins in
reaction to trough movements. All safety pins will be extended whenever the trough is
raised out of the catwalk. All safety pins will be retracted whenever the trough is fully
lowered into the catwalk.
The secondary function of the safety pins is to prevent tubulars from rolling directly
through the trough when loading tubulars onto the trough. The CCS automatically
operates the safety pins in reaction to indexer outer raise movements. When the DS
indexer outer raise control is activated, the ODS safety pins will automatically extend.
After a preset amount of time, the indexer pins will automatically retract.
CAUTION: If all of the safety pins do not automatically extend when the trough
is raised out of the catwalk, immediately lower the trough and fix the
problem before continuing.
5.9.4 Kickers
Refer to the Trough Kicker and Safety Pin Assembly, drawing

M231002471-ASM-001, and the "PipeCat™" Operational
Layout ~ Pipe Racks/Kickers/Indexers, drawing 9800L015.
The kickers are used to eject the tubulars off the trough and
onto the driller side or the off driller side catwalk.
There are two sets of kickers contained within the trough –

one set of three to eject a tubular towards the driller side pipe Illustration: Kicker
rack and one set of three to eject a tubular towards the off
driller side pipe rack.
The kickers can be operated with the WRC or the LCS using the driller side and the off
driller side kicker up/kicker down controls.
Each set of kickers is actuated simultaneously – the hydraulic flow dividers synchronize
their movements. The speed of the kickers is mechanically limited and is not adjustable.
The kickers will not function when the trough is raised out of the catwalk or while the
skate is moving. The kicker will also not function unless the skate is retracted near its
home position.
Figure #6
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5.10 Skate
Refer to the Skate Assembly, drawing M231003073-ASM-001.
The skate moves and supports the tubulars and tools along the length of the trough. It
travels within an enclosed track on the trough and includes an adjustable hood and a
shock absorbing bumper.
The main functions of the skate include:
• Controlling weight distribution on the trough by
positioning and supporting loads close to the v-door
ramp end.
• Pushing tubulars off the end of the trough towards well
centre and positioning them for elevator latching.
• Supporting heavy tubulars during lay-down.
• Positioning the tubulars for unloading to the catwalk.
• Moving drill tools between the drill floor and catwalk. Photo: Skate
The skate can be controlled using the WRC or the LCS using the skate forward/back
control. The skate control is fully proportional in both directions, with the speed of travel
only limited by the available hydraulic power.
CAUTION: The CCS is unaware of the exact skate position and does not
automatically stop the skate at either extent of travel – the
operator is responsible for slowing and stopping the skate
appropriately.
CAUTION: All personnel should maintain a safe distance from the end of the
trough when the skate pushes the tubulars off the trough towards
well centre.
5.10.1 Skate Drive
Refer to the Skate Hydraulic Drive Assembly, drawing M231001573-ASM-001.
The skate is driven by a hydraulic motor, planetary gearbox, and two double roller
chains. The skate drive is located inside the v-door ramp end of the trough.
When the skate is stopped, it is automatically locked into place with a brake integral to
the gearbox. A pressure switch monitors the hydraulic pressure supplied to the skate.
The CCS will disable the skate control and the brake will not release if the pressure is
less than 50 psi (345 kPa).
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Illustration: PipeCat™ Skate Travel
5.10.2 Skate Chain Tensioner
Refer to the Skate Tension Idler Shaft Assembly, drawing M231004896-ASM-001.
The skate chain tensioner assembly is located inside the HPU end of the trough and is
only accessible when the trough is raised out of the catwalk. The skate chain tensioner
assembly is used to adjust the tension on the skate drive chains.

NEVER work on, or pass under, a raised trough. Ensure the
trough is safely supported before working nearby.
CAUTION: Over-tightening the chains will result in premature wear and/or

equipment failure.
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6. RIG UP/RIG DOWN

6.1 Rig Up Procedure
6.2 Rig Down Procedure
6.1 Rig Up Procedure
WARNING: Position equipment in accordance with the appropriate drawing

dimensions. Failure to comply with this warning could result in
personal injury and/or damage to the equipment.
WARNING: Making or breaking high-voltage connections when they are

energized could result in electrical shock and/or death. Always
ensure all sources of power are switched off before handling any
connections.
WARNING: The catwalk must be completely level and well supported before
the v-door ramp may be raised.
WARNING: Ensure all lifting/rigging equipment is sufficiently rated to handle

the weight of the v-door ramp.

WARNING: Ensure the cables are not pinching or binding when the v-door
ramp is raised.
Refer to the “PipeCatTM ~ Pipe Handler General Assembly,

drawing M231010639-GAD-001, sheet 2 of 3, for the following
PipeCatTM laydown system rig up procedure.
1. Position the PipeCatTM laydown system frame relative to the

drill floor as shown in drawing M231010639-GAD-001,
sheet 2 of 3.
2. Ensure the frame is completely level and well supported.
3. Extend all pipe racks to be perpendicular to the PipeCatTM
laydown system frame. Rotate the bearing pads.
4. Lock the bearing pads in place using the bearing pad tie-
downs.
5. Lower the drag chain tray onto the ground and ensure it is Photo: Pipe Rack
flush and level with the inside floor of the frame. Bearing Pad
6. Open the four covers on the through-beam sensors.
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7. Lower the wing walk at the local control station near the HPU.
8. Ensure all PipeCatTM laydown system power sources are switched off. There is one
208V supply and one 460V supply.
9. Ensure the main 460V breaker in the PCC cabinet is in the off position.
10. Ensure the wireless controller on/off key switch is in the off position.
11. Connect the four power and control cables (460VAC three-phase main power,
208VAC single-phase control power, DFSD e-stop control, and Amphion fiber optic
control) to the PipeCatTM laydown system plug board.
12. Start the PipeCatTM laydown system using the Local Control Station (LCS) Start Up
Procedure, Section 7.2.
13. Manually operate the winch control valves to slack the cable by one complete drum
rotation. Refer to the Valve Location Diagram below for valve location.
14. Using the lugs provided on the end of the v-door ramp, lift and pivot the v-door ramp
to rest on the edge of the drill floor. This can be done with either a mobile crane or a
combination of a tugger winch on the rig, and a cable connected to the pull-back
post, run through a pulley on the v-door and anchored to a loader/forklift. Use the
tugger to bring the v-door up to the over-center point, and the loader/forklift to lower
the v-door from the over-center point until it rests on the substructure. If using a
mobile crane, the crane should be positioned beside the catwalk approximately 5’
(1,524 mm) from the v-door ramp pivot point. Ensure the rotation of the v-door ramp
is slow and controlled as it rotates past the over-centre point.
15. Secure the v-door ramp to the drill floor using the supplied safety turnbuckle and
lugs. Refer to the V-door Tie-Down Assembly, drawing M231003023-ASM-001.
16. Ensure the lift cables are properly aligned in the sheaves and the guide blocks on
the underside of the trough.
17. Manually operate the winch control valves to remove any slack in the lift cables and
lift the trough a short distance up the v-door ramp. Look under the trough and verify
the winch cables are properly routed.
18. Replace the manual control valve
covers and return to normal operation
mode. Completely lower the trough to
reset the trough home position.
19. Enable pipe rack setup mode. Operate
the WRC or LCS to adjust the height of
each pipe rack. Disable the pipe rack
setup mode.
20. Rig-up is complete.
Illustration: Valve Location Diagram
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6.2 Rig Down Procedure

Refer to the “PipeCatTM” ~ Pipe Handler General Assembly, drawing M231010639-
GAD-001, sheet 2 of 3, for the following PipeCatTM laydown system rig down procedure:
WARNING: Ensure all lifting/rigging equipment is sufficiently rated to handle

the weight of the v-door ramp.
WARNING: Making or breaking high-voltage connections when they are

energized could result in electrical shock and/or death. Always
ensure all sources of power are switched off before handling any
connections.
1. Start the PipeCatTM laydown system using the Local Control Station (LCS) Start Up
Procedure, Section 7.2.
2. Manually operate the winch control valves to slack the cable by one complete drum
rotation. Refer to the Valve Location Diagram in Rig Up Procedure, Section 6.1, for
valve location.
3. Detach the turnbuckles that secure the v-door ramp to the drill floor. Refer to the
V-Door Tie-Down Lug Assembly, drawing M231003023-ASM-001.
4. Using the lugs provided on the end of the v-door ramp, pivot and lower the v-door
ramp to rest on the PipeCatTM laydown system frame. This can be done with either a
mobile crane or a combination of the tugger winch and a cable on the pull-back post
connected to a loader/forklift through a pulley on the v-door. If using a mobile crane,
the crane should be positioned beside the catwalk approximately 5’ (1,524 mm) from
the v-door ramp pivot point. Ensure the rotation of v-door ramp is slow and
controlled as it rotates past the over-centre point.
5. Manually operate the winch control valves to slowly remove the majority of the slack
in the lift cables. Do not over-tighten the cables.
6. Lift each pipe rack to rotate the bearing pads 90°. Lift and fold each pipe rack onto
their transportation mounts and pin them in place.
7. Fold the drag chain tray and secure to the end of catwalk using the supplied chains.
8. Power down the PipeCatTM laydown system – reference the Power Down Procedure,
Section 7.3.
9. Turn off all PipeCatTM laydown system power sources.
10. Disconnect the four power and control cables from the PipeCatTM laydown system
plug board.
11. Raise the wing walk at the LCS and pin into transport position.
12. Close the covers on the through-beam sensors.
13. Secure all components for safe transportation. Protect the PipeCatTM laydown
system according to the Storage and Preservation, Section 3.
14. Rig down is complete.
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7. START UP/POWER DOWN PROCEDURES

7.1 Wireless Radio Control (WRC) Start Up Procedure
7.2 Local Control Station (LCS) Start Up Procedure
7.3 Power Down Procedure
7.1 Wireless Radio Control (WRC) Start Up Procedure
Refer to the following WRC start up procedure to prepare the PipeCatTM laydown
system for operation.
1. Ensure all four power and control cables are properly connected to the PipeCatTM
laydown system plug board.
2. Ensure the four through-beam sensor covers are open.
3. Turn on the external 460V three-phase and the 208V single-phase power supplies.
4. Open the ball valves on the HPU for all supply and return lines. (Ensure the ball
valve for tank drain remains closed.)
5. Ensure all e-stop buttons are reset (pulled up).
6. Ensure all the hand/off/auto controls are set to the off position.
7. Open the PCC cabinet and turn on the main 460V breaker. Close the PCC cabinet.
8. Set the HPU oil cooler control on the LCS to the auto position.
9. Turn both of the HPU hand/off/auto controls on the LCS to the auto position.
10. Turn the on/off key-switch on the wireless radio control to the on position.
11. Check battery indicator beside the on/off key-switch.
12. Press the system start button to start the PipeCatTM laydown system.
13. Confirm both the HPU #1 and HPU #2 run indicator lights illuminate within five
seconds.
14. Confirm the HYDR pressure indicator light is off.
15. Confirm the interlock alarm indicator light is off.
16. If there are no alarms or interlocks, the PipeCatTM laydown system has been
successfully started and is ready for operation.
WARNING: Operating the PipeCatTM laydown system from the local control
console when the trough is near the drill floor is not
recommended. When operating the PipeCat™ laydown system
from the wireless radio control (WRC), ensure the entire machine
is in full view. Ensure all personnel maintain a safe distance from
the end of the trough or tubular as it moves towards well center.
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7.2 Local Control Station (LCS) Start Up Procedure
Refer to the following LCS start up procedure to prepare the PipeCatTM laydown system
for operation.
1. Ensure all four power and control cables are properly connected to the PipeCatTM
laydown system plug board.
2. Ensure the four through-beam sensor covers are open.
3. Turn on the external 460V three-phase and 208V single-phase power supplies.
4. Open the ball valves on the HPU for all supply and return lines. (Ensure the ball
valve for tank drain remains closed.)
5. Ensure the wireless controller on/off key switch is in the off position.
6. Ensure all e-stop buttons have been reset.
7. Ensure all the hand/off/auto controls are set to the off position.
8. Open the PCC cabinet and turn on the main 460V breaker. Close the PCC cabinet.
9. Set the HPU oil cooler control on the LCS to the auto position.
10. Turn both of the HPU hand/off/auto controls on the LCS to the auto position.
11. Press the tool on/off button. Confirm both the HPU #1 and HPU #2 run indicator
lights are illuminated.
12. Confirm the interlock alarm indicator light is off.
13. If there are no alarms or interlocks, the PipeCatTM laydown system has been
successfully started and is ready for operation.
WARNING: When operating the PipeCatTM laydown system from the remote
control console, ensure the entire machine is in full view. Ensure
all personnel maintain a safe distance from the trough or
tubulars as they are being handled.
NOTE: The PipeCatTM laydown system can also be started from the WRC by
pressing the system start, provided power is available and all the
hand/off/auto controls are set to auto on the LCS.
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7.3 Power Down Procedure

Refer to the following procedure to properly power down the PipeCatTM laydown system.
1. Ensure the trough is lowered completely into the catwalk and the skate has moved
fully into its rear-most position.
2. Push the e-stop button.
3. If using the WRC, turn the on/off key-switch to the off position.
4. If using the LCS, press the tool on/off button.
5. Open the PCC cabinet and turn off the main 460V breaker. Close the PCC cabinet.
6. Set all of the hand/off/auto controls on the LCS to the off position.
7. Close the ball valves on the HPU for all supply and return lines.
8. Close the four through-beam sensor covers.
9. Turn off the external 460V three-phase and the 208V single-phase power supplies.
10. The PipeCatTM laydown system has now successfully been powered down.
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8. OPERATING INSTRUCTIONS
8.1 Loading Tubulars to the Drill Floor
8.2 Unloading Tubulars from the Drill Floor
8.1 Loading Tubulars to the Drill Floor
Refer to the procedure below to correctly load tubulars to the drill floor:

1. Set the indexer pin positions according to the size of the tubulars to be loaded on the
pipe racks. Refer to "PipeCatTM" Operational Layout ~ Pipe Racks/Kickers/Indexers,
drawing 9800L015.
NOTE: The indexer should be able to catch more than half of the tubular when
resting against the indexer pins.
2. Load the tubulars onto the pipe rack as close to the v-door ramp as possible in the
safest possible manner.
3. Adjust the skate hood to the lowest position that still allows clearance for the tubular
to sit against the skate bumper.
4. Raise the outer end of the pipe racks to roll the tubulars against the indexer pins.
CAUTION: Ensure all personnel maintain a safe distance from the pipe racks
as the racks are adjusted. Do NOT rely solely on the anti-rollback
or indexer pins to protect personnel from rolling tubulars.
5. Move the skate past the end of the tubulars to be loaded.
CAUTION: The skate must be in a safe position, which is clear of any

tubulars, before operating the indexers. It is the responsibility of
the operator to ensure the indexers do not send a tubular into the
side of the skate as the CCS cannot prevent this on its own.
6. Use the indexer control to lift one tubular over the indexer pins. The opposing safety
pins will automatically extend.
7. Release the indexer control when the tubular rolls past the indexer pins.
NOTE: The speed of the tubulars can be controlled by how long the indexers
are held in the raised position.
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8. Once the tubular has settled into the trough, use the skate to push the tubular
forward and closer to the v-door ramp.
9. Use the trough lift control to start raising the trough to the drill floor.
10. Ensure the safety pins have automatically extended.
11. Continue raising the trough until it stops at the trough set point.
12. Use the skate control to push the tubulars off the end of the trough and towards the
well centre.
CAUTION: Ensure all personnel maintain a safe distance from the end of the
trough when the skate pushes tubulars off the trough.
13. Latch the elevators and lift the tubular off the trough.
CAUTION: Ensure all personnel maintain a safe distance from the free end of
the tubular as it slides off the end of the trough.
14. Use the trough lift and skate controls simultaneously to lower the trough and move
the skate back.
15. Once the trough is fully lowered and the safety pins are retracted, the PipeCatTM
laydown system is ready for another loading cycle.
8.2 Unloading Tubulars from the Drill Floor
Refer to the procedure below to correctly unload tubulars from the drill floor:

1. Lower the outer end of the pipe racks to unload all tubulars.
CAUTION: Ensure all personnel maintain a safe distance from the pipe racks
as they are adjusted. Do NOT rely solely on the anti-rollback or
indexer pins to protect personnel from rolling tubulars.
2. Remove all indexer pins.

3. Adjust the skate hood to the lowest position that still allows clearance for the tubular
to sit against the skate bumper.
4. Use the trough lift and skate controls simultaneously to raise the trough to the drill
floor. Position the skate to the desired position on the trough.
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5. Ensure the safety pins have automatically extended.

6. Place a thread protector on the end of the tubular.
7. Push the end of the tubular over the end of the trough.
8. Lower the tubular onto the trough.
9. Release the elevators when the tubular is completely supported by the trough.
WARNING: Do not release the elevators before the tubular is completely

supported by the trough. Do not release the elevators unless the
skate is positioned near the end of the tubular. An uncontrolled
tubular may bounce or slide off the trough and fall to the v-door
or catwalk, or may even fall all the way to the ground. Failure to
comply with this warning could result in personal injury and/or
death.
10. Move the skate backwards to ensure the tubular is completely on the trough. Check
that no portion of the tubular is overhanging the trough roller.
11. If the tubular sticks to the trough and does not slide with the skate, increase the
trough angle by lowering the trough a short distance until the tubular starts to slide.
12. Use the trough lift control to completely lower the trough and automatically retract
the safety pins.
13. Move the skate back and clear of the tubular and kickers.
14. Use the kicker control to roll the tubular off the trough and onto the pipe racks.
15. If the tubular stops on the catwalk use the index out control to send the tubular onto
the pipe rack.
16. The PipeCatTM laydown system is ready for another unloading cycle once the tubular
is safely on the pipe rack.
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9. CONTROL LAYOUTS AND DESCRIPTIONS

19.1 Local Control Station (LCS) Controls
19.2 Wireless Radio Control (WRC) Console Controls
19.3 Ownership Take/Release Function
9.1 Local Control Station (LCS) Controls
The Local Control Station (LCS) is the main start-up operator and backup operator for the PipeCatTM laydown system.
It has two distinct operating modes: normal operation and pipe rack setup.
D F H M N
A B C E G K
W X Y Z
AA AB P R S T U V
Illustration: Local Control Console
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9.1.1 Normal Operation Mode
NOTE: All controls will automatically return to their centre/neutral position when
released.
A ESD (E-Stop) Button

• Press to immediately stop all PipeCatTM laydown system movement.
B Ownership Take/Release Button and Light

• Press to release control ownership from the LCS. Light will extinguish when
ownership is released.
• Press to take control ownership at the LCS. Light will illuminate green when
ownership is taken.
C Ownership Available Indicator Light

• Illuminated green when the PipeCatTM laydown system is available for
ownership.
D Interlock Reset Switch

• Rotate counter clockwise to reset interlock conditions. Interlock indicator light
will extinguish if the CCS is able to reset the interlock condition. Interlock
indicator light will remain illuminated if the CCS is unable to reset the interlock
condition.
• Hold in the reset position to override and move the trough past the custom
trough setpoint. If no new setpoint is made, hold in the reset position to override
and move the trough back past the custom trough setpoint.
• Rotate clockwise to test lamps. All lights on panel should illuminate.
E Interlock Alarm Indicator Light

• Illuminated red when there is an interlock alarm.
• Illuminated red when the maximum trough travel setpoint is reached.
F Tool On/Off Button and Light

• Press to turn on the PipeCatTM laydown system. Light will illuminate green
when the tool is on.
• Press to turn off the PipeCatTM laydown system. Light will extinguish when the
tool is off.
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G HPU#1 Hand/Off/Auto Switch

• Turn switch to hand position to manually start HPU pump #1 when power is
available.
• Turn switch to off position when powering down the PipeCatTM laydown system.
• Turn switch to auto to allow HPU pump #1 to start automatically when the tool
on/off button is pressed.
H HPU#1 Indicator Light

• Illuminated green when HPU#1 is running.
• Extinguished when HPU#1 is not running.
K HPU#2 Hand/Off/Auto Switch

• Turn switch to hand position to manually start HPU pump #2 when power is
available.
• Turn switch to off position when powering down the PipeCatTM laydown
system.
• Turn switch to auto to allow HPU pump #2 to start automatically when the tool
on/off button is pressed.
M HPU#2 Indicator Light

N Trough Setpoint Button

• Position the trough at the desired stop point above the drill floor and press the
trough setpoint button to teach the CCS where to automatically stop the
trough during operation.
NOTE: If necessary, hold the interlock switch to reset to override the current
setpoint and move the trough past, where a new setpoint can be set.
If no new setpoint is set, hold the interlock switch in the reset
position and move the trough back past the custom setpoint.
P DS Load Arms Up/Down Switch

• Rotating the switch to the up position raises all three DS pipe rack arms
simultaneously to move the tubulars up against the indexing pins.
• Rotating the switch to the down position lowers all three DS pipe rack arms.
• Also refer to the Pipe Rack Setup Mode, Section 9.1.2.
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R DS Index In/Out Switch

• Rotating the switch to the in position raises the DS indexer to load a single
tubular onto the catwalk. The ODS safety pins will automatically extend for a
preset time.
• Rotating the switch to the out position raises the DS indexer causing a single
tubular to eject from the catwalk to the DS pipe racks.
• Indexers will automatically lower when the control is released. The operator
must hold the control in the raised position to keep the indexers raised.
S DS Kicker Up/Down Switch

• Rotating the switch to the up position raises the DS kicker to eject a single
tubular from the trough to the driller’s side of the catwalk. The switch must be
held in the up position to keep the kickers raised.
• Releasing the switch will lower the kickers into the trough. There is no need to
rotate the switch to the down position to lower the kickers.
T ODS Load Arms Up/Down Switch

• Rotating the switch to the up position raises all three ODS pipe rack arms
simultaneously to move the tubulars up against the indexing pins.
• Rotating the switch to the down position lowers all three ODS pipe rack arms.
U ODS Index In/Out Switch

• Rotating the switch to the in position rises the ODS indexer to load a single
tubular onto the catwalk. The DS safety pins will automatically extend for a
preset time.
• Rotating the switch to the out position raises the ODS indexer causing a single
tubular to eject from the catwalk to the ODS pipe racks.
V ODS Kicker Up/Down Switch

• In normal mode, rotating the switch to the up position raises the ODS kicker to
eject a single tubular from the trough to the off driller’s side of the catwalk. The
switch must be held in the up position to keep the kickers raised.
• Releasing the paddle will lower the kickers into the trough. There is no need to
rotate the switch to the down position to lower the kickers.
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W Pipe Rack Setup Button

• The pipe rack setup button is available only when the trough is fully lowered
into the catwalk.
• Press to enable the pipe rack setup mode.
• Press again when finished pipe rack levelling to return the LCS to normal
operation.
X Pipe Rack Setup Mode Indicator Light

• Illuminated green when the pipe rack set up mode is enabled.
Y Safety Pins Up/Down Switch

• Set to the up position to raise the pins.
• Set to the down position to lower the pins.
• The safety pins automatically raise when trough leaves the home position, or
when the indexers are used.
Z Oil Cooler Hand/Off/Auto Switch

• Turn switch to hand position to manually start the oil cooler when power is
available.
• Turn switch to off position when powering down the PipeCatTM laydown
system.
• Turn switch to auto to allow oil cooler to start automatically when the oil
temperature becomes too hot.
AA Trough Lift Up/Down Joystick

• Pushing the joystick up will raise the trough and pushing the joystick down will
lower the trough.
• The speed of the trough at any given point is automatically limited by the CCS.
The operator only has to push the joystick to its furthest position to move the
trough at its fastest speed. The CCS will automatically decrease the trough
speed as required to ensure smooth operation.
AB Skate Forward/Back Joystick

• Pushing the joystick up will move the skate forward.
• Pushing the joystick down will move the skate back.
CAUTION: The operator is responsible for slowing and stopping the
skate before it hits the hard stops at either end of the
trough.
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9.1.2 Pipe Rack Setup Mode
Only the following controls listed below are enabled in the pipe rack setup mode. All
other controls are disabled.
released.

P DS Load Arms Up/Down Switch

• Rotating the switch to the up position raises the left DS pipe rack arm.
• Rotating the switch to the down position lowers the left DS pipe rack arm.
R DS Index In/Out Switch

• Rotating the switch to the in position raises the middle DS pipe rack arm.
• Rotating the switch to the out position lowers the middle DS pipe rack arm.
S DS Kicker Arms Up/Down Switch

• Rotating the switch to the up position raises the right DS pipe rack arm.
• Rotating the switch to the down position lowers the right DS pipe rack arm.
T ODS Load Arms Up/Down Switch

• Rotating the switch to the up position raises the ODS pipe rack arm.
• Rotating the switch to the down position lowers the left ODS pipe rack arm.
U ODS Index In/Out Switch

• Rotating the switch to the in position raises the middle ODS pipe rack arm.
• Rotating the switch to the out position lowers the middle ODS pipe rack arm.
V ODS Kicker Arms Up/Down Switch

• Rotating the switch to the up position raises the right ODS pipe rack arm.
• Rotating the switch to the down position lowers the right ODS pipe rack arm.
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9.2 Wireless Radio Control (WRC) Console Controls
The wireless radio control (WRC) is the primary operator control for the PipeCatTM laydown system. It has two distinct
operating modes: normal operation and pipe rack setup.
A B C D E F G
ESD PIPE RACK

TROUGH LIFT ODS INDEX ODS KICKER DS KICKER DS INDEX SKATE
PIPE RACK
SETPOINT
UP OUTER RAISE UP UP OUTER RAISE FORWARD
TROUGH
SETUP
H M
INTERLOCK
SYSTEM
START
RESET
K TROUGH LIFT ODS INDEX ODS KICKER DS KICKER DS INDEX SKATE
N
DOWN INNER RAISE DOWN DOWN INNER RAISE BACK
V DOOR MID FLARE V DOOR MID FLARE

SAFETY PINS
OFF/ON
UP PIPE RACK HYDR.
TOOL ON SETUP HPU #1 HPU #2 PRESS. INTERLOCK
P
DOWN
R S T U V W X Y
Illustration: Wireless Radio Control
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9.2.1 Normal Operation Mode

released.

B Trough Lift Up/Down Paddle

• Pushing the paddle up will raise the trough and pushing the paddle down will
lower the trough.
• The paddle is proportional, which means the further the paddle is pushed, the
faster the trough will move. The speed of the trough at any given point is
automatically limited by the CCS.
• The operator only has to push the paddle to its furthest position to move the
trough at its fastest speed. The CCS will automatically decrease the trough
speed as required to ensure smooth operation.
C ODS Index Outer/Inner Raise Paddle

• Pressing the paddle up will raise the outer end of the off driller side indexers to
load a single tubular from the off driller side pipe racks. The DS safety pins will
automatically extend for a preset time.
• Pressing the paddle down will raise the inner end of the off driller side indexers,
causing a single tubular to eject from the catwalk to the off driller side pipe
racks.
D ODS Kicker Up/Down Paddle

• Pressing the paddle up will raise the off driller side kickers to eject a single
tubular from the trough to the off driller side of the catwalk. The paddle must be
held in the up position to keep the kickers raised.
press the paddle down to lower the kickers.
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E DS Kicker/Up Down Paddle

• Pressing the paddle up will raise the driller side kickers to eject a single tubular
from the trough to the driller side of the catwalk. The paddle must be held in the
up position to keep the kickers raised.
press the paddle down to lower the kickers.
F DS Indexer Outer/Inner Raise Paddle

• Pressing the paddle up will raise the outer end of the driller side indexers to
load a single tubular from the driller side pipe racks. The ODS safety pins will
automatically extend for a preset time.
• Pressing the paddle down will raise the inner end of the driller side indexers to
eject a single tubular from the catwalk to the driller side pipe racks.
G Skate Forward/Back Paddle

• Pushing the paddle up will move the skate forward.
• Pushing the paddle down will move the skate back.
• The paddle is proportional. The further the paddle is pushed, the faster the
skate will move. The speed of the skate is only limited by the available
hydraulic power.
• The operator is responsible for slowing and stopping the skate before it hits the
hard stops at either end of the trough.
H Pipe Rack Setup Button

• The pipe rack setup button is available only when the trough is fully lowered
into the catwalk.
• Press to enable the pipe rack setup mode.
• Press again when finished pipe rack levelling to return the wireless radio control
to normal operation.
K System Start Button

• Press to enable the wireless radio control.
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M Trough Setpoint Button

• Position the trough at the desired stop point above the drill floor and press the
trough setpoint button to teach the CCS where to automatically stop the trough
during operation.
NOTE: Trough setpoint can only be set once after the wireless control is
turned on.
N Interlock Reset Button

• Press to reset interlock conditions.
• Interlock indicator light will extinguish if the CCS is able to reset the interlock
condition.
• Interlock indicator light will remain illuminated if the CCS is unable to reset the
interlock condition.
P On/Off Key-Switch
• Turn to the on position to power-up the wireless radio control. Always check the
battery indicator light.
• Turn to the off position to stop all PipeCatTM laydown system operation and
power-down the wireless control.
R Safety Pins Up/Down Toggle Switch

• Set to the up position to raise the pins.
• Set to the down position to lower the pins.
• The safety pins automatically raise when the trough leaves the home position,
or when the indexers are used.
S Tool On Indicator Light

• Illuminated green when the wireless radio control is enabled.
T Pipe Rack Setup Indicator Light

• Illuminated red when the pipe rack set up mode is enabled.
U HPU#1 Indicator Light

V HPU#2 Indicator Light

W HYDR Press Indicator Light
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• Illuminated red when HPU #1 and HPU #2 are not running or the hydraulic
pressure is low.
• Extinguished when either HPU #1 or HPU #2 are running and the hydraulic
pressure is normal.
X Interlock Indicator Light

• Illuminated red when an interlock condition is present.
• Extinguished when interlock conditions are cleared.
Y Battery Indicator Light

• Illuminated green when battery voltage is normal.
• Flashes green during wireless control transmission.
• Illuminated yellow when the battery voltage is low.
• Illuminated red when the battery needs to be changed.
9.2.2 Pipe Rack Setup Mode
Only the following controls are enabled in this mode. All other controls are disabled.
NOTE: All paddle controls will automatically return to their centre/neutral

position when released.
Each paddle adjusts the height of one pipe rack. Pushing the paddle up will raise the
outboard end of the pipe rack, while pushing the paddle down will lower the outboard
end. Each pipe rack is automatically held in position when the paddle is released.

B Trough Lift Up/Down Paddle

• Operates the v-door ramp end pipe rack on the ODS.
C ODS Index Outer/Inner Raise Paddle

• Operates the middle pipe rack on the ODS.
D ODS Kicker Up/Down Paddle

• Operates the flare end pipe rack on the ODS.
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E DS Kicker Up/Down Paddle

• Operates the v-door ramp end pipe rack on the DS.
F DS Indexer Outer/Inner Raise Paddle

• Operates the middle pipe rack on the DS.
G Skate Forward/Back Paddle

• Operates the flare end pipe rack on the DS.
9.3 Ownership Take/Release Function
The ownership take/release function is designed to ensure that only one of the
operator’s control devices, either the LCS or the WRC, is active at any time. Only the
device that has control ownership is able to command machine movements. No
machine movements are possible without either the LCS or the WRC having ownership.
The LCS has an ownership take/release button and an ownership available indicator.
When the ownership available indicator is illuminated, pushing the ownership
take/release button will take control ownership.
The WRC does not have a take/release button or ownership available indicator; instead,
the ownership is handled automatically in response to the WRC’s on/off key switch.
When the WRC key switch is turned to the on position and control ownership is
available, the WRC will automatically take control ownership. When the WRC already
as control ownership, turning the key to the off position will automatically release control
ownership.
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10. MAINTENANCE AND LUBRICATION

10.1 General Instructions
10.2 Maintenance Charts
10.3 Recommended Oils and Lubricants
10.4 Storage Lubrication
10.5 Skate Chain Tensioning Procedure
10.1 General Instructions
Regular maintenance and lubrication will ensure a long service life and prevent
premature component wear and/or failure of the PipeCatTM laydown system.
The operator must review all of the drawings and vendor information included with this
manual to become familiar with the PipeCatTM laydown system and recognize the
maintenance requirements of each component and assembly.
Before starting a new machine, the operator must grease all parts and fill all reservoirs
with the prescribed lubricants. New units should be drained and refilled with oil after the
first few weeks of operation. Thereafter, it should not be necessary to change the oil
more than once every six months except when the oil may have been contaminated or
when the temperature changes enough to require a change in the viscosity of the oil
being used.
Where grease fittings are present, apply grease at the fittings until the old grease starts
to seep around the seal, flushing out the used grease along with any accumulated water
or debris. Maintain a coat of grease on all sliding surfaces, and unpainted, machined
surfaces for lubrication and corrosion protection.
At all times, ensure the following are kept clean and free of all debris (including mud,
snow, and ice):
• Bottom of v-door ramp, top of catwalk, trough guide tracks at v-door ramp, top of
trough, top of pipe racks.
• Entire area inside catwalk, including the lifting leg stop and track.
• Drag chain tray and entire path of drag chain travel.
• Trough home position sensor (on top of catwalk near HPU).
• Catwalk and v-door ramp stairs (if equipped).
For proper maintenance and lubrication information, follow the recommended

maintenance charts in Maintenance Charts, Section 10.2, and refer to the
Recommended Oils and Lubricants, Section 10.3. Locations of common lubrication
points are shown on PipeCAT Lubrication Points, drawing M231001985-LUB-001.
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10.2 Maintenance Charts
DAILY MAINTENANCE CHECKED

1. Check oil level in hydraulic tank.
2. Check for hydraulic leaks.
3. Inspect skate drive chains.
4. Inspect skate drive chain connecting links.
5. Inspect winch cables.
6. Inspect winch cable connections and tensioner nuts in wire
tensioner assembly.
WEEKLY MAINTENANCE CHECKED

1. Check level of oil in winch drum gearbox.
2. Check level of oil in skate drive gearbox.
3. Grease bearings in v-door roller assembly.
4. Grease bearings in v-door sheave assembly.
5. Grease bearings in skate tension idler shaft assembly.
6. Inspect sealed bearings in skate drive shaft assembly.
7. Inspect plain rollers on front of trough.
8. Inspect v-rollers on rear of trough.
9. Inspect v-rollers on lifting leg.
10. Inspect lifting leg stop bumpers.
11. Inspect skate travel stop bumpers.
12. Ensure cooling fans on electric motors are unobstructed.
13. Ensure HPU oil cooler fan and radiator is unobstructed.
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MONTHLY MAINTENANCE CHECKED

1. Clean and/or lubricate both winch cables.
2. Clean and/or lubricate skate drive chains.
3. Check to ensure the winch cables are equally tensioned.
4. Check winch drum for excessive grooving.
5. Check skate drive sprockets for excessive wear.
6. Check skate drive chain tension.
7. Check hydraulic filter indicators.
8. Check entire unit for leaks
– hydraulic system, winch, skate drive, etc.
9. Check wear pads on sides of lifting leg.
10. Check wear pads on skate assembly.
11. Check wear pads on bottom of drag chain.
12. Check wear pads on bottom of drag chain support tray.
13. Check plastic pad on face of skate bumper.
14. Inspect drag chain assembly.
SIX MONTH MAINTENANCE CHECKED

1. Grease bearings in electric motors.
2. Check cleanliness of hydraulic oil. Must have ISO level
17/15/12.
3. Check lubrication oil in winch drum gearbox for contamination
and particulates.
4. Check lubrication oil in skate drive gearbox for contamination
and particulates.
5. Check nitrogen pre-charge pressure (1,500 psi (10,342 kPa))
in hydraulic noise suppressors. Refer to Vendor Information,
Section 17 for checking and charging the noise suppressors.
6. Check skate bumper springs.
7. Check self-lubricated bearings in trough front roller.
8. Check self-lubricated bearings in trough to lifting leg
connection.
9. Check self-lubricated bearings in kicker assemblies.
WARNING: Do not fill the hydraulic tank with unfiltered oil. The hydraulic
fluid must have a cleanliness rating of ISO 17/15/12 (NAS 6) or
better. Never fill the tank by pouring the oil from a pail or barrel.
New oil from a barrel or pail will not meet this cleanliness rating
and must be filtered prior to being put into the hydraulic tank.
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10.3 Recommended Oils and Lubricants
National Oilwell Varco recommends using the oils and lubricants listed in the following
chart. These brands are recommended because of their excellent lubricating properties.
Other brands may be used as long as the oil/lubricant has the same properties and
operating ranges as the recommended brands. Refer to the following charts for the
recommended oils and lubricants and for their typical properties. If unsure of an
equivalent brand, contact National Oilwell Varco for assistance.
Equipment Lubricant/Oil Ambient Temp. Recommended

Hydraulic Hydraulic Oil -40°F to 50°F Esso Univis N22
System (-40°C to +10°C)
-4°F to 86°F Esso Univis N32 *
(-20°C to +30°C)
32°F to 122°F Esso Univis N46
(0°C to +50°C)
Skate Drive Gear Oil Refer to Brevini gearbox Esso Spartan
Gearbox manual EP All Season
Winch Drum Gear Oil Refer to Lantec winch Esso Spartan
Gearbox manual EP All Season
Electric Motor Grease All Mobil Polyrex EM †
Bearings (polyurea-based)
Other Bearings Grease All Esso Unirex EP 2
(lithium-based)
Wireline Wireline Lube All Bridon Brilube 30†† or
Crosby Vitalife 400††
Or equivalent
Chain Chain Lube All Esso Millcot K 100
TM
* Oil supplied with new PipeCat laydown system.
† Substitutions are not recommended.
†† For Bridon and/or Crosby lubricant properties, refer to Vendor Information, Section 17.
Lubricant Type
ESSO Spartan EP ESSO UNIREX EP 2 ESSO MILLCOT K 100
Property or equivalent or equivalent or equivalent
Additives X X X
Rust Protection X X X
Water Resistant -- X --
Corrosion X X --
Resistant
Anti-wear and
Friction -- -- X
Reducing
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10.4 Storage Lubrication
Applying super premium greases to every fitting in quantities sufficient to flush out most
of the old greases will go a long way towards protecting the equipment from rust and
corrosion during storage. For maximum protection against rust and corrosion during
prolonged storage, it is best not to rely on the oil that was clinging to the parts when the
equipment was powered down. Use a compound specifically designed and formulated
for this purpose. Apply according to the manufacturer's recommendations.
In selecting a special storage lubricant, use one that does not require any special
cleaning before operating the equipment again. The lubricant should have compounds
that will be flushed away by normal lubrication oil and can mix with other oils
harmlessly.
10.5 Skate Chain Tensioning Procedure
Refer to the following drawings and the below procedure to correctly adjust the skate
chain tension:
• Skate Drive Shaft Assembly, drawing M231001423-ASM-001
• Skate Assembly, drawing M231003073-ASM-001
• Skate Tension Idler Shaft Assembly, drawing M231004896-ASM-001
1. Raise the trough approximately 3’ (914 mm) up the v-door to expose the front
sprocket covers above the catwalk deck.
2. Secure the trough in a raised position using adequate supports. Power down the
PipeCatTM laydown system and lock-out power sources.
3. Remove the front sprocket covers. Check the sprockets to ensure all keys are in
place and that the keyways in the sprockets align with the keyways in the shaft.
Refer to Skate Drive Shaft Assembly, drawing M231001423-ASM-001. Re-install the
front sprocket covers.
4. Remove the power lock-outs and restart the PipeCatTM laydown system.
5. Remove the trough supports then raise trough up the v-door to expose the rear
sprocket covers above the catwalk deck.
6. Position the skate approximately 18’ (5,486 mm) from the home position.
7. Secure the trough in the raised position using adequate supports. Power down the
PipeCatTM laydown system and lock-out power sources.
8. Loosen, but do not remove, all bolts (item 17) fastening the skate to the sliders
(items 2 & 3) – drawing M231003073-ASM-001.
9. Remove the rear sprocket covers. Check sprockets to ensure all keys are in place
and that the keyways in the sprockets align with the keyways in the shaft. Refer to
Skate Tension Idler Shaft Assembly, drawing M231004896-ASM-001.
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10. Ensure any chain slack is even on both sides of the trough. If the slack difference is
greater than ½” then chain will have to jump a sprocket tooth on one side only.
11. Loosen, but do not remove, the four bearing mount bolts (item 10) from each side of
the tensioner assembly – drawing M231004896-ASM-001.
12. Back off the lock nut on tensioner bolt (item 12) – drawing M231004896-ASM-001.
13. Tension the chain using the nut (item 11) on the tensioner bolt. Tighten the nut
(item 11) until the spacer (item 6) is positioned half way into the spring cover tube –
drawing M231004896-ASM-001.
14. Tighten the lock nut on tensioner bolt (item 12) – drawing M231004896-ASM-001.
15. If the tensioner runs out of travel or the spring becomes fully compressed before the
chain reaches proper tension, then repeat step 13 after backing off the tensioner and
removing equal pitches from each skate chain. The tensioner travel should allow an
even number of pitches to be removed. If an offset link is needed, it must be
installed on the rear side of the skate sliders where it never has to support the
weight of a tubular.
16. Tighten all bolts fastening skate to sliders. Ensure the position of the bill on the skate
is centered on the trough.
17. Tighten the bearing mounting bolts in the tensioner assembly and re-install the rear
sprocket covers.
18. Remove the power lock-outs and restart the PipeCatTM laydown system.
19. Remove the trough supports and lower the trough into the catwalk.
20. Check the chain tension weekly.
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11. GENERAL ROLLER CHAIN MAINTENANCE

11.1 Roller Chain Maintenance
11.2 Chain and Connecting Link Installation
11.3 Retaining Devices
11.4 Lubrication of Roller Chains
11.5 Methods of Lubrication
11.6 Drive Guarding
11.1 Roller Chain Maintenance
National Oilwell Varco’s PipeCat™ laydown systems are designed with a roller chain
skate drive. There are three chains to maintain. Two are attached directly to the skate
and are externally exposed at all times. These chains can be tensioned by adjusting the
idler sprocket shaft. The third chain is connects the motor shaft to the driving sprocket
shaft and can be tensioned by adjusting the drive motor location.
All chains should be inspected at least once every month and tensioned accordingly. As
the chains wear, pitches of chain may be removed to bring the chain length back into
the adjustable range. However, the chain should be replaced as soon as it has
stretched to 1.5% of its nominal pitch length. This means that the approximately 1,200
pitch long pieces of 1” chain should be discarded as soon as the chain has stretched to
a length of 1,218”, or 18 pitches of chain have been removed. The drive motor chain is
60 pitches of 1” chain, and should be replaced when it has stretched to 60.9”. This can
be measured by checking a smaller portion of the chain (i.e. 10 pitches of 1” chain
should not be more than 10.15” long).
11.2 Chain and Connecting Link Installation
Installing the Chain: Fit the chain around the sprockets in the drive and bring the free
ends together (normally between the sprockets) for final connection. Look for the
access cover for the master link installation. A rope or chain tightener should be used to
bring the ends of the chain together.
Installing the Connecting Link: The connecting link depending upon the size and type
of chain, may employ either a slip-fit or press-fit cover plate, combined with either a
spring clip or cotters as the final retainer.
Press-fit cover plates: The press-fit cover plates are those which have an interference
fit on the pins and provide integrity equal to the base chain itself.
To assemble the press-fit cover plates:

1. Insert the “Master Link” (the portion containing the pins); provide support or backing
to resist the forces needed to drive the cover plate on.
2. Place the press-fit cover plate over the exposed pin ends and ensure there is proper
alignment.
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3. Drive the cover plate on until it is flush with the ends of the pins.
4. Obtain a hollow punch (perhaps a small piece of pipe or a discarded chain’s roller)
and locate it over/around the flush pin end.
5. Alternately from one pitch hole to the other, continue to drive the ends of the link
plate onto the pins until it is clear of the spring clip groove or cotter hole. Care should
be taken not to drive the plate on so far as to squeeze against or pinch the roller
links. This will result in stiff or binding joints.
6. Install the retaining device, either spring clip or cotter.
CAUTION: Never drill out or enlarge the pitch holes of a press-fit cover plate to
make the installation easier. This will lower the integrity of the link.
Slip-fit cover plates are plates which have a clearance fit on the pins. These
connecting links are far easier to install but reduce the working load capacity of the
chain.
To assemble the slip-fit cover plate:

1. Insert the “Master Link,” the link portion that contains the pins, into the chain.
2. Slide the plate over the pin ends to a location which clears either the spring clip
groove or cotter hole.
3. Install the retaining device, either spring clip or cotter.
NOTE: When a slip-fit cover plate is used, a chain’s working capacity can be reduced
by as much as 30%.
11.3 Retaining Devices
Spring clips are provided for chain models #25 - #60. They provide a quick and easy
method for securing the cover plate. Installation is performed by first determining the
direction of chain travel and locating the closed end of the clip over the leading pin’s
groove. Final installation is performed by “snapping” the clip over the trailing pin, locking
it into the groove. Care should be taken not to bend or deform the clip during installation
as this may cause it to come loose during operation.
Direction of Travel
Cotters are normally provided on #80 and larger models’ connecting links as the
method of retaining the cover plate. These cotters are specially heat treated to obtain
specific properties which are beneficial in service. After insertion, the legs should not be
spread in excess of 90° (included angle) and if removed should not be reused. It is not
recommended to use commercial cotters as they may not provide satisfactory
performance in severe applications.
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Proper Chain Tension: Expect new chains to elongate slightly more during the first few
days of service then in the months of subsequent operation. This is due to the “running-
in” of the chain which removes minute imperfections from the surfaces of the pins and
bushings. Because of this, it is good practice to establish and adjust centre distances or
idlers for an initially snug-fitting chain. After the initial run-in period, the drive should
always be adjusted so that there is some degree of slack in the unloaded section of
chain. This slack is very important as it allows the pin/bushing joint to lubricate itself
prior to entering the working or loaded portion of the drive.
The following diagram represents the recommended mid-span movements for a

properly tensioned drive.
Recommended Possible Mid-Span Movement, A-C, of Slack Span
Dimensions in Inches
Drive Tangent Length Between Sprockets
Centre-Line 5 10 15 20 30 40 60 80 100
Horizontal to 45 0.25 0.50 0.75 1.00 1.50 2.00 3.00 4.00 5.00
Vertical to 45 0.12 0.25 0.38 0.50 0.75 1.00 1.50 2.00 2.50
Roller chain drives suffer more harm from faulty lubrication than from years of normal service!
Roller chains consist of a series of connected journal bearings which must be properly
lubricated to obtain the maximum service life. Although many slow speed drives operate
successfully with little or no lubrication beyond the amount of lubrication initially applied
at the time of manufacture, continued proper lubrication will greatly extend the useful life
of every chain drive.
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11.4 Lubrication of Roller Chains
Chain drives require lubrication for six primary purposes:

1. Resist wear of the pin-bushing joint
2. Cushion impact loads
3. Dissipate heat
4. Flush away foreign materials
5. Lubricate chain-sprocket contact surfaces
6. Prevent rust or corrosion
In selecting a lubricant, a good grade of clean petroleum oil without additives is most
commonly recommended. Certain additives in oil can leave a varnish or gum build-up
which will prevent additional lubricant from entering chain joints.
The viscosity of the lubricant greatly affects its ability to flow into the internal areas;
therefore, the highest viscosity oil which will flow between the chain link plates and fill
the pin-bushing areas will provide the greatest film thickness and best wear life.
Greases, applied to the exterior of the chain, serve no purpose with the exception of
protecting the external surfaces from rust or corrosion and should not be relied upon to
provide any internal lubricating benefits.
The following table provides a guideline for selecting the proper lubricant viscosity at
various ambient temperatures:
Recommended Lubricants
Ambient
SUS Viscosity SAE Engine SAE Gear
Temp.° F ISO AGMA
100° F Oil Oil
20- 40 200-400 20 80W 46 or 68 1 or 2
40-100 400-650 30 85W 100 3
100-120 650-950 40 90 150 4
120-140 950-1450 50 90 220 5
NOTE: National Oilwell Varco recommends the use of ISO 150 gear oil for warmer
climates and an ISO all season gear oil for colder climates.
The elongation of roller chain is the result of wear

caused by friction between the pins and bushings and
regardless of the size or type of chain. In order for any
lubricant to reach the critical pin/bushing area, it
should be applied to the upper edges of link plates in
the slack span. Lubricant applied only to the chain’s
rollers will not provide an adequate supply to the
internal wearing surfaces. However, the chain’s rollers
will receive adequate lubrication due to spillage over
the link plate edges when lubricant is properly applied.
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NOTE: When applying lubricant to

multiple strand chain, it is
important that lubricant be
directed to each row of chain link
plates, not just the outermost
rows; and, in conveying
applications, oil should be
directed between the rollers and
bushings as well as between the
chain link plates, as significant
wear can result from external
loading.
11.5 Methods of Lubrication
There are three basic methods of lubrication for roller chain drives. Close adherence to
these recommended types of lubrication is essential in obtaining the maximum service
life of a chain drive. These recommended types of lubrication, as shown in the
horsepower rating tables, are determined by the chain speed and the amount of power
transmitted.
Manual or Drip Lubrication (Type A): Lubricant

applied manually with a brush or oil can is
acceptable for slow speed drives, generally not
over 600 feet per minute. When lubrication must
be accomplished with a minimum amount of oil, it
is advisable to equip the system with either felt
pads or brushes which are fed by lubricant from a
reservoir and carefully positioned to direct oil into
the clearances between each row of link plates in
the slack span of chain.
Bath Lubrication (Type B): Lubricant is applied

to the chain by allowing the oil level within an
enclosed casing to cover the chain at
approximately the pitch line at its lowest point of
operation. This is by far the most desirable
method for chains operating at up to
approximately 1,500 feet per minute.
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Forced or Circulating Lubrication (Type

C): This is similar to bath lubrication with
the exception that the lubricant is pumped
onto the chain under pressure. The oil
should be delivered to the upper edges of
each row of link plates across the lower
span of chain just prior to the chain’s entry
into one of the sprockets.
The following table can be used as a guide for determining the type of lubricating
system based upon the speed of the chain in feet per minute. The final selection should
be based upon the type of lubrication system recommended in the horsepower rating
tables for the specific chain, sprocket, speed, and horsepower transmitted.
Chain No 35 40 50 60 80 100 120 140 160 200

Type A 350 300 250 215 165 145 125 110 100 80
Type B 2650 2200 1900 1750 1475 1250 1170 1050 1000 865
Type C Use for speeds higher than Type B limits
*Chain Speed in Feet/Minute
11.6 Drive Guarding
All chain drives should receive regular maintenance. Each drive should be inspected
after the initial 100 hours of operation. Thereafter, most drives may be inspected at 500
hour intervals. Chains should be inspected every three months minimum. However,
drives subjected to shock loads or severe operating conditions should be inspected at
more frequent intervals. This section will provide guidance as to what items should be
evaluated during regular inspection intervals.
The strongest chain with the highest quality standards can still break in normal service
due to the effects of wear, fatigue, or unexpected overloads. Therefore, a roller chain
drive should have adequate guarding to prevent personal injury or property damage.
If a roller chain breaks on a drive while operating at speed, the chain can be thrown off
the sprockets with considerable force. The user should either provide adequate
guarding to contain a broken chain, or prevent personnel from entering an area where a
broken chain could strike them.
There are applications where a broken chain could release a load and cause personal
injury or property damage. Provisions for a brake or other restraining device which will
stop and hold the load in the event of a broken chain should be incorporated into the
machinery’s design.
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Regular Inspections: At each inspection, the following items should be checked, the
condition corrected, or the chain replaced as necessary:
1. Check Lubrication
On slow speed drives, ensure the lubrication schedule is being followed and if the
chain is covered with dirt and debris, clean the chain with an approved solvent and
lubricate it. If drip lubrication is used, check for adequate oil flow and ensure it is
being applied at the proper location on the chain - refer to Lubrication of Roller
Chains, Section 11.4.
2. Check Chain Tensions

Refer to the Chain and Connecting Link Installation, Section 11.2, and check chain
tension. Adjust the drive as needed to maintain the proper sag in the slack span. If
elongation exceeds the available adjustment, remove two pitches of chain and
reconnect.
3. Check Chain Wear

Roller chains should be replaced promptly when worn (elongated beyond 1.5%) or
when the chain rollers begin to “ride high” near the tips of the teeth on relatively
large sprockets. If the chain is worn excessively, replace the entire chain. Do not
connect or splice a new section to a worn chain. Do not continue to run a chain,
worn in excess of 1.5% (or less in some applications); because the chain will not
engage the sprockets properly and increased damage to the sprockets may occur.
4. Check Sprocket Tooth Wear

Check for roughness or binding when the chain
engages or disengages from the sprocket. Inspect
the sprocket teeth for reduced tooth section and
“hooked” tooth tips. If these conditions are present,
the sprocket teeth are excessively worn and the
sprocket should be replaced. Do not run new chain
on worn sprockets as it will cause the new chain to
wear rapidly. Do not run a worn chain on new
sprockets as it will cause the new sprockets to
wear rapidly. As a general rule, replace the
sprockets with every third chain replacement.
5. Check Sprocket Alignment

If there is noticeable wear on the inside surface of the chain roller link plates, the
sprockets may be misaligned. Realign the sprockets accordingly to prevent further
abnormal chain and sprocket wear.
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6. Check for Drive Interference

Check for interference between the drive and other parts of the equipment. If there is
any, correct it immediately. Interference can cause abnormal and potentially
destructive wear on the chain or the interfering part. If the edges of the chain link
plates impact against a rigid part, link plate fatigue and chain failure can result.
Check for and eliminate any build-up of debris or foreign material between the chain
and sprockets. Even small amounts of debris in the sprocket roll seat can cause
tensile loads great enough to break the chain if forced through the drive.
7. Check for Failure

Inspect the chain for cracked, broken, or deformed parts. If any of these conditions
are found, replace the entire chain. Even though portions of the chain may appear
to be in good condition, in all likelihood, the entire chain has been damaged.
WARNING: Roller chains damaged under excessive loading due to an

accident, or otherwise, should be completely replaced because
the chain, as well as the damaged component, has been loaded to
a degree that has impaired its ability to transmit normal loading.
8. Evidence of Lubrication
One of the first indications that a roller chain is not receiving adequate lubrication is
that the external areas around the joints will most likely have a reddish/brown (rusty)
colour. The inadequate lubrication can be confirmed by removing a link (most
commonly the connecting link) and examining the surface of the pins. If the chain
has been running with inadequate lubrication, the colour of the pins will generally be
dark brown, even blue. Additionally, the surface of poorly lubricated pins will be
rough, grooved, or even show evidence of galling.
Properly lubricated chains will not exhibit the rusty colour at the joints and the pins of
the connecting links, when removed, will be generally smooth, shiny, and have an
obvious coating of lubricant on the surface.
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12. TROUBLESHOOTING
12.1 Overview
12.2 Manual Hydraulic Valve Actuation
12.3 Emergency Trough Lowering Procedure
12.4 Machine Interlocks Indicator
12.5 Status and Information Screen
12.1 Overview
There are many variables that could play a factor in field operation; therefore, if there
are problems not listed and cannot be solved, contact National Oilwell Varco for
assistance.
Assuming the equipment is properly installed and operated, and undergoes routine
maintenance, little or no trouble should be expected from the equipment. Since the
symptoms of a failed or worn component may differ with the equipment operating
conditions, observe those conditions which best indicate the symptoms.
12.2 Manual Hydraulic Valve Actuation
All hydraulic solenoid valves can be actuated manually.
The valves for the winch drive, pipe racks, and indexers are located behind covers on
the driller side of the catwalk near the HPU.
The valves for the skate drive, kickers, and safety pins are located under access panels
near the HPU end of the trough.
The winch brake can be manually released to lower the trough when hydraulic power is
unavailable.
WARNING: All personnel are to remain clear of the PipeCatTM laydown

system during manual valve actuation as unexpected
movements could result in personal injury.
WARNING: All manual valve actuation should be done carefully as

component collisions and movements beyond the normal
operations could result in equipment damage and/or personal
injury.
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12.3 Emergency Trough Lowering Procedure
Refer to the following procedure to correctly lower the trough:
1. Ensure no pipe is on the trough. If

there is pipe on the trough, ensure it
is on the trough properly.
2. Connect a hand pump (customer
supplied) to the port provided on the
small bracket near the v-door. Refer
to the Hydraulic Schematic, drawing
M231010616-SCH-001, for the hand
pump arrangement. Refer to the
circled area in the photo for visual on
the port.
3. Open the needle valve one turn from
the fully closed position.
4. Pump slowly while simultaneously
closing the needle valve. As the
pressure in the brake release port
rises, the tough will begin to lower at
some point. Adjust the needle valve
so that the hand pump must be
Photo: Hand Pump Port
continually pumped to lower the
trough. This results in the safest
operating mode.
5. If at any time control is lost, stop pumping and open the needle valve to set the winch
brake.
6. Continue to “pump” the trough down until it rests completely in the catwalk.
7. Open the needle valve, remove the pump, and re-cap the brake release port.
Needle
Valve
Photo: Example of Emergency Lowering Pump (Customer Supplied)
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12.4 Machine Interlocks Indicator
An interlock is set when the machine operator commands a movement that is not valid
or when there is a problem within the electrical or hydraulic systems. If a machine
interlock condition is detected, the movement of the PipeCat™ laydown system tubular
shuttle will stop and the Interlock indicator on the WRC or LCS will illuminate. Machine
movement will not be re-enabled until the interlock has been cleared.
Listed below are several, but not all, possible causes for an interlock:
• Interrupting the safety curtains on the catwalk.

• Attempting to operate the kickers, indexers, or safety pins when the trough is not at
home position.
• Attempting to move past the trough setpoint.
• Low or high hydraulic oil temperature.
• Low hydraulic oil level.
• Plugged pressure filter on the HPU.
• Low hydraulic pressure for brake release on the main winch or skate gearbox.
12.5 Status and Information Screen
In cases where the cause of an interlock is not readily diagnosed, a laptop may be
connected directly to the SBC (Single Board Computer) to access a special status and
information screen. Refer to the following sections to locate the SBC Ethernet Ports and
to setup the laptop.
Screen Capture: PipeCat Status and Information Screen
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1. Connect the laptop to the SBC using the Ethernet cable.

2. Enter 192.168.31.28 into the address bar of the web browser on the laptop. The
basic sensor and machine status will be displayed, along with any text messages or
interlocks at the bottom of the screen.
NOTE: The Status and Information Screen is for troubleshooting only – no

machine control or configuration is available through this connection.
12.5.1 Location of the SBC Ethernet Ports
The SBC is located inside the CCS/LCS cabinet near the HPU. Two Ethernet ports are
available and are typically labelled as X001 and X002.
Ethernet Ports
Illustration: Typical SBC Layout
12.5.2 Laptop Setup
The laptop requires web browser software (Internet Explorer or equivalent), an available
Ethernet port, and a regular Ethernet patch cable (a crossover patch cable is not
required).
The laptop’s network interface for the Ethernet port must be manually configured with
an IP address within the Amphion 192.168.31.XXX network.
NOTE: There is no DHCP server on the SBC to automatically assign IP

addresses.
• IP address: 192.168.31.7
• Subnet Mask: 255.255.255.0
• Default gateway: empty
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The IP address must be unique on the Amphion network – the connection to the SBC
will fail if the IP address is already in use by another device connected to the system.
NOTE: The alternate IP addresses 192.168.31.8 or 192.168.31.9 may also be

used.
NOTE: If the laptop has multiple network interfaces, ensure the correct
network interface is being configured. Refer to the computers'
documentation for more information.
Screen Capture: Typical IP Address Setup
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13. TIGHTENING TORQUE GUIDE

13.1 Bolt Torque Charts
13.2 Socket Head Capscrew Tensile Requirements
13.3 Turn-of-Nut Tightening
13.1 Bolt Torque Charts
Tightening Torque Guide

SAE Grade 5 - Fine Thread
Size Clamp Load Plain Plated
lbs kN ft·lbs N·m ft·lbs N·m
1
/4 - 28 (0.250) 2,325 10 10 13 7 10
5
/16 - 24 (0.3125) 3,675 16 19 26 14 19
3
/8 - 24 (0.375) 5,588 25 35 47 26 36
7
/16 - 20 (0.4375) 7,575 34 55 75 41 56
1
/2 - 20 (0.500) 10,200 45 85 115 64 86
9
/16 - 18 (0.5625) 12,975 58 122 165 91 124
5
/8 - 18 (0.625) 16,350 73 170 231 128 173
3
/4 - 16 (0.750) 23,775 106 297 403 223 302
7
/8 - 14 (0.875) 32,475 144 474 642 355 482
1 - 12 (1.000) 42,300 188 705 956 529 717
1 - 14 (1.000) 43,275 193 721 978 541 733
1 1/8 - 12 (1.125) 47,475 211 890 1,207 668 905
1 1/4 - 12 (1.250) 59,550 265 1,241 1,682 930 1,262
1 3/8 - 12 (1.375) 72,975 325 1,672 2,267 1,254 1,701
1 1/2 - 12 (1.500) 87,750 390 2,194 2,974 1,645 2,231

SAE Grade 5 - Coarse Thread
1
/4 - 20 (0.250) 2,025 9 8 11 7 9
5
/16 - 18 (0.3125) 3,338 15 17 24 13 18
3
/8 - 16 (0.375) 4,950 22 31 42 23 31
7
/16 - 14 (0.4375) 6,788 30 50 68 37 50
1
/2 - 13 (0.500) 9,075 40 76 103 57 77
9
/16 - 12 (0.5625) 11,625 52 109 148 82 111
5
/8 - 11 (0.625) 14,400 64 150 203 112 152
3
/4 - 10 (0.750) 21,300 95 266 361 200 271
7
/8 - 9 (0.875) 29,475 131 430 583 322 437
1 - 8 (1.000) 38,625 172 644 873 483 655
1 1/8 - 7 (1.125) 42,375 189 794 1,077 596 808
1 1/4 - 7 (1.250) 53,775 239 1,120 1,519 840 1,139
1 3/8 - 6 (1.375) 64,125 285 1,470 1,992 1,102 1,494
1 1/2 - 6 (1.500) 78,000 347 1,950 2,644 1,462 1,982
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SAE Grade 8 - Fine Thread
1
/4 - 28 (0.250) 3,263 15 14 18 10 14
5
/16 - 24 (0.3125) 5,113 23 27 36 20 27
3
/8 - 24 (0.375) 7,875 35 49 65 37 50
7
/16 - 20 (0.4375) 10,650 47 78 106 58 79
1
/2 - 20 (0.500) 14,400 64 120 163 90 122
9
/16 - 18 (0.5625) 18,300 81 172 233 129 174
5
/8 - 18 (0.625) 23,025 102 240 325 180 244
3
/4 - 16 (0.750) 33,600 150 420 569 315 427
7
/8 - 14 (0.875) 45,825 204 668 906 501 680
1 - 12 (1.000) 59,700 266 995 1,349 746 1,012
1 - 14 (1.000) 61,125 272 1,019 1,381 764 1,036
1 1/8 - 12 (1.125) 77,025 343 1,444 1,958 1,083 1,469
1 1/4 - 12 (1.250) 96,600 430 2,012 2,728 1,509 2,046
1 3/8 - 12 (1.375) 118,350 527 2,712 3,677 2,034 2,758
1 1/2 - 12 (1.500) 142,275 633 3,557 4,822 2,668 3,617

SAE Grade 8 - Coarse Thread
1
/4 - 20 (0.250) 2,850 13 12 16 9 12
5
/16 - 18 (0.3125) 4,725 21 25 33 18 25
3
/8 - 16 (0.375) 6,975 31 44 59 33 44
7
/16 - 14 (0.4375) 9,600 43 70 95 52 71
1
/2 - 13 (0.500) 12,750 57 106 144 80 108
9
/16 - 12 (0.5625) 16,350 73 153 208 115 156
5
/8 - 11 (0.625) 20,325 90 212 287 159 215
3
/4 - 10 (0.750) 30,075 134 376 510 282 382
7
/8 - 9 (0.875) 41,550 185 606 822 454 616
1 - 8 (1.000) 54,525 243 909 1,232 682 924
1 1/8 - 7 (1.125) 68,700 306 1,288 1,746 966 1,310
1 1/4 - 7 (1.250) 87,225 388 1,817 2,464 1,363 1,848
1 3/8 - 6 (1.375) 103,950 463 2,382 3,230 1,787 2,422
1 1/2 - 6 (1.500) 126,450 563 3,161 4,286 2,371 3,215
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13.2 Socket Head Capscrew Tensile Requirements
per ASTM A574-83

Screw Ø (inches) Threads (inches) Rec. UNC Torque
(in-lbs)
UNC UNF UNRC UNRF
0.060 - 80 - 2
0.073 64 72 4 4
0.086 56 64 6 7
0.099 48 56 10 11
0.112 40 48 15 16
0.125 40 44 20 21
0.138 32 40 28 30
0.184 32 36 49 50
0.190 24 32 64 76
¼ 20 28 150 170
5/16 18 24 305 325
3 /8 16 24 545 570
7/16 14 20 840 900
½ 13 20 1,300 1,370
5 /8 11 18 1,850 1,970
¾ 10 16 2,630 2,660
7 /8 9 14 4,400 4,800
1 8 12 7,000 7,600
1 1/8 7 12 10,400 11,000
1¼ 7 12 14,900 15,600
1 3/8 6 12 21,000 22,600
1½ 6 12 27,800 29,300
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13.3 Turn-of-Nut Tightening
Reference: Research Council on Structural Connections (RCSC), Specifications for

Structural Joints using ASTM A325 or A490 Bolts (June, 2004)
With any tensioning method of making connections, it is important to install bolts in all
holes of the connection and bring them to a snug-tight condition to compact the joint.
Tightening should begin at the most rigidly fixed or stiffest point and progress toward the
free edges both in the initial snugging-up and in the final tightening.
Equipment consistency and reliability depends on assuring that the joint is well
compacted and that all bolts at a joint are at a snug-tight condition prior to application of
the final required partial turn. It is critical that the element not turned in tightening must
be prevented from rotating while the required degree of turn is applied to the turned
element.
Nut-Rotation from Snug-Tight Condition a,b

Disposition of Outer Face of Bolted Parts
One face normal to bolt Both faces sloped no
axis and other sloped more than 1:20 from
Bolt Length Both faces no more than 1:20 normal to the bolt axis
(under side of head to normal to (beveled washer not (beveled washer not
end of bolt) bolt axis used) used)
1 1 2
Up to and including /3 turn /2 turn /3 turn
four diameters
1 2 5
Over four diameters /2 turn /3 turn /6 turn
but not exceeding
eight diameters
2 5
Over eight diameters /3 turn /6 turn 1 turn
but not exceeding
12c diameters
a Nut rotation is relative to bolt regardless of the element (nut or bolt) being turned. For bolts
installed by 1/2 turn and less, tolerance is ± 30°; for bolts installed by 2/3 turn and more,
tolerance is ± 45°.
b Applicable only on connection in which all materials within the grip of the bolt are steel.
c No research has been performed by AISC to establish the turn-of-nut values for bolt lengths
exceeding 12 diameters. Therefore, the required rotation must be established by actual test
in a suitable tension measuring device that simulates conditions of solidly fitted steel.
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14. SENSOR INFORMATION

14.1 Solenoid Chart
14.2 Sensor Chart
14.1 Solenoid Chart
SOLENOID SOLENOID I.D.

V-door End – Up (DS Pipe Rack) SOV-01
V-door End – Down (DS Pipe Rack) SOV-02
Middle – Up (DS Pipe Rack) SOV-03
Middle – Down (DS Pipe Rack) SOV-04
HPU End – Up (DS Pipe Rack) SOV-05
HPU End – Down (DS Pipe Rack) SOV-06
Inner Raise – Up (DS Indexer) SOV-07
Inner Raise – Down (DS Indexer) SOV-08
Outer Raise – Up (DS Indexer) SOV-09
Outer Raise –Down (DS Indexer) SOV-10
Kicker – Up (DS Pipe Rack) SOV-11
Kicker – Down (DS) SOV-12
Safety Pin – Up (DS) SOV-13
Safety Pin – Down (DS) SOV-14
V-door End – Up (ODS Pipe Rack) SOV-15
V-door End – Down (ODS Pipe Rack) SOV-16
Middle – Up (ODS Pipe Rack) SOV-17
Middle – Down (ODS Pipe Rack) SOV-18
HPU End – Up (ODS Pipe Rack) SOV-19
HPU End – Down (ODS Pipe Rack) SOV-20
Inner Raise – Up (ODS Indexer) SOV-21
Inner Raise – Down (ODS Indexer) SOV-22
Outer Raise – Up (ODS Indexer) SOV-23
Outer Raise – Down (ODS Indexer) SOV-24
Kicker – Up (ODS) SOV-25
Kicker – Down (ODS) SOV-26
Safety Pin – Up (ODS) SOV-27
Safety Pin – Down (ODS) SOV-28
Winch Motor Gear – High/Low SOV-29
Trough – Up/Down SOL #1 (PROP) PRV-100
Trough – Up/Down SOL #2 (PROP) PRV-200
Skate – FWD/Back SOL #1 (PROP) PRV-300
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14.2 Sensor Chart
SENSOR SENSOR I.D.

Pressure Transmitter (HPU#1) PT-01
Differential Pressure Switch (HPU#1) PS-01
Pressure Transmitter (HPU#2) PT-02
Differential Pressure Switch (HPU#2) PS-02
Safety Curtain – Emitter (DS) ZT-100T
Safety Curtain – Receiver (DS) ZT-100R
Safety Curtain – Emitter (ODS) ZT-200T
Safety Curtain – Receiver (ODS) ZT-200R
Trough – Landed PROX Switch ZS-100
Trough – Pressure XMTR PT-03
Trough – Brake Pressure Switch PS-03
Skate – Pressure Switch PS-04
Heater (Hydraulic Tank) HTR-01
Thermostat (Hydraulic Tank) THM-01
Oil Cooler/Fan (Hydraulic Tank) OC-01
Level Switch (Hydraulic Tank) LS-01
Temperature RTD (Hydraulic Tank) RTD-01
Encoder ENC-01
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15. SPARE PARTS

15.1 General Spare Parts Listing
15.2 Control Spare Parts Listing
15.1 General Spare Parts Listing
Refer to the National Oilwell Varco PipeCat™ Laydown System Spare Parts List,
document D231002703-SPL-001.
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PipeCat™ Laydown System
Spare Parts List
PC-5-47 PipeCat
ADDITIONAL INFORMATION
This document contains proprietary and confidential DRECO ENERGY SERVICES ULC
information of National Oilwell Varco. Reproduction, use NATIONAL OILWELL VARCO
of this design or distribution information by others is
permissible only if expressly authorized in writing by 6415-75 Street
National Oilwell Varco. Edmonton, AB, T6E 0T3
Canada
Copyright National Oilwell Varco Ph. (780) 944-3800
DOCUMENT NO. Rev.
D231002703-SPL-001 01
WWW.NOV.COM
Copyrighted as an unpublished work.
All RIGHTS RESERVED

© COPYRIGHT 2012 by National Oilwell Varco
This work contains the CONFIDENTIAL AND PROPRIETARY INFORMATION of National Oilwell Varco. Neither
this document nor any information disclosed herein, shall be reproduced in any form, used or disclosed to others
for any purpose including manufacturing without express written permission from National Oilwell Varco.
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Document No. D231002703-SPL-001
Page 1 of 7
REVISION HISTORY
01 11.15.2012 Initial Release AC CJK/IC TW

Rev Date Change Description Prepared Checked Approved
(mm.dd.yyyy)
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TABLE OF CONTENTS
1. SPARE PARTS LIST 3
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Page 3 of 7
1. Spare Parts List

This list is only intended as a recommended spare parts list. It is the responsibility of the operator to decide on the final
quantities of each spare part.
1 Year Operational
Commissioning
Insurance
Spare
Spare
Spare
Part Part Where Used
Number Description Description
Filter Element for

7030B078 4 12 - HPU Schematic
Case Drain Filters
Filter Element for
P231000519 2 6 - HPU Schematic
High Pressure Filters
Filter Element for
Return Filters
Filter Element for
Filler Filter
Filter Element for
P231001616 - 3 - HPU Schematic
Tank Breather Filter
Trough Kicker and
7004B057 Self-Lubricating Bearing - 6 -
Safety Pin Assembly
Trough Kicker and
7004B058 Self-Lubricating Bearing - 6 -
Safety Pin Assembly
7018B986 Skate Stop Bumper - 8 - Trough Assembly
9800D283 Lifting Leg Slider Plate - 2 - Lifting Leg Assembly
9800D310 Skate Bumper Wear Pad - 4 - Skate Assembly
www.nov.com
Page 4 of 7
1 Year Operational
Commissioning
Insurance
Spare
Spare
Spare
Drag Chain Support Tray

9800D327 - 3 - Drag Chain Assembly
Wear Pad
Lifting Leg Stop and
9800D394 Trough Rest Bumper Pad - 4 -
Trough Rest Assembly
M231001280 Skate Front Wear Pad - 4 - Skate Assembly
M231001281 Skate Slider Upper Wear Pad - 4 - Skate Assembly
M231001282 Skate Slider Lower Wear Pad - 2 - Skate Assembly
P231000384 Sleeve Bearing - 2 - Drag Chain Assembly
Trough Kicker and

P231000585 Spring Pin - 6 -
Safety Pin Assembly
Hydraulic Cylinder Seal Kit
P231000589 - 1 - Hydraulic Schematic
for 9800D375 (Safety Pin)
for 9800D377 (Indexer)
for 9800D379 (Pipe Racks)
for M231002289 (Kickers)
V-door Sheave
7004A001 Tapered Roller Bearing - - 1
Cluster Assembly
www.nov.com
Page 5 of 7
1 Year Operational
Commissioning
Insurance
Spare
Spare
Spare
V-door Sheave
7004A009 Bearing Seal - - 2
Cluster Assembly
Single Row Deep Groove
7006B334 - - 1 Skate Drive Shaft Assembly
Ball Bearing
7006B387 Round Flange Bearing Unit - - 1 Skate Tension Idler Shaft Assembly
Trough Leg Pivot Assembly

7006B561 Sleeve Bearing - - 1
Trough Roller Assembly
Trough Leg Pivot Assembly
7006B562 Thrust Bearing - - 1
Trough Roller Assembly
V-Door Ramp
7006B569 Square Flange Bearing - - 1
Roller Assembly
7008B065 Retaining Ring - - 2 Skate Drive Shaft Assembly
7018B087 Plain Stud Roller - - 1 Trough Assembly
Drag Chain Drag Chain

7018C022 - - 4
Nylon Glide Block Spare Parts Assembly
7024B181 Counterbalance Valve - - 2 Hydraulic Schematic
7024B367 Solenoid Valve - - 2 Hydraulic Schematic
Hydraulic Cylinder
9800D375 - - 1 Hydraulic Schematic
(Safety Pin)
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Page 6 of 7
1 Year Operational
Commissioning
Insurance
Spare
Spare
Spare
Hydraulic Cylinder
(Indexer)
Hydraulic Cylinder
(Pipe Racks)
Trough Kicker and
M231001829 Cylinder Rod End Fitting - - 3
Safety Pin Assembly
Hydraulic Cylinder
M231002289 - - 1 Hydraulic Schematic
(Kickers)
Lifting Leg Stop and
9800D323 Lifting Leg Stop Bumper - - 1
Trough Rest Assembly
P231000343 - - 24
Hinge Pin Spare Parts Assembly
V-Groove Roller Lifting Leg Assembly
7006B560 - - 1
(c/w Nut & LW) Trough Assembly
P231000421 - - 16
Self-Locking Screw Spare Parts Assembly
P231000424 - - 16
Anti-Friction Disc Spare Parts Assembly
P231000426 - - 8
Push-On Hinge Pin Retainer Spare Parts Assembly
P231000496 Coupling - - 1 Encoder Mount Assembly
7/8” Wire Rope

7014B010 - - 1 General Assembly
c/w Open Spelter
www.nov.com
Page 7 of 7
1 Year Operational
Commissioning
Insurance
Spare
Spare
Spare

P231000582 - - 4
Complete 12” Length Spare Parts Assembly
P231000583 - - 1
Complete End Bracket Kit Spare Parts Assembly
Roller Chain – Double #80
P231000688 - - 1 Trough Assembly
1202 Pitches (1” Pitch)
Roller Chain – Double #80
P231000689 - - 1 Skate Hydraulic Drive Assembly
56 Pitches (1” Pitch)
www.nov.com
Page 75
15.2 Control Spare Parts Listing
15.2.1 Ideal Rig 131
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Page 76
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Page 103
16. DRAWINGS
16.1 Overall Drawing List
16.2 Electrical Drawing List
16.1 Overall Drawing List
Drawing No. Drawing Title

General Assembly Drawings
M231010639-GAD-001 “PipeCatTM” – Pipe Handler General Assembly
(Includes Transportation and Rig-Up Layouts)
Schematic Drawings
M231007689-SCH-001 HPU Schematic – High Ambient – 460V
M231010616-SCH-001 Hydraulic Schematic
Sub-Assembly Drawings
9800A071 Pipe Rack Assembly
9800A072 Indexer Assembly
9800A075 V-Door Sheave Cluster Assembly
9800A077 Encoder Mount Assembly
9800L015 “PipeCatTM” Operational Layout – Pipe
Racks/Kickers/Indexers
9800L016 “PipeCatTM” Layout ~ Raising Tubulars with Trough
9800L017 “PipeCatTM” Layout ~Lowering Tubulars with Trough
M231000573-ASM-001 Proximity Sensor and Target Installation
M231000967-ASM-001 Drag Chain Support Tray Hose Clamp Assembly
M231001015-ASM-001 Hose Clamp Assembly
M231001339-ASM-001 Trough Roller Assembly
M231001384-ASM-001 Pipe Handler V-Door Ramp Roller Assembly
M231001423-ASM-001 Skate Drive Shaft Assembly
M231001446-ASM-001 Pipe Handler Trough Leg Pivot Assembly
M231001546-ASM-001 Trough Chain Guard Assembly
M231001573-ASM-001 Skate Hydraulic Drive Assembly
M231001985-LUB-001 “PipeCatTM” Lubrication Locations
M231002192-ASM-001 Pipe Handler Catwalk Fold Up Platform Assembly
M231002290-ASM-001 Pipe Handler Lifting Leg Assembly
M231002471-ASM-001 Trough Kicker and Safety Pin Assembly
M231002718-ASM-001 Catwalk Drag Chain Assembly
M231002843-ASM-001 PipeCat Control Panel Cover Assembly
M231002851-ASM-001 Photo Eye Sensor Assembly
www.nov.com
Page 104
Drawing No. Drawing Title

Sub-Assembly Drawings continued
M231002866-ASM-001 Trough Hydraulic Component Mounting
M231002901-ASM-001 Catwalk Hydraulic Component Assembly
M231003023-ASM-001 V-door Tie Down Assembly
M231003073-ASM-001 Skate Assembly
M231003185-ASM-001 Pipe Handler Catwalk HPU End Drainage Assembly
M231004212-ASM-001 Hydraulic Motor Assembly
M231004896-ASM-001 Skate Tension Idler Shaft Assembly
M231004963-ASM-001 Drag Chain Spare Parts Assembly
M231005513-ASM-001 PipeCat V-Door Assembly
M231005536-ASM-001 V-door Hydraulic Mounts & Accessories Assembly
Hydraulic Pump and Filter Assembly – High
M231005774-ASM-001
Ambient/460V
M231005807-ASM-001 PipeCat™ Trough Wire Tensioner Assembly
M231005832-ASM-001 Lifting Leg Stop and Trough Rest Assembly
M231005839-ASM-001 Trough Center Rest Assembly
M231006891-ASM-001 Hydraulic Return Piping
M231006892-ASM-001 HPU Assembly – High Ambient/460V
M231006807-ASM-001 Hydraulic Tank Internal Return Piping
M231007009-ASM-001 Trough Assembly
M231008616-ASM-001 Catwalk Frame Assembly
M231008627-ASM-001 Electrical Enclosure Assembly
www.nov.com
Page 105
16.2 Electrical Drawing List
Electrical Drawings
Assy, Power Control, PipeCat™ AC Ideal Rig
10546369-ASM
(High Ambient) (8 Sheets)
Assy, Remote I/O/Local Control Panel, AC Ideal Rig,
10546371-ASM
PipeCat™ (23 Sheets)
Ideal 131
Block Diagram, PipeCatTM AC Ideal Rig 131, High Ambient
10621970-DIA
(7 Sheets)
Interconnect Diagram, PipeCatTM AC Ideal Rig 131,
10621971-DIA
High Ambient (21 Sheets)
Cable Schedule, PipeCatTM, AC Ideal Rig 131, High
10621972-IDX
Ambient (3 Sheets)
Hazardous Equip. Index PipeCatTM AC Ideal Rig 131, High
10621973-IDX
Ambient (3 Sheets)
I/O Map Index, PipeCatTM AC Ideal Rig 131, High Ambient
10621974-IDX
(4 Sheets)
Ideal 132
10622215-DIA
(7 Sheets)
10622216-DIA
10622217-IDX
Ambient (3 Sheets)
10622219-IDX
Ambient (3 Sheets)
10622220-IDX
(4 Sheets)
Ideal 133
10622455-DIA
(7 Sheets)
10622456-DIA
10622457-IDX
Ambient (3 Sheets)
10622458-IDX
Ambient (3 Sheets)
10622460-IDX
(4 Sheets)
www.nov.com
Page 106
Electrical Drawings Continued

Ideal 134
10622556-DIA
(7 Sheets)
10622557-DIA
10622558-IDX
Ambient (3 Sheets)
10622559-IDX
Ambient (3 Sheets)
10622560-IDX
(4 Sheets)
Ideal 135
10622571-DIA
(7 Sheets)
10622572-DIA
10622573-IDX
Ambient (3 Sheets)
10621661-IDX
Ambient (3 Sheets)
10621662-IDX
(4 Sheets)
Ideal 137
10627167-DIA
(7 Sheets)
10627169-DIA
10627171-IDX
Ambient (3 Sheets)
10627172-IDX
Ambient (3 Sheets)
10627173-IDX
(4 Sheets)
Ideal 139
10627261-DIA
(7 Sheets)
10627263-DIA
10627264-IDX
Ambient (3 Sheets)
10627265-IDX
Ambient (3 Sheets)
10627267-IDX
(4 Sheets)
www.nov.com
PART NO.: 10546369-001
POWER CONTROL PANEL
AC IDEAL RIG PipeCat™
PNJB-01
ELECTRICAL RATING
VOLTAGE: 480/240/120 VAC
FREQUENCY: 50/60 Hz
™
™
™
PART NO.: 10546371-001
PipeCat™
REMOTE I/O
/LOCAL CONTROL PANEL
AC IDEAL RIG
PSNJB-01
ELECTRICAL RATING
VOLTAGE: 208/120 VAC
FREQUENCY: 50/60 Hz
UPS AMPS: 2/5 AMPS
NON UPS AMPS: 6/12 AMPS
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
This document contains proprietary and confidential information which belongs to National-Oilwell
Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned
for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use
of this design or distribution of this information to others is not permitted without the express written
consent of NOV. This document is to be returned to NOV upon request and in any event upon
completion of the use for which it was loaned. This document and the information contained and TITLE
represented herein is the copyrighted property of NOV. © National Oilwell Varco
NEXT ASSY USED ON CABLE SCHEDULE, PipeCat™
APPLICATION DRAWN R. VELEZ
AC IDEAL RIG 131, HIGH AMBIENT
CHECKED V. GARCIA SIZE DWG NO REV
APPVD V. GARCIA B 10621972-IDX 01
DATE 11/4/2011 SCALE NONE WT LBS SHEET 1 OF 3
D74DCF0049-TPL-001 (REV B)
NATIONAL OILWELL VARCO CABLE SCHEDULE, PipeCat™ DATE 11/7/2011 3:01:57 PM
CABLE ID CABLE VARCO GLAND GLAND CABLE FROM TO BLOCK DIAG. INTERCONNECT REMARKS CABLE
TAG NO. CONSTRUCTION PART NO. SIZE P/N TYPE TAG NO. LOCATION TAG NO. LOCATION DWG. NO. SHT. DWG. NO. SHT. SUPPLIED BY
HP-P01 4C X 2AWG 10042203-043 Power PNJB-01 Power Control HPM-01 HPU #1 Motor 10621970-DIA 7 10621971-DIA 19 NOV
HP-P02 4C X 2 AWG 10042203-043 Power PNJB-01 Power Control HPM-02 HPU #2 Motor 10621970-DIA 7 10621971-DIA 19 NOV
HP-P03 4C X 12 AWG - Power PNJB-01 Power Control OC-01 HPU Oil Cooler Fan 10621970-DIA 7 10621971-DIA 21 NOV
HP-N05 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control LS-01 Hydraulic Fluid Level Switch 10621970-DIA 2 10621971-DIA 10 NOV
HP-N06 1 TSP x 16 AWG 10044375-001 N.I.S. PSNJB-01 Remote I/O / Local Control RTD-01 Hydraulic Tank RTD 10621970-DIA 2 10621971-DIA 18 NOV
PCAT-D100 PROFIBUS & POWER 10517034-001 Data PSNJB-01 Remote I/O / Local Control DJB-01 Winch Encoder J-Box 10621970-DIA 6 10621971-DIA 10 NOV
PCAT-D100A PROFIBUS & POWER PigTail Data DJB-01 Winch Encoder J-Box ENC-01 Winch Encoder 10621970-DIA 6 10621971-DIA 10 NOV
PCAT-F01 4C FIBER 10052385-001 Data Connector Driller's Cabin Connector Plug Plate 10621970-DIA 2 10621971-DIA 18 NOV
PCAT-F01A 4C FIBER 10052385-001 Data Connector Plug Plate Connector PipeCat Plug Plate 10621970-DIA 2 10621971-DIA 18 NOV
PCAT-F01B 4C FIBER 10504903-001 Data Connector PipeCat Plug Plate Connector Remote I/O / Local Control 10621970-DIA 2 10621971-DIA 18 NOV
PCAT-N01 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-01 DS V-Door Up Solenoid 10621970-DIA 3 10621971-DIA 2 NOV
PCAT-N02 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-02 DS V-Door Down Solenoid 10621970-DIA 3 10621971-DIA 2 NOV
PCAT-N03 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-03 DS Middle Up Solenoid 10621970-DIA 3 10621971-DIA 2 NOV
PCAT-N04 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-04 DS Middle Down Solenoid 10621970-DIA 3 10621971-DIA 2 NOV
PCAT-N05 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-05 DS Flare End Up Solenoid 10621970-DIA 3 10621971-DIA 2 NOV
PCAT-N06 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-06 DS Flare End Down Solenoid 10621970-DIA 3 10621971-DIA 2 NOV
PCAT-N07 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-07 DS Inner Indexer Up Solenoid 10621970-DIA 3 10621971-DIA 3 NOV
PCAT-N08 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-08 DS Inner Indexer Down Solenoid 10621970-DIA 3 10621971-DIA 3 NOV
PCAT-N09 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-09 DS Outer Indexer Up Solenoid 10621970-DIA 3 10621971-DIA 3 NOV
PCAT-N10 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-10 DS Outer Indexer Down Solenoid 10621970-DIA 3 10621971-DIA 3 NOV
PCAT-N11 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-11 DS Kicker Up Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N12 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-12 DS Kicker Down Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N13 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-13 DS Safety Pin Up Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N14 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-14 DS Safety Pin Down Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N15 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-15 ODS V-Door Up Solenoid 10621970-DIA 3 10621971-DIA 4 NOV
PCAT-N16 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-16 ODS V-Door Down Solenoid 10621970-DIA 3 10621971-DIA 4 NOV
PCAT-N17 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-17 ODS Middle Up Solenoid 10621970-DIA 3 10621971-DIA 4 NOV
PCAT-N18 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-18 ODS Middle Down Solenoid 10621970-DIA 3 10621971-DIA 4 NOV
PCAT-N19 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-19 ODS Flare End Up Solenoid 10621970-DIA 3 10621971-DIA 4 NOV
PCAT-N20 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-20 ODS Flare End Down Solenoid 10621970-DIA 3 10621971-DIA 4 NOV
PCAT-N21 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-21 ODS Inner Indexer Up Solenoid 10621970-DIA 4 10621971-DIA 5 NOV
PCAT-N22 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-22 ODS Inner Indexer Down Solenoid 10621970-DIA 4 10621971-DIA 5 NOV
PCAT-N23 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-23 ODS Outer Indexer Up Solenoid 10621970-DIA 4 10621971-DIA 5 NOV
PCAT-N24 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-24 ODS Outer Indexer Down Solenoid 10621970-DIA 4 10621971-DIA 5 NOV
PCAT-N25 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-25 ODS Kicker Up Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N26 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-26 ODS Kicker Down Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N27 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-27 ODS Safety Pin Up Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N28 3C x 16 AWG 10067357-001 N.I.S. NJB-03 Trough Mounted J-Box SOV-28 ODS Safety Pin Down Solenoid 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N29 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control SOV-29 Winch High/Low Solenoid 10621970-DIA 5 10621971-DIA 8 NOV
PCAT-N35 14C X14 AWG N.I.S. PSNJB-01 Remote I/O / Local Control PNJB-01 Power Control 10621970-DIA 7 10621971-DIA 20 NOV
PCAT-N40 37C x 14 AWG 10042204-038 N.I.S. PSNJB-01 Remote I/O / Local Control NJB-04 Frame Mounted J-Box 10621970-DIA 4 10621971-DIA 6&7 NOV
PCAT-N40A 18C x 16 AWG 10068343-001 N.I.S. NJB-04 Frame Mounted J-Box NJB-03 Trough Mounted J-Box 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N40B 18C x 16 AWG 10068343-001 N.I.S. NJB-04 Frame Mounted J-Box NJB-03 Trough Mounted J-Box 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N41 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control PS-01 HPU #1 Filter Pressure Switch 10621970-DIA 2 10621971-DIA 8 NOV
PCAT-N100 4C x 16 AWG 10042204-006 N.I.S. PSNJB-01 Remote I/O / Local Control PRV-100 Trough Winch Solenoid 1A & 1B Lower/Rasie10621970-DIA 5 10621971-DIA 9 NOV
PCAT-N101 1 TSP x 16 AWG 10044375-001 N.I.S. PSNJB-01 Remote I/O / Local Control PT-01 HPU #1 Pressure Transmitter 10621970-DIA 2 10621971-DIA 8 NOV
PCAT-N104 7C x 14 AWG 10042224-016 N.I.S. Connector Driller's Cabin Connector Pipecat Plug Plate 10621970-DIA 2 10621971-DIA 18 NOV
PCAT-N104A 7C x 14 AWG 10042224-016 N.I.S. Connector Pipecat Plug Plate PSNJB-01 Remote I/O / Local Control 10621970-DIA 2 10621971-DIA 18 NOV
SHEET 2 OF 3 DWG NO 10621972-IDX REV 01

PCAT-N105 3C x 16 AWG 10067357-001 N.I.S. PSNJB-01 Remote I/O / Local Control IND-01 Pipecat Operational Strobe Light 10621970-DIA 6 10621971-DIA 10 NOV
PCAT-N106 3C x 14 AWG A&S 10043641-001 N.I.S. PSNJB-01 Remote I/O / Local Control PS-03 Trough Lift Winch Brake Pressure Switch 10621970-DIA 6 10621971-DIA 10 NOV
PCAT-N107 1 TSP x 16 AWG 10044375-001 N.I.S. PSNJB-01 Remote I/O / Local Control PT-03 Trough Lift Winch Brake Pressure Transmitte 10621970-DIA 6 10621971-DIA 10 NOV
PCAT-N111 1 TSP x 16 AWG 10044375-001 N.I.S. PSNJB-01 Remote I/O / Local Control ZS-111 Trough Landed Proximity Switch 10621970-DIA 5 10621971-DIA 12 NOV
PCAT-N110 3 TSP x 16 AWG 10046396-001 N.I.S. PSNJB-01 Remote I/O / Local Control NJB-13 Driller Side Infrared Sensor J-Box 10621970-DIA 5 10621971-DIA 11&12 NOV
PCAT-N110TA 1 TSP x 16 AWG 10044375-001 N.I.S. NJB-13 Drillers Side Safey Curtain J-Box NJB-11 J-Box 10621970-DIA 5 10621971-DIA 11 NOV
PCAT-N110TB 3C x 18 AWG CORDSET 10067439-001 N.I.S. NJB-11 J-Box ZT-100T DS Infrared Sensor Transmitter 10621970-DIA 5 10621971-DIA 11 NOV
PCAT-N110R 3C x 18 AWG CORDSET 10067439-001 N.I.S. NJB-13 Drillers Side Infrared Sensor J-Box ZT-100R DS Infrared Sensor Reciver 10621970-DIA 5 10621971-DIA 11 NOV
PCAT-N200 4C x 16 AWG 10042204-006 N.I.S. PSNJB-01 Remote I/O / Local Control PRV-200 Trough Winch Solenoid 2A & 2B Lower/Raise10621970-DIA 5 10621971-DIA 9 NOV
PCAT-N204 3C x 14 AWG A&S 10043641-001 N.I.S. NJB-03 Trough Mounted J-Box PS-04 Skate Pressure Switch 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-N210 3 TSP x 16 AWG 10046396-001 N.I.S. PSNJB-01 Remote I/O / Local Control NJB-14 Off Driller Side Infrared Sensor J-Box 10621970-DIA 5 10621971-DIA 11&12 NOV
PCAT-N210TA 1 TSP x 16 AWG 10044375-001 N.I.S. NJB-14 Off Drillers Side Infrared Sensor J-Box NJB-12 J-Box 10621970-DIA 5 10621971-DIA 11 NOV
PCAT-N210TB 3C x 18 AWG CORDSET 10067439-001 N.I.S. NJB-12 J-Box ZT-200T ODS Infrared Sensor Transmitter 10621970-DIA 5 10621971-DIA 11 NOV
PCAT-N210R 3C x 18 AWG CORDSET 10067439-001 N.I.S. NJB-14 Off Drillers Side Infrared Sensor J-Box ZT-200R ODS Infrared Sensor Receiver 10621970-DIA 5 10621971-DIA 11 NOV
PCAT-N300 4C x 16 AWG 10042204-006 N.I.S. NJB-03 Trough Mounted J-Box PRV-300 Skate Solenoid A & B, Forward/Reverse 10621970-DIA 4 10621971-DIA 6 NOV
PCAT-P01 3C x 12 AWG 10050874-001 N.I.S. Connector Driller's Cabin Connector Pipecat Plug Plate 10621970-DIA 2 10621971-DIA 18 NOV
PCAT-P01A 3C x 12 AWG 10050874-001 N.I.S. Connector Pipecat Plug Plate PSNJB-01 Remote I/O / Local Control 10621970-DIA 2 10621971-DIA 18 NOV
PCAT-P03 3C X 12 AWG 10050874-001 Power PSNJB-01 Remote I/O / Local Control PNJB-01 Power Control 10621970-DIA 7 10621971-DIA 17 & 21 NOV
PCAT-P05 3C X 12 AWG 10050874-001 Power PSNJB-01 Remote I/O / Local Control LGT-01 Ambient Light (Optional) 10621970-DIA 6 10621971-DIA 17 NOV
PCAT-P10 4C X 2/0 AWG 10042203-046 Power Connector MCC Connector Plug Plate 10621970-DIA 7 10621971-DIA 19 NOV
PCAT-P10A 4C X 2/0 AWG 10042203-046 Power Connector Plug Plate Connector Pipecat Plug Plate 10621970-DIA 7 10621971-DIA 19 NOV
PCAT-P10B 4C X 2/0 AWG 10042203-046 Power Connector Pipecat Plug Plate PNJB-01 Power Control 10621970-DIA 7 10621971-DIA 19 NOV

completion of the use for which it was loaned. This document and the information contained and
represented herein is the copyrighted property of NOV. © National Oilwell Varco TITLE
NEXT ASSY USED ON CURRENT INITIAL HAZARDOUS EQUIP. INDEX PipeCat™

DRAWN
APPLICATION R. VELEZ
AC IDEAL RG 131, HIGH AMBIENT
CHECKED
V. GARCIA SIZE DWG NO REV
APPVD
V. GARCIA B 10621973-IDX 01
DATE
11/4/2011 SCALE NONE WT LBS SHEET 1 OF 3
NATIONAL OILWELL VARCO HAZARDOUS EQUIP. INDEX PipeCat™ DATE 11/7/2011 3:19:58 PM
VARCO VARCO DESCRIPTION LOCATION MANUFACTURER MANUFACTURER HAZARDOUS HAZARDOUS CERTIFICATION CERTIFICATE TEMP. IP MATERIAL BLOCK DIAG. INTERCONNECT ASSOCIATED REMARKS
TAG NO. P/N: P/N: RATING ZONE AGENCY No. RATING RATING DWG. NO. SHT. DWG. NO. SHT. COMPONENT
SAFE AREA
o
PSNJB-01 10546371-001 REMOTE I/O /LOCAL CONTROL JBOX PIPECAT NOV - SAFE AREA - - - -20 to +55 C IP66 ST.ST. 10621970-DIA 2-7 10621971-DIA 20-21
o
PNJB-01 10546369-001 POWER CONTROL JBOX PIPECAT NOV - SAFE AREA - - - -20 to +55 C IP66 ST.ST. 10621970-DIA 2-7 10621971-DIA 20-21
o
HPM-01 7036B109 HPU #1 MOTOR PIPECAT SAFE AREA - - - -26 to +121 C IP55 CAST IRON 10621970-DIA 7 10621971-DIA 19
o
OC-01
SUPPL. W/COOLER HPU OIL COOLER/FAN PIPECAT SAFE AREA - - - 10621970-DIA 7 10621971-DIA 21
o
LS-01 P231000506 HYDRAULIC FLUID LEVEL SWITCH PIPECAT JO-BELL L1-29-1-66 SAFE AREA - - - -25 to +125 C 10621970-DIA 2 10621971-DIA 10
o
RTD-01 10072969-001 HYDRAULIC TANK RTD PIPECAT HEAT TECHNOLOGIES R9BGL-01W-R02-5-075-W SAFE AREA - - - -40 to +85 C IP67 ST.ST. 10621970-DIA 2 10621971-DIA 19
0 o
IND-01 10068361-001 PIPECAT OPERATIONAL STROBE PIPECAT FEDERAL SIGNAL WV450XD15-024A EEx d IIB + H2 T4+T3 ZONE 2 DEMKO 06ATEX 0425693X -55 to +55 C IP66 POLYESTER 10621970-DIA 5 10621971-DIA 10
o
S0V-01 7024B367 DS-V DOOR UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 2
o
S0V-02 7024B367 DS-V DOOR DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 2
o
S0V-03 7024B367 DS MIDDLE UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 2
o
S0V-04 7024B367 DS MIDDLE DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 2
o
S0V-05 7024B367 DS FLARE END UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 2
o
S0V-06 7024B367 DS FLARE END DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 2
o
S0V-07 7024B367 DS INNER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 3
o
S0V-08 7024B367 DS INNER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 3
o
S0V-09 7024B367 DS OUTER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 3
o
S0V-10 7024B367 DS OUTER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 3
o
S0V-11 7024B367 DS KICKER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
S0V-12 7024B367 DS KICKER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
S0V-13 7024B367 DS SAFETY PIN UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
SOV-14 7024B367 DS SAFETY PIN DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
SOV-15 7024B367 ODS-V DOOR UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 4
o
S0V-16 7024B367 ODS-V DOOR DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 4
o
S0V-17 7024B367 ODS MIDDLE UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 4
o
S0V-18 7024B367 ODS MIDDLE DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 4
o
S0V-19 7024B367 ODS FLARE END UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 4
o
S0V-20 7024B367 ODS FLARE END DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 3 10621971-DIA 4
o
S0V-21 7024B367 ODS INNER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 5
o
S0V-22 7024B367 ODS INNER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 5
o
S0V-23 7024B367 ODS OUTER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 5
o
S0V-24 7024B367 ODS OUTER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 5

o
S0V-25 7024B367 ODS KICKER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
S0V-26 7024B367 ODS KICKER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
S0V-27 7024B367 ODS SAFETY PIN UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
S0V-28 7024B367 0DS SAFETY PIN DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70 C IP65 10621970-DIA 4 10621971-DIA 6
o
S0V-29 SUPPL. W/WINCH WINCH SELECT-HI/LO PIPECAT ATOS SYSTEMS, INC 000290-DHA-0631/M/7-24VDC II 2G, EEx d IIC T6,T4,T3 ZONE 2 CESI 02ATEX014 -20 to +70 C IP66 ST.ST. 10621970-DIA 5 10621971-DIA 8
LGT-01 TBD PIPECAT 120VAC LIGHT (OPTIONAL) PIPECAT NOV SAFE AREA - - - - - - 10621970-DIA 5 10621971-DIA 17
o
NJB-03 10073453-001 TROUGH MOUNTED J-BOX PIPECAT NOV SAFE AREA - - - -20 to +55 C IP66 ST.ST. 10621970-DIA 4 10621971-DIA 6
o
NJB-04 10073454-001 FRAME MOUNTED J-BOX PIPECAT NOV SAFE AREA - - - -20 to +55 C IP66 ST.ST. 10621970-DIA 4 10621971-DIA 6
o
NJB-11 10046598-001 J-BOX PIPECAT HAWK PL612 II 2GD, Exe II, Ex tD ZONE 1 & 2 BASEEFA 06ATEX0117X -60 to +75 C IP66&67 POLYESTER 10621970-DIA 5 10621971-DIA 11
o
o
o
o
DJB-01 10042724-001 J-BOX PIPECAT HAWK PL630 II 2GD, Exe II, Ex tD ZONE 1 & 2 BASEEFA 06ATEX0117X -60 to +75 C IP66&67 POLYESTER 10621970-DIA 6 10621971-DIA 10
0 o
ENC-01 10052305-001 WINCH ENCODER - HE-040 PIPECAT HENGSTLER AX71/1214EK.42DPX-FO:5604 EExd IIC 2 G EExd II C T4/T6 ZONE 2 PTB 00ATEX1107 -40 to +60 C IP66&67 ST.ST. 10621970-DIA 6 10621971-DIA 10
o
PS-01 SUPPL. W/FILTER HPU #1 FILTER PRESSURE SWITCH PIPECAT - - SAFE AREA - - - -30 to +121 C IP65 - 10621970-DIA 2 10621971-DIA 8
o
o
PS-03 P231000538 TROUGH LIFT WINCH BRAKE PS PIPECAT NEO-DYN P232P41C6 CLASS 1 DIV 1 ll 2G ZONE 2 FACTORY MUTUAL J.I.1R5A9.AE -40 to +82 C NEMA 7&9 STEEL 10621970-DIA 6 10621971-DIA 10
o
PT-01 10052507-001 HPU #1 PRESSURE TRANSMITTER -3.0K PIPECAT GE DRUCK X7800-185S-4283 II 2G EEx d IIC T6 ZONE 2 SIRA 02ATEX1089X -40 to +75 C IP66 ST.ST. 10621970-DIA 2 10621971-DIA 8
o
o
PT-03 10052508-001 TROUGH WINCH PRESSURE XMTR -3.0K PIPECAT GE DRUCK X7800-185S-4283 II 2G EEx d IIC T6 ZONE 2 SIRA 02ATEX1089X -40 to +75 C IP66 ST.ST. 10621970-DIA 6 10621971-DIA 10
o
PRV-100 70244B530 TROUGH WINCH SOLENOID 1 PIPECAT HAWE SAFE AREA - - - -40 to +80 C IP65 10621970-DIA 5 10621971-DIA 9
o
o
PRV-300 70244B538 SKATE SOLENOID PIPECAT HAWE SAFE AREA - - - -40 to +80 C IP65 10621970-DIA 4 10621971-DIA 6
o
ZS-111 10055174-001 TROUGH LANDED PROX SWITCH PIPECAT PEPPERL & FUCHS NJ15S+U4+N II 1G, Ex ia IIC T6 ZONE 1 & 2 PTB 00ATEX2049X -40 to +100 C IP68 METAL 10621970-DIA 5 10621971-DIA 12
o
ZT-100R 10067392-001 DS INFRARED SENSOR RECEIVER PIPECAT BANNER SMI30AN6RQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70 C IP67 POLYESTER 10621970-DIA 5 10621971-DIA 11
o
ZT-200R 10067392-001 ODS INFRARED SENSOR RECEIVER PIPECAT BANNER SMI30AN6RQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70 C IP67 POLYESTER 10621970-DIA 5 10621971-DIA 11
o
ZT-100T 10067393-001 DS INFRARED SENSOR TRANS PIPECAT BANNER SMI306EQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70 C IP67 POLYESTER 10621970-DIA 5 10621971-DIA 11
o
ZT-200T 10067393-001 ODS INFRARED SENSOR TRANS PIPECAT BANNER SMI306EQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70 C IP67 POLYESTER 10621970-DIA 5 10621971-DIA 11
HAZARDOUS AREA
PS-04 P231000538 SKATE PRESSURE SWITCH PIPECAT NEO-DYN P232P41C6N Ex d IIC T6 ZONE 2 SIRA 10ATEX1017X -40 to +70oC NEMA 7&9 SS 10621970-DIA 4 10621971-DIA 6
o
WR-01 30183157-1-XX-XXX WIRELESS TRANSMITTER PIPECAT HBC Ex II 2G EEx ib II B T4 ZONE 1 TUV EX5 99 04 31016 001 -25 to +70 C IP55 10621970-DIA 2 10621971-DIA 16

This document contains proprietary and confidential information which belongs to National-Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for limited
purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this design
or distribution of this information to others is not permitted without the express written consent of NOV.
This document is to be returned to NOV upon request and in any event upon completion of the use for
which it was loaned. This document and the information contained and represented herein is the
copyrighted property of NOV. © National Oilwell Varco TITLE
NEXT ASSY USED ON CURRENT INITIAL I/O MAP INDEX, PipeCat™

NATIONAL OILWELL VARCO I/O MAP INDEX, PipeCat™ DATE 11/7/2011 3:47:36 PM
I/O SIGNAL NETWORK NODE I/O DESCRIPTION I/O 1 FUNCTION 0 FUNCTION ENG. MIN ENG. MAX ENG.
ADDRESS TYPE ID No. LOCATION UNITS UNITS UNITS
40DI0.0 24VDC DP1 40 POWER SUPPLY 1 STATUS POS 2 (1) POWER SUPPLY 1 OK POWER SUPPLY 1 FAULT - - -
40DI0.2 24VDC DP1 40 OLM FAULT (SPARE) POS 2 (4) OLM OK OLM FAULT - - -
40DI0.3 24VDC DP1 40 REMOTE I/O COOLER ALARM (SPARE) POS 2 (8) REMOTE I/O COOLER FAULT REMOTE I/O COOLER FAULT - - -
40DI0.4 24VDC DP1 40 TROUGH LIFT DOWN POS 3 (1) TROUGH LIFT DOWN - - - -
40DI0.5 24VDC DP1 40 TROUGH LIFT UP POS 3 (5) TROUGH LIFT UP - - - -
40DI0.6 24VDC DP1 40 SKATE BACK POS 3 (4) SKATE BACK - - - -
40DI0.7 24VDC DP1 40 SKATE FWD POS 3 (8) SKATE FWD - - - -
40DI1.0 24VDC DP1 40 DS INDEX IN POS 4 (1) DS INDEX IN - - - -
40DI1.1 24VDC DP1 40 DS INDEX OUT POS 4 (5) DS INDEX OUT - - - -
40DI1.2 24VDC DP1 40 DS KICKER UP POS 4 (4) DS KICKER UP - - - -
40DI1.3 24VDC DP1 40 DS KICKER DOWN POS 4 (8) DS KICKER DOWN - - - -
40DI1.4 24VDC DP1 40 DS LOAD ARMS UP POS 5 (1) DS LOAD ARMS UP - - - -
40DI1.5 24VDC DP1 40 DS LOAD ARMS DOWN POS 5 (5) DS LOAD ARMS DOWN - - - -
40DI1.6 24VDC DP1 40 ODS INDEX IN POS 5 (4) ODS INDEX IN - - - -
40DI1.7 24VDC DP1 40 ODS INDEX OUT POS 5 (8) ODS INDEX OUT - - - -
40DI2.0 24VDC DP1 40 ODS KICKER UP POS 6 (1) ODS KICKER UP - - - -
40DI2.1 24VDC DP1 40 ODS KICKER DOWN POS 6 (5) ODS KICKER DOWN - - - -
40DI2.2 24VDC DP1 40 ODS LOAD ARMS UP POS 6 (4) ODS LOAD ARMS UP - - - -
40DI2.3 24VDC DP1 40 ODS LOAD ARMS DOWN POS 6 (8) ODS LOAD ARMS DOWN - - - -
40DI2.4 24VDC DP1 40 SAFETY PIN UP POS 7 (1) SAFETY PIN UP - - - -
40DI2.5 24VDC DP1 40 SAFETY PIN DOWN POS 7 (5) SAFETY PIN DOWN - - - -
40DI2.6 24VDC DP1 40 INTERLOCK RESET POS 7 (4) INTERLOCK RESET - - - -
40DI2.7 24VDC DP1 40 INTERLOCK LAMP RESET-LOCAL POS 7 (8) INTERLOCK LAMP RESET - - - -
40DI3.0 24VDC DP1 40 PIPE RACK SETUP POS 8 (1) PIPE RACK SETUP - - - -
40DI3.1 24VDC DP1 40 TOOL ON-LOCAL POS 8 (5) TOOL ON - - - -
40DI3.2 24VDC DP1 40 OWNERSHIP TAKE/RELEASE-LOCAL POS 8 (4) OWNERSHIP TAKE/RELEASE FROM LOCAL - - - -
40DI3.3 24VDC DP1 40 ESTOP-LOCAL POS 8 (8) ESTOP-LOCAL NOT ACTIVATED ESTOP-LOCAL ACTIVATED - - -
40DI3.4 24VDC DP1 40 SKATE PRESSURE SWITCH POS 10 (1) SKATE PRESSURE SWITCH SET SKATE PRESSURE SWITCH NOT SET - - -
40DI3.5 24VDC DP1 40 HPU 1 FILTER PRESSURE SWITCH POS 10 (5) HPU 1 FILTER OK HPU 1 FILTER CLOGGED - - -
40DI3.7 24VDC DP1 40 SPARE POS 10 (8) - - - - -
40DI4.0 24VDC DP1 40 WINCH BRAKE PRESSURE SWITCH POS 11 (1) WINCH BRAKE PRESSURE SWITCH SET WINCH BRAKE PRESSURE SWITCH NOT SET - - -
40DI4.1 24VDC DP1 40 HYDRAULIC TANK LEVEL SWITCH POS 11 (5) HYDRAULIC TANK LEVEL OK HYDRAULIC TANK LEVEL LOW - - -
40DI4.4 24VDC DP1 40 TROUGH LANDED PROX SWITCH POS 12 (1) TROUGH LANDED TROUGH NOT LANDED - - -
40DI4.5 24VDC DP1 40 SPARE (SKATE HOME LANDED PROX SWITCH) POS 12 (5) SKATE LANDED SKATE NOT LANDED - - -
40DI4.6 24VDC DP1 40 SPARE (TROUGH SETPOINT) (REMOTE) POS 12 (4) - - - - -
40DI4.7 24VDC DP1 40 TROUGH SETPOINT (LOCAL) POS 12 (8) - - - - -
40DI5.0 24VDC DP1 40 OIL COOLER HAND POS 13 (1) OIL COOLER HAND ON - - - -
40DI5.1 24VDC DP1 40 HPU #2 HAND POS 13 (5) HPU#2 ON - - - -

40DI5.2 24VDC DP1 40 HPU #1HAND POS 13 (4) HPU#1 ON - - - -
40DI5.3 24VDC DP1 40 SPARE (TANK HEATER ON) POS 13 (8) (TANK HEATER ON) (TANK HEATER OFF) - - -
40DI5.4 24VDC DP1 40 HPU #1 ON POS 14 (1) HPU #1 ON HPU #1 OFF - - -
40DI5.6 24VDC DP1 40 POWER CONTROL COOLER ALARM POS 14 (4) POWER CONTROL COOLER FAULT POWER CONTROL COOLER OK - - -
40DI5.7 24VDC DP1 40 OIL COOLER ON POS 14 (8) OIL COOLER ON OIL COOLER OFF - - -
40AI6 4-20mA DP1 40 TROUGH LIFT UP/DOWN POS 16 (1) - - - - -

40AI8 4-20mA DP1 40 SKATE FWD/BACK POS 16 (5) - - - - -
40AI10 4-20mA DP1 40 DRILLER'S SIDE INFRARED SENSOR POS 17 (1) - - - - -
40AI12 4-20mA DP1 40 OFF DRILLER'S SIDE INFRARED SENSOR POS 17 (5) - - - - -
40AI14 4-20mA DP1 40 TROUGH WINCH PRESSURE POS 18 (1) - - - - -
40AI16 4-20mA DP1 40 SPARE POS 18 (5) - - - - -
40AI18 4-20mA DP1 40 HPU #1 PRESSURE XMTR POS 19 (1) - - - - -
40AI22 4-20mA DP1 40 HYDRAULIC TANK TEMP SENSOR POS 22(1) - - - - -
40AI24 4-20mA DP1 40 SPARE POS 22(5) - - - - -
40DQ0.0 24VDC DP1 40 TOOL ON (LOCAL) POS 20 (1) TOOL ON TOOL OFF - - -
40DQ0.1 24VDC DP1 40 OWNERSHIP (LOCAL) POS 20 (5) OWNERSHIP (LOCAL) - - - -
40DQ0.2 24VDC DP1 40 INTERLOCK ALARM (LOCAL) POS 20 (4) INTERLOCK ALARM ON INTERLOCK ALARM OFF - - -
40DQ0.3 24VDC DP1 40 SPARE POS 20 (8) - - - - -
40DQ0.4 24VDC DP1 40 OWNERSHIP AVAILABLE (LOCAL) POS 21 (1) OWNERSHIP AVAILABLE (LOCAL) OWNERSHIP NOT AVAILABLE (LOCAL) - - -
40DQ0.5 24VDC DP1 40 PIPE RACK MODE (LOCAL) POS 21 (5) PIPE RACK MODE ON PIPE RACK MODE OFF - - -
40DQ0.6 24VDC DP1 40 WIRELESS OPERATOR STOP BYPASS POS 21 (4) WIRELESS OPERATOR STOP BYPASSED WIRELESS OPERATOR STOP NOT BYPASSED - - -
40DQ1.0 24VDC DP1 40 DS V-DOOR UP SOLENOID POS 24 (1) DS V-DOOR UP - - - -
40DQ1.1 24VDC DP1 40 DS V-DOOR DOWN SOLENOID POS 24 (5) DS V-DOOR DOWN - - - -
40DQ1.2 24VDC DP1 40 DS MIDDLE UP SOLENOID POS 25 (1) DS MIDDLE UP - - - -
40DQ1.3 24VDC DP1 40 DS MIDDLE DOWN SOLENOID POS 25 (5) DS MIDDLE DOWN - - - -
40DQ1.4 24VDC DP1 40 DS FLARE END UP SOLENOID POS 26 (1) DS FLARE END UP - - - -
40DQ1.5 24VDC DP1 40 DS FLARE END DOWN SOLENOID POS 26 (5) DS FLARE END DOWN - - - -
40DQ1.6 24VDC DP1 40 DS INNER INDEXER UP SOLENOID POS 27 (1) DS INNER INDEXER UP - - - -
40DQ1.7 24VDC DP1 40 DS INNER INDEXER DOWN SOLENOID POS 27 (5) DS INNER INDEXER DOWN - - - -
40DQ2.0 24VDC DP1 40 DS OUTER INDEXER UP SOLENOID POS 28 (1) DS OUTER INDEXER UP - - - -
40DQ2.1 24VDC DP1 40 DS OUTER INDEXER DOWN SOLENOID POS 28 (5) DS OUTER INDEXER DOWN - - - -
40DQ2.2 24VDC DP1 40 ODS V-DOOR UP SOLENOID POS 30 (1) ODS V-DOOR UP - - - -
40DQ2.3 24VDC DP1 40 ODS V-DOOR DOWN SOLENOID POS 30 (5) ODS V-DOOR DOWN - - - -
40DQ2.4 24VDC DP1 40 ODS MIDDLE UP SOLENOID POS 31 (1) ODS MIDDLE UP - - - -
40DQ2.5 24VDC DP1 40 ODS MIDDLE DOWN SOLENOID POS 31 (5) ODS MIDDLE DOWN - - - -
40DQ2.6 24VDC DP1 40 ODS FLARE UP SOLENOID POS 32 (1) ODS FLARE UP - - - -
40DQ2.7 24VDC DP1 40 ODS FLARE DOWN SOLENOID POS 32 (5) ODS FLARE DOWN - - - -
40DQ3.0 24VDC DP1 40 ODS INNER INDEXER UP SOLENOID POS 33 (1) ODS INNER INDEXER UP - - - -

40DQ3.1 24VDC DP1 40 ODS INNER INDEXER DOWN SOLENOID POS 33 (5) ODS INNER INDEXER DOWN - - - -
40DQ3.2 24VDC DP1 40 ODS OUTER INDEXER UP SOLENOID POS 34 (1) ODS OUTER INDEXER UP - - - -
40DQ3.3 24VDC DP1 40 ODS OUTER INDEXER DOWN SOLENOID POS 34 (5) ODS OUTER INDEXER DOWN - - - -
40DQ3.4 24VDC DP1 40 WINCH HI/LO SOLENOID POS 36 (1) WINCH HI/LO - - - -
40DQ3.5 24VDC DP1 40 SKATE SOLENOID 1 ENABLE POS 36 (5) SKATE SOLENOID 1 ENABLED SKATE SOLENOID 1 NOT ENABLE - - -
40DQ3.6 24VDC DP1 40 TROUGH SOLENOID 1 ENABLE POS 37 (1) TROUGH SOLENOID 1 ENABLED TROUGH SOLENOID 1 NOT ENABLE - - -
40DQ4.0 24VDC DP1 40 DS KICKER UP SOLENOID POS 38 (1) DS KICKER UP - - - -
40DQ4.1 24VDC DP1 40 DS KICKER DOWN SOLENOID POS 38 (5) DS KICKER DOWN - - - -
40DQ4.2 24VDC DP1 40 DS SAFETY PIN UP SOLENOID POS 39 (1) DS SAFETY PIN UP - - - -
40DQ4.3 24VDC DP1 40 DS SAFETY PIN DOWN SOLENOID POS 39 (5) DS SAFETY PIN DOWN - - - -
40DQ4.4 24VDC DP1 40 ODS KICKER UP SOLENOID POS 40 (1) ODS KICKER UP - - - -
40DQ4.5 24VDC DP1 40 ODS KICKER DOWN SOLENOID POS 40 (5) ODS KICKER DOWN - - - -
40DQ4.6 24VDC DP1 40 ODS SAFETY PIN UP SOLENOID POS 41 (1) ODS SAFETY PIN UP - - - -
40DQ4.7 24VDC DP1 40 ODS SAFETY PIN DOWN SOLENOID POS 41 (5) ODS SAFETY PIN DOWN - - - -
40DQ5.1 24VDC DP1 40 OP STATUS STROBE POS 43 (5) OP STATUS STROBE ON OP STATUS STROBE OFF - - -
40DQ5.2 24VDC DP1 40 HPU #1 ON POS 44 (1) HPU #1 ON - - - -
40DQ5.4 24VDC DP1 40 HPU OIL COOLER/ FAN ON POS 45 (1) HPU OIL COOLER/FAN ON - - - -

NATIONAL OILWELL VARCO CABLE SCHEDULE, PipeCat™ DATE 11/8/2011 9:23:30 AM



DRAWN
CHECKED
APPVD
DATE
NATIONAL OILWELL VARCO HAZARDOUS EQUIP. INDEX PipeCat™ DATE 11/8/2011 10:28:38 AM
SAFE AREA
o
o
o
o
OC-01
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o

o
o
o
o
o
o
o
o
o
o
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
HAZARDOUS AREA
o


NATIONAL OILWELL VARCO I/O MAP INDEX, PipeCat™ DATE 11/8/2011 11:03:19 AM


40AI16 4-20mA DP1 40 SPARE POS 18 (5) - - - - -
40AI24 4-20mA DP1 40 SPARE POS 22(5) - - - - -





DRAWN
CHECKED
APPVD
DATE
SAFE AREA
o
o
o
o
OC-01
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o

o
o
o
o
o
o
o
o
o
o
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
HAZARDOUS AREA
o




40AI16 4-20mA DP1 40 SPARE POS 18 (5) - - - - -
40AI24 4-20mA DP1 40 SPARE POS 22(5) - - - - -





DRAWN
CHECKED
APPVD
DATE
SAFE AREA
o
o
o
o
OC-01
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o

o
o
o
o
o
o
o
o
o
o
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
HAZARDOUS AREA
o




40AI16 4-20mA DP1 40 SPARE POS 18 (5) - - - - -
40AI24 4-20mA DP1 40 SPARE POS 22(5) - - - - -





DRAWN
CHECKED
APPVD
DATE
SAFE AREA
o
o
o
o
OC-01
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o

o
o
o
o
o
o
o
o
o
o
o
o
0 o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
HAZARDOUS AREA
o




40AI16 4-20mA DP1 40 SPARE POS 18 (5) - - - - -
40AI24 4-20mA DP1 40 SPARE POS 22(5) - - - - -


™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
Ø
(P/N 7036B109)
Ø
(P/N 7036B109)
™
™
™
for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or
use of this design or distribution of this information to others is not permitted without the express
written consent of NOV. This document is to be returned to NOV upon request and in any event
upon completion of the use for which it was loaned. This document and the information contained
TITLE
and represented herein is the copyrighted property of NOV. © National Oilwell Varco
DRAWN
APPLICATION B. BOEPPLE
CHECKED
APPVD
DATE

PCAT-N107 1 TSP x 16 AWG 10044375-001 N.I.S. PSNJB-01 Remote I/O / Local Control PT-03 Trough Lift Winch Brake Pressure Transmitte10627167-DIA 6 10627169-DIA 10 NOV


DRAWN
CHECKED
APPVD
DATE
SAFE AREA
PSNJB-01 10546371-001 REMOTE I/O /LOCAL CONTROL JBOX PIPECAT NOV - SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627167-DIA 2-7 10627169-DIA 20-21
PNJB-01 10546369-001 POWER CONTROL JBOX PIPECAT NOV - SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627167-DIA 2-7 10627169-DIA 20-21
HPM-01 7036B109 HPU #1 MOTOR PIPECAT SAFE AREA - - - -26 to +121oC IP55 CAST IRON 10627167-DIA 7 10627169-DIA 19
OC-01
o
RTD-01 10072969-001 HYDRAULIC TANK RTD PIPECAT HEAT TECHNOLOGIES R9BGL-01W-R02-5-075-W SAFE AREA - - - -40 to +85oC IP67 ST.ST. 10627167-DIA 2 10627169-DIA 19
IND-01 10068361-001 PIPECAT OPERATIONAL STROBE PIPECAT FEDERAL SIGNAL WV450XD15-024A EEx d IIB + H2 T4+T3 ZONE 2 DEMKO 06ATEX 0425693X -550 to +55oC IP66 POLYESTER 10627167-DIA 5 10627169-DIA 10
S0V-01 7024B367 DS-V DOOR UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 2
o
S0V-03 7024B367 DS MIDDLE UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 2
S0V-04 7024B367 DS MIDDLE DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 2
S0V-05 7024B367 DS FLARE END UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 2
o
S0V-07 7024B367 DS INNER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 3
S0V-08 7024B367 DS INNER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 3
S0V-09 7024B367 DS OUTER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 3
S0V-10 7024B367 DS OUTER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 3
o
S0V-12 7024B367 DS KICKER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 6
S0V-13 7024B367 DS SAFETY PIN UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 6
SOV-14 7024B367 DS SAFETY PIN DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 6
o
S0V-16 7024B367 ODS-V DOOR DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 4
S0V-17 7024B367 ODS MIDDLE UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 4
S0V-18 7024B367 ODS MIDDLE DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 4
o
S0V-20 7024B367 ODS FLARE END DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 3 10627169-DIA 4
S0V-21 7024B367 ODS INNER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 5
S0V-22 7024B367 ODS INNER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 5
S0V-23 7024B367 ODS OUTER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 5
o

S0V-25 7024B367 ODS KICKER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 6
o
S0V-27 7024B367 ODS SAFETY PIN UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 6
S0V-28 7024B367 0DS SAFETY PIN DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627167-DIA 4 10627169-DIA 6
S0V-29 SUPPL. W/WINCH WINCH SELECT-HI/LO PIPECAT ATOS SYSTEMS, INC 000290-DHA-0631/M/7-24VDC II 2G, EEx d IIC T6,T4,T3 ZONE 2 CESI 02ATEX014 -20 to +70oC IP66 ST.ST. 10627167-DIA 5 10627169-DIA 8
NJB-03 10073453-001 TROUGH MOUNTED J-BOX PIPECAT NOV SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627167-DIA 4 10627169-DIA 6
NJB-04 10073454-001 FRAME MOUNTED J-BOX PIPECAT NOV SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627167-DIA 4 10627169-DIA 6
NJB-11 10046598-001 J-BOX PIPECAT HAWK PL612 II 2GD, Exe II, Ex tD ZONE 1 & 2 BASEEFA 06ATEX0117X -60 to +75oC IP66&67 POLYESTER 10627167-DIA 5 10627169-DIA 11
o
o
DJB-01 10042724-001 J-BOX PIPECAT HAWK PL630 II 2GD, Exe II, Ex tD ZONE 1 & 2 BASEEFA 06ATEX0117X -60 to +75oC IP66&67 POLYESTER 10627167-DIA 6 10627169-DIA 10
ENC-01 10052305-001 WINCH ENCODER - HE-040 PIPECAT HENGSTLER AX71/1214EK.42DPX-FO:5604 EExd IIC 2 G EExd II C T4/T6 ZONE 2 PTB 00ATEX1107 -400 to +60oC IP66&67 ST.ST. 10627167-DIA 6 10627169-DIA 10
o
PS-02 SUPPL. W/FILTER HPU #2 FILTER PRESSURE SWITCH PIPECAT - - SAFE AREA - - - -30 to +121oC IP65 - 10627167-DIA 2 10627169-DIA 8
PS-03 P231000538 TROUGH LIFT WINCH BRAKE PS PIPECAT NEO-DYN P232P41C6 CLASS 1 DIV 1 ll 2G ZONE 2 FACTORY MUTUAL J.I.1R5A9.AE -40 to +82oC NEMA 7&9 STEEL 10627167-DIA 6 10627169-DIA 10
PT-01 10052507-001 HPU #1 PRESSURE TRANSMITTER -3.0K PIPECAT GE DRUCK X7800-185S-4283 II 2G EEx d IIC T6 ZONE 2 SIRA 02ATEX1089X -40 to +75oC IP66 ST.ST. 10627167-DIA 2 10627169-DIA 8
o
PT-03 10052508-001 TROUGH WINCH PRESSURE XMTR -3.0K PIPECAT GE DRUCK X7800-185S-4283 II 2G EEx d IIC T6 ZONE 2 SIRA 02ATEX1089X -40 to +75oC IP66 ST.ST. 10627167-DIA 6 10627169-DIA 10
PRV-100 70244B530 TROUGH WINCH SOLENOID 1 PIPECAT HAWE SAFE AREA - - - -40 to +80oC IP65 10627167-DIA 5 10627169-DIA 9
PRV-300 70244B538 SKATE SOLENOID PIPECAT HAWE SAFE AREA - - - -40 to +80oC IP65 10627167-DIA 4 10627169-DIA 6
o
ZT-100R 10067392-001 DS INFRARED SENSOR RECEIVER PIPECAT BANNER SMI30AN6RQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70oC IP67 POLYESTER 10627167-DIA 5 10627169-DIA 11
ZT-200R 10067392-001 ODS INFRARED SENSOR RECEIVER PIPECAT BANNER SMI30AN6RQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70oC IP67 POLYESTER 10627167-DIA 5 10627169-DIA 11
ZT-100T 10067393-001 DS INFRARED SENSOR TRANS PIPECAT BANNER SMI306EQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70oC IP67 POLYESTER 10627167-DIA 5 10627169-DIA 11
o
HAZARDOUS AREA
WR-01 30183157-1-XX-XXX WIRELESS TRANSMITTER PIPECAT HBC Ex II 2G EEx ib II B T4 ZONE 1 TUV EX5 99 04 31016 001 -25 to +70oC IP55 10627167-DIA 2 10627169-DIA 16


DRAWN
CHECKED
APPVD
DATE


40AI16 4-20mA DP1 40 SPARE POS 18 (5) - - - - -
40AI24 4-20mA DP1 40 SPARE POS 22(5) - - - - -


™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
™
Ø
(P/N 7036B109)
Ø
(P/N 7036B109)
™
™
™
for limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or
use of this design or distribution of this information to others is not permitted without the express
written consent of NOV. This document is to be returned to NOV upon request and in any event
upon completion of the use for which it was loaned. This document and the information contained
TITLE
and represented herein is the copyrighted property of NOV. © National Oilwell Varco
DRAWN
CHECKED
APPVD
DATE

PCAT-N107 1 TSP x 16 AWG 10044375-001 N.I.S. PSNJB-01 Remote I/O / Local Control PT-03 Trough Lift Winch Brake Pressure Transmitte10627261-DIA 6 10627263-DIA 10 NOV


DRAWN
CHECKED
APPVD
DATE
SAFE AREA
PSNJB-01 10546371-001 REMOTE I/O /LOCAL CONTROL JBOX PIPECAT NOV - SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627261-DIA 2-7 10627263-DIA 20-21
PNJB-01 10546369-001 POWER CONTROL JBOX PIPECAT NOV - SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627261-DIA 2-7 10627263-DIA 20-21
OC-01
o
RTD-01 10072969-001 HYDRAULIC TANK RTD PIPECAT HEAT TECHNOLOGIES R9BGL-01W-R02-5-075-W SAFE AREA - - - -40 to +85oC IP67 ST.ST. 10627261-DIA 2 10627263-DIA 19
IND-01 10068361-001 PIPECAT OPERATIONAL STROBE PIPECAT FEDERAL SIGNAL WV450XD15-024A EEx d IIB + H2 T4+T3 ZONE 2 DEMKO 06ATEX 0425693X -550 to +55oC IP66 POLYESTER 10627261-DIA 5 10627263-DIA 10
S0V-01 7024B367 DS-V DOOR UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 2
o
S0V-03 7024B367 DS MIDDLE UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 2
S0V-04 7024B367 DS MIDDLE DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 2
S0V-05 7024B367 DS FLARE END UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 2
o
S0V-07 7024B367 DS INNER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 3
S0V-08 7024B367 DS INNER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 3
S0V-09 7024B367 DS OUTER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 3
S0V-10 7024B367 DS OUTER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 3
o
S0V-12 7024B367 DS KICKER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 6
S0V-13 7024B367 DS SAFETY PIN UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 6
SOV-14 7024B367 DS SAFETY PIN DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 6
o
S0V-16 7024B367 ODS-V DOOR DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 4
S0V-17 7024B367 ODS MIDDLE UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 4
S0V-18 7024B367 ODS MIDDLE DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 4
o
S0V-20 7024B367 ODS FLARE END DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 3 10627263-DIA 4
S0V-21 7024B367 ODS INNER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 5
S0V-22 7024B367 ODS INNER INDEXER DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 5
S0V-23 7024B367 ODS OUTER INDEXER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 5
o

S0V-25 7024B367 ODS KICKER UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 6
o
S0V-27 7024B367 ODS SAFETY PIN UP SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 6
S0V-28 7024B367 0DS SAFETY PIN DOWN SOLENOID PIPECAT ATOS SYSTEMS, INC DHI-0713/X 24VDC SAFE AREA - - - -20 to +70oC IP65 10627261-DIA 4 10627263-DIA 6
S0V-29 SUPPL. W/WINCH WINCH SELECT-HI/LO PIPECAT ATOS SYSTEMS, INC 000290-DHA-0631/M/7-24VDC II 2G, EEx d IIC T6,T4,T3 ZONE 2 CESI 02ATEX014 -20 to +70oC IP66 ST.ST. 10627261-DIA 5 10627263-DIA 8
NJB-03 10073453-001 TROUGH MOUNTED J-BOX PIPECAT NOV SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627261-DIA 4 10627263-DIA 6
NJB-04 10073454-001 FRAME MOUNTED J-BOX PIPECAT NOV SAFE AREA - - - -20 to +55oC IP66 ST.ST. 10627261-DIA 4 10627263-DIA 6
o
o
DJB-01 10042724-001 J-BOX PIPECAT HAWK PL630 II 2GD, Exe II, Ex tD ZONE 1 & 2 BASEEFA 06ATEX0117X -60 to +75oC IP66&67 POLYESTER 10627261-DIA 6 10627263-DIA 10
ENC-01 10052305-001 WINCH ENCODER - HE-040 PIPECAT HENGSTLER AX71/1214EK.42DPX-FO:5604 EExd IIC 2 G EExd II C T4/T6 ZONE 2 PTB 00ATEX1107 -400 to +60oC IP66&67 ST.ST. 10627261-DIA 6 10627263-DIA 10
o
PS-02 SUPPL. W/FILTER HPU #2 FILTER PRESSURE SWITCH PIPECAT - - SAFE AREA - - - -30 to +121oC IP65 - 10627261-DIA 2 10627263-DIA 8
PS-03 P231000538 TROUGH LIFT WINCH BRAKE PS PIPECAT NEO-DYN P232P41C6 CLASS 1 DIV 1 ll 2G ZONE 2 FACTORY MUTUAL J.I.1R5A9.AE -40 to +82oC NEMA 7&9 STEEL 10627261-DIA 6 10627263-DIA 10
PT-01 10052507-001 HPU #1 PRESSURE TRANSMITTER -3.0K PIPECAT GE DRUCK X7800-185S-4283 II 2G EEx d IIC T6 ZONE 2 SIRA 02ATEX1089X -40 to +75oC IP66 ST.ST. 10627261-DIA 2 10627263-DIA 8
o
PT-03 10052508-001 TROUGH WINCH PRESSURE XMTR -3.0K PIPECAT GE DRUCK X7800-185S-4283 II 2G EEx d IIC T6 ZONE 2 SIRA 02ATEX1089X -40 to +75oC IP66 ST.ST. 10627261-DIA 6 10627263-DIA 10
PRV-300 70244B538 SKATE SOLENOID PIPECAT HAWE SAFE AREA - - - -40 to +80oC IP65 10627261-DIA 4 10627263-DIA 6
o
ZT-100R 10067392-001 DS INFRARED SENSOR RECEIVER PIPECAT BANNER SMI30AN6RQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70oC IP67 POLYESTER 10627261-DIA 5 10627263-DIA 11
ZT-200R 10067392-001 ODS INFRARED SENSOR RECEIVER PIPECAT BANNER SMI30AN6RQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70oC IP67 POLYESTER 10627261-DIA 5 10627263-DIA 11
ZT-100T 10067393-001 DS INFRARED SENSOR TRANS PIPECAT BANNER SMI306EQ DIV 2 FM 090317/ 3Y9A5.AX -40 to +70oC IP67 POLYESTER 10627261-DIA 5 10627263-DIA 11
o
HAZARDOUS AREA
WR-01 30183157-1-XX-XXX WIRELESS TRANSMITTER PIPECAT HBC Ex II 2G EEx ib II B T4 ZONE 1 TUV EX5 99 04 31016 001 -25 to +70oC IP55 10627261-DIA 2 10627263-DIA 16


DRAWN
CHECKED
APPVD
DATE


40AI16 4-20mA DP1 40 SPARE POS 18 (5) - - - - -
40AI24 4-20mA DP1 40 SPARE POS 22(5) - - - - -


Page 107
17. VENDOR INFORMATION

17.1 Vendor Listing
17.1 Vendor Listing
VENDOR MANUAL No. DESCRIPTION/MODEL

Amphenol Star Line EX Assembly
Amphenol L-2120-2
Instructions
Atos E001-10/E Basics for Solenoid Directional Valves
Gearboxes for Industrial Applications and
Brevini Riduttori MT-0830-0902/21 Slewing Drives Installation and
Maintenance Manual
Bridon 02/2011 Edition 7 Crane Rope Catalogue (excerpts)
Crosby 9999485 Vitalife Wire Rope Lubricant
Gleason Bulletin 054414 PowerTrak Cable and Hose Guidelines
HBC – Radio Control, Radio Transmitter
HBC-radiomatic 0702165
Spectrum EEX
HBC – Radio Control, Radio Receiver FSE
HBC-radiomatic 0702166
735
HBC – Radio Control Configuration
HBC-radiomatic N/A Instructions (profibus DP Configuration,
Version 1.4)
Absolute Shaft Encoder Installation
Hengstler 3 131008EL
Instructions
Intelligent Electronic Enclosure Thermal
Ice Qube N/A
Management Systems Manual
55668 to 55682 LHS Series Installation and Maintenance
Lantec
55743 to 55757 Manual
Linde BA GK 0306E Axial Piston Closed Loop
Oil Air Bulletin OAQEGO98 OAO Cooler – Air Oil Cooler Brochure
Oil Gear Type “PVG” Pumps – Service
Oil Gear Bulletin 947019B
Instructions
Series 40 Axial Piston Pumps Technical
Sauer Danfoss 520L0636
Information
Horizontal and Vertical Induction Motors –
Siemens LR-226
OMM
Siemens NMIM-L1000 Induction Motors 143-449 Frame OMM
Induction Motors Integral Horsepower –
Siemens NMIM-L1004
Storage Requirements - OMM
Wilkes & McLean N/A Suppressor
www.nov.com
Crane Rope Catalogue
Bridon - the world’s leading specialist
in the manufacture of wire and rope
solutions for the most demanding
applications, delivering reassurance
through unrivalled experience.
High quality performance wire

ropes for the crane industry and
other specialist applications
Drawing from a background of long standing experience
and technology, Bridon is an acknowledged world leader
in the design, manufacture, development and supply of
wire & rope to meet the needs of the crane industry.
High quality ropes for

cranes, hoists and general
engineering offering
improved performance.
02 BRIDON Crane
Contents
Introduction ............................................ 2-3
General Guidance on Rope Selection.... 4-7
Product Selection ..................................8-17
Products ..............................................18-28
Bridon’s products are manufactured under
Terminations ........................................29-39 controls that conform to quality
Services & Training .................................. 40 management system ISO 9001:2000.
Brilube Advanced Rope Dressings......41-42

Technical Information ..........................43-78
Contacts ....................................................79
ISO 14001
All statements, technical information and recommendations
contained herein are believed to be reliable, but no guarantee is Bridon operates environmental
given as to their accuracy and/or completeness. The user must management systems which, where
determine the suitability of the product for his own particular
purpose, either alone or in combination with other products and required by legislation or risk, comply with
shall assume all risk and liability in connection therewith. the requirements of EN ISO 14001:2004
Whilst every attempt has been made to ensure accuracy in the and are assessed and registered by
content of the tables, the information contained in this catalogue
accredited certification bodies.
does not form part of any contract.
Before using any products contained within this

brochure read, understand and follow the guidance
given in ISO 4309:2004 Cranes - Wire Ropes - Care,
Maintenance, Installation, Examination and Discard.
For Offshore Cranes refer to API RP 2D

Recommended Practice for Operation and
Maintenance of Offshore Cranes.
BRIDON Crane 03
Brilube Advanced Rope Dressings

Ropes are like any other machine and to achieve maximum
operating life in service lubrication must be applied.
Composition 30 40 50 60 70 90
The type of service lubricant and frequency of application
varies with the rope construction the operating conditions petroleum/oil base • •
and its functional application. petroleum thixotropic gel • •
synthetic •
Bridon’s unequalled experience in the world of wire rope
biodegradeable •
manufacture and many years spent in the development of
specialist in service lubricants have been used in the Properties
formulation of the Brilube range of products.
excellent penetration • • •
Brilube’s advanced formulation with proven performance excellent corrosion protection • • • •
helps to get the best from your rope. stable over wide temperature range • • • • •
slip resistant •
Brilube 30, 40 and 50 can be applied by brush, drip feed or
minimise fling off • • • •
portable pressurised sprayer.
semi dry thin film •
Brilube 60, 70 and 90 can be pressure applied using in-line water repellent • • • • •
application systems which are available to suit a wide range
Application
of rope sizes and constructions. These systems operate by
forcing the lubricant into the rope under high pressure, whilst general industries • • • • •
simultaneously cleaning the rope and removing the moisture, marine/offshore • • • •
residual lubricant and contaminants. static ropes/rigging • •
fishing ropes • •
• Advanced corrosion protection lifts/elevators •
• High lubricity friction drive systems •
• Reduced fling off drilling lines • •
• Enhanced rope life cranes • • • •
• Effective penetration
• Easy application
The air supply to the

Brilube Health & Safety
pump should be 6-7 bar.
Recommendations
General Precautions
Do
AIR
• Keep away from heat and open flame
The complete Masto
system consists of: • Keep container closed
• Store under cover
- High pressure pump
with flow controlvalve,
• Ensure maximum temperature 25°C
ballvalve, drumcover • Keep away from food and drink
9 ft. of 1/2” flexible hose. • Avoid prolonged and frequent skin contact and ensure
- Masto Lubricating
good standards of personal hygiene
chamber.
- 2 lengths of chains.
Do Not
• Keep oily rags in pockets or wear contaminated clothing
Typical wire rope bend fatigue results • Inhale fumes or vapours
• Swallow
200%
Fire Extinguishing Media
• Carbon dioxide, dry chemicals, foam
Cycles to Failure
150% 160%
Spillage
• Soak up with absorbent clay
100%
100% Waste Disposal
• Burn or dispose of in an approved area
50% • Do not allow to contaminate water supplies
35%
0%
As manufactured Dry As manufactured
with Brilube service
dressing
BRIDON Crane 41
Potential Hazards
No significant hazard when properly used in the application • Aspiration. If there is any suspicion of aspiration
for which it is designed. Prolonged and/or frequent skin into the lungs (e.g. vomiting) admit to hospital
contact may cause some defatting leading to irritation and immediately.
it is recommended that protective gloves are worn.* • Inhalation. Remove from exposure into fresh air.
If necessary give artificial respiration or oxygen.
First Aid
Seek medical advice.
• Ingestion. Do not induce vomiting due to risk of aspiration.
Give 1/2 pint (300ml) of milk. Seek medical advice. *See Cautionary Notice SHW 397 “Effects of mineral Oil on the Skin”
• Skin Contact. Mildly irritating. Remove by wiping and published by the Health & Safety Executive.
wash with soap and water.
For further details please contact Bridon for COSHH data sheet.
• Eye Contact. Mildly irritating. Flush with copious amounts
of warm water. If necessary seek medical advice.

BRILUBE 30 - a semi-dry thin film lubricant with excellent penetration and
30
corrosion resisting properties.
Tower Cranes Formulated for frequent use in harsh working conditions, whilst minimising
Mobile Cranes lubricant build-up and abrasive particle contamination.
Dockside Cranes Effective operating range -30ºC to +60ºC
Fishing Ropes Minimum application temperature -5ºC
BRILUBE 40 - a synthetic lubricant which deposits a slip-resistant film on the wire

40
surfaces.
Lifts & Elevators Formulated for use where frictional grip is vital, it provides internal lubrication whilst
Friction Hoists avoiding excessive build-up with repeated applications.
BRILUBE 40 is recommended for use on lifts, elevators and similar friction driven
rope installations.
Effective operating range -80ºC to +40ºC
Minimum application temperature -5ºC
BRILUBE 50 - an oil based lubricant with additives to increase adherence and

50 enhance corrosion protection. It has excellent penetration and lubrication
Indoor Cranes properties for working ropes in normal industrial environments.
Piling Applications BRILUBE 50 is recommended for overhead cranes, hoist ropes and similar
Small Excavators working ropes, where fatigue is the major factor in rope deterioration.
BRILUBE 60 - a medium thixotropic gel lubricant with excellent corrosion protection

60 and stable properties over a wide temperature range.
Excavators Formulated for long life on static or dynamic ropes.
Guy Ropes BRILUBE 60 is recommended for outdoor use providing effective lubrication and
Winch Ropes corrosion protection where only infrequent lubrication is possible.
BRILUBE 70 - a medium thixotropic gel lubricant with stable properties over a wide
70 temperature range offering corrosion protection against marine working conditions.
Off-shore Cranes Formulated for long life on static or dynamic ropes in highly aggressive
Rigging environments.
Mooring & Towing BRILUBE 70 is recommended for use in off-shore and other hostile environments
Cables where effective lubrication and optimum corrosion protection are vital.
Fishing Ropes Effective operating range -55ºC to +100ºC
BRILUBE 90 - a BIODEGRADABLE heavy duty, marine quality wire rope lubricant,

90
developed by Bridon to meet the needs of wire ropes working in highly aggressive
Off-shore Installations conditions and the demand for environmental acceptability.
Lake & River Ferries Formulated for heavy duty applications in environmentally sensitive locations.
Dock Facilities BRILUBE 90 is recommended for use wherever rope lubrication is a problem due
Water Treatment to environmental concerns.
Operations Effective operating range -20ºC to +120ºC
42 BRIDON Crane
Technical Information
Guide to Examination
The continued safe operation of lifting equipment, lifting Some of the More Common Types of Wire
accessories (e.g. slings) and other systems employing wire Fractures Can Include:
rope depends to a large extent on the operation of well
programmed periodic rope examinations and the A Severed B Tension C Fatigue D Corrosion
by wear fatigue
assessment by the competent person of the fitness of the
rope for further service.
Examination and discard of ropes by the competent person

should be in accordance with the instructions given in the
original equipment manufacturer’s handbook. In addition,
account should be taken of any local or application specific
Regulations.
The competent person should also be familiar, as

appropriate, with the latest versions of related International,
European or National standards such as ISO 4309 “Cranes
- Wire ropes - code of practice for examination.
Particular attention must be paid to those sections of E Plastic F Martensite G Sheared

rope which experience has shown to be liable to wear end
deterioration. Excessive wear, broken wires,
distortions and corrosion are the more common
visible signs of deterioration.
Note: This publication has been prepared as an aid for rope

examination and should not be regarded as a substitute for the
competent person.
Wear is a normal feature of rope service and the use of the

correct rope construction ensures that it remains a
secondary aspect of deterioration. Lubrication may help to
reduce wear.
Broken wires are a normal feature of rope service towards

the end of the rope’s life, resulting from bending fatigue Factors Affecting Rope
and wear. The local break up of wires may indicate some
mechanical fault in the equipment. Correct lubrication in Performance
service will increase fatigue performance.
Multi-coiling of the rope on the drum can result in severe
Distortions are usually as a result of mechanical damage,
distortion in the underlying layers.
and if severe, can considerably affect rope strength.
Bad coiling (due to excessive fleet angles or slack
Visible rusting indicates a lack of suitable lubrication,
winding) can result in mechanical damage, shown
resulting in corrosion. Pitting of external wire surfaces
as severe crushing, and may cause shock loading
becomes evident in some circumstances. Broken wires
during operation.
ultimately result.
Small diameter sheaves can result in permanent set of
Internal corrosion occurs in some environments when
the rope, and will certainly lead to early wire breaks due
lubrication is inadequate or of an unsuitable type.
to fatigue.
Reduction in rope diameter will frequently guide the
observer to this condition. Confirmation can only be made Oversize grooves offer insufficient support to the rope
by opening the rope with clamps or the correct use of spike leading to increased localised pressure, flattening of the
and needle to facilitate internal inspection. rope and premature wire fractures. Grooves are deemed to
be oversize when the groove diameter exceeds the
Note: Non-destructive testing (NDT) using electromagnetic means
nominal rope diameter by more than 15% steel, 20%
may also be used to detect broken wires and/or loss in metallic area.
polyurethane liners.
This method complements the visual examination but does not
replace it. Undersize grooves in sheaves will crush and deform the
rope, often leading to two clear patterns of wear and
Pictures courtesy of S.M.R.E. Crown Copyright 1966
associated wire breaks.
Excessive angle of fleet can result in severe wear of the

rope due to scrubbing against adjacent laps on the drum.
Rope deterioration at the Termination may be exhibited in
the form of broken wires. An excessive angle of fleet can
also induce rotation causing torsional imbalance.
BRIDON Crane 51
Guide to Examination
The continued safe operation of lifting equipment, lifting Some of the More Common Types of Wire
accessories (e.g. slings) and other systems employing wire Fractures Can Include:
rope depends to a large extent on the operation of well
programmed periodic rope examinations and the A Severed B Tension C Fatigue D Corrosion
by wear fatigue
assessment by the competent person of the fitness of the
rope for further service.
Examination and discard of ropes by the competent person

should be in accordance with the instructions given in the
original equipment manufacturer’s handbook. In addition,
account should be taken of any local or application specific
Regulations.
The competent person should also be familiar, as

appropriate, with the latest versions of related International,
European or National standards such as ISO 4309 “Cranes
- Wire ropes - code of practice for examination.
Particular attention must be paid to those sections of E Plastic F Martensite G Sheared

rope which experience has shown to be liable to wear end
deterioration. Excessive wear, broken wires,
distortions and corrosion are the more common
visible signs of deterioration.
Note: This publication has been prepared as an aid for rope

examination and should not be regarded as a substitute for the
competent person.
Wear is a normal feature of rope service and the use of the

correct rope construction ensures that it remains a
secondary aspect of deterioration. Lubrication may help to
reduce wear.
Broken wires are a normal feature of rope service towards

the end of the rope’s life, resulting from bending fatigue Factors Affecting Rope
and wear. The local break up of wires may indicate some
mechanical fault in the equipment. Correct lubrication in Performance
service will increase fatigue performance.
Multi-coiling of the rope on the drum can result in severe
Distortions are usually as a result of mechanical damage,
distortion in the underlying layers.
and if severe, can considerably affect rope strength.
Bad coiling (due to excessive fleet angles or slack
Visible rusting indicates a lack of suitable lubrication,
winding) can result in mechanical damage, shown
resulting in corrosion. Pitting of external wire surfaces
as severe crushing, and may cause shock loading
becomes evident in some circumstances. Broken wires
during operation.
ultimately result.
Small diameter sheaves can result in permanent set of
Internal corrosion occurs in some environments when
the rope, and will certainly lead to early wire breaks due
lubrication is inadequate or of an unsuitable type.
to fatigue.
Reduction in rope diameter will frequently guide the
observer to this condition. Confirmation can only be made Oversize grooves offer insufficient support to the rope
by opening the rope with clamps or the correct use of spike leading to increased localised pressure, flattening of the
and needle to facilitate internal inspection. rope and premature wire fractures. Grooves are deemed to
be oversize when the groove diameter exceeds the
Note: Non-destructive testing (NDT) using electromagnetic means
nominal rope diameter by more than 15% steel, 20%
may also be used to detect broken wires and/or loss in metallic area.
polyurethane liners.
This method complements the visual examination but does not
replace it. Undersize grooves in sheaves will crush and deform the
rope, often leading to two clear patterns of wear and
Pictures courtesy of S.M.R.E. Crown Copyright 1966
associated wire breaks.
Excessive angle of fleet can result in severe wear of the

rope due to scrubbing against adjacent laps on the drum.
Rope deterioration at the Termination may be exhibited in
the form of broken wires. An excessive angle of fleet can
also induce rotation causing torsional imbalance.
BRIDON Crane 51
Troubleshooting Guide
Typical examples of Wire Rope deterioration
1 Mechanical damage 9 Typical wire fractures

due to rope movement as a result of bend
over sharp edge fatigue.
projection whilst under
load.
2 Localised wear due to 10 Wire fractures at the

abrasion on supporting strand, or core
structure. interface, as distinct
from ‘crown’ fractures.
3 Narrow path of wear 11 Break up of IWRC

resulting in fatigue resulting from high
fractures, caused by stress application.
working in a grossly
oversize groove, or
over small support
rollers.
4 Two parallel paths of 12 Looped wires as a

broken wires indicative result of torsional
of bending through an imbalance and/or shock
undersize groove in the loading.
sheave.
5 Severe wear, 13 Typical example of

associated with high localised wear and
tread pressure. deformation.
6 Severe wear in Lang’s 14 Multi strand rope ‘bird

Lay, caused by caged’ due to torsional
abrasion. imbalance.
7 Severe corrosion. 15 Protrusion of rope

centre resulting from
build up of turn.
8 Internal corrosion 16 Substantial wear and

whilst external surface severe internal
shows little evidence of corrosion.
deterioration.
52 BRIDON Crane
The following is a simplified guide to common wire rope problems. More detailed advice can be obtained from any Bridon
distributor. In the event of no other standard being applicable, Bridon recommends that ropes are inspected/examined in
accordance with ISO 4309.
Problem Cause/Action
Mechanical damage caused by the rope contacting the • Generally results from operational conditions.
structure of the installation on which it is operating or an
• Check sheave guards and support/guide sheaves to
external structure - usually of a localised nature.
ensure that the rope has not “jumped out” of the
intended reeving system.
• Review operating conditions.
Opening of strands in rotation resistant, low rotation and • Check sheave and drum groove radii using sheave
parallel closed ropes - in extreme circumstances the rope gauge to ensure that they are no smaller than nominal
may develop a “birdcage distortion” or protrusion of inner rope radius +5% - Bridon recommends that the sheave
strands. and drum groove radii are checked prior to any rope
installation.
Note - rotation resistant and low rotation ropes are designed
with a specific strand gap which may be apparent on • Repair or replace drum/sheaves if necessary.
delivery in an off tension condition. These gaps will close
• Check fleet angles in the reeving system - a fleet angle
under load and will have no effect on the operational
in excess of 1.5 degrees may cause distortion
performance of the rope.
(see page 48).
• Check installation method - turn induced during

installation can cause excessive rope rotation resulting
in distortion (See pages 57 - 64).
• Check if the rope has been cut “on site “ prior to

installation or cut to remove a damaged portion from
the end of the rope. If so, was the correct cutting
procedure used? Incorrect cutting of rotation resistant,
low rotation and parallel closed ropes can cause
distortion in operation (See page 61).
• Rope may have experienced a shock load.
Broken wires or crushed or flattened rope on lower layers • Check tension on underlying layers. Bridon
at crossover points in multi - layer coiling situations. recommends an installation tension of between 2% and
10% of the minimum breaking force of the wire rope.
Wire breaks usually resulting from crushing or abrasion.
Care should be taken to ensure that tension is retained
in service. Insufficient tension will result in these lower
layers being more prone to crushing damage.
• Review wire rope construction. Dyform wire ropes are

more resistant to crushing on underlying layers than
conventional rope constructions.
• Do not use more rope than necessary.
• Check drum diameter. Insufficient bending ratio

increases tread pressure.
Wires looping from strands. • Insufficient service dressing.
• Consider alternative rope construction.
• If wires are looping out of the rope underneath a

crossover point, there may be insufficient tension on the
lower wraps on the drum.
• Check for areas of rope crushing or distortion.
Continued on next page BRIDON Crane 53

“Pigtail” or severe spiralling in rope. • Check that the sheave and drum diameter is large
enough - Bridon recommends a minimum ratio of the
drum/sheave to nominal rope diameter of 18:1.
• Indicates that the rope has run over a small radius or

sharp edge.
• Check to see if the rope has “jumped off” a sheave and

has run over a shaft.
Two single axial lines of broken wires running along the • Check sheave and drum groove radii using sheave
length of the rope approximately 120 degrees apart gauge to ensure that they are no smaller than nominal
indicating that the rope is being “nipped” in a tight rope radius + 5% - Bridon would recommend that the
sheave. sheave/drum groove radii are checked prior to any
rope installation.
• Repair or replace drum/sheaves if necessary.
One line of broken wires running along the length of the • Check to see if the groove diameter is no greater than
rope indicating insufficient support for the rope, generally 15% greater than the nominal rope diameter.
caused by oversize sheave or drum grooving.
• Check for contact damage.
Short rope life resulting from evenly/randomly distributed • Bending fatigue is accelerated as the load increases
bend fatigue wire breaks caused by bending through the and as the bending radius decreases (see page 45).
reeving system. Consider whether either factor can be improved.
Fatique induced wire breaks are characterised by flat • Check wire rope construction - Dyform ropes are
ends on the broken wires. capable of doubling the bending fatigue life of a
conventional steel wire rope.
Short rope life resulting from localised bend fatigue wire • Bending fatigue is accelerated as the load increases
breaks. and as the bending radius decreases (see page 45).
Consider whether either factor can be improved.
Fatique induced wire breaks are characterised by flat
ends on the broken wires. • Check wire rope construction - Dyform ropes are
capable of doubling the bending fatigue life of a
conventional steel wire rope.
• Localised fatigue breaks indicate continuous repetitive

bends over a short length. Consider whether it is
economic to periodically shorten the rope in order to
move the rope through the system and progressively
expose fresh rope to the severe bending zone. In order
to facilitate this procedure it may be necessary to begin
operating with a slightly longer length of rope.
54 BRIDON Crane
Broken rope - ropes are likely to break when subjected to • Review operating conditions.
substantial overload or misuse particularly when a rope
has already been subjected to mechanical damage.
Corrosion of the rope both internally and/or externally can

also result in a significant loss in metallic area. The rope
strength is reduced to a level where it is unable to sustain
the normal working load.
Wave or corkscrew deformations normally associated • Check sheave and drum groove radii using sheave
with multistrand ropes. gauge to ensure that they are no smaller than nominal
rope radius +5% - Bridon recommends that the
sheave/drum groove radii are checked prior to any
rope installation.
• Check fleet angles in the reeving system - a fleet angle

in excess of 1.5 degrees may cause distortion
(see page 48).
• Check that rope end has been secured in accordance

with manufacturers instructions (see page 61).
• Check operating conditions for induced turn.
Rotation of the load in a single fall system. • Review rope selection.
• Consider use of rotation resistant or low rotation rope.

Force
Anchored Creates
Turn
Free to
Rotate
Rotation of the load in a • Review rope selection.

multi - fall system
Remedy • Consider use of rotation resistant or low rotation rope.
resulting in “cabling” of (Release
3 turns)
the rope falls. • Review installation procedure (See pages 57 - 64)
or operating procedures.
Possibly due to induced
turn during installation or
operation.
1.5 turns
L.H. cable
RIGHT HAND
LAY ROPE
Continued on next page
BRIDON Crane 55
Core protrusion or broken core in single layer six or eight • Caused by repetitive shock loading - review
strand rope. operating conditions.
Rope accumulating or “stacking” at drum flange - due to •Review drum design with original equipment
insufficient fleet angle. manufacturer - consider adding rope kicker, fleeting
sheave etc.
Sunken wraps of rope on the drum normally associated •Check correct rope diameter.
with insufficient support from lower layers of rope or
•If grooved drum check groove pitch.
grooving.
•Check tension on underlying layers - Bridon recommend
an installation tension of between 2% and 10% of the
minimum breaking force of the wire rope - Care should
be taken to ensure that tension is retained in service.
Insufficient tension will result in these lower layers being
more prone to crushing damage.
•Make sure that the correct rope length is being used.

Too much rope (which may not be necessary) may
aggravate the problem.
Short rope life induced by excessive wear and abrasion. •Check fleet angle to drum.
•Check general alignment of sheaves in the reeving

system.
•Check that all sheaves are free to rotate.
•Review rope selection. The smooth surface of Dyform

wire ropes gives better contact with drum and sheaves
and offers improved resistance to “interference”
betweeen adjacent laps of rope.
External corrosion. •Consider selection of galvanised rope.
•Review level and type of service dressing.
Internal corrosion. •Consider selection of galvanised rope.
•Review frequency amount and type of service dressing.
•Consider selection of plastic impregnated (PI) wire rope.
56 BRIDON Crane
Product Safety: Instructions & Warnings on the use of steel wire rope
The following Instructions and Warnings combine to Ensure that the rope does not make any direct
provide guidance on Product Safety and are intended for contact with the floor and that there is a flow of air
use by those already having a working knowledge of wire under the reel.
ropes, as well as the new user. They should be read,
followed and passed on to others.
WARNING
Failure to read, understand and follow these instructions
Failure to do so may result in the rope becoming
could result in harmful and damaging consequences.
contaminated with foreign matter and start the onset
A ‘Warning’ statement indicates a potential hazardous of corrosion before the rope is even put to work.
situation which could result in a significant reduction in rope
performance and/or put at risk, either directly or indirectly,
Support the reel on a simple A-frame or cradle,
the safety or health of those persons within the danger
located on ground which is capable of supporting the
zone of the rope and its associated equipment.
total mass of rope and reel. (See Fig. 2) Ensure that
Note: As a result of the creation of the single European market and the rope is stored where it is not likely to be affected
the ‘New Approach’ Directives which set out ‘essential requirements’ by chemical fumes, steam or other corrosive agents.
(e.g. for safety) designers, manufacturers, suppliers, specifiers and
users need to keep themselves abreast of any changes to the
appropriate Regulations and national standards.
1. Storage
1.1 Unwrap the rope and examine the rope immediately

after delivery to check its identification and condition
and verify that it is in accordance with the details on
the Certificates and/or other relevant documents.
Fig 2
Note: The rope should not be used for lifting purposes without the
user having a valid Certificate in his possession. WARNING
Check the rope diameter and examine any rope Failure to do so may seriously affect its condition
terminations to ensure that they are compatible with rendering it unfit for safe use.
the equipment or machinery to which they are to be
fitted. (See Fig. 1)
1.3 Examine ropes in storage periodically and, when
necessary, apply a suitable dressing which is
compatible with the manufacturing lubricant. Contact
the rope supplier, Bridon or original equipment
manufacturer’s (OEM) manual for guidance on types
of dressings available, methods of application and
equipment for the various types of ropes
and applications.
Fig 1 Re-wrap the rope unless it is obvious that this will be

detrimental to rope preservation. (Refer to the relevant
1.2 Select a clean, well ventilated, dry, undercover Product Data sheets on rope dressings for more
location. Cover with waterproof material if the delivery detailed information.)
site conditions preclude inside storage.
Rotate the reel periodically during long periods of WARNING

storage, particularly in warm environments, to prevent
migration of the lubricant from the rope. Failure to apply the correct dressing may render
the original manufacturing lubricant ineffective and
rope performance may be significantly affected.
WARNING
Never store wire rope in areas subject to elevated Ensure that the rope is stored and protected in such a
temperatures as this may seriously affect its future manner that it will not be exposed to any accidental
performance. In extreme cases its original as- damage either during the storage period or when
manufactured strength may be severely reduced placing the rope in, or taking it out of storage.
rendering it unfit for safe use.
BRIDON Crane 57
3.3 Ensure that the correct rope has been supplied by
WARNING
checking to see that the description on the Certificate
Failure to carry out or pay attention to any of the is in accordance with that specified in the purchaser’s
above could result in a loss of strength and/or a order.
reduction in performance. In extreme cases the
3.4 Check by measurement that the nominal diameter of
rope may be unfit for safe use.
the new rope conforms to the nominal size stated on
the Certificate.
2. Certification and Marking
For verification purposes, measure the diameter by
Make sure that the relevant Certificate has been using a suitable rope vernier fitted with jaws broad
obtained before taking the rope into use for a lifting enough to cover not less than two adjacent strands.
operation. (Refer to statutory requirements) Take two sets of measurements spaced at least 1
metre apart, ensuring that they are taken at the
Check to verify that the marking on the rope or its
largest cross-sectional dimension of the rope. At
package matches the relevant Certificate.
each point take measurements at right angles to
Note: The rating of a component part of a machine or lifting each other.
accessory is the responsibility of the designer of the machine or
The average of these four measurements should be
accessory. Any re-rating of a lifting accessory must be approved by a
within the tolerances specified in the appropriate
competent person.
Standard or Specification.
Retain the Certificate in a safe place for identification
For a more general assessment of rope diameter use
of the rope when carrying out subsequent periodic
a rope calliper. (See Fig 1)
statutory examinations in service. (Refer to statutory
requirements) 3.5 Examine the rope visually to ensure that no damage
or obvious signs of deterioration have taken place
3. Handling and Installation
during storage or transportation to the
3.1 Handling and installation of the rope should be installation site.
carried out in accordance with a detailed plan and
3.6 Check the working area around the equipment for any
should be supervised by a competent person.
potential hazards which may affect the safe
installation of the rope.
WARNING
3.7 Check the condition of the rope-related equipment in
Incorrectly supervised handling and installation accordance with the OEM’s instructions.
procedures may result in serious injury to Include the following -
persons in the vicinity of the operation as well as
Drum
those persons directly involved in the handling and
installation. Check the general condition of the drum.
If the drum is grooved, check the radius and pitch
3.2 Wear suitable protective clothing such as overalls, and ensure that the grooves will satisfactorily
industrial gloves, helmet, eye protectors and safety accommodate the size of the new rope (see Fig 3)
footwear (and respirator, particularly where the PITCH
emission of fumes due to heat is likely).
US
DI
RA
WARNING
Failure to wear suitable protective clothing and

equipment may result in skin problems from over
Fig 3
exposure to certain types of rope lubricants and
dressings; burns from sparks, rope ends, molten Check the condition and position of the kicker plates
lubricants and metals when cutting ropes or or wear plates, if fitted, to ensure that the new rope
preparing sockets for re-use; respiratory or other will spool correctly on the drum.
internal problems from the inhalation of fumes
when cutting ropes or preparing sockets for re-
use; eye injuries from sparks when cutting ropes;
lacerations to the body from wire and rope ends;
bruising of the body and damage to limbs due to
rope recoil, backlash and any sudden deviation
from the line of path of rope.
58 BRIDON Crane
Sheaves Coils
Ensure that the grooving is of the correct shape and Place the coil on the ground and roll it out straight
size for the new rope ensuring that it does not become contaminated with
Check that all sheaves are free to rotate and in dust/grit, moisture or any other harmful material.
good condition. (See Fig. 5)
Rope guards
Check that any rope guards are correctly fitted and
are in good condition.
Check the condition of any wear plates or rollers
which are protecting structural members.
WARNING
Failure to carry out any of the above could result in Fig 5

unsatisfactory and unsafe rope performance.
If the coil is too large to physically handle it may be
placed on a ‘swift’ turntable and the outside end of
Note: Grooves must have clearance for the rope and provide the rope pulled out allowing the coil to rotate.
adequate circumferential support to allow for free movement of the (See Fig. 5)
strands and facilitate bending. When grooves become worn and the
rope is pinched at the sides, strand and wire movement is restricted
and the ability of the rope to bend is reduced. (See Fig. 4)
WARNING
Never pull a rope away from a stationary coil as

Fig 4 this will induce turn into the rope and kinks will
form. These will adversely affect rope
Wrong Wrong
performance. (See Fig. 6)
Sheave groove Sheave groove

too narrow too wide
Fig 6
rIgHT Wrong
Sheave groove correctly Note the kinks
supporting the rope for
33% of its circumference forming
When a new rope is fitted a variation in size

compared with the old worn rope will be apparent.
The new rope may not fit correctly into the previously
worn groove profile and unnecessary wear and rope
distortion is likely to occur. This may be remedied by
machining out the grooves before the new rope is
installed. Before carrying out such action the sheaves
or drum should be examined to ensure that there will
be sufficient strength remaining in the underlying
material to safely support the rope.
The competent person should be familiar with the

requirements of the appropriate
application/machinery standard.
Note: General guidance to users is given in ISO 4309 Code of

practice for the selection, care and maintenance of steel wire rope.
Transfer the wire rope carefully from the storage area

to the installation site.
BRIDON Crane 59
Reels Ensure that the reel stand is mounted so as not to
create a reverse bend during reeving (i.e. for a winch
Pass a shaft through the reel and place the reel in a
drum with an overlap rope, take the rope off the top of
suitable stand which allows it to rotate and be braked
the reel). (See Fig. 7)
to avoid overrun during installation. Where multi-layer
coiling is involved it may be necessary for the reel to 3.9 Ensure that any equipment or machinery to be roped
be placed in equipment which has the capability of is correctly and safely positioned and isolated from
providing a back tension in the rope as it is being normal usage before installation commences. Refer
transferred from reel to drum. This is to ensure that to the OEM’s instruction manual and the relevant
the underlying (and subsequent) laps are wound ‘Code of Practice’.
tightly on the drum. (See Fig. 7)
3.10 When releasing the outboard end of the rope from a
reel or coil, ensure that this is done in a controlled
manner. On release of the bindings and servings
used for packaging, the rope will want to straighten
itself from its previously bent position. Unless
controlled, this could be a violent action. Stand clear.
WARNING
Fig 7
Failure to control could result in injury.
Position the reel and stand such that the fleet angle
during installation is limited to 1.5 degrees.
Ensure that the as-manufactured
(See Fig. 8)
condition of the rope is maintained
during installation.
If installing the new rope with the aid

of an old one, one method is to fit a
wire rope sock (or stocking) to each
ANGLE OF of the rope ends. Always ensure that
FLEET
the open end of the sock (or
stocking) is securely attached to the
rope by a serving or alternatively by a
CENTRE LINE
OF REEL clip
(See Fig. 9). Connect the two ends
via a length of fibre rope of adequate
CENTRE LINE strength in order to avoid turn being
OF SHEAVE
transmitted from the old rope into the
Fig 8 new rope. Alternatively a length of
fibre or steel rope of adequate
If a loop forms in the rope ensure that it does not strength may be reeved into the
tighten to form a kink. system for use as a pilot/messenger
line. Do not use a swivel during the
WARNING Fig 9 installation of the rope.
A kink can severely affect the strength of a six

strand rope and can result in distortion of a
rotation- resistant or low rotation rope leading to
its immediate discard.
60 BRIDON Crane
3.11 Monitor the rope carefully as it is being pulled into the A minimum of two servings either side of the cut (see
system and make sure that it is not obstructed by any fig 10) is normally sufficient for ropes up to 100mm
part of the structure or mechanism which may cause diameter and for larger ropes a minimum of four
the rope to come free. servings either side of the cut should be applied. It is
essential that the correct size serving wire or strand
(see fig 10a) is used and that adequate tension is
applied during the serving process to ensure the
integrity of the rope is maintained. It is particularly
important to maintain the integrity of non-preformed
ropes, multistrand rotational resistant ropes and
parallel closed ropes as failure to do so could affect
the ropes breaking strength and performance in
service. During the serving procedure, serving
mallets and hand operated serving machines can be
used to generate tight servings.
Bridon ‘On-site serving instructions’
Diameter of Serving
Wire or Strand
Rope Diameter
1x7 Wire
Single Wire
Strand
<22mm 1.32mm 1.70mm
22mm to 38mm 1.57mm 1.70mm

Fig 10
40mm to 76mm 1.83mm 2.60mm
WARNING 76mm to 100mm 2.03mm 3.00mm
Failure to monitor during this operation could >100mm n/a 3.60mm
result in injury.
Fig 10a
This entire operation should be carried out carefully and Arrange and position the rope in such a manner that
slowly under the supervision of a competent person. at the completion of the cutting operation the rope
ends will remain in position, thus avoiding any
3.12 Take particular care and note the manufacturer’s backlash or any other undesirable movement.
instructions when the rope is required to be cut.
Apply secure servings on both sides of the cut mark. Cut the rope with a high speed abrasive disc cutter.
(See Fig. 10 for typical method of applying a serving Other suitable mechanical or hydraulic shearing
to a multi-layer rope.) equipment may be used although not recommended
when a rope end is required to be welded or brazed.
Ensure that the length of serving is at least equal to two
For serving instructions for FL and HL ropes refer to
rope diameters. (Note: Special servings are required for
Bridon.
spiral ropes, i.e. spiral strand and locked coil.)
BRIDON Crane 61
When terminating a rope end with a wedge socket,
WARNING
ensure that the rope tail cannot withdraw through the
When using a disc cutter be aware of the danger socket by securing a clamp to the tail or by following
from sparks, disc fragmentation and fumes. the manufacturer’s instructions.
(Refer 3.2.)
(See Fig. 11 for two recommended methods of
securing the rope tail of a wedge socket termination).
Ensure adequate ventilation to avoid any build-up of
fumes from the rope and its constituent parts
including any fibre core (natural or synthetic) any rope
lubricant(s) and any synthetic filling and/or covering
material.
WARNING
Some special ropes contain synthetic material

which, when heated to a temperature higher than
normal production processing temperatures, will
decompose and may give off toxic fumes.
WARNING
Rope produced from carbon steel wires in the form

shipped is not considered a health hazard. During
subsequent processing (e.g. cutting, welding,
grinding, cleaning) dust and fumes may be
produced which contain elements which may
affect exposed workers.
Fig 11
The products used in the manufacture of steel wire

The loop back method uses a rope grip and the loop
ropes for lubrication and protection present minimal
should be lashed to the live part of rope by a soft wire
hazard to the user in the form shipped. The user must
serving or tape to prevent flexing of the rope
however, take reasonable care to minimise skin and
in service.
eye contact and also avoid breathing their vapour
and mist. The method of looping back should not be used if
there is a possibility of interference of the loop with
After cutting, the rope cross-sections of non-
the mechanism or structure.
preformed ropes, multi-layer ropes and parallel
closed ropes must be welded, brazed or fused and
tapered such that all wires and strands in the rope are WARNING
completely secured.
Failure to secure in accordance with instructions
could lead to loss of the rope and/or injury.
WARNING
Failure to correctly secure the rope end is likely to

3.14 When coiling a rope on a plain (or smooth) barrel
lead to slackness, distortions, premature removal
drum ensure that each lap lies tightly against the
from service and a reduction in the breaking force
preceding lap. The application of tension in the rope
of the rope.
greatly assists in the coiling of the rope.
3.13 Ensure that any fittings such as clamps or fixtures are

clean and undamaged before securing rope ends.
Make sure that all fittings are secure in accordance

with the OEM’s instruction manual or manufacturer’s
instructions and take particular note of any specific
safety requirements e.g. torque values (and
frequency of any re-application of torque).
62 BRIDON Crane
the termination is fitted in accordance with the OEM’s
WARNING
instruction manual or manufacturer’s instructions.
Any looseness or uneven winding will result in
When re-using a socket and depending on its type
excessive wear, crushing and distortion of the rope.
and dimensions, the existing cone should be pressed
out. Otherwise, heat may be necessary.
With plain barrel drums it is difficult to achieve
satisfactory multi-layer coiling beyond three layers.
WARNING
The direction of coiling of the rope on the drum is
When melting out sockets which have previously
important, particularly when using plain barrel drums,
been filled with hot metal, the emission of toxic
and should be related to the direction of lay of the
fumes is likely. Note that white metal contains a
rope in order to induce close coiling.
high proportion of lead.
(See Fig. 12 for proper method of locating rope
anchorage point on a plain drum.)
Correctly locate and secure any connection pins and
fittings when assembling end terminations to fixtures.
Proper method of locating rope anchorage point Refer to manufacturer’s instructions.
on a plain drum
WARNING
RIGHT HAND
LAY ROPE-
Failure to pay attention to any of the above could
UNDERWIND
result in unsafe operation and
START ROPE potential injury.
AT LEFT
RIGHT HAND
FLANGE
LAY ROPE-
RIGHT
HAND
OVERWIND 3.16 Limit switches, if fitted, must be checked and
re-adjusted, if necessary, after the rope has
LEFT
been installed.
HAND LEFT HAND
LAY ROPE- 3.17 Record the following details on the Certificate after
UNDERWIND
installation has been completed: type of equipment,
location, plant reference number, duty and date of
LEFT installation and any re-rating information/signature of
HAND LEFT HAND
LAY ROPE-
competent person. Then safely file the Certificate.
OVERWIND
3.18 ‘Run in’ the new rope by operating the equipment
slowly, preferably with a low load, for several cycles.
note: Thumb indicates side of rope anchorage
This permits the new rope to adjust itself gradually to
working conditions.
Fig 12
Note: Unless otherwise required by a certifying authority, the rope
When multi layer coiling has to be used it should be should be in this condition before any proof test of the equipment or
realised that after the first layer is wound on a drum, machinery is carried out.
the rope has to cross the underlying rope in order to
Check that the new rope is spooling correctly on the
advance across the drum in the second layer. The
drum and that no slack or cross laps develop.
points at which the turns in the upper layer cross
those of the lower layer are known as the cross-over If necessary, apply as much tension as possible
points and the rope in these areas is susceptible to to ensure tight and even coiling, especially on the
increased abrasion and crushing. Care should be first layer.
taken when installing a rope on a drum and when
Where multi-layer coiling is unavoidable,
operating a machine to ensure that the rope is coiled
succeeding layers should coil evenly on the
and layered correctly.
preceding layers of rope.
3.15 Check the state of re-usable rope end terminations
for size, strength, defects and cleanliness before use.
Non-destructive testing may be required depending
on the material and circumstances of use. Ensure that
BRIDON Crane 63
Note: Shortening the rope re-positions the areas of maximum
WARNING
deterioration in the system. Where conditions permit, begin operating
Irregular coiling usually results in severe surface with a rope which has a slightly longer length than necessary in order
wear and rope malformation, which in turn is likely to allow for periodic shortening.
to cause premature rope failure.
When a non-preformed rope, multi-layer rope or
parallel closed rope ie (DSC) is used with a wedge
3.19 Ensure that the as-manufactured condition of the socket and is required to be shortened, it is essential
rope is maintained throughout the whole of the that the end of the rope is secured by welding or
handling and installation operation. brazing before the rope is pulled through the main
body of the socket to its new position. Slacken the
3.20 If samples are required to be taken from the rope for
wedge in the socket. Pass the rope through the
subsequent testing and/or evaluation, it is essential
socket by an amount equivalent to the crop length or
that the condition of the rope is not disturbed. Refer
sample required. Note that the original bent portion of
to the instructions given in 3.12 and, depending on
the rope must not be retained within the wedge
the rope type and construction, any other special
socket. Replace the wedge and pull up the socket.
manufacturer’s instructions.
Prepare and cut in accordance with section 3.12.
4. In Service Ensure that the rope tail cannot withdraw through the
socket, see section 3.13.
4.1 Inspect the rope and related equipment at the
beginning of every work period and particularly
following any incident which could have damaged the WARNING
rope or installation.
Failure to observe this instruction will result in a
The entire length of rope should be inspected and significant deterioration in the performance of the
particular attention paid to those sections that rope and could render the rope completely unfit for
experience has proven to be the main areas of further service.
deterioration. Excessive wear, broken wires, distortion
and corrosion are the usual signs of deterioration. For
In cases where severe rope wear takes place at one
a more detailed examination special tools are
end of a wire rope, the life of the rope may be
necessary (see Fig. 13) which will also facilitate
extended by changing round the drum end with the
internal inspection (see Fig. 14.)
load end, i.e. turning the rope ‘end for end’ before
deterioration becomes excessive.
Fig 13
4.2 Remove broken wires as they occur by bending
backwards and forwards using a pair of pliers until
they break deep in the valley between two outer
strands (see Fig. 15). Wear protective clothing such
as overalls, industrial gloves, helmet, eye protectors
and safety footwear during this operation.
Fig 14
In the case of ropes working over drums or sheaves it Fig 15

is particularly necessary to examine those areas
entering or leaving the grooves when maximum loads WARNING
(i.e. shock loads) are experienced, or those areas
Do not shear off the ends of broken wires with
which remain for long periods in exposed places
pliers as this will leave an exposed jagged edge
such as over a Jib Head sheave.
which is likely to damage other wires in the rope
On some running ropes, but particularly relevant to and lead to premature removal of the rope from
standing ropes (e.g. pendant ropes) the areas service. Failure to wear adequate protective
adjacent to terminations should be given special clothing could result in injury.
attention. (see Fig. 14).
64 BRIDON Crane
Note: Broken wires are a normal feature of service, more so towards
WARNING
the end of the rope’s life, resulting from bending fatigue and wear.
The local break up of wires may indicate some mechanical fault in Failure to take adequate precaution could result in
the equipment. injury or damage to health.
Record the number and position in the rope of any

removed broken wires.
Only use compatible cleaning fluids which will not
4.3 Do not operate an appliance if for any reason (e.g. impair the original rope lubricant nor affect the rope
rope diameter, certified breaking force, rope associated equipment.
construction, length or strength and type of rope
termination) the wire rope and its termination is
WARNING
considered unsuitable for the required duty.
The use of cleaning fluids (particularly solvent
4.4 Do not operate an appliance if the wire rope fitted has
based) is likely to ‘cut back’ the existing rope
become distorted, been damaged or has deteriorated
lubricant leading to a greater quantity of lubricant
to a level such that discard criteria has been reached
accumulating on the surface of the rope. This may
or is likely to be reached prior to normal expected life
create a hazard in appliances and machinery which
based on historical performance data.
rely on friction between the rope and the drive
sheave (e.g. lifts, friction winders and cableways).
WARNING
Rope distortion is usually a result of mechanical 4.8 Lubricants selected for in-service dressing must be
damage and can significantly reduce rope strength. compatible with the rope manufacturing lubricant and
should be referenced in the OEM’s instruction manual
or other documents approved by the owner of the
4.5 An authorised competent person must examine the
appliance.
rope in accordance with the appropriate Regulations.
If in doubt contact Bridon or your rope supplier.
4.6 Do not carry out any inspection, examination,
dressing/lubrication, adjustment or any other 4.9 Take particular care when applying any in-service
maintenance of the rope whilst it is suspending a lubricant/dressing. Application systems which involve
load, unless otherwise stated in the OEM’s instruction pressure should only be operated by trained and
manual or other relevant documents. authorised persons and the operation carried out strictly
in accordance with the manufacturer’s instructions.
Do not carry out any inspection or maintenance of the
rope if the appliance controls are unattended unless the Most wire ropes should be lubricated as soon as they
surrounding area has been isolated or sufficient warning are put into service and at regular intervals thereafter
signs have been posted within the immediate vicinity. (including cleaning) in order to extend
safe performance.
If the appliance controls are attended, the authorised
person must be able to communicate effectively with
the driver or controller of the appliance during the WARNING
inspection process.
A ‘dry’ rope unaffected by corrosion but subject to
4.7 Never clean the wire rope without recognising the bend fatigue, is likely to achieve only 30% of that
potential hazards associated with working on a normally attained by a ‘lubricated’ rope.
moving rope.
Do not dress/lubricate the rope if the application

WARNING required it to remain dry. (Refer OEM’s
instruction manual.)
Failure to pay attention or take adequate
precaution could result in injury. Reduce the period between examinations when ropes
are not subjected to any in-service dressing and
when they must remain dry.
If cleaning by cloth/waste, the material can be
snagged on damaged surfaces and/or broken wires. Note: The authorised person carrying out a rope inspection must be
If cleaning by brush, eye protectors must be worn. If capable of recognising the potential loss of safe performance of
using fluids it should be recognised that some such a rope in comparison with lubricated rope.
products are highly inflammable. A respirator should
Clean the rope before applying a fresh
be worn if cleaning by a pressurised spray system.
dressing/lubricant if it is heavily loaded with foreign
matter e.g. sand, dust.
BRIDON Crane 65
4.10 The authorised person responsible for carrying out Ensure that the sample is kept straight throughout the
wire rope maintenance must ensure that the ends of whole procedure and ensure that the minimum
the rope are secure. At the drum end this will involve sample length is 4 metres for ropes up to and
checking the integrity of the anchorage and ensuring including 76mm diameter and 8 metres for larger
that there are at least two and a half dead laps tightly diameter ropes.
coiled. At the outboard end the integrity of the
The rope should be cut with a high speed abrasive
termination must be checked to ensure that it is in
disc cutter or an oxyacetylene torch. Weld the rope
accordance with the OEM’s manual or other
ends of the sample as described in section 3.12, after
documents approved by the owner of the appliance.
which the clamp or grip can be removed.
Adjust the lengths of ropes in multi-rope systems in
The identification of the rope must be established and
order that equal forces (within approved limits)
the sample suitably marked and packed. It is
are evident.
recommended that the 3 metre sample is retained
If a wire rope needs cutting refer to 3.12. straight and secured to a wood batten for
transportation. For a 12 metre sample, coil to a
When securing rope ends refer to 3.13.
diameter as large as practically possible and never
When re-usable end terminations are used refer to 3.15. less than 2 metres.
When re-connecting any end terminations to fixtures Note: Samples taken for destruction testing are required to be
refer to 3.15. terminated in accordance with a recognised resin socketing
standard (e.g. BS EN 13411-4).
4.11
WARNING
WARNING
Damage to, or removal of component parts
Failure to comply with these procedures will result in
(mechanical or structural) caused by abnormal
measured breaking force values which are not truly
contact with wire rope can be hazardous to the
representative of the actual strength of the rope.
safety of the appliance and/or the performance
of the rope (e.g. damage to the drum grooving,
such that coiling is erratic and/or the rope is 5. Wire Rope Discard
‘pulled down’ into underlying layers, which
5.1 Discard the wire rope in accordance with current
might cause a dangerous condition or,
Regulations and in accordance with the OEM’s
alternatively, cause localised rope damage at
instruction manual.
‘cross-over’ positions, which might then
radically affect performance; loss/removal of Note: The authorised competent person should also be familiar with
wear plates protecting the structure leading to the latest versions of International Standard ISO 4309 ‘Cranes
major structural damage by cutting and/or failure - wire ropes - Code of practice for examination and discard’
of the wire rope due to mechanical severance). and B.S. 6570 ‘ The selection, care and maintenance of steel
wire ropes’ which provide greater detail than that given in the
relevant Regulations. Other standards and instructions
4.12 Following any periodic statutory examination or
covering rope discard may also be applicable. In the case of
routine or special inspection where any corrective
synthetic sheaves (or synthetic linings) refer to the OEM’s
action is taken the Certificate should be updated and
instruction manual or contact the sheave (or lining)
a record made of the defects found, the extent of the
manufacturer for specific discard criteria.
changes and the condition of the rope.
5.2 If a wire rope is removed from service at a level of
4.13 Apply the following procedures for the selection and
performance substantially different to historically
preparation of samples, from new and used lengths
established performance data and without any
of rope, for the purpose of examination and testing to
obvious reason(s), contact Bridon or Bridon’s
destruction.
distributor for further guidance.
Check that the rope end, from which the sample will
5.3 Only qualified and experienced personnel, taking the
be taken, is secured by welding or brazing. If not,
appropriate safety precautions and wearing the
select the sample length further away from the rope
appropriate protective clothing, should be
end and prepare new servings (see 3.12).
responsible for removing the wire rope.
Handle the rope in accordance with the instructions
given in section 3. Serve the rope, using the buried
WARNING
wire technique (see Fig. 10) and apply a rope clamp
or grip as close to the cut mark as practically Take particular care when removing ropes with
possible. Do not use solder to secure the servings. mechanical damage as they may fail abruptly
during the change-out procedure.
66 BRIDON Crane
Take the utmost care when removing ‘exhausted/failed’
WARNING
ropes from drums and sheaves as they may be grossly
distorted, lively and tightly coiled. Wire rope which bends around sheaves, rollers or
drums will deteriorate through ‘bending fatigue’.
Reverse bending and high speed will accelerate
WARNING
the process. Therefore, under such conditions
Failure to take adequate precautions could result select a rope with high bending fatigue resistance.
in injury. Refer to Product Data Information, and if in doubt
ask for advice.
5.4 Store discarded rope in a safe and secure location or

compound and ensure that it is suitably marked to 6.3 Abrasion
identify it as rope which has been removed from
Wire rope which is subject to abrasion will become
service and not to be used again.
progressively weaker as a result of:
Externally - dragging it through overburden, sand or

WARNING
other abrasive materials and passing around a
Discarded rope can be a danger (e.g. protruding sheave, roller or drum.
broken wires, excessive grease/lubricant and rope
Internally - being loaded or bent.
mass) to personnel and equipment if not handled
correctly and safely during disposal.
WARNING
5.5 Record the date and reason for discard on the Abrasion weakens the rope by removing metal
Certificate before filing for future reference. from both the inner and outer wires. Therefore,
a rope with large outer wires should normally
5.6 Pay attention to any Regulations affecting the safe
be selected.
disposal of steel wire rope.
6. Rope Selection Criteria

6.4 Vibration
Ensure that the correct type of wire rope is selected
Vibration in wire rope will cause deterioration. This
for the equipment by referring to the OEM’s
may become apparent in the form of wire fractures
instruction manual or other relevant documents. If in
where the vibration is absorbed.
doubt contact Bridon or Bridon’s distributor
for guidance.
WARNING
6.1 Rope Strength
These fractures may be internal only and will not
If necessary, refer to the appropriate Regulations
be visually identified.
and/or application standards and calculate the
maximum force to which the rope will be subjected.
6.5 Distortion
The calculation may take into account the mass to be
lifted or moved, any shock loading, effects of high Wire rope can be distorted due to high pressure
speed, acceleration, any sudden starts or stops, against a sheave, improperly sized grooves or as a
frequency of operation and sheave bearing friction. result of multi-layer coiling on a drum.
By applying the relevant coefficient of utilisation Rope with a steel core is more resistant to crushing
(safety factor) and, where applicable, the efficiency of and distortion.
the rope termination, the required minimum breaking
6.6 Corrosion
load or force of the rope will be determined, the
values of which are available from the relevant Rope with a large number of small wires is more
National, European or International standards or from susceptible to corrosion than rope with a small
specific Product Data literature. number of large wires. Therefore, if corrosion is
If in doubt ask for advice from Bridon or expected to have a significant effect on rope
Bridon’s distributor. performance select a galvanised rope with as large
an outer wire size as possible bearing in mind the
6.2 Bending fatigue
other conditions (e.g. bending and abrasion) under
The size and number of sheaves in the system will which the rope will be operating.
influence the performance of the rope.
BRIDON Crane 67
6.7 Cabling
6.10 Rope Length
‘Cabling’ of rope reeving due to block rotation can
Rope length and /or difference in length between two
occur if the rope is incorrectly selected (see Fig.16).
or more ropes used in a set may be a critical factor
Applications involving high lifts are particularly
and must be considered along with rope selection.
vulnerable to this condition therefore, ropes specifically
designed to resist rotation need to be selected.
WARNING
Corrective procedure
for cabling, where the Wire rope will elongate under load. Other
Remedy
(Release rope length involved is factors such as temperature, rope rotation and
3 turns)
relatively short, may be internal wear will also have an effect.
simply to disconnect These factors should also be considered
both ends of the rope during rope selection.
and pull the rope out
straight along the
6.11 Preformed and Non-preformed Ropes
ground. This will allow
1.5 turns
any build up of turn in Single layer round strand rope is normally supplied
L.H. cable the rope to be preformed. However, if a non-preformed rope is selected
released before the then personnel responsible for its installation and/or
rope is re-installed on maintenance need to take particular care when handling
the crane. If cabling such rope, especially when cutting. For the purposes of
persists, or the rope this instruction, multi-layer, parallel closed and spiral
length involved is ropes should be regarded as non-preformed ropes.
relatively long, it may
6.12 Operating Temperatures
be necessary to
RIGHT HAND LAY ROPE
correct by releasing or Wire rope with a steel core should be selected if there
correct by releasing or is any evidence to suggest that a fibre core will not
Fig 16 inducing turn at the provide adequate support to the outer strands and/or
outboard anchorage. If left hand cabling is produced if the temperature of the working environment may be
in the reeving system, correction is usually achieved expected to exceed 100˚C.
(on the right hand lay ropes, see Fig. 16) by releasing
For operating temperatures above 100˚C de-rating of
turn at the anchorage. Effort must be made to work
the minimum breaking force of the rope is necessary
released or induced turn throughout the working
(e.g. between 100˚C and 200˚C reduce by 10%;
length of rope, by operating the crane at maximum
between 200˚C and 300˚C reduce by 25%; between
height of lift with a light load. It may be necessary to
300˚C and 400˚C reduce by 35%).
repeat the process until the cabling has been
corrected. For right hand cable it will normally be Do not use ropes with high carbon wires above 400˚C.
necessary to induce turn at the anchorage.
6.8 Fixing of Rope Ends WARNING

Ropes which have high rotation characteristics (such as Failure to observe this general guidance could
single layer Lang’s lay rope and parallel closed rope result in failure of the ropes to support the load.
e.g. DSC) must not be selected unless both ends of the
rope are fixed or the load is guided and unable to rotate.
For temperatures over 400˚C, other materials such as
6.9 Connecting Ropes stainless steel or other special alloys should be
In the event that it is necessary to connect one rope to considered.
another (in series) it is essential that they have the
required strength, are of the same type and both have the WARNING
same lay direction (i.e. connect ‘right’ lay to ‘right’ lay).
Rope lubricants and any synthetic filling and/or
covering materials may become ineffective at
WARNING certain low or high operating temperature levels.
Failure to heed this warning could result in
catastrophic failure particularly at a termination Certain types of rope end terminations also have
which is capable of being pulled apart (i.e. limiting operating temperatures and the manufacturer
splice) due to unlaying. or Bridon should be consulted where there is any
doubt. Ropes with aluminium ferrules must not be
used at temperatures in excess of 150˚C.
68 BRIDON Crane
WARNING
Wire rope will fail if worn-out, shock loaded, overloaded, misused, damaged, improperly
maintained or abused.
• Always inspect wire rope for wear, damage or abuse before use
• Never use wire rope which is worn-out, damaged or abused
• Never overload or shock load a wire rope
• Inform yourself: Read and understand the guidance on product safety given in this catalogue;
also read and understand the machinery manufacturer’s handbook
• Refer to applicable directives, regulations, standards and codes concerning inspection, examination
and rope removal criteria
Protect yourself and others - failure of wire rope may cause serious injury or death!
WARNING
CAUTIONARY NOTICE – RESTRICTIONS ON THE being in the region of half the breaking strength
USE OF LARGE DIAMETER MULTISTRAND ROPES. of the rope.
All wire ropes are prone to damage if they are not The best way of preventing difficulties of this sort
properly supported when used at high loads. is to avoid conditions that are likely to generate
Larger Multistrand ropes are particularly damagingly high contact stresses. A simple
susceptible to this form of abuse, due to their rigid method of assessing the severity of the contact
construction and the relatively fine wire sizes conditions is to firstly calculate the tread pressure
involved in their manufacture/construction. based on the projected nominal area and then
Instances have been recorded of ropes being apply a factor (of say 10*) to allow for the highly
heavily worked over plain drums and failing localised and intermittent nature of the actual wire
"prematurely", despite the nominal tension being contacts, as indicated below :-
Type of contact Close-fitting U-groove Oversize U-groove Plain drum

Level of support Good Fair Poor
Tread path width 100% of rope dia. 50% of rope dia. 20% of rope dia.
Tread pressure = 2T/Dd 4T/Dd 10T/Dd
Contact stress = 20T/Dd 40T/Dd 100T/Dd
Note: Contact stresses which exceed 10% of the wire UTS Worked example:
should be considered a cause for concern, especially if the
Consider case of a 50mm Multistrand rope (MBL=2100kN)
rope is operating at a low factor of safety.
operating at a 3:1 factor of safety. Then, for the Contact
[* This is because the true contact area is very much less than the stress < 200 Mpa say, the following minimum bending
projected nominal area.] diameters are indicated:
Close-fitting groove – 1400mm

Oversize U-groove - 2800mm
Un-grooved drum - 7000mm
BRIDON Crane 69
Material Safety Data

Introduction external covering. No Occupational Exposure Limits
(OEL’s) exist for steel wire rope and the values provided in
Steel wire rope is a composite material and dependent
this publication relate to component elements and
upon its type may contain a number of discrete materials.
compounds. The actual figures quoted in relation to the
The following provides full details of all the individual
component parts are taken from the latest edition of EH40.
materials which may form part of the finished wire rope.
Rope produced from carbon, coated or stainless steel
The description and/or designation of the wire rope stated on
wires in the as-supplied condition is not considered a
the delivery note and/or invoice (or certificate, when
health hazard. However during any subsequent processing
applicable) will enable identification of the component parts.
such as cutting, welding, grinding and cleaning, dust and
The main component of a steel wire rope is the wire, which fumes may be produced which contain elements that may
may be carbon steel, coated (zinc or Zn95/A15) steel or affect exposed workers.
stainless steel.
The following indicates the order in which specific
The other three components are (i) the core, which may be information is provided:-
of steel of the same type as used in the main strands or
Carbon steel wire, Coated steel wire, Stainless steel wire,
alternatively fibre (either natural or synthetic), (ii) the rope
Manufacturing rope lubricants, Fibre cores,
lubricant and, where applicable, (iii) any internal filling or
Filling and covering materials, General information
Carbon Steel Wire - Hazardous Ingredients
Long term exposure limit Short term exposure limit

Component % Weight (Max) (8-hour TWA reference (10-minute reference
period) mg/m3 period) mg/m3
BASE METAL
Aluminium 0.3 10 20
Carbon 1.0 None Listed
Chromium 0.4 0.5
Cobalt 0.3 0.1
Copper 0.5 0.2
Iron Balance 5 10
Manganese 1.0 5 5
Molybdenum 0.1 5 10
Nickel 0.5 1
Phosphorus 0.1 0.1 0.3
Silicon 0.5 10
Sulphur 0.5 None Listed
Vanadium 0.25 0.5
Boron 0.1 10 20
Titanium 0.1 10
Nitrogen 0.01 5 9
Lead 0.1 0.15
Arsenic 0.01 0.2
Zirconium 0.05 5 10
COATED
Sodium 0.5 None Listed
Calcium 0.5 2
Boron 1.0 10 20
Iron 1.0 5 10
Zinc 1.0 5 10
Oil may be applied 5.0 5 10
Physical Data
Specific Gravity: 7.5 - 8.5 Vapour Pressure: N/A
Melting Point: 1350 - 1500 oC Vapour Density: N/A
Appearance & Odour: Solid. Odourless Metal Evaporation: N/A
Solubility in water: Insoluble % Volatiles: N/A
Flash Point: None Boiling Point: > 2800 oC
70 BRIDON Crane

Coated (Zinc and Zn95/A 15) Steel Wire - Hazardous Ingredients
Long term exposure limit Short term exposure limit

Component % Weight (Max) (8-hour TWA reference (10-minute reference
period) mg/m3 period) mg/m3
BASE METAL
Aluminium 0.3 10 20
Carbon 1.0 None Listed
Chromium 0.4 0.5
Cobalt 0.3 0.1
Copper 0.5 0.2
Iron Balance 5 10
Manganese 1.0 5 5
Molybdenum 0.1 5 10
Nickel 0.5 1
Silicon 0.5 10
Vanadium 0.25 0.5
Boron 0.1 10 20
Titanium 0.1 10
Nitrogen 0.01 5 9
Lead 0.1 0.15
Arsenic 0.01 0.2
Zirconium 0.05 5 10
COATED
Zinc 10.0 5 10
Aluminium 1.5 10 20
Iron 5.0 5 10
Sodium 0.5 None Listed
Calcium 0.5 2
Boron 1.0 100 20
Oil may be applied 5.0 5 10
Wax may be applied 5.0 2 6
Physical Data
Specific Gravity: 7.5 - 8.5 Vapour Pressure: N/A
Melting Point: 1350 - 1500 oC Vapour Density: N/A
Appearance & Odour: Solid. Odourless Metal Evaporation: N/A
Solubility in water: Insoluble % Volatiles: N/A
Flash Point: None Boiling Point: > 2800 oC
BRIDON Crane 71

Manufacturing Rope Lubricants The worker should:
1) use oil impermeable gloves, or if not available, suitable
The products used in the manufacture of steel wire ropes
oil repellent type barrier creams,
for lubrication and protection present minimal hazard to the
2) avoid unnecessary contact with oil using protective clothing,
user in the as-supplied condition. The user must, however,
3) obtain first aid treatment for any injury, however slight,
take reasonable care to minimise skin and eye contact and
4) wash hands thoroughly before meals, before using the
also avoid breathing their vapours and mists.
toilet and after work,
A wide range of compounds is used as lubricants in the 5) use conditioning creams after washing, where provided.
manufacture of steel wire rope. These products, in the
The worker should not:
main, consist of mixtures of oils, waxes, bitumens,
1) put oily rags or tools into pockets, especially trousers,
resins, gelling agents and fillers with minor concentrations
2) use dirty or spoiled rags for wiping oil from the skin,
of corrosion inhibitors, oxidation stabilizers and
3) wear oil soaked clothing,
tackiness additives.
4) use solvents such as parafin, petrol etc., to remove oil
Most of them are solid at ambient temperatures and from the skin.
provided skin contact with the fluid types is avoided, none
Concentrations of oil mists, fumes and vapours in the working
present a hazard in normal rope usage.
atmosphere must be kept as low as is reasonably practicable.
However, to assist in the assessment of the hazard caused Levels quoted in the current edition of HSE Guidance Note
by these products, the following table contains all the EH40 ‘Occupational Exposure Limits’ must not be exceeded.
components which may be incorporated into a wire rope
Health Hazards
lubricant and which may be considered hazardous to health.
Inhalation of oil mists or fumes from heated rope lubricants
Hazardous Ingredients:
in high concentrations may result in dizziness, headache,
Long term Short term respiratory irritation or unconsciousness. Eye contact may
exposure limit exposure limit produce mild transient irritation to some users.
Component (8-hour TWA (10-minute
Fumes from heated rope lubricants in high concentrations
reference reference
period) mg/m3 period) mg/m3 may cause eye irritation.
Oil mist 5 10 If heated rope lubricants contacts skin, severe burns may result.
Paraffin wax fume 2 6 Prolonged or repeated skin contact may cause irritation,
Bitumen 5 10 dermatitis or more serious skin disorders.
Silica, fused
Total inhalable dust 0.3 Fibre Cores
Respirable dust 0.1
Being in the centre of a steel wire rope, the materials
Aluminium flake 10 20
(natural or synthetic) from which fibre cores are produced
Zinc oxide, fume 5 10
do not present a health hazard during normal rope
Butane 1430 1780
handling. Even when the outer core strands are removed
(for example when the rope is required to be socketed) the
There are no other known constituents of any wire rope
core materials present virtually no hazard to the users,
lubricant used that are classified as hazardous in the
except, maybe, in the case of a used rope where, in the
current edition of EH40.
absence of any service dressing or as a result of heavy
General advice on handling ropes with lubricants working causing internal abrasive wear of the core, the core
may have decomposed into a fibre dust which might be
To avoid the possibility of skin disorders, repeated or inhaled, although this is considered extremely unlikely.
prolonged contact with mineral or synthetic hydrocarbons
must be avoided and it is essential that all persons who The principal area of hazard is through the inhalation of
come into contact with such products maintain high fumes generated by heat, for example when the rope is
standards of personal hygiene. being cut by a disc cutter.
72 BRIDON Crane

Under these conditions, natural fibres are likely to yield Safety Information
carbon dioxide, water and ash, whereas synthetic materials
1) Fire and explosion - In the solid state, steel components
are likely to yield toxic fumes.
of the rope present no fire or explosion hazard. the organic
The treatment of natural fibres, such as rotproofing, may elements present, i.e. lubricants, natural and synthetic
also produce toxic fumes on burning. fibres and other natural or synthetic filling and covering
materials are capable of supporting fire.
The concentrations of toxic fumes from the cores, however,
2) Reactivity - Stable under normal conditions.
will be almost negligible compared with the products
generated by heating from the other primary materials, e.g. Spill or leak procedures
wire and manufacturing lubricant in the rope.
1) Spill or leak - Not applicable to steel in the solid form.
The most common synthetic core material is polypropylene, 2) Disposal - Dispose of in accordance with
although other polymers such as polyethylene and nylon local Regulations.
may occasionally be used.
Filling and Covering Materials Rope Terminology

Filling and covering materials do not present a health hazard
during handling of the rope in its as-supplied condition. Wires
The principal area of hazard is by the inhalation of fumes Outer wires: All wires positioned in the outer layer of wires
generated by heat, for example when the rope is being cut in a spiral rope or in the outer layer of wires in the outer
by a disc cutter. strands of a stranded rope.
Under these conditions, fillings and coverings, which are Inner wires: All wires of intermediate layers positioned
generally polypropylene, polyethylene and polyamid (but in between the centre wire and outer layer of wires in a spiral
some cases may be of natural fibre) are likely to produce rope or all other wires except centre, filler, core and outer
toxic fumes. wires of a stranded rope.
General Information Core wires: All wires of the core of a stranded rope.
Occupational protective measures Centre wires: Wires positioned either at the centre of a
1) Respiratory protection - Use general and local spiral rope or at the centres of strands of a stranded rope.
exhaust ventilation to keep airborne dust or fumes Layer of wires: An assembly of wires having one pitch
below established occupational exposure standards circle diameter. The exception is Warrington layer
(OES’s). Operators should wear approved dust and comprising alternately laid large and small wires where the
fume respirators if OES’s are exceeded. smaller wires are positioned on a larger pitch circle
(The OES for total dust is 10mg/m3 and for respirable diameter than the larger wires. The first layer is that which is
dust is 5mg/m3). laid immediately over the strand centre.
2) Protective equipment - Protective equipment should
be worn during operations creating eye hazards. A Note: Filler wires do not constitute a separate layer.
welding hood should be worn when welding or burning. Tensile strength grade of wires: A level of requirement of
Use gloves and other protective equipment tensile strength of a wire and its corresponding tensile
when required. strength range. It is designated by the value according to
3) Other - Principles of good personal hygiene should the lower limit of tensile strength and is used when
be followed prior to changing into street clothing or specifying wire and when determining the calculated
eating. Food should not be consumed in the minimum breaking force or calculated minimum aggregate
working environment. breaking force of a rope.
Emergency medical procedures Wire finish: The condition of the surface finish of a wire,
1) Inhalation - Remove to fresh air; get medical attention. e.g. bright, zinc coated.
2) Skin - Wash areas well with soap and water.
3) Eyes - Flush well with running water to remove
particulate; get medical attention.
4) Ingestion - In the unlikely event that quantities of rope or
any of its components are ingested, get medical attention.
BRIDON Crane 73
Rope Terminology
Strands Combined parallel lay: Parallel lay strand construction
having three or more layers of wires, e.g. 14-7+7-7-1;
Strand: An element of rope usually consisting of an 16-8+8-8-1; 14-14-7F-7-1; 16-16-8F+8-1.
assembly of wires of appropriate shape and dimensions
laid helically in the same direction in one or more layers Note: The first two examples above are also referred to as
around a centre. Warrington-Seale construction. The latter two examples are also
referred to as Seale-Filler contruction.
Note: Strands containing three or four wires in the first layer or certain
shaped (e.g. ribbon) strands may not have a centre. Multiple operation lay strand: Strand construction
containing at least two layers of wires, at least one of which
Round strand: A strand with a cross-section which is is laid in a separate operation. All of the wires are laid in the
approximately the shape of a circle. same direction.
Triangular strand: A strand with a cross-section which is Cross-lay: Multiple operation strand construction in which
approximately the shape of a triangle. the wires of superimposed wire layers cross over one
Note: Triangular strands may have built-up centres (i.e. more than another and make point contact, e.g. 12/6-1.
one wire forming a triangle). Compound lay: Multiple operation strand which contains a
Oval strand: A strand with a cross-section which is minimum of three layers of wires, the outer layer of which is
approximately the shape of an oval laid over a parallel lay centre, e.g. 16/6+6-6-1.
Flat ribbon strand: A strand without a centre wire with a Ropes

cross-section which is approximately the shape of a
rectangle. Spiral Rope: An assembly of two or more layers of shaped
and/or round wires laid helically over a centre, usually a
Compacted strand: A strand which has been subjected to single round wire. There are three categories of spiral rope,
a compacting process such as drawing, rolling or swaging viz. spiral strand, half-locked coil and full-locked coil.
whereby the metallic cross-sectional area of the wires
remains unaltered and the shape of the wires and the Spiral Strand: An assembly of two or more layers of round
dimensions of the strand are modified. wires laid helically over a centre, usually a single round
wire.
Note: Bridon’s brands of Dyform rope contain strands which have
been compacted. Half-locked Coil Rope: A spiral rope type having an
outer layer of wires containing alternate half lock and
Single lay strand: Strand which contains only one layer of round wires.
wires, e.g. 6-1.
Full-locked Coil Rope: A spiral rope type having an outer
Parallel lay strand: Strand which contains at least two layer of full lock wires.
layers of wires, all of which are laid in one operation (in the
same direction), e.g. 9-9-1; 12-6F-6-1; 14-7+7-7-1. Each Stranded Rope: An assembly of several strands laid
layer of wires lies in the interstices of the underlying layer helically in one or more layers around a core or centre.
such that they are parallel to one another, resulting in There are three categories of stranded rope, viz. single
linear contact. layer, multi-layer and parallel-closed.
Note: This is also referred to as equal lay. The lay length of all the Single Layer Rope: Stranded rope consisting of one layer
wire layers are equal. of strands laid helically over a core.
Seale: Parallel lay strand construction with the same Note: Stranded ropes consisting of three or four outer strands may,
number of wires in each wire layer, each wire layer or may not, have a core. Some three and four strand single layer
containing wires of the same size, e.g. 7-7-1; 8-8-1; 9-9-1. ropes are designed to generate torque levels equivalent to those
generated by rotation-resistant and low rotation ropes.
Warrington: Parallel lay strand construction having an
outer layer of wires containing alternately large and small Rotation-resistant Rope: Stranded rope having no less
wires, the number of wires in the outer layer being twice than ten outer strands and comprising an assembly of at
that in the underlying layer of wires, e.g. 6+6-6-1; 7+7-7-1. least two layers of strands laid over a centre, the direction
of lay of the outer strands being opposite (i.e. contra - lay)
Filler: Parallel lay strand construction having an outer layer to that of the underlying layer of strands.
of wires containing twice the number of wires than in the
inner layer with filler wires laid in the intersticeswires of the Low Rotation Rope: Rotation resistant rope having at
underlying layer of wires, e.g. 12-6F-6-1; 14-7F-7-1. least fifteen outer strands and comprising an assembly of
at least three layers of strands laid over a centre in
two operations.
Note: this category of rotation resistant rope is constructed in such a

manner that it displays little or no tendency to rotate, or if guided,
generates little or no torque when loaded.
74 BRIDON Crane
Rope Terminology
Compacted Strand Rope: Rope in which the outer Braided Rope: An assembly of several round strands
strands, prior to closing of the rope, are subjected to a braided in pairs.
compacting process such as drawing, rolling or swaging.
Electro-mechanical Rope: A stranded or spiral rope
Note: Bridon’s products containing compacted strands are identified containing electrical conductors.
by “Dyform”.
Compacted Rope: Rope which is subjected to a

Strand and Rope Lays
compacting process after closing, thus reducing its diameter. Lay direction of strand: The direction right (z) or left (s)
corresponding to the direction of lay of the outer layer of
Solid Polymer Filled Rope: Rope in which the free
wires in relation to the longitudinal axis of the strand.
internal spaces are filled with a solid polymer. The polymer
extends to, or slightly beyond, the outer circumference of Lay direction of rope: The direction right (Z) or left (S)
the rope. corresponding to the direction of lay of the outer strands in
relation to the longitudinal axis of a stranded rope or the
Cushioned Rope: Stranded rope in which the inner layers,
direction of lay of the outer wires in relation to the
inner strands or core strands are covered with solid
longitudinal axis of a spiral rope.
polymers or fibres to form a cushion between adjacent
strands or layers of strands. Ordinary lay: Stranded rope in which the direction of lay of
the wires in the outer strands is in the opposite direction to
Cushion Core Rope: Stranded rope in which the core is
the lay of the outer strands in the rope. Right hand ordinary
covered (coated) or filled and covered (coated) with a
lay is designated sZ and left hand ordinary lay is
solid polymer.
designated zS.
Solid Polymer Covered Rope: Rope which is covered
Note: This type of lay is sometimes referred to as ‘regular’ lay.
(coated) with a solid ploymer.
Lang’s lay: Stranded rope in which the direction of lay of
Solid Polymer Covered and Filled Rope: Rope which is
the wires in the outer strands is the same as that of the
covered (coated) and filled with a solid polymer.
outer strands in the rope. Right hand Lang’s lay is
Rope Grade (Rr): A number corresponding to a wire designated zZ and left hand Lang’s lay is designated sS.
tensile strength grade on which the minimum breaking
Alternate lay: Stranded rope in which the lay of the outer
force of a rope is calculated.
strands is alternatively Lang’s lay and ordinary lay. Right
Note: It does not imply that the actual tensile strength grades of the hand alternate lay is designated AZ and left hand alternate
wires in a rope are necessarily the same as the rope grade. lay is designated AS.
Preformed Rope: Stranded rope in which the wires in the Contra-lay: Rope in which at least one inner layer of wires
strands and the strands in the rope have their internal in a spiral rope or one layer of strands in a stranded rope is
stresses reduced resulting in a rope in which, after removal laid in the opposite direction to the other layer(s) of wires or
of any serving, the wires and the strands will not spring out strands respectively.
of the rope formation.
Note: Contra-lay is only possible in spiral ropes having more than
Note: Multi-layer stranded ropes should be regarded as non- one layer of wires and in multi-layer stranded ropes.
preformed rope even though the strands may have been partially
Rope lay length (Stranded Rope): That distance parallel
(lightly) preformed during the closing process.
to the axis of the rope in which the outer strands make one
Rope Class: A grouping of rope constructions where the complete turn (or helix) about the axis of the rope.
number of outer strands and the number of wires and how
they are laid up are within defined limits, resulting in ropes Cores
within the class having similar strength and rotational
Core: Central element, usually of fibre or steel, of a single
properties.
layer stranded rope, around which are laid helically the
Rope Construction: System which denotes the outer strands of a stranded rope or the outer unit ropes of a
arrangement of the strands and wires within a rope, e.g. cable-laid rope.
6x36WS, 6x19S, 18x7, 34xK7.
Fibre core: Core made from natural fibres(e.g. hemp,
Note: K denotes compacted strands. sisal) and designated by its diameter and runnage.
Cable-laid Rope: An assembly of several (usually six) Synthetic Core: Core made from synthetic fibres (e.g.
single layer stranded ropes (referred to as unit ropes) laid polypropylene) and designated by its diameter and
helically over a core (usually a seventh single layer runnage.
stranded rope).
BRIDON Crane 75
Rope Terminology
Steel core: Core produced either as an independent wire Minimum breaking force (Fmin): Specified value, in kN,
rope (IWRC)(e.g. 7x7) or wire strand (WSC)(e.g. 1x7). below which the measured breaking force is not allowed to
fall in a prescribed test and, for ropes having a grade,
Solid polymer core: Core produced as a single element
obtained by calculation from the product of the square of
of solid polymer having a round or grooved shape. It may
the nominal diameter, the rope grade and the breaking
also contain internal elements of wire or fibre.
force factor.
Insert: Element of fibre or solid polymer so positioned as
Minimum aggregate breaking force (Fe,min): Specified
to separate adjacent strands or wires in the same or
value, in kN, below which the measured aggregate
overlying layers and fill, or partly fill, some of the interstices
breaking force is not allowed to fall in a prescribed test and,
in the rope. (see Zebra)
for ropes having a grade, obtained from the product of the
square of the nominal rope diameter (d), the metallic cross-
Rope Characteristics and Properties sectional area factor (C) and the rope grade (Rr).
Calculated Minimum aggregate Breaking Force: Value
Norminal length mass: The nominal mass values are for
of minimum aggregate breaking force is obtained by
the fully lubricated ropes.
calculation from the sum of the products of the cross-
sectional area (based on nominal wire diameter) and tensile Rope torque: Value, usually expressed in N.m, resulting
strength grade of each wire in the rope, as given in the from either test or calculation, relating to the torque
manufacturer’s rope design. generated when both ends of the rope are fixed and the
rope is subjected to tensile loading.
Calculated Minimum breaking Force: Value of minimum
breaking force based on the nominal wire sizes, wire tensile Rope turn: Value, usually expressed in degrees per metre,
strength grades and spinning loss factor for the rope class resulting from either test or calculation, relating to the
or construction as given in the manufacturer’s rope design. amount of rotation when one end of the rope is free to
rotate and the rope is subjected to tensile loading.
Fill factor: The ratio between the sum of the nominal
cross-sectional areas of all the load bearing wires in the Initial extension: Amount of extension which is attributed
rope and the circumscribed area of the rope based on its to the initial bedding down of the wires within the strands
nominal diameter. and the strands within the rope due to tensile loading.
Spinning loss factor (k): The ratio between the calculated Note: This is sometimes referred to as constructional stretch.
minimum breaking force of the rope and the calculated
Elastic extension: Amount of extension which follows
minimum aggregate breaking force of the rope.
Hooke’s Law within certain limits due to application of a
Breaking force factor (K): An empirical factor used in the tensile load.
determination of minimum breaking force of a rope and
Permanent rope extension: Non-elastic extension.
obtained from the product of fill factor for the rope class or
construction, spinning loss factor for the rope class or
construction and the constant π/4.
76 BRIDON Crane
Contacts
BRIDON
Sales Offices
UNITED KINGDOM INDONESIA SINGAPORE
Doncaster PT Bridon Bridon Singapore (Pte) Ltd.
Balby Carr Bank, Doncaster Graha Inti Fauzi Loyang Offshore Supply Base
South Yorkshire 2nd Floor (SOPS Way)
DN4 5JQ Jl. Buncit Raya No.22 Box No: 5064
United Kingdom Jakarta 12510 Loyang Crescent
[email protected] [email protected] Singapore 508988
Phone: +44(0) 1302 565100 Phone: +62 (021) 791 81919 [email protected]
Fax: +44(0) 1302 565190 Fax: +62 (021) 799 2640 Phone: +65 654 64 611
Fax: +65 654 64 622
UNITED STATES AFRICA
Bridon American Angola
CHINA
C280 New Commerce Blvd. Sonils Base Bridon Hong Kong Ltd.
Wilkes Barre Luanda Unit B G/F Roxy Industrial Centre
PA 18706 Angola 58-66 Tai Lin Pai Road
USA [email protected] Kwai Chung
[email protected] Phone: + 244 923 726890 Northern Territory
Phone: +1 800 521 5555 Fax: + 244 923 854180 Hong Kong
Fax: +1 800 233 8362 Kwanda Base [email protected]
Soyo Phone: +852 240 11 166
GERMANY Angola Fax: +852 240 11 232
[email protected] Bridon Hangzhou
Bridon International GmbH
Phone: + 244 935 939761
Magdeburger Straße 14a Fax: + 244 937 638565 57 Yonghua Street
D-45881 Xiacheng District
Gelsenkirchen Hangzhou City
Germany
SOUTH AFRICA Zhejiang Province
[email protected] [email protected] 310022.P.R.China
Phone: +49(0) 209 8001 0 Phone: +27 (0) 11 867 3987 [email protected]
Fax: +49(0) 209 8001 275 Cell: +27 (0) 79 887 2747 Phone: +86 571 8581 8780
Fax: +27 (0) 11 867 3987 Fax: +86 571 8813 3310
RUSSIA
MIDDLE EAST AUSTRALIA
Bridon International Moscow
Bridon Middle East [email protected]
Ivovaya Street 2/8
Phone: +61 429 999 756
Building 1, Office 215 PO Box 16931
129329 Moscow Dubai
Russia United Arab Emirates NEW ZEALAND
[email protected] [email protected] 6-10 Greenmount Drive
Phone: +7 495 1808001 Phone: +971 488 35 129 East Tamaki
Fax: + 7 495 1809231 Fax: +971 488 35 689 PO Box 14 422
Panmure
AUCKLAND
[email protected]
Phone: +64 9 2744299
Fax: +64 9 2747982
BRIDON Crane 79
Ground Floor, Icon Building,
First Point, Balby Carr Bank,
Doncaster, South Yorkshire
DN4 5JQ United Kingdom
Phone: +44(0) 1302 565100
Fax: +44(0) 1302 565190
02/2011 Edition 7
Email: [email protected]
www.bridon.com
Configuration Instructions
Profibus
BE-PROFIBUS-V2-0 [PMRS]
HBC – Radio Control

Profibus DP Configuration
OS72601_
HBC-radiomatic GmbH • 74564 Crailsheim • Germany Radio Control System

Information and specifications subject to change without notice. 01.09.2008
Profibus
Table of Contents
1 Safety Instructions ........................................................................

2 Profibus Address ..........................................................................
3 Profibus Configuration ..................................................................
3.1 Configuration Example: Siemens S5 ........................................................
3.2 Configuration Example: Siemens S7 ........................................................
Manufacturer:
HBC-radiomatic GmbH • Haller Strasse 45 – 53 • 74564 Crailsheim • Germany • Tel. +49 7951 393-0 • [email protected].
HBC radiomatic GmbH is not liable for any misprints or errors! – All rights reserved.
® radiomatic und radiobus are registered German trademarks.
© 09 / 2008, HBC-radiomatic GmbH, 74564 Crailsheim, Germany
No part of any software or of the present document may be reproduced in any manner whatsoever without the expressed written
permission of HBC-radiomatic GmbH.
Radio Control System HBC-radiomatic GmbH • 74564 Crailsheim • Germany

01.09.2008 Information and specifications subject to change without notice.
Profibus
1 Safety Instructions
¾ The operator undertakes to strictly adhere to the instructions and proceedings
described in this manual, as well as to follow the general rules and regulations for
worker safety and accident prevention. Ignoring any such instructions or regulations
could pose a fatal threat to the operator or others.
¾ Read the Configuration Instructions Manual carefully and thoroughly before working
with the Profibus for the first time!
¾ Keep this Configuration Instructions Manual on location and readily available at all
times!
¾ Only authorized and properly trained personnel may operate the Profibus.
¾ Anyone who is under the influence of drugs, alcohol or medication that has a
detrimental effect on a person's reactions may at no time commission, operate,
maintain or repair the Profibus.

Profibus
2 Profibus Address
Use the DIP-switch S3 to set the Profibus address (binary format) on the Profibus card
(OS726___). S3/1 represents the least significant bit and S3/7 represents the most
significant bit of the Profibus address. S3/8 is not used.
Example:
Profibus address DIP-switch S3

decimal hexadecimal 8 7 6 5 4 3 2 1
3 03 - 0 0 0 0 0 1 1
100 64 - 1 1 0 0 1 0 0
Note:
The system reads the set address with each enabling of the receiver.

Profibus
3 Profibus Configuration
Each Profibus comes with SPS project engineering software for configuration
programming. The slave is programmed either with a GSD file or manually.
The following represents examples for the project engineering configurations using
various software programs.
The configuration telegram is drawn as follows:

− special identification format (special format) with 6 input Bytes
− subassembly consistency
3.1 Configuration Example: Siemens S5
Fig.: Projecting the Profibus (DP)

Profibus
Fig.: Slave characteristics
Fig.: Parameter setting
Fig.: Configuration
Fig.: Special identification format Fig.: Identification

Profibus
3.2 Configuration Example: Siemens S7
Fig.: Projecting the Profibus (DP)
Fig.: Slave characteristics

Profibus
Fig.: Address overview
Note:
Should the subassembly consistency extend over larger data areas (e.g. more than 4
bytes with Siemens S7), the SFC components
SFC14 or SFC15 (see online help)

for the respective slaves must be included in the project.

© by HENGSTLER
Für diese Dokumentation beansprucht die Firma HENGSTLER Urheberrechtschutz.
Diese Dokumentation darf ohne vorherige schriftliche Zustimmung der Firma HENGSTLER, weder
abgeändert, erweitert oder vervielfältigt, oder an Dritte weitergegeben werden.
ACURO® ist eine eingetragene Marke von Hengstler.
Technische Änderungen und Verbesserungen, die dem Fortschritt unserer Geräte dienen,
behalten wir uns vor.
HENGSTLER GmbH
Uhlandstr. 49
78554 Aldingen / Germany
Tel. +49 (0) 7424-89 0
Fax +49 (0) 7424-89 500
E-Mail: [email protected]
© by HENGSTLER
HENGSTLER claims copyright protection for this documentation.
This documentation must not be modified, amended, copied or given to third parties without prior
written approval by HENGSTLER.
ACURO® is a registered trademark by HENGSTLER.
We reserve the right to make technical modifications and improvements that serve the
advancement of our products.
HENGSTLER GmbH
Uhlandstr. 49
78554 Aldingen / Germany
Tel. +49 (0) 7424-89 0
Fax +49 (0) 7424-89 500
E-Mail: [email protected]
www.hengstler.com
2 von 22 Sach - Nr.: 2-539-099, Version: 3 131008 EL (HOR)

Installationsanleitung
Absolut - Drehgeber
AX70 / AX71
mit PROFIBUS - DP
Vorwort
Diese Installationsanleitung soll Ihnen den Anschluss und die Inbetriebnahme der Drehgeber
ermöglichen.
Dieser Geber ist Ex - geprüft und zugelassen. Die entsprechende Baumusterprüfbescheinigung
PTB00 ATEX 1107 senden wir Ihnen auf Anforderung gerne zu.
Informationen zur Software und Parametrierung finden Sie in den Technischen Handbüchern mit
folgenden Sachnummern:
2 565 090 - in Deutsch
2 565 255 - in Englisch
Die Handbücher erhalten Sie auf Bestellung oder per Internet - Download von unserer
Homepage www.hengstler.de
Weitere Informationen erhalten Sie auf Anfrage.
Zusätzlich erhältlich: GSD - Datei HEN100B7.gsd unter Sach - Nr. 1 547 511
GSD - Datei HEN200B7.gsd unter Sach - Nr. 1 547 512
oder von unserer Homepage.
Dieses Symbol steht bei Textstellen, die besonders zu beachten sind, damit der
ordnungsgemäße Einsatz gewährleistet ist und Gefahren ausgeschlossen werden.
Sicherheits- und Betriebshinweise

Die Absolut - Drehgeber der Modellreihe AX70 / AX71 sind nach den anerkannten Regeln der
Elektrotechnik hergestellte Qualitätsprodukte.
Die Geräte haben das Herstellerwerk in sicherheitstechnisch einwandfreiem Zustand verlassen.
Um diesen Zustand zu erhalten und um einen störungsfreien Betrieb sicherzustellen, sind die
technischen Spezifikationen in dieser Dokumentation zu berücksichtigen.
Einbau und Montage elektrischer Geräte dürfen nur durch eine
Elektrofachkraft erfolgen!
Die Geräte dürfen nur innerhalb der Grenzwerte betrieben werden, wie sie in den technischen Daten
vorgegeben sind.
Die maximalen Betriebsspannungen dürfen nicht überschritten werden!
Die Geräte sind nach DIN EN 61010 - Teil 1, Schutzklasse III gebaut.
Sie müssen zur Verhinderung von gefährlichen Körperströmen mit Sicherheitskleinspannung (SELV)
betrieben werden und sich in einem Bereich mit Potentialausgleich befinden.
Verwenden Sie zum Schutz eine externe Sicherung (siehe Elektrische Daten).
Anwendungsbereich: Industrielle Prozesse und Steuerungen.
Überspannungen an den Anschlussklemmen müssen auf Werte der Überspannungskategorie II
begrenzt werden.
Vermeiden Sie die Einwirkung von Schocks auf das Gehäuse - vor allem auf die
Geberwelle - sowie axiale und radiale Überbelastung der Geberwelle.
Die maximale Genauigkeit und Lebensdauer der Geber wird nur bei Verwendung einer geeigneten
Kupplung garantiert.
Sach - Nr.: 2-539-099, Version: 3 131008 EL (HOR) 3 von 22
Die guten EMV - Werte gelten nur in Verbindung mit den serienmäßig gelieferten Kabeln und
Steckern.
Bei geschirmten Kabeln ist der Schirm beidseitig und großflächig mit Erde zu verbinden. Auch die
Leitungen zur Spannungsversorgung sollten vollständig geschirmt sein. Ist dies nicht möglich, so
sind entsprechende Filtermaßnahmen zu ergreifen.
Die Einbauumgebung und Verkabelung hat maßgeblich Einfluss auf die EMV des Gebers, so dass vom
Installateur die EMV der Gesamten Anlage (Gerät) sicherzustellen ist.
In elektrostatisch gefährdeten Bereichen ist bei der Installation auf einen guten ESD - Schutz für
Stecker und anzuschließendes Kabel zu achten.
Am Anfang und am Ende jedes Segments muss der DP - Bus durch einen aktiven Busabschluss
abgeschlossen werden!
Für einen störungsfreien Betrieb muss sichergestellt sein, dass die beiden Busabschlüsse immer
mit Spannung versorgt werden.
Das Anschlusskabel ist nur für feste Verlegung geeignet (kein Schleppbetrieb).
Die Auswahl des Kabels unter Berücksichtigung der EX - Vorschriften unterliegt der Verantwortung
des Anlagenerrichters.
Das druckfest gekapselte Gebergehäuse darf nicht geöffnet werden!
EX - Klassifizierung
Die Hengstler EX - Drehgeber sind klassifiziert nach EX II 2 G EEx d IIC T6 / T4
(nach EN 50014 und EN 50018).
Konformitätsbescheinigung: PTB00 ATEX 1107
EX II 2 G EEx d IIC T6 / T4
Ex II 2 G E EX d II C T6/T4
Temperaturklasse T6 bzw. T4
Gasgruppe C
Explosionsgruppe II (alle Bereiche, außer schlagwettergefährdeter Grubenbaue)
druckfeste Kapselung
explosionsgeschütztes Betriebsmittel
nach europäischer Norm gebaut
Zum Einsatz in Bereichen mit Gasen, Dämpfen, Nebel
Kategorie 2
Explosionsgruppe II (alle Bereiche, außer schlagwettergefährdeter Grubenbaue)
Explosionsgeschütztes Betriebsmittel mit Baumusterprüfbescheinigung
T6 = Höchstzulässige Oberflächentemperatur +85°C 1)

T4 = Höchstzulässige Oberflächentemperatur +130°C 2)
1)
EEx d IIC T6: max. Drehzahl = 6000 min -1 und Betriebstemperatur –40°C ... +40°C
2)
EEx d IIC T4: max. Drehzahl =10000 min-1 und Betriebstemperatur –40°C ... +60°C
4 von 22 Sach - Nr.: 2-539-099, Version: 3 131008 EL (HOR)

Mechanische Daten
Wellendurchmesser 10mm
Wellenbelastung radial 100N, axial 40N
Drehzahl max. 10000min-1 (EEx d IIC T4), 6000min-1 (EEx d IIC T6)
Drehmoment ≤ 1Ncm
Trägheitsmoment ca. 14gcm2
Schutzart Gehäuse IP65, Kugellager IP641)
Umgebungstemperaturbereich -40°C ... +60°C (T6: max +40°C)
Lagertemperatur -25°C ... +85°C
Schwingfestigkeit (IEC 68-2-6) 100m/s2) (10 ... 60Hz 1.5mm; 60 ... 2000Hz 100m/s2))
Schockfestigkeit (IEC 68-2-27) 1000m/s2) (6ms)
Anschluss Kabel axial oder radial für feste Verlegung
Baugröße ø70mm
Befestigung Klemmflansch, Bohrungen 3xM6
Masse AX70 ca. 1400g; AX71 ca. 4800g
1)
stehendes Wasser am Welleneingang oder Kugellager nicht zulässig.
Elektrische Daten
Allgemeine Auslegung gemäß EN 61010 - 1, Schutzklasse III
Verschmutzungsgrad 2, Überspannungskategorie II
Versorgungsspannung (SELV) 10 ... 30 VDC mit Verpolschutz
Eigenstromaufnahme max. 230mA
externe Sicherung T 0.25 A
1)
EMV Störaussendung nach EN 50081 - 2; Störfestigkeit nach EN 50082 - 2
Schnittstelle RS485
Protokoll Profibus - DP mit Encoder - Profil Klasse C2 (parametrierbar)
Baudrate wird im Bereich von 9.6 KBit/s bis 12 MBit/s automatisch eingestellt
Geräteadresse über Bus (durch DPM2 - Gerät2) einstellbar)
Auflösung3) 1024 Schritte (10 Bit) Singleturn
4096 Schritte (12 Bit) Singleturn
4096 Schritte / 4096 Umdrehungen (24 Bit) Multiturn
Linearität ± ½ LSB (±1 LSB bei Auflösung 13, 14, 25, 26 Bit)
Codeart Binär
Code - Wertefolge programmierbar (Standard: cw)
1)
bei Einhaltung der Abschirmhinweise
2)
Klasse 2 Master
3)
tatsächliche Auflösung der Sensoreinheit, zusätzlich kann die gewünschte Auflösung durch
Geberprogrammierung verringert werden.
Sach - Nr.: 2-539-099, Version: 3131008EL(HOR) 5 von 22
Inbetriebnahme
Busanschluss des Gebers
Die Datenübertragung erfolgt gemäß RS - 485.
Die Busstruktur erlaubt das rückwirkungsfreie Ein - und Auskoppeln von Stationen oder die schritt-
weise Inbetriebnahme des Systems.
Die Übertragungsgeschwindigkeit (Baudrate) wird bei der Inbetriebnahme des
Systems von der SPS (Master) einheitlich für alle Geräte am Bus festgelegt.
Anschlussbelegung
Farbe Signal Beschreibung
rot B Receive / Transmit Data
grün A Receive / Transmit Data
blau 10 ... 30 VDC Versorgungsspannung +UB
schwarz 0V Versorgungsspannung Ground
gelb / grün GND GND mit Gehäuse verbunden
Achtung! Sie müssen sicherstellen, dass eine zusätzliche externe Zugentlastung

angebracht ist. Der Abstand zwischen Kabelverschraubung und externer Zugentlastung
darf max. 10cm betragen.
Anschlusskabel: AmerCable 3x0.75mm² + Profibus
Busabschluss: entsprechend DIN 50170/2
Leitungstyp A
Einstellen der Geräteadresse
Die DIP - Schalter des druckfest gekapselten EX - Drehgebers AX70 / AX71 sind nicht zugänglich.
Deshalb kann die Geräteadresse nur über den Bus durch ein DPM2 - Gerät (Klasse 2 Master) einge-
stellt werden. Die Geräteadresse darf im Bereich 1 ... 125 eingestellt werden.
Standardeinstellung bei Auslieferung ab Werk:

Geräteadresse = 32
6 von 22 Sach - Nr.: 2-539-099, Version: 3 131008EL(HOR)

Masszeichnung
AXIAL
Radial
Maße in mm
Bestellschlüssel (siehe Typenschild)
Befesti- Schutz Kabellän-

Typ Auflösung Versorgung Welle Schnittstelle Anschluss
gung art ge
/ . - :5604
AX70 1212 12 Bit ST E DC 10-30 V K Klemm 4 IP 64 2 10 mm DP Profibus- DP X Sonder- F0 5 m Kundenspezi-

= Aluminium + 12 Bit MT flansch kabel M2 12,2 m fische Aus-
AX71 1213 13 Bit ST führung ge-
= Edelstahl + 12 Bit MT mäß diesem
1214 14 Bit ST Datenblatt
+ 12 Bit MT :5604 axial
:5982 radial
Sach - Nr.: 2-539-099, Version: 3 131008 EL (HOR) 7 von 22

Konfiguration (DDLM_Chk_Cfg)
Der DP - Master legt mit dieser Routine die Anzahl der Bytes für den Datenaustausch fest.
Octet Bit Daten Funktion
1 7 - 0 D1h = Eingangsdaten 2 Worte 32 Bit Positionswert (class1)
(Standardkonfiguration)
F1h = Eingangsdaten 2 Worte, Ausgangsdaten 32 Bit Positionswert / Preset (class2)

(Standardkonfiguration)
D0h = Eingangsdaten 1 Wort 16 Bit Positionswert (class1)

(Optionale Konfiguration)
F0h = Eingangsdaten 1 Wort, 16 Bit Positionswert / Preset (class2)

Ausgangskonfiguration (Optionale Konfiguration)
D3h = Eingangsdaten 4 Worte Positionswert + Geschwindigkeit

(Herstellerspezifische Konfiguration) + Beschleunigung
F3h = Eingangsdaten 4 Worte, Ausgangsdaten Positionswert + Geschwindigkeit

4 Worte (Herstellerspezifische Konfiguration) + Beschleunigung / Preset
Betriebsparameter (DDLM_Set_PRM)
Parameter Datentyp Parameter Klasse Vorbelegte Werte laut
Octet - Nummer GSD - Datei
Stationsstatus Octet string 1 DIN 19245 - 3 88h
Ansprechüberwachungszeit (TWD) 16 Bit 2-3 DIN 19245 - 3 340ms
Min. Station Delay Responder Octet string 4 DIN 19245 - 3 11

(min. TSDR)
PNO - Ident - Number 16 Bit 5-6 DIN 19245 - 3 00B7h
Group - Ident Octet string 7 DIN 19245 - 3 0
Codefolge Bit 0 9 1 0 = aufsteigend

bei Drehung cw
Klasse 2 Funktionalität Bit 1 9 2 1 = Ein
Wartungsdiagnose Bit 2 9 optional 0 = Aus
Skalierungsfunktion Bit 3 9 2 1 = Ein
Abtastung Bit 7 9 2 0 = 1ms
Messschritte pro Umdrehung 32 Bit 10 - 13 2 4096 (12Bit)
Gesamtanzahl der Messschritte 32 Bit 14 - 17 2 67.108.864 (26Bit)

Datenaustausch (DDLM_Data_Exchange)
Der Datenaustausch wird mit der Routine DDML_Chk_Cfg koniguriert
(siehe Konfiguration).
Positionswert
Die Geber - Eingangsdaten mit einer Länge von 32Bit (herstellerspezifisch auch 64Bit möglich) wer-
den benutzt für den Positionswert (bei 64Bit zusätzlich Geschwindigkeit und Beschleunigung).
Optional unterstützt der Geber auch Positionswerte mit 16Bit Länge. Der Wert ist im Datenfeld rechts
angeordnet.
Preset Funktion
Die Preset Funktion unterstützt die Anpassung des Geber - Nullpunkts zum mechanischen Nullpunkt
des Systems. Die Preset Funktion setzt den aktuellen Positionswert des Gebers auf den Preset - Wert.
In der Data_Exchange_Funktion wird der Preset - Wert als Ausgangswert gespeichert. Die Preset
Funktion wird verwendet nach der Skalierung, d.h., der Preset - Wert wird in den programmierten
Messschritten angegeben.
Das MSB des Preset - Wertes kontrolliert die Preset Funktion folgendermaßen:
Normaler Betriebszustand: MSB = 0 (Bit
Bit 31
31, optional Bit 15 bzw. Bit 63)
Preset - Wert wird nicht übernommen.
Preset - Mode: MSB = 1 (Bit
Bit 31
31, optional Bit 15 bzw. Bit 63)
Mit MSB = 1 übernimmt der Geber den übertragenen Wert (Bit 0 - 30)
als Preset - Wert im Binärcode.
Der Geber liest den aktuellen Positionswert und berechnet aus dem Preset - Wert und dem gelesenen
Positionswert einen Offset - Wert. Der Positionswert wird durch den Preset - Wert ersetzt. Wenn der
Ausgangswert und der Preset - Wert gleich sind, wird der Preset - Mode beendet, und das MSB kann
vom Master auf Null gesetzt werden. Mit der Diagnose - Funktion kann der Offset - Wert gelesen wer-
den. Der Wert wird nach Netzausfall und bei jedem Neustart neu geladen.
Die Preset - Funktion darf nur bei Stillstand des Gebers verwendet werden.
Die Skalierungsparameter müssen vorher übertragen werden (nur falls Skalierung

eingestellt werden soll).
Sach - Nr.: 2-539-099, Version: 3 131008EL(HOR) 9 von 22

Konfiguration und Parametrierung des Gebers
Als Hilfsmittel für die Verwendung von Standard-Profibus DP -Tools dient die so genannte
GSD - Datei. Sie ist als Download-Datei auf unserer Internet-Homepage verfügbar.
Die GSD - Datei "henx00b7.gsd“ enthält die verfügbaren Geberparameter.
Bsp.: Einbinden des Gebers mit Hilfe der STEP7 - Software
Wenn Sie das Programm HW - Konfigurator starten, darf kein Hardwareprojekt geöffnet sein.
• Starten Sie den HW - Konfigurator der Step7 Software

• Wählen Sie das Kommando „Neue GSD installieren“ aus dem Menü „Extras“
• hen100b7.gsd auswählen und öffnen
• Wählen Sie das Kommando „Katalog aktualisieren“ aus dem Menü „Extras“

Geber in den Profibus aufnehmen (Vorraussetzung: Master ist bereits konfiguriert)
• RA58-P* aus dem Hardwarekatalog - Fenster auswählen:
Pfad: Profibus - DP => weitere Feldgeräte => Geber => RA58 - P und im oberen Stations - Fenster
an die Profibusleitung hängen (a).
• Gewünschtes Modul anklicken und ins untere Stationseigenschaften - Fenster ziehen (b).
a *
* alter Produktname von ACURO mit Profibus

• Doppelklick auf Geber - Icon. Es öffnet sich das Fenster mit den Slave - Eigenschaften.
Zum Ändern eines Parameterwertes klicken auf den Wert.

Sach - Nr.: 2-539-099, Version: 3 131008EL(HOR) 11 von 22
Anpassung der S7 - Programmbausteine
Binden Sie ggf. folgende OBs bzw. Funktionen mit ein:

OB82 (Diagnose):
Zum Abfangen der Geberdiagnose, die durch Inkrementierung des Geber-Betriebsstundenzählers alle
6 min ausgelöst wird.
OB86 (Stationsfehler):
Bei Fehler oder Ausfall des Gebers geht die SPS in Stop. Ist dies nicht gewünscht,
muss OB86 eingebunden werden.
SFC14 (Daten >32 Bit konsistent lesen)
Muss eingebunden werden, wenn das Gebermodul „Spec1: 64 Bit Inp (POS,VEL,AC)“ oder
„Spec2: 64 Bit I/O (P,V,A/PRES)“ verwendet wird, da die S7 standardmäßig sonst nur
max. 32 Bit Daten konsistent einlesen kann.
SFC15 (Daten >32 Bit konsistent schreiben)
Muss eingebunden werden, wenn das Gebermodul „Spec2: 64 Bit I/O (P,V,A/PRES)“ verwendet wird
und ein Preset - Wert an den Geber geschrieben werden soll.

Installation instructions
Absolute - Encoder
AX70 / AX71
with PROFIBUS - DP
Introduction
These installation instructions are provided for the connection and starting procedure of your
shaft encoder.
This encoder is EX - tested and licensed. On request, we will be pleased to send you the respective
certificate of conformity PTB 00 ATEX 1107.
For information concerning software and set parameter please refer to the Technical Manuals with
following item numbers:
2 565 090 - in German
2 565 255 - in English
You can obtain these manuals by order or by Internet - download from our homepage
www.hengstler.de
You will get further information on request.
Additionally available: GSD file HEN100B7.gsd with item number 1 547 511
GSD file HEN200B7.gsd with item number 1 547 512
or by download from our homepage.
These sign marks paragraphs particularly to be observed to assure proper use and to
avoid risks.
Safety and Operating Instructions

The absolute shaft encoder of type AX70 / AX71 model series are quality products manufactured in
accordance with established electrical engineering standards.
The units have been delivered from the factory in perfect conformance to safety regulations.
To maintain this condition and to ensure trouble - free operation, please observe the technical
specifications of this document.
Installation and mounting may only be performed by an electrotechnical expert!
The units may only be operated within the limits specified by the technical data.
Maximum operating voltages must not be exceeded!
The units are designed complying with DIN EN 61010 - part 1, protection class III.
To prevent dangerous structure - borne currents, the equipment has to be run on safety extra - low
voltage (SELV) and must be in an area of equipotential bonding.
Please use an external fuse for protection (see Electrical Data).
Fields of application: industrial processes and controls.
Overvoltage at the connection terminals must be limited to overvoltage - class - II values.
Please avoid shocks to the housing - especially to the encoder shaft - and axial or radial overload to
the encoder shaft.
Maximum accuracy and durability of our shaft encoders are only granted when using suitable
couplings.
Item number: 2-539-099, version: 3 131008EL(HOR) 13 of 22

The high - quality EMC - specifications are only valid together with standard - type cables and plugs.
When using screened cables, the screen must broadly be connected with ground on both ends.
Likewise, the voltage - supply cables should entirely be screened. If this is not possible you will
have to take appropriate filtering measures.
Installation environment and wiring are influential on the encoder`s EMC: Thus the installer must
secure EMC of the whole facility (device).
In electrostaticly threatened areas please take care for neat ESD - protection of plug and connecting
cable during installation work.
At the beginning and at the end of each segment, the DP bus must be terminated by an active
bus termination!
For trouble - free operation, the voltage supply of both bus terminations must always be ensured.
The connecting cable is only suitable for fixed installation (no haulage operating).
The facility installer is responsible for cable selection with consideration of EX - rules.
The pressure - proofly encapsulated encoder housing must not be opened!
Explosion protection classification

Hengstler explosion - proof shaft encoders are classified according to EX II 2 G EEx d IIC T6/T4
(as per EN 50014 and EN 50018).
Certified of conformity: PTB00 ATEX 1107
EX II 2 G EEx d IIC T6 / T4
Ex II 2 G E EX d II C T6/T4
Temperature class T6 res. T4

Gas group C
Explosion group II (all areas except for fire - damp mining)
Compression resistant enclosure

Explosion proof production facilities
Manufactured according to EN
Application in areas with gas, steam, mist
Category 2
Explosion group II (all areas except for fire - damp mining)
Explosion proof production facilities with PTB approval
T6 = Maximum permissible surface temperature +85°C 1)

T4 = Maximum permissible surface temperature +130°C 2)
1)
EEx d IIC T6: max. speed = 6,000 RPM and ambient temperature –40°C ... +40°C
2)
EEx d IIC T4: max. speed =10,000 RPM and ambient temperature –40°C ... +60°C
14 of 22 Item number: 2-539-099, version: 3 131008EL(HOR)

Mechanical data
Shaft diameter 10mm
Shaft load radial 100N, axial 40N
Max. speed 10,000 RPM (EEx d IIC T4), 6,000min RPM (EEx d IIC T6)
Torque ≤ 1Ncm
Moment of inertia 14gcm2 approx.
Protection class housing IP65, bearing IP641)
ambient temperature -40°C ... +60°C (T6: max +40°C)
Storage temperature -25°C ... +85°C
Vibration performance (IEC 68-2-6) 100m/s2) (10 ... 60Hz 1.5mm; 60 ... 2000Hz 100m/s2))
Shock resistance (IEC 68-2-27) 1000m/s2) (6ms)
Connection cable axial or radial for fixed installation
Size ø70mm
Mounting clamping flange, bores 3xM6
Weight AX70 1400g approx. ; AX71 4800g approx.
1)
no standing water allowed at the shaft entrance or at the ball bearing
Electrical data
General design as per EN 61010 - 1, protection class III
contamination level 2, overvoltage class II
Supply voltage (SELV) 10 ... 30 VDC with pole protection
Intrinsic power consumption max. 230mA
external fuse T 0.25 A
1)
EMC Noise emission as per EN 50081 - 2; Noise immunity as per EN 50082 - 2
Interface RS485
Protocol Profibus - DP with encoder profile class C2 (can be parameterised)
Baud rate automatically adjusted in a range from 9.6 KBit/s up to 12 MBit/s
Device address adjustable by DIP switches or bus (by DPM2 device2) )
Resolution3) 1024 steps (10 Bit) Singleturn
4096 steps (12 Bit) Singleturn
4096 steps / 4096 turns (24 Bit) Multiturn
Linearity ± ½ LSB (±1 LSB with resolution 13, 14, 25, 26 Bit)
Type of code Binary
Code - sequence programmable (standard: cw)
1)
With compliance with screening indications
2)
Class 2 Master
3)
real resolution of sensor device, additionally lower resolutions could be programmed.

Start - up procedure
Bus connection of the encoder
Data are transferred according to RS - 485.
The bus structure permits to connect and disconnect stations without inverse operation, or to start up
the system step by step.
On system start - up, the transmission rate (Baud rate) is fixed uniformly for all bus devices by the
SPS (Master).
Connection diagram
Color Signal Description
red B Receive / Transmit Data
green A Receive / Transmit Data
blue 10 ... 30 VDC supply voltage +UB (P24)
black 0V supply voltage Ground
yellow / green GND Ground connection to housing
Attention! You have to ensure that an additional external strain relief is fixed!
(The distance between gland and external stain relief has to be max. 10cm)
Cable: AmerCable 3x0.75mm² + Profibus
Bus end: meets the enquirements of DIN EN 50170/2
Type A
Setting the device address
The DIP switches of the pressure - proofly encapsulated EX - encoder AX70 / AX71 are not
accessible. Hence, only a DPM2 device (Class 2 Master) can set the device address via the bus!
The device address may be set in a range from 1 up to 125.
Standard setting delivered from factory:

Device address = 32
16 of 22 Item number: 2-539-099, version: 3 131008EL(HOR

Dimensioned Drawing
AXIAL
Radial
Dimension in mm
Identification code (see identification plate)
Power Moun- Pro- Connecti- Cable

Type Resolution Shaft Interface
supply ting tection on lenght
/ . - :
AX70 1212 12 Bit ST E DC 10-30 V K Clam- 4 IP 64 2 10 mm DP Profibus- DP X Special F0 5 m Customized

= Aluminum + 12 Bit MT ping cable M2 12,2 m version desc-
AX71 1213 13 Bit ST flange ribed within
= Stainless + 12 Bit MT this data
1214 14 Bit ST sheet
+ 12 Bit MT :5604 axial
:5982 radial
Item number: 2-539-099, Version: 3 131008 EL (HOR) 17 of 22

Configuration (DDLM_Chk_Cfg)
By this routine, the DP master defines the number of bytes for data exchange.
Octet Bit Data Function
1 7 - 0 D1h = 2 words of input data 32 Bit position value (class1)
(standard configuration)
F1h = 2 words of input data, output data 32 Bit position valuet / Preset (class2)
(standard configuration)
D0h = 1 word of input data 16 Bit position value (class1)

(optional configuration)
F0h = 1 word of input data, output data 16 Bit position value / Preset (class2)
(optional configuration)
D3h = 4 words of input data Position value + speed + acceleration

(manufacturer configuration)
F3h = 4 words of input data, 4 words of output data, Position value + speed
(manufacturer configuration) + acceleration / Preset
Operating parameter (DDLM_Set_PRM)

Parameter Data type Parameter Class Default values
Octet number according to GSD file
Stations status Octet string 1 DIN 19245 - 3 88h
Response check time (TWD) 16 Bit 2-3 DIN 19245 - 3 340ms
Min. station delay responder Octet string 4 DIN 19245 - 3 11

(min. TSDR)
PNO - Ident. - Number 16 Bit 5-6 DIN 19245 - 3 00B7h
Group - Ident Octet string 7 DIN 19245 - 3 0
Code sequence Bit 0 9 1 0 = ascending for

cw rotation
Class 2 functionality Bit 1 9 2 1 = On
Maintenance diagnosis Bit 2 9 optional 0 = Off
Scaling function Bit 3 9 2 1 = On
Sampling Bit 7 9 2 0 = 1ms
Measuring steps per turn 32 Bit 10 - 13 2 4096 (12Bit)
Total number of measuring steps 32 Bit 14 - 17 2 67.108.864 (26Bit)

Data exchange (DDLM_Data_Exchange)
Data exchange is configured by the DDML_Chk_Cfg routine (see Configuration).
Position value
The encoder input data - with a 32 bit length (also with 64 bit, depending on the manufacturer) - are
used for the position value (with 64 bit, speed and acceleration in addition). Optionally, the encoder
also supports position values with a 16 bit length. In the data field, the value is right - adjust.
Preset function
The preset function supports adaptation of the encoder zero to the mechanical system zero.
It sets the actual encoder position value to the preset value. By the Data_Exchange function,
the preset value is stored as a base value. The preset function is used according to the scaling,
i.e., the preset value is given by the programmed measuring steps.
The preset value MSB controls the preset function as follows:

Normal operation state: MSB = 0 (Bit
Bit 31
31, optionally Bit 15 or Bit 63)
Preset value will not be accepted.
Preset - Mode: MSB = 1 (Bit
Bit 31
31, optionally Bit 15 or Bit 63)
With MSB = 1, the encoder accepts the transmitted value
(Bit 0 … 30) as binary - coded preset value.
The encoder reads the actual position value, calculating an offset value from the preset value and the
read - in position value. The position value is replaced by the preset value. If the base value is
identical with the preset value, the preset mode will be terminated and the master can set the MSB to
zero. The offset value can be read by the diagnostic function. The value will be reloaded after a mains
failure and with each restart.
The preset function must only be used at encoder standstill.
The scaling parameters must be transferred in advance

(only if scaling is to be set).

Start up procedure
As an aid for the use of standard Profibus-DP tools, there is a so-called GSD file (electronically data
sheet) with device master information. It is available by download from our Internet homepage.
The GSD file "HENx00B7.GSD" contains the available encoder parameters.
Example for configuration with Step 7

All hardware projects have to be closed before starting the program HW-configurator.
• start HW-
HW-configurator of the Step 7 software
• choose „Install
Install New GSE“
GSE from menu “options“
• choose and open hen100b7.gsd
• choose “update
update catalogue“
catalogue from „Extras“

Integrate the encoder into the Profibus (requires that master is already configured)
• choose RA58-P* from the hardware catalogue window: Path: Profibus DP – Additional Field Devices -
Encoder - RA58-P and put in on the Profibus line the upper window (a).
• click on selected module and draw it into lower window (b)
*
a
* former product name for ACURO with Profibus
• double-click the encoder icon to open the window with the slave-characteristics
For changing the value of a parameter double-click on the value and insert the new value in the opening window.

Adjusting the S7-program-modules
If necessary integrate following OBs or functions:

OB82 (Diagnosis):
For catching the encoder diagnosis, that is initiated every six minutes by the working time counter of
the encoder.
OB86
If fault or a breakdown occurs the SPS stops. Integrate OB86 to avoid this.
SFC14 (read data > 32 bit consistent)
Must be integrated, if the encoder part is “Spec1:64 bit Inp (POS,VEL,AC)” or “Spec2: 64 bit I/O
(P,V,A/PRES)”, since normally the S7 only reads in 32 bit consistent.
SFC15 (write data > 32 bit consistent)

Must be integrated, if the encoder part is “Spec2: 64 bit I/O (P,V,A/PRES)” and a preset value is to
be written in the encoder.

Intelligent Electronic Enclosure
Thermal Management Systems
OPERATION AND INSTALLATION MANUAL
*** IMPORTANT ***

PLEASE READ this manual and follow the instructions for safe and satisfactory installation and
operation of this system. Keep this manual for future reference. Some information may not
apply to all systems.
TABLE OF CONTENTS
Introduction Page 3
Basic operation Page 3

Figure 1: Flow Diagram Page 3
Unpacking Inspection Page 4
Pre-Installation Test Page 4

Figure 2: Top mounted unit Page 4
Figure 3: Side mounted unit Page 4
Preparing the Enclosure Page 6
Operating the System Page 7
Programming the Controller Page 8

Figure 4: Digital Controller Page 8
Alarm Operation Page 11
Maintenance Page 11
Trouble Shooting Page 12
Trouble Shooting Check List Page 13
Schematic Wiring Diagram Page 14
Schematic Wiring Diagram – Top Mount Units Page 15
Warranty Back Cover
2
INTRODUCTION:
Ice Qube’s Thermal Management System, TMS, is designed to cool, dehumidify or heat the
internal environment of modern electrical enclosures. Ice Qube offers efficient and aesthetically
appealing packages that can be mounted on top or on the side of your enclosure. Our closed-
loop circulation design protects your equipment from air-borne dust and contaminants which
may hinder equipment operations, causing unnecessary down time. Ice Qube is able to provide
cooling capacities from 800 to 20,000 BTU per hour - a wide range of cooling systems to satisfy
many of your conditioning needs.
BASIC OPERATION:
The Ice Qube’s Thermal Management System, TMS, is actually a combination of three
independent systems which function simultaneously to maintain environmentally friendly
conditions for various types of electronic equipment enclosures. These three thermal related
systems are: the closed-loop cool air system; the warm air system; and the vapor-compression
refrigeration system. Please refer to Figure 1.
The closed-loop cool air system circulates cold air from the Ice Qube TMS to the electronics
enclosure. This air returns to the Ice Qube system bringing with it unwanted heat and humidity
from inside the enclosure. Heat and humidity is then removed by a heat exchanger located
within the Ice Qube TMS. This heat exchanger is part of the vapor-compression refrigeration
system.
At the heart of the vapor-compression refrigeration’s system is a quiet, energy efficient rotary
compressor which circulates environmentally friendly NON-CFC refrigerant. The main purpose
of this compressor is to transfer heat laden refrigerant from the evaporator, located within the
closed-loop cool air system, to a condenser, located in the warm air system. In the warm air
system, air is circulated from the ambient surrounding the enclosure, through a filter, and across
the warm air system heat exchanger. Here, heat from the enclosure is transferred from the
warm air heat exchanger into the warm air stream and dissipated to the ambient.
Figure 1: Flow Diagram
3
UNPACKING INSPECTION:
1. The shipping container leaves the factory banded to a pallet with red arrows imprinted on
the box. These red arrows should be pointing in the proper (upward) direction. The Ice
Qube TMS is position sensitive. Ice Qube recommends the unit to remain in the proper
upright position for a minimum of 24 hours before initial operation. This is to ensure the oil
has returned to the compressor. Operation before the 24 hour time period may cause
damage to the compressor, hence shortening the life of the system.
Note: Operating the unit before maintaining an upright position for 24 hours will
void all warranties.
2. Check for any damage to the shipping container. If the shipping container has been
damaged or marred in any way, carefully check to see if the Ice Qube TMS incurred any
damage. Check for scratches, dents, rattles (which may indicate loose components), the
presence of oil, and any other irregularities. Any evidence of damage will need to be
recorded on the freight bill and reported to the carrier. The freight carrier will provide
instructions on filing a claim. Ice Qube cannot accept responsibility for damages that
occur during shipping.
PRE-INSTALLATION TEST:
Before installing the Ice Qube system on the enclosure, it is recommended the unit operate for
20 to 30 minutes to ensure it is functioning properly. Although the Ice Qube TMS has been
tested at the factory, internal damage may have occurred during shipping which may have not
been apparent during the unpacking inspection.
1. Place the system on a solid base such as a workbench or table. Verify whether the unit is a
Top or a Side Mount air conditioner. Be sure to allow adequate space for airflow. There are
two air streams that must not be restricted, the cool air stream and the warm air stream.
Top mount units must be elevated to provide adequate airflow for the cool air stream located
on the bottom of the system.
Top mount units can only be mounted on a flat horizontal surface. Side mount units can
only be mounted on a flat vertical surface.
Figure 2: Top mounted unit Figure 3: Side mounted unit
4
PRE-INSTALLATION TEST: -continued-
2. Check that the warm air system filter is in place, location varies with model type.
Models with the optional rain or wash down hood do not have a warm air filter and will
require regular routine condenser maintenance.
3. Check the data tag for proper electrical requirements. The data tag lists the design voltage
and amperage requirements of the system. Verify that the electrical outlet where the system
will be connected has the proper capacity. After noting the above, connect the power cord
to a properly grounded electrical connection. The use of an extension cord is not
recommended.
NOTE: If any unusual noise or vibration is present during the testing procedure,
immediately disconnect the power cord and inspect the unit for the cause of
the noise or vibration. Contact Ice Qube immediately.
4. As soon as power is supplied to the system, the cool air evaporator blower will begin to
operate, (excluding Top mount models – see following note). The compressor and warm air
condenser blower will not operate if the room air temperature is below 80°F. This is due to
the fact the programmable controller has a factory setpoint of 80°F. (The digital display on
the face of the controller will be displaying room temperature.) If the display is indicating
80°F or warmer, the “Cool” status LED will flash for 3½ minutes before the compressor and
the warm air condenser blower will operate.
NOTE: Top mount unit evaporator blowers are electrically connected to cycle with the
compressor and condenser blower.
If the display is indicating a temperature less than 80°F, adjust the setpoint to a temperature
lower than the room temperature in order for the compressor and warm air condenser
blower to operate. Refer to the “Programming the Controller” section of this manual in order
to change the factory set points.
5. With the compressor and both blowers functioning, allow the unit to operate for 20 to 30
minutes. This will provide sufficient time for the vapor compression system to achieve
equilibrium. Measure the cool air outlet temperature with an accurate thermometer. This
temperature should be at least 10 degrees colder than the inlet air temperature, (if the room
temperature is warmer than 70°F). Inlet air temperature will be displayed on the
programmable controller. In areas of high humidity, the temperature difference may be less
than 10 degrees.
6. After completing the above check points, the electrical enclosure is ready to be prepared for
the installation of the Ice Qube system.
5
PREPARING THE ENCLOSURE:
Ice Qube air conditioning systems have been designed to be light weight for ease of installation.
Side enclosure or vertical mount units have been designed with a simple “two stud” alignment
feature to make initial fastening to the enclosure quick and easy. A few modifications must be
made to the enclosure to provide proper airflow, to maintain enclosure integrity, and to assure a
secure installation. Required modifications will vary with each air conditioner model.
1. Determine the location of the Ice Qube system on the enclosure.
*** CAUTION ***

Verify the weight of the air conditioning system will not cause the enclosure to become
unbalanced. Equipment instability may cause bodily harm or equipment damage. For
units mounted on enclosure doors, confirm the hinges will support the weight of the Ice
Qube system. Refer to system specifications for model weights.
2. Upon deciding the location of the Ice Qube system on the enclosure, attach the included
template to the enclosure surface. This template drawing will assist the installer in placing
the air conditioning unit on the enclosure. Be sure the Ice Qube system will be mounted
level and the cool air inlet and outlet connections will not be restricted by equipment or
shelving within the enclosure. Also check that the air flow of the warm air stream will not be
effected or restricted by the surroundings.
3. Outline the modifications for the enclosure with a marking pencil. Note the bolt hole
locations, the cutouts for the inlet and outlet air streams, the power cord and the locations
for any optional equipment. Additional cable openings may be required for units with
optional heating or alarm outputs, or for units connected to a network communications link.
4. Using a drill, make the holes for the studs, bolts and power cord and any other option. The
bit size will need to vary depending upon the model. Protect any equipment located within
the enclosure from debris produced during the installation procedure.
5. Drill a pilot hole for a saber saw to cut the inlet and outlet air passages. File all cuts to
provide a uniform cutout.
6. Slide the mounting studs through the matching holes in the enclosure. Verify that all of the
openings are aligned. Top mount units do not have mounting studs.
7. After checking that all openings and bolt holes are in alignment, apply the gasket material
provided to the Ice Qube air conditioning system cabinet to ensure enclosure integrity.
*** CAUTION ***

Be careful while removing the backing on the gasket material. The material may
stretch and the holes will not align.
NOTE: If the enclosure is not air tight or the air conditioning system operates with the
enclosure door(s) open, moisture will condensate inside the air conditioning
system and may cause the condensate management system to overflow.
8. After the gasket material has been installed, mount the Ice Qube system onto the enclosure
and fasten it using the supplied nuts and bolts. Check to see if the power cord and all
optional cables are in place. Fasteners need to be tightened securely and the gasket
6
material needs to be in place in order to maintain enclosure integrity. The gasket material
should be slightly compressed with no visible gaps. The Ice Qube system is now ready to
begin operation.
NOTE: Near the bottom or on the side of the Ice Qube system cabinet is a nipple for
condensate overflow. Although all vertical or side mounted Ice Qube air
conditioners have built-in condensate management systems, it may be
necessary to attach a drain hose to this nipple on enclosures which are located
in extremely humid conditions, or where enclosure doors are left open or the
door seals are leaking.
Top mount models do not have a built in condensate evaporation system. In

order for the drainage system to operate properly, the factory supplied drain kit
with a “Tee” must be installed per factory instructions. Ice Qube cannot be
held responsible for improper installation.
OPERATING THE SYSTEM:

Once the Ice Qube system has been installed onto the enclosure and the power cord has been
attached to a properly grounded electrical outlet with adequate voltage and current supply, the
unit is ready for operation. As soon as electrical power is supplied to the Ice Qube system, the
cool air stream blower will start to operate, (except for Top mount units). The blower will run
continuously so that the controller can monitor the enclosure’s internal temperature. The
enclosure temperature will be displayed on the face of the controller.
If the enclosure temperature is greater than the factory cooling setpoint of 80°F, the “Cool”
status LED will flash. This indicates that the compressor’s automatic off cycle timer is working.
(The off cycle timer is factory set at 3½ minutes). At the end of 3½ minutes, the compressor
and the condenser air blower will begin to operate. This signifies that the cooling system has
begun operation to remove heat and humidity from the enclosure. This procedure may take 20
to 30 minutes before it reaches full capacity.
If the heat load within the enclosure is less than the cooling capacity of the Ice Qube system,
the temperature on the digital display will begin to decrease. When the temperature inside the
enclosure decreases 7 degrees Fahrenheit below the “Cooling on” setpoint, the compressor and
the condenser blower will cycle off. The cool air blower will continue to operate, circulating air
within the enclosure. The controller has a factory programmed temperature differential of 7
degrees Fahrenheit. Example: “Cooling on” @ 80°F; “Cooling off” @ 73°F.
Ice Qube also offers an optional External Heat Output (EHO) to provide power to an external
heater, typically located within the equipment enclosure. If the enclosure temperature is below
the factory heating setpoint of 50º F, the heat status LED will be ‘”on”. This indicates the heat
relay has been energized and is providing power to the field connected heater. (There is no time
delay before heating begins). When the temperature of the enclosure rises 7 degrees Fahrenheit
above the setpoint, the controller will de-energize the heat relay and cycle the heater “off”.
NOTE: There is a dead band programmed into the controller that prevents heating
and cooling from operating simultaneously.
See label attached to the rear of the air conditioner for maximum wattage
heater that may be connected to the External Heat Output (EHO).
7
PROGRAMMING THE CONTROLLER:
The digital controller has many features that may or may not be required for your application.
However, the controller has been programmed at the factory with typical default settings for
immediate system operation. Please review the following default settings:
1. Cooling system on temperature 80° F

2. Heating system on temperature 50° F (optional)
3. High enclosure temperature alarm 100° F
4. Low enclosure temperature alarm 40° F
5. Audible and Visual alarm “ON”
6. Digital display in degrees Fahrenheit
7. Filter maintenance alarm 0 days - Disabled
8. High condenser temperature alarm 170° F
Figure 4: Digital Controller
To change the factory default settings, enter the programming code sequence:
“1 Adjust-up” arrow
“2 Adjust-down” arrow
“3 Select”
“4 Exit”
After pressing the above sequence the program LED should illuminate along with three
alternating flashing boxes on the display face, indicating the code was accepted. If no selection
is made within one minute, the system returns to the normal operating mode.
Note: Pressing the “4 Exit” button at any time while in the programming mode
returns the controller to the normal operating mode.
Press the “3 Select” button to continue programming. The set temperature “HI” LED illuminates
with the display indicating the ‘cooling on’ setpoint. The compressor will begin operation at this
temperature and will remain operating until the enclosure temperature decreases
approximately seven degrees Fahrenheit (four degrees Celsius). Press the “1 Adjust-up” or “2
Adjust-down” arrow until the desired set point is displayed. The range for this adjustment is
70° to 126°F, (21° to 52°C). When the adjustment is complete, press the “3 Select” button to
continue.
8
PROGRAMMING THE CONTROLLER: -continued-
The set temperature “LO” LED is on with the display indicating the (optional) ‘heating on’ set
point. The heating system will begin operation at this temperature and remain operating until
the enclosure temperature increases approximately seven degrees Fahrenheit (four degrees
Celsius). Press the “1 Adjust-up” or “2 Adjust-down” arrow until the desired set point is
displayed within a range of 0°F to 63°F (-17.8°C to +17°C).
NOTE: Review alarm settings if the ‘cool on’ or ‘heat on’ set points have been changed.
Press the “3 Select” button to continue. The set alarm “HI” LED is on with the display indicating
the high temperature alarm setpoint. The alarm will activate at this temperature and will
automatically reset at two degrees Fahrenheit (one degree Celsius) below this temperature.
Press the “1 Adjust-up” or “2 Adjust-down” arrow to change the alarm setpoint within a range
of 8ºF (or 4ºC) above the set temperature “HI” set point, to 135°F (or 57°C).
Press the “3 Select” button to continue. The set alarm “LO” LED is on with the display
indicating the low temperature alarm set point. The alarm will activate at this temperature and
will automatically reset at two degrees Fahrenheit (or one degree Celsius) above this
temperature. Press the “1 Adjust-up” or “2 Adjust-down” arrow to change the alarm setpoint
within a range of 8º F (4ºC) below the set temperature “LO” set point to -20°F (or -29°C).
Press the “3 Select” button to continue. The alarm LED will flash and the display will show
“ALL”, indicating the “ALL” alarm on/off status. Press “3 Select” and the display will show either
“ON” or “OFF”, indicating current alarm status. Press “1 Adjust-up” or “2 Adjust-down” to
toggle the mode as desired. If the “OFF” mode is selected, no alarms will activate and the
audible on/off select function is skipped.
Press the “3 Select” button to continue. The audible LED will flash and the display will show
“AUD”, indicating the audible alarm on/off status. Press “3 Select” and the display shows “ON”
or “OFF” indicating the current audible alarm status. Press “1 Adjust-up” or “2 Adjust-down”
arrow to toggle the mode desired.
Press the “3 Select” button to continue. The “C” LED flashes and the display shows either “F”
for degrees Fahrenheit or “C” for degrees Celsius. Press the “1 Adjust-up” arrow or “2 Adjust-
down” arrow to toggle the mode as desired.
Press the “3 Select” button to continue. The code LED is on and the display shows “PIN”. To
set a new user PIN code, press the “1 Adjust-up” button. The display will flash “4”, prompting
an entry of a four button sequence using the “1 Adjust-up”, “2 Adjust-down”, “3 Select”
and/or “4 Exit” buttons. (Any sequence of the four buttons may be programmed as the code.)
As the buttons are pressed, the display will show the number of buttons that were pressed.
NOTE: After pressing a button, there will only be 5 seconds to press the next button. If
the next button is not pressed within the allotted time, the system will default to
no PIN code, indicated by “0” on the display. Once the sequence is entered the
display will no longer flash, and will show “4”.
9
PROGRAMMING THE CONTROLLER: -continued-
To program the no PIN code mode, press “2 Adjust-down” and the display will show “0”,
indicating no PIN code. With no PIN code, pressing any button will permit access to the
program.
*** CAUTION ***
Always record the selection sequence (PIN code) and store in a secure place.
Press the “3 Select” button to continue. The filter LED flashes and the display will show “FIL”,
indicating the filter alarm days selection. Press the “3 Select” button and the display will show
the number of days that the alarm is set in one-half day increments. (Example: 10.5 indicates
the alarm will activate every ten and one-half days).
Press the “1 Adjust-up” or the “2 Adjust-down” arrow to vary the desired number of days.
Programming 0 days will disable the alarm.
NOTE: The required number of days to set this alarm will be determined by the
ambient air conditions. If rain or wash down hoods are installed on the
system, no filter is supplied and the filter alarm should be set to “0”. This will
disable the filter alarm.
Press the “3 Select” button to continue. (Making adjustments to this setting is necessary
only for installation of the ICENET communication network. Omit this otherwise.)
The program LED will be lit and the display will show “Add”. This is where the numerical
address of the Ice Qube air conditioning system communication network, ICENET, is inputted.
Press the “1 Adjust-up” or the “2 Adjust-down” arrow until the desired numerical address is
displayed. (Maximum range is 0.5 to 32.0 in 0.5 increments). Please make record of this
numerical address and system location in order that it may be entered into the ICENET Unit
Description folder on the Options Screen.
Programming of the microprocessor is now complete. Press the “3 Select” button to review all
of the settings. Press the “4 Exit” button to enter the selected settings and to return to the
normal operating mode.
NOTE: If the “(4) Exit” button is not pressed, any changes to the program settings will
not be saved.
ALARM OPERATION:
1. The enclosure temperature is above or below the alarm setpoint:
The alarm LED will light, the display flashes, either “HI” or “LO” LEDs flash with the display
and the audible alarm sounds (if activated). The enclosure temperature must rise or fall two
degrees Fahrenheit (one degree Celsius) before the alarm will reset.
2. The condenser temperature is above the condenser alarm setpoint:

The alarm LED lights, the display flashes the condenser temperature, and the audible alarm
sounds (if activated). The condenser temperature must fall four degrees Fahrenheit (two
degrees Celsius) before the alarm will reset. The above alarms can be manually reset by
entering the PIN code into the system.
10
ALARM OPERATION: -continued-
3. The filter day timer has expired:
The alarm LED lights, the display flashes showing “FIL”, the filter LED flashes with the
display and the audible alarm sounds (if activated). The filter alarm may be cleared by
pressing “4 Exit”.
4. Optional Alarm Output:

Ice Qube also offers an optional alarm output that is provided through an alarm relay. This
option is a dry contact (no voltage) set of contacts that may be configured as:
Normally Open (X01 – close on alarm condition), Black & White wires
Normally Closed (X02 – open on alarm condition), Black & Red wires
Normally Open and Normally Closed (X03 – close on alarm condition),
Black, White & Red wires.
5. Sensor Malfunctions:
E-O - Evaporator sensor open
E-C - Evaporator sensor shorted
C-O - Condenser sensor open
C-C - Condenser sensor shorted
NOTE: An alternating E-O … C-O display may indicate the sensor connector has
become disconnected from the rear of the controller.
6. Incorrect Voltage Supply

A continual flashing value of “3.15” on the display screen indicates the supply voltage is
either too high or too low.
MAINTENANCE:
The Ice Qube air conditioning system is designed to provide many years of trouble-free
operation with minimal amount of maintenance. Primary maintenance consists of checking the
condition of the ambient air filter and the condensate management system.
1. Ambient Air Filter: It is recommended that the ambient air filter be inspected and
cleaned regularly, at least every 30 days, or more frequently depending upon ambient
conditions. To check the condition of the air filter, it is recommended to first remove
electrical power from the Ice Qube system. Next, locate the filter cover and filter,
(location will vary by model). Slide the filter from the filter rack through the end slot and
clean by soaking in warm soapy water. Rinse with clean water. Use a shop-vac to
remove excess water from the filter before returning it to the system. Replace the filter if
it is showing signs of deterioration.
NOTE: If rain or wash down hoods have been installed, a filter would not have been
supplied, therefore no filter maintenance is required. However systems
equipped with rain or wash down hoods will require regular condensing section
maintenance by qualified personnel. For systems equipped with filters, it is
recommended to have a spare clean filter in stock in order to prevent prolonged
cooling system downtime. The dirty filter may be cleaned at a more convenient
time.
11
MAINTENANCE: -continued-
2. Condensate Management System: The condensate management system should be
checked periodically for scale, sludge and debris that may cause the system to fail. On
open type enclosures and in areas where the enclosure door is opened frequently within
dirty or industrial environments, maintenance should be performed on a regular basis.
On sealed enclosures, clean environments, or where the door is not opened frequently,
maintenance may be performed annually. The type of environment will determine the
frequency of required maintenance.
Maintenance of the condensate management system will require removal of electrical

power from the Ice Qube system and removal of the cover. To remove the cover, use a
screw driver to loosen the screws which attach the cover to the base.
*** CAUTION ***

Electrical wires are connected from the cover to the base.
Removing the cover will allow access to the primary condensate management pan,
which is located below the evaporator. Inspect the condensate pan and the drain nipple
for signs of scale, sludge or debris that may prevent water flow through the nipple. To
clean the debris from the pan, use a clean absorbent cloth or shop-vac. Nipples may be
cleaned using a ¼ inch tubing brush, then flush with clean water.
Also inspect the neoprene tubing that is attached to the nipples on the condensate
management system. Replace the tubing if it appears to have internal build-up or has
become brittle.
NOTE: If there is a secondary condensate management pan, maintenance will

need to be performed in the same manner as explained above.
After all debris has been removed from the system, replace the cover onto the unit –
being careful not to pinch or damage the wiring connecting the cover to the base.
3. Cooling system cabinet: The cooling system cabinet may also need to be cleaned
occasionally. To clean the system cabinet, simply wipe it with a damp, lint free cloth. A
mild soap solution may be used if necessary.
TROUBLE SHOOTING:
Contact Ice Qube if the air conditioning system should fail to operate satisfactorily during the
first year of operation. DO NOT remove the cover without first notifying the factory. Removal
of the cover will immediately void the warranty.
If an operating problem should occur, please review the items outlined in the following “Trouble
Shooting Check List”. If the problem persists, contact Ice Qube for technical assistance.
12
TROUBLE SHOOTING CHECK LIST
Model No: S/N Number:
Voltage Rating: Amps: Phase: Hz:
Is electrical power available at the outlet? YES NO
Is the power cord connected to the electrical outlet? YES NO
Is the controller set point temperature above the enclosure temperature? YES NO
Is the evaporator (cold air stream) blower operating? YES NO
Is the compressor and condenser (warm air stream) blower operating? YES NO
Is the enclosure door closed tightly? YES NO
Are all of the gaskets in place? YES NO
Has the warm air filter been cleaned or changed recently? YES NO
Is the system mounted level on the enclosure? YES NO
Is there adequate space within the enclosure for air flow? YES NO
Is there adequate space around the enclosure for air flow? YES NO
Have you recently added electronic equipment to the enclosure? YES NO
Still experiencing Problems?

Call Ice Qube at 1-888-867-8234
13
SCHEMATIC WIRING DIAGRAM
14
SCHEMATIC WIRING DIAGRAM – Top Mount Units
15
LANTEC
LHS Winch Series
Installation and
Maintenance Manual
When ordering repair parts for LANTEC planetary winches

always quote the serial number of the unit.
Model Code LHS430A-99.10-02-CC-D2-13D-DR-ED-GD-SP
Serial No. 55668 to 55682
Date Shipped June 2011
Revision: D
Revision Date: 10/10
Specifications and Performance
This winch is "power in/power out" and equal speed in both directions.
Model LHS430
Specifications Units
Prime Mover (Supplied by Others)
Gear Ratio 99.10 : 1
Input Speed 1,000 rpm
Input Torque 4,500 lbf-in
Drum Speed 10 rpm
Drum Torque 413,330 lbf-in
Line Pull -- 1st Layer 33,950 lb
Line Speed -- 1st Layer 64 fpm
Barrel Diameter 23.475 in
Barrel Length 40.06 in
Wire Rope Size 0.875 in
Minimum Dead Wraps 5 @ Each End -
Wire Rope Capacity (Dead Wraps + Active) 102 x 2 Ropes ft
Design Service Temperature (MIN) 0 °C
Oil Capacity 30 US gal.
Weight 2,750 lb
Brake Pressure – Minimum Full Release 700 psi
Brake Pressure – Maximum Allowable 3,000 psi

Configurations, Optional Equipment, and Accessories
The following table shows the configuration and options which are included in this manual. Consult
LANTEC for manuals and information on other configurations, options, and accessories.
Configuration / Option Included within this manual
Installation Drawing 205966
Assembly Drawing 205965
Motor Mounting Flange SAE D2 Bolt
Motor Mounting Shaft SAE D 13T Spline
Motor Type & Displacement Supplied by Others
Brake LANTEC Spring Applied / Hydraulic Release
Optional Accessories Drum Roller & Encoder Drive
Notes
LANTEC Product Support – Installation and Maintenance Manual
Important Safety Information

Prior to performing any work on the winch please read and thoroughly
understand this Important Safety Information and observe all DANGER,
WARNING, and CAUTION safety notations, and informational callouts
used in this manual.
! DANGER
This emblem indicates a situation in which a hazard is
imminent and will result in a high probability of serious
injury or death.
! WARNING
This emblem indicates a potential hazardous situation
which could result in some probability of serious injury or
death.
! CAUTION
which could result in minor injury or moderate injury and
product or property damage.
Notice
This emblem contains informational notes and tips related
to good work practice.
v

Operating Safety Tips torque or input speed stated in the winch
1. Be sure personnel are clear of work area specifications
BEFORE operating winch. 11. Do not weld on any part of the winch.
2. Read all danger warning and caution tag 12. Use only recommended gear lubricant
information provided for safe operation of and hydraulic oil.
winch.
13. Keep hydraulic system clean and free
3. Inspect winch at the beginning of each from contamination at all times.
work shift. Defects should be corrected
immediately. Wire Rope Safety Tips
4. An equipment warm-up procedure is 14. Inspect rigging at the beginning of each
recommended for all start-ups and work shift. Defects should be corrected
essential at ambient temperatures below immediately.
+40°F. Refer to "Warm-up Procedure" in 15. Leather gloves should be used when
section 3.2 of this manual. handling wire rope.
5. Operate winch line speeds to match job
16. Never attempt to handle wire rope when
conditions. Move heavy loads slowly.
the hook end is not free.
6. ALWAYS maintain the required number
17. When winding wire rope on the winch
of dead wraps of rope on the drum as
indicated in the “Specification and drum, never attempt to maintain tension
Performance” section of this manual. by allowing wire rope to slip through
hands. Always use "Hand-Over-Hand"
Servicing Safety Tips technique.
7. Be certain equipment (boom, sheave 18. Never use wire rope with broken strands.
blocks, pendants, etc.) is either lowered Replace wire rope.
to the ground/deck or blocked securely 19. Use the correct wire rope anchor for the
before servicing, adjusting, or repairing wire rope in the drum pocket.
the winch.
20. Do not use knots to secure or attach wire
8. Read all danger warning and caution tag rope.
information provided for safe service of
the winch. 21. ALWAYS maintain the required number
9. Keep equipment in good operating indicated in the “Specification and
condition. Perform scheduled servicing Performance” section of this manual.
and adjustments listed in the "Preventive
Maintenance" section of this manual.
10. Do not exceed the maximum pressure Notice
(PSI) or flow (GPM) stated in the winch LANTEC Winches contain
specifications. For winches shipped NO Asbestos materials.
without motors, do not exceed maximum
vi
Table of Contents
1. Introduction ........................................................................................................................................1
1.1. Forward ......................................................................................................................................1
1.2. Product Identification and Serial Number ...................................................................................1
1.3. Personnel Handling Notice .........................................................................................................2
1.4. Configurations, Optional Equipment, and Accessories ..............................................................2
1.5. Theory of Winch Operation .........................................................................................................3
2. Installation..........................................................................................................................................4
2.1. General Requirements ...............................................................................................................4
2.2. Storage .......................................................................................................................................4
2.3. Winch Position ............................................................................................................................4
2.4. Foundation and Mounting ...........................................................................................................5
2.5. Lubricants ...................................................................................................................................7
2.6. Wire Rope Installation ................................................................................................................9
3. Operation of Winch ..........................................................................................................................10
3.1. Pre Operation Inspection ..........................................................................................................10
3.2. Warm-up Procedure .................................................................................................................10
3.3. Operating Tips ..........................................................................................................................11
4. Periodic Inspection and Testing.......................................................................................................12
4.1. General .....................................................................................................................................13
4.2. Internal (tear down) Inspection .................................................................................................13
4.3. Predictive Inspections ...............................................................................................................13
4.4. Wire Rope Inspection ...............................................................................................................14
5. Maintenance ....................................................................................................................................15
5.1. Oil Change ................................................................................................................................15
5.2. Vent Cleaning ...........................................................................................................................17
5.3. Mounting Bolts ..........................................................................................................................17
6. Trouble Shooting .............................................................................................................................18
6.1. Winch will not Haul In the rated load ........................................................................................19
6.2. Winch will not Pay Out the load ................................................................................................20
6.3. Brake will not hold the load when control valve is returned to neutral ......................................20
6.4. Winch runs hot ..........................................................................................................................21
6.5. Wire rope does not spool smoothly on the drum ......................................................................22
7. Reference ........................................................................................................................................23
7.1. Factory Limited Warranty .........................................................................................................23
7.2. Fastener Torque Chart .............................................................................................................23
7.3. Service Bulletins (if any) ...........................................................................................................23
7.4. Manual Supplements (if any) ....................................................................................................23
7.5. Installation Drawing ..................................................................................................................23
7.6. Assembly Drawing ....................................................................................................................23
7.7. Hydraulic Schematic (optional) .................................................................................................23
vii
Notes
viii
1. Introduction
1.1. Forward
This manual has been published to provide information on operation, installation, maintenance and periodic
inspection, troubleshooting, for this LANTEC Winch.
LANTEC strongly recommends that, prior to performing any work on the winch, the relevant sections of this
manual are read and understood.
LANTEC regularly implements product improvements, which may result in your winch differing from that
shown in this manual. Contact LANTEC Product Support directly to resolve any concerns regarding your
LANTEC winch or the content of this manual.
Prior to performing any work on the winch please read and thoroughly understand the Important Safety
Information shown at the front of this manual and observe all DANGER CAUTION, and WARNING safety
notations.
1.2. Product Identification and Serial Number
Notice
When information on the winch is needed, always reference
the Model and Serial Number of the winch. The
Identification Plate is normally located on the end of the
winch base, next to the drive group
1
1.3. Personnel Handling Notice

This LANTEC Winch is NOT intended and NOT approved for personnel handling.
1.4. Configurations, Optional Equipment, and

Accessories
LANTEC Winch are available in a wide variety of optional configurations and with optional attachments and
accessories. This manual is intended to cover only basic winch configurations and therefore some pictorials
and information may differ from your winch. Contact LANTEC Product Support directly to resolve any
concerns regarding your LANTEC winch or the content of this manual.
1.4.1. Hydraulic Motor and Brake Valve

The standard configuration of the LANTEC Winch is where the motor and brake valve are supplied and
installed by LANTEC. Winches can be supplied less motor and/or brake valve.
For winches supplied without motor and/or brake valve see Technical Bulletins 30040 (Customer Supplied
Motor and Brake Valve) and 30050 (Selecting a Brake Valve) included with this manual.
2
1.5. Theory of Winch Operation

The LANTEC Winch is made up of these basic assemblies:
1. Input adapter to suit hydraulic motor (Supplied by Others)

2. Friction Brake: Spring applied / hydraulic released multi-disc Friction Brake, and sprag type
Overrunning Clutch.
3. Multi-stage Planetary Gear Reduction.
4. Winch drum, winch base, outboard bearing.
5. Drum Roller & Encoder Drive
The hydraulic motor (supplied by others) is coupled directly to the input of the planetary reduction. The
output of the planetary reduction is coupled directly to the drum.
The coupling, which joins the hydraulic motor to the input of the planetary reduction, is also the inner
race of the sprag-type-overrunning clutch ("sprag clutch"). The outer race of the sprag clutch is
connected to the friction discs of the friction brake.
The friction brake is a static parking brake. The friction discs are held from rotation by the clamping
force of a spring-applied piston. The piston forms part of a hydraulic cylinder which, when pressurized,
retracts the spring applied piston permitting the friction discs to rotate.
The sprag clutch is a device which permits free rotation of its inner race in one direction (the haul in
direction), but when the inner race is rotated in the opposite direction the sprag cams lock the inner race
to the outer race.
While hauling in, the friction brake remains applied. As the motor rotates in the haul-in direction, the
sprag clutch allows free rotation of the inner race. The motor drives the input to the planetary reduction,
which in turns rotates the drum in the haul-in direction. When stopped, the sprag clutch locks up,
holding the load. To pay-out the load, hydraulic pressure is applied to fully release the friction brake.
While paying out, the dynamic braking is performed by the brake valve and hydraulic system (supplied
by others).
3
2. Installation
2.1. General Requirements
DO NOT WELD TO ANY PART OF THE WINCH
! CAUTION
Do not operate or perform any lubrication, maintenance or
repair on this product, until you have read and understood
the operation, lubrication, maintenance and repair
information.
2.2. Storage
LANTEC routinely ships winches with a small amount of vaporizing storage oil (oxidization inhibitor) in the
gear drive compartment to protect the components during shipping. This protection is sufficient for
temporary storage indoors of up to 4 weeks prior to startup.
When LANTEC products require storage for longer than 4 weeks please refer to our Service Bulletin 40060
“Term Storage of Winches and Drives”, available upon request, or from our website; www.lantecgear.com.
2.3. Winch Position

The position of the winch must provide access to motor ports and to fill and drain ports and the oil level
gauge/port.
The winch must be mounted with the centerline of the drum in a horizontal position. The mounting plane
can be rotated to any position around this centerline, with due consideration to various port and vent
locations, which may require repositioning. Unless otherwise ordered, winches are shipped from the factory
are arranged for mounting on a horizontal plane.
Make certain that the winch drum is centered behind the first sheave and that the fleet angle is between 0.5
degrees and 1.5 degrees to help insure even spooling. The winch axis should also be mounted
perpendicular to an imaginary line from the center of the drum to the first sheave to insure even spooling.
4
2.4. Foundation and Mounting

2.4.1. Bolting:
The mounting holes on a LANTEC winch are suitably designed for general purpose installations using
SAE grade 5 bolts.
The installer is responsible for overall connection design including bolt type and size specifications,
tightening specifications and any other mounting hardware that may be needed.
2.4.2. Qualifications:
LANTEC recommends that a qualified Millwright carry out mounting and installation of the winch.
2.4.3. Foundation:
It is important to note that LANTEC machines its winch base mounting pads so they are flat and planar
(all on the same plane). It is critical that internal alignment of bearings and gears in the winch not be
disturbed.
Ideally, the winch should be installed onto a foundation, which is within the tolerances specified in
Section 2.4.4. If the foundation is not completely flat and planar then a shimming or grouting process
must be used to ensure that the winch base is not twisted during installation.
2.4.4. Misalignment:
Misalignment can be caused by a combination of two elements; forced misalignment by inaccurate
mounting procedures, and misalignment caused by distortion or flexing of the foundation under load.
Both elements must be accounted for when determining a suitable mounting for the winch.
The total allowable operating misalignment, considering all sources, is stated as the distance that one
mounting pad is out of plane with the other three mounting pads. The maximum allowable distance is
dependent upon the dimension between mounting holes at the end of the winch.
The maximum permitted misalignment is 0.001" per inch of distance from mounting hole center
to mounting hole center at the end of the winch. Example: If the distance from mounting hole
center to mounting hole center at the end of the winch is 21.00" then the maximum misalignment
permitted is 0.021".
5
2.4.5. Mounting Procedure:

1. Sling the winch by the drum.
! CAUTION
The winch base is not structurally rigid. The winch
base could twist under its own weight, thus it is
important to support the weight of the winch during
installation by slinging the drum.
2. Carefully lower the winch until three of the four winch base pads just contact the foundation.
3. Install mounting bolts, nuts, and washers on the three pads in contact with the foundation and
torque them to 1/4 of their correct value.
Notice
Hardened flat washers should be used under the bolt
heads and nuts; LANTEC does NOT recommend the
use of lockwashers.
4. Measure any gap between the fourth pad and the foundation with a feeler gauge and shim the
gap.
5. Once the correct shims are in place, the remaining bolt(s) can be installed and all of the bolts
and nuts are torqued to their correct value.
6
2.5. Lubricants
! WARNING
Using the correct type and viscosity of lubricating oil
is critical to the proper function of this winch. The
sprag clutch is particularly sensitive to EP (extreme
pressure) additives.
Some gear lubricants contain large amounts of EP

(extreme pressure) and anti-friction additives, which
may contribute to sprag clutch slippage and damage
to brake friction discs or seals.
Failure to use the correct type and viscosity of oil may

cause failure of the winch to hold the load and result
in property damage, personal injury or death.
! CAUTION
The winch is shipped WITHOUT Lubricating oil and
MUST be filled to the proper level with the
recommended lubricant prior to operation.
Failure to fill the winch with lubricant will cause

accelerated wear resulting in failure of the winch to
hold the load and may result in property damage,
personal injury or death.
2.5.1. Lubricants for Outboard Bearing

Lubricate outboard bearing group using Lithium Based Grease (NLGI-2).
7
2.5.2. Lubricants for Gear Drive.

The following table gives the recommended viscosity in relation to ambient temperature. Other brand products
may be acceptable, be certain that your lubricant supplier provides oil that is equivalent to those shown here.
Ambient Temperature
0° to +15° C 0 to +30°C +10° to +50° C
+14° to +59° F 32 to +86°F +50° to +122° F
ISO 100 ISO 150 ISO 220

Oil Grade / Type
AGMA 3EP AGMA 4EP AGMA 5EP
Texaco Products Meropa 100 Meropa 150 Meropa 220
Exxon Products Spartan EP 100 Spartan EP 150 Spartan EP 220
Mobil Products Mobilgear 627 Mobilgear 629 Mobilgear 630
Shell Products Omala 100 Omala 150 Omala 220
Note: cSt is the same as mm2/s.

For special conditions consult factory for recommendations.
The recommended working temperature of the sump should be between 50 and 70°C (122 to 158°F).
The intermittent peak temperature of the sump should be no greater than 95°C (203°F).
The winch is filled via the filler plug. Fill with gear oil until it reaches the oil level port. Refer to the
Installation Drawing included with this manual for port locations.
Notice
DO NOT OVERFILL as this may cause the winch to
overheat.
The Winch is supplied with a VENT, which must be kept clear at all times.
8
2.6. Wire Rope Installation
! WARNING
Check the wire rope. If wire rope is worn or frayed install a
new wire rope. Worn or frayed wire rope could cause
! CAUTION
When winding wire rope on the winch drum, never attempt
to maintain tension by allowing wire rope to slip through
hands. Always use "Hand-Over-Hand" technique.
! CAUTION
Wedge-Type Cable Ferrules are intended for use only with
new 6x19 or 6x37 Class, Right Regular Lay EIP or IWRC
Wire Ropes.
Notice
To optimize spooling characteristics and wire rope life it is
recommended that the wire rope have the proper tensioning
as it is installed on the drum.
2.6.1. Cable Anchor
Cable anchors should be properly secured and rechecked on a regular basis.
9
3. Operation of Winch
! WARNING
The winch wire rope anchor alone is not intended to hold
rated loads.
Operator of winch must always maintain the required

number of dead wraps on the drum as indicated in the
“Specification and Performance” section of this manual.
3.1. Pre Operation Inspection

A Pre-operation Inspection should be performed prior to each shift of use and periodically during extended
shifts.
1. Check for external oil leaks and repair as necessary. This is extremely important due to the
accelerated wear that can be caused by insufficient lubricating oil in the winch.
2. Check the lubricant level in the winch using sight glass. Top up as necessary.
3. Check the ratchet and pawl mechanism (if installed) for proper operation and for full engagement of
the pawl with the ratchet wheel. Adjust and/or repair as necessary.
4. Check hydraulic hose and fittings for damage, such as, chafed or deteriorated hoses and repair as
necessary.
5. Check for loose, missing, or corroded bolts, pins, keepers, and cotter pins and replace or tighten as
necessary.
3.2. Warm-up Procedure

A warm-up procedure is essential at ambient temperatures below +40°F (4°C). The prime mover should be
run at its lowest recommended RPM with the hydraulic winch control valve in neutral allowing sufficient
time to warm up the system. The winch should then be operated at low speeds, forward and reverse,
several times to prime all lines with warm hydraulic oil, and to circulate gear lubricant through the planetary
gear sets.
! WARNING
Failure to properly warm up the winch, particularly under
low ambient temperature conditions, may result in
temporary brake slippage due to high backpressures
attempting to release the brake, which could result in
property damage, severe personal injury or death.
10
3.3. Operating Tips

1. Be sure personnel are clear of work area BEFORE operating winch.
2. Read all warning and caution tag information provided for safe operation of winch.
3. Inspect winch at the beginning of each work shift. Defects should be corrected immediately.
4. An equipment warm-up procedure is recommended for all start-ups and essential at ambient
temperatures below +40°F. Refer to "Warm-up Procedure" in section 3.2 of this manual.
5. Operate winch line speeds to match job conditions. Move heavy loads more slowly.
6. ALWAYS maintain the required number of dead wraps of rope on the drum as indicated in the
7. In order to obtain smooth control during low speed pay out, it is recommended that the hydraulic
pump be operated at maximum speed.
11
4. Periodic Inspection and Testing
! WARNING
Before operating or servicing the LANTEC Winch ensure that
you have read and understand this entire set of instructions.
Failure to properly operate, maintain, and service a winch may

lead to loss of control of the load and result in property damage,
! DANGER
Winch must be immediately decommissioned and subject
to Internal Inspection upon the occurrence of any of the
following:
1. Winch fails to stop and hold the load securely.
2. Unusual noise emanating from within the winch. This

indicates possible impending failure.
3. Leakage of gear lubricant from the winch. This

suggests that the winch may have operated without
adequate lubricant.
4. Unusual amounts of particulate and/or other

contaminants in the gear lubricant, as found during
performance of Predictive Methods Inspections.
5. An overload that could have been in excess of the

rated load.
Failure to comply could lead to loss of control of the load

and result in property damage, personal injury or death.
12
4.1. General
LANTEC recommends adherence to the latest revision of any code and/or regulation that is applicable to
the specific use or application of this winch.
4.2. Internal (tear down) Inspection

Any machine will eventually be subject to fatigue (developing cracks as a result of a sufficient number of
load cycles) and potential failure. Depending on the duty cycle and typical load quantity, the winch owner
may determine that an inspection of load bearing parts is warranted.
Additionally, the winch must be immediately decommissioned and subject to Internal Inspection upon the
occurrence of any of the following:

2. Unusual noise emanating from within the winch. This indicates possible impending failure.
3. Substantial leakage of gear lubricant from the winch. This suggests that the winch may have operated
without adequate lubricant.
4. Unusual amounts of particulate and/or other contaminants in the gear lubricant.
5. An overload that could have been in excess of the rated load.
Internal "tear down" Inspection should be performed by a trained and qualified person.
Inspection should include; complete disassembly, cleaning, measurement of critical tolerances,
non-destructive crack detection inspection, appropriate replacement of parts, re-assembly,
painting, and final testing.
4.3. Predictive Inspections

Using predictive tools to monitor the condition of the Winch can reduce the risk of failure. The purpose of
predictive inspection is to evaluate the mechanical integrity of the winch by detecting unusual amounts of
wear. Periodic analysis of the lubrication oil and inspection for particulate on the magnetic plug are
recommended.
A Magnetic Plug can help separate iron particles from suspension and hold them for easy removal from the
lubrication oil. When looking at the material held by the magnet, the experience of the service personnel is
as important as the service history of the winch.
The following are general notes regarding material found on a magnetic plug;
• Large particles generally indicate that substantial damage exists within the drive and requires a
tear down to investigate.
• Smaller particles and “fines” require judgment from the service personnel as to whether the
condition is serious or not. A small quantity of fines in this type of drive after a suitable break-in
period would be considered normal, and the service personnel who examines and maintains these
winches will, over time, become knowledgeable in “reading” the material found on the plug.
13
4.4. Wire Rope Inspection

Although the wire rope is not part of the winch, a regular inspection will help to prevent potential accidents.
Inspect the wire rope according to the rope manufacturer instructions.
14
5. Maintenance
5.1. Oil Change
! WARNING
Using the correct type and viscosity of lubricating oil is
critical to the proper function of this winch. The sprag
clutch is particularly sensitive to EP (extreme pressure)
additives.

cause failure of the winch to hold the load and result in
property damage, personal injury or death.
5.1.1. Changing Oil for Cleanliness and Lubricating Properties
5.1.1.1. Break-in Period

In order to limit contaminants to an acceptable level in new or rebuilt winches more frequent oil
changes are required until the winch is through the break-in period. The initial oil change should
be at 50 hours of service and then every 250 hours of service until contaminant levels indicate
that extended intervals between oil changes are appropriate.
To maximize the life of a winch, metallic contamination levels at the time of oil change should
not exceed 500 PPM. Additionally, there should be no indication that the oil has lost its
lubricating properties.
5.1.1.2. After the Break-in Period

Following the break-in period, when contaminant levels indicate that extended intervals
between oil changes are appropriate, then follow the frequency as shown in the following table.
If there are significant changes to the ambient temperature then refer to “Changing Oil for
Correct Viscosity (Ambient Temperature Change) below.
15
5.1.1.3. Winch Usage/Duty and Oil Change Frequency
Hours usage per month

Crane Usage
based on the average usage Oil Change Requirement
Category
over a 3 month period
Infrequent Usage less than 10 hours

Annually
Light Usage 10-25 hours
(every 12 months)
Moderate Usage 25-50 hours
Semi-annually
Heavy Usage 50-200 hours
(every 6 months)
Operated at loads over 75% of

rated load for more than 75% of Quarterly
Severe Usage
lifts. And/or over 200 hours per (every 3 months)
month
If winch has not

been used for 3 0 hours Required
months
5.1.2. Procedure for Changing Oil
! WARNING
Hot oil and components can cause personal injury. Do not
allow hot oil or components to contact skin.
1. Before changing oil, consider taking an oil sample for analysis.

2. Run the winch to warm up oil and to ensure particles are suspended in the oil.
3. Place an oil pan or bucket beneath the drain port to collect the oil.
4. To allow oil to drain from the winch, loosen and remove the plug.
5. Remove the filler plug to allow air into the gear case.
5.1.3. Upon completion of oil draining:

1. Replace and tighten the drain plug.
2. Fill with the correct oil to the correct level.
3. Operate the winch for 30 seconds.
4. Stop the winch for 30 seconds then re-check for correct oil level.
5. Check that fittings and plugs are correctly tightened.
6. Dispose of used oil and clean up any spillage in an environmentally sound way.
16
5.2. Vent Cleaning

The location of the vent fitting is shown in attached Installation drawing in Appendix. It is very important to
keep this vent clean and unobstructed. Whenever gear oil is changed, remove vent fitting, clean in solvent
and reinstall. Do not paint over the vent and do not replace with a plug.
Winches fitted with optional Vent Filter / Breathers must be changed when the Desiccant color changes
from Blue to Pink.
5.3. Mounting Bolts

Tighten all winch base mounting bolts to recommended torque after the first one hundred (100) hours of
operation, then every 1000 operating hours or six (6) months, whichever occurs first.
17
6. Trouble Shooting
! WARNING
following:


adequate lubricant.


rated load.

This trouble-shooting guide is included to help an experienced mechanic maintain and repair the winch.
More information should be obtained from the hydraulic system supplier and the manufacturers of other
components in the system.
18
6.1. Winch will not Haul In the rated load

No. Probable Cause Remedy
Check the following items:
a) Is the load within the rated load for the

winch (see Specification and
Performance).
b) Has the reduced pull of the winch when

Load may exceed the maximum operating above the 1st layer been
1
rated load for the winch. considered?
c) Have the friction losses in the sheaves

been considered? This can be as high as
3% per sheave.
d) Has the correct number of parts of line

been considered?
Sheaves and rigging may not be Perform rigging service as recommended by

2
operating efficiently. the crane manufacturer.
Winch may be mounted on an

uneven surface and not shimmed Follow the mounting procedure as specified in
3 properly. This will cause distortion in Section 2.4 ensuring that miss-alignment is
the winch base and may cause within the tolerance specified.
binding in the gear train.
Winch mounting surface may distort Reinforce the mounting surface so that under
under load. This will cause full load the combined miss-alignment from
4
distortion in the winch base and mounting and distortion is within the tolerance
may cause binding in the gear train. specified in Section 2.4.
After all the causes listed above Disassemble winch referring to the assembly
have been investigated and it is drawing. Check that all gears turn freely. If
found that the winch will stall at gears and bearings are found to be
5
maximum pressure without satisfactory, inspect the hydraulic motor,
developing the rated pull, the according to the service instructions for the
trouble may be in the winch. hydraulic motor.
19
6.2. Winch will not Pay Out the load

Check for brake piston seal leakage as follows:
a) Connect a hand pump, with an accurate

pressure gauge (0-2000 psi) and a positive
Friction brake may not be releasing shut-off valve, directly to the brake release
due to a defective (leaking) brake port on the winch.
piston seal.
1 b) Apply 1000 psi to the brake. Close the
Note: If a brake piston seal is hand pump shut off valve and let stand for
defective you will usually find oil five (5) minutes.
leaking from the winch vent fitting.
c) A loss in pressure in five (5) minutes
indicates a damaged brake piston seal.
Disassemble winch referring to the
assembly drawing and repair as required.
Friction brake may not be releasing

Disassemble brake and inspect brake discs.
2 as a result of damaged friction
Replace as required.
and/or divider discs.
6.3. Brake will not hold the load when control valve is
returned to neutral
Remove all hoses from control valve and with
the spool in neutral, blow air through the work
Control valve is not correct type.
ports. The air should escape through the
The correct control valve must have
1 return port on the valve. If the motor ports in
all ports open to tank when the
the valve are blocked by the spool when the
spool is returned to neutral.
spool is in neutral, remove the valve and
replace with correct valve.
If back pressure is excessive (over 90 psi)

Excessive hydraulic system then corrective measures must be taken to
backpressure may result in reduced reduce to acceptable limits, such as:
friction brake holding capacity.
a) Increase hose sizes
This backpressure is usually caused
2
by the use of a control valve and b) Increase control valve size
hoses that are too small. It can also
be caused by a restriction in the Excessive system backpressure may occur
return line from the control valve to due to high oil viscosity on cold start-ups.
the reservoir. Always perform the warm-up procedure before
loading winch. (see section 3.2).
20

Refer to section 2.5 for gear oil
recommendation.
Incorrect type of gear oil. The sprag
clutch element may slip or engage
3 If unapproved gear oil with excessive additives
erratically if the incorrect gear oil is
has been used then complete disassembly
used.
and thorough cleaning is required. Brake
friction discs must be replaced.
4 Winch is being overloaded. Refer to Section 6.1 cause 1.
Disassemble the winch brake assembly

according to the disassembly instructions.
Friction brake may not hold load due Inspect the brake springs, friction and divider
5
to excessive wear or damage. discs, and sprag clutch assembly. Check that
the sprag clutch assembly will "lock up" in the
required direction of rotation.
6.4. Winch runs hot

uneven surface and not shimmed
properly. This will cause distortion in Follow the mounting procedure as specified in
1 the winch base and may cause section 2.4.5 ensuring that the miss-alignment
binding in the gear train, which in is within the tolerance specified.
turn increases the heat generated by
friction.
Winch mounting surface may distort

under load. This will cause distortion Reinforce the mounting surface so that under
in the winch base and may cause full load the combined miss-alignment from
2
binding in the gear train, which in mounting and distortion is within the tolerance
turn increases the heat generated by specified in Section 2.4.4.
friction.
Check that the gear lubricant is within the

3 Low gear lubricant level.
sight glass range.

4 Excessive gear lubricant level.
sight glass range.
Excessively worn or damaged Disassemble winch and inspect parts.

5
internal parts in the winch. Replace worn parts.
21
6.5. Wire rope does not spool smoothly on the drum

Check the mounting distance and
Winch may be mounted too close or too far
fleet angle. Reposition winch if
from the main sheave. Fleet angle (see
1 required. Consult LANTEC regarding
section 2.3) should be between 0.5 and 1.5
the benefits of grooved drum or
degrees.
grooved lagging.
Winch may not be mounted in line with the

main sheave (see section 2.3). The winch
2 axis must be mounted perpendicular to an Reposition winch if required.
imaginary line between the center of the wire
rope drum and the main sheave.
Wire rope type may be incorrect. Selecting Consult your wire rope manufacturer
3 the correct “lay” of wire rope is critical to for recommended type for your
achieve proper spooling. application.
Rope may be worn or may have been

Inspect wire rope frequently. Replace
4 overloaded, causing a permanent set in the
as required.
rope.
22
7. Reference
7.1. Factory Limited Warranty
7.2. Fastener Torque Chart
7.3. Service Bulletins (if any)
7.4. Manual Supplements (if any)
7.5. Installation Drawing
7.6. Assembly Drawing
7.7. Hydraulic Schematic (optional)
23
LANTEC
Effective 8/1/2008
SUPERSEDES ALL PRIOR WARRANTIES
LIMITED WARRANTY 50130-0
Seller warrants that each article (whether Gear Drive Products, Brake Products and/or Winch Products, all of which are covered
hereunder) sold under this order shall at the time of shipment (i) conform to applicable specifications, and (ii) be free from defects in
material and workmanship during normal and ordinary use and service (the "Warranty").
Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or
part thereof which has proven to be defective, or to refund the purchase price of such article or part thereof. Buyer acknowledges that
Buyer is knowledgeable concerning the articles covered by this Warranty and sold in connection therewith which are being purchased,
that Buyer has reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer.
This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach of this Warranty
must be given by Buyer to Seller within the applicable period. Such notice shall include an explanation of the claimed warranty defect
and proof of date of purchase of the article or part thereof for which warranty coverage is sought. No allowances shall be made by
Seller for any transportation, labor charges, parts, "in and out" costs, adjustments or repairs, or any other work, unless such items are
authorized in writing and in advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are
expendable.
If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications, Sell er will either
examine the article at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or
parts thereof which have been installed, used, or serviced otherwise than in conformity with Seller's applicable specifications,
manuals, bulletins, or instructions, or which shall have been subjected to improper installation, operation, or usage, misapp lication,
neglect, incorrect installation, overloading, or employment for other than normal and ordinary use and service. This Warranty shall not
apply to any article which has been repaired, altered or disassembled, or assembled by personnel other than those of Seller. This
Warranty shall not apply to any article upon which repairs or alterations have been made (unless authorized in writing and in advance
by Seller). This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer's specifications and/or furnished
by Buyer or acquired from others at Buyer's request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN THE WARRANTY
EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to torsional vi bration
issues and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is
installed. Buyer acknowledges, understands and agrees that this Warranty does not cover failures of the unit which result in any
manner from the operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in
such a way that damage may result. Buyer expressly agrees that Seller is not responsible for failure damage or accelerated wear
caused by machine or ambient vibration. Further, Buyer acknowledges and agrees that Buyer is always solely responsible for
determination and final approval of the “application factor” which may be used in Seller’s calculations and this application factor is 1.0
unless otherwise stated in Seller’s quotation specifications.
The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other remedies of
whatsoever kind. The limited remedies set forth above shall be deemed exclusive, even though they may fail their essential purpose.
No agreement varying or extending the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in writing
signed by an executive officer of Seller and Buyer. This Warranty is non-transferable. If a party who had purchased articles from
Buyer, or from persons in privity with Buyer, brings any action or proceeding against Seller for remedies other than those set forth in
this Warranty, Buyer agrees to defend Seller against the claims asserted in such action or proceeding at Buyer’s expense, including
the payment of attorneys’ fees and costs, and indemnify Seller and hold Seller harmless of, from and against all such claims, actions,
proceedings or judgments therein. Buyer also agrees to defend and indemnify Seller of, from and against any loss, cost, damage,
claim, debt or expenses, including attorneys’ fees, resulting from any claims by Buyer or third parties to property or injury to persons
resulting from faulty installation, repair or modification of the article and misuse or negligent operation or use of the article, whether or
not such damage to property or injury to persons may be caused by defective material, workmanship, or construction. ADVISORY:
Winches and hoists are not approved for lifting or handling personnel or persons unless specifically approved in writing from Seller for
the specific intended application.
Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted article or part
thereof, or (ii) for any special, indirect, incidental, or consequential damage or loss, even though such expenses, damages, or losses
may be foreseeable.
The foregoing limitations on Seller's liability in the event of breach of warranty shall also be the absolute limit of Sel ler's liability in the
event of Seller's negligence in manufacture, installation, or otherwise, with regard to the articles covered by this Warranty, and at the
expiration of the Warranty period as above stated, all such liabilities shall terminate. Buyer’s purchase of any article(s) covered by this
Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer’s representatives,
heirs and assigns. The laws of the Province of British Columbia shall govern Buyer’s rights and responsibilities in regard to this
Warranty and the transaction(s) subject thereto, and the Province of British Columbia shall be the exclusive forum and jurisdiction for
any action or proceedings brought by Buyer in connection herewith or any dispute hereunder. If any of the terms and conditions
contained within this Warranty are void, the remaining provisions thereof are and shall remain valid and enforceable.
Recommended Capscrew Torque Values

Values are for dry assembly
Coarse Threads
Torque Value lb.ft. Torque Value lb.ft.
Capscrew Size
Grade 5 Grade 8
1/4 - 20 8 12
5/16 – 18 17 25
3/8 – 16 30 45
7/16 – 12 50 70
1/2 - 13 75 110
9/16 – 12 110 150
5/8 – 11 150 220
3/4 - 10 260 380
7/8 – 9 430 600
1–8 640 900
1 1/8 – 7 800 1280
1 1/4 - 7 1120 1820
1 3/8 – 6 1460 2380
1 1/2 - 6 1940 3160
Fine Threads
Capscrew Size
Grade 5 Grade 8
1/4 - 28 10 14
5/16 – 24 19 25
3/8 – 24 35 50
7/16 – 20 55 80
1/2 - 20 90 120
9/16 – 18 120 170
5/8 – 18 180 240
3/4 - 16 300 420
7/8 – 14 470 660
1 – 14 730 1020
1 1/8 – 12 880 1440
1 1/4 - 12 1240 2000
1 3/8 – 12 1680 2720
1 1/2 - 12 2200 3560
II
LANTEC 107197 REV: 1 Page: 1 of 3
Technical Bulletin 30040

Author: JWM Approved: DJM 02-05-28
Service
Customer Supply of Hydraulic Motor & Brake Valve
Bulletin
LANTEC reserves the right to change this bulletin without notice and without obligation
Product Scope: LANTEC LH & LW Series Only
Customers may elect to purchase a LANTEC LH Series Hoist or LW Series Winch without
the Hydraulic Motor and Brake Valve normally supplied by LANTEC. In these cases the
customer accepts responsibility for the proper selection, supply, installation, testing,
support and warranty of the Hydraulic Motor and Brake Valve.
Important Note for Hoists to be Rated for Personnel Handling
LANTEC LH (not LW) Series Hoists are rated for personnel handling only if the
hoist is an integral part of an Offshore Crane carrying a valid API Spec 2C
nameplate, and other conditions are met (see LANTEC Sales Bulletin 50010
“Personnel Handling Statement”, available upon request).
The Motor and Brake Valve are critical components of the hoist system. The
Brake Valve (Counterbalance Valve) fulfills the API Spec 2C requirement for a
secondary braking system. When the customer elects to supply the Motor and
Brake Valve, they take on the responsibility for declaring and authorizing the
hoist for Personnel Handling. In such cases LANTEC will NOT label the hoist as
rated for Personnel Handling. LANTEC will provide a “Statement of Conditional
Approval”, rating the hoist for Personnel Handling subject to satisfactory
integration with the customer supplied Motor, Brake Valve and other circuit
components and features as may be required to comply with API Spec 2C and
safe operation of the hoist. The customer will have the responsibility to label the
hoist as “Rated for Personnel Handling”, if required.
LANTEC provides this document to include the following items for customer’s
consideration.
LANTEC Winch & Gear D R I V E N T O E X C E L L E N C E
5827 Production Way, Langley, BC V3A 4N5 Canada T 604-530-0737 F 604-530-2889 www.team-twg.com [email protected]

Motor Selection
The customer must select the appropriate motor type and displacement giving due
consideration to the desired operating pressure, motor starting torque efficiency
versus running torque efficiency, and life expectancy.
LANTEC will provide, upon request, specifications for the motor performance
requirements and limitations such as motor shaft torque required for rated load and
the maximum motor shaft speed permitted.
The customer must order the hoist specifying the appropriate motor mounting flange
and shaft configuration to match the selected motor.
Brake Valve (Counterbalance Valve) Selection

LANTEC LH hoists employ a multi-disc brake for static and emergency load holding,
however, dynamic braking while lowering the load is a function performed by the
Brake Valve.
LANTEC will provide to the customer specifications for the operating characteristics
required of the Brake Valve (see LANTEC Technical Bulletin 30050 “Selecting a
Brake Valve”, available upon request). The proper selection of the Brake Valve is
perhaps the most critical task leading to a successful hoist installation. Great care
must be exercised to ensure a stable operating performance over the full range of
operating conditions.
Brake Pressure Limit

LANTEC LH hoists employ a multi-disc brake for static and emergency load holding.
The brake is spring force applied and hydraulic pressure released. The maximum
allowable pressure permitted in the brake cylinder is 3000 psi. This restriction must
be considered during the hydraulic circuit design.
Factory Testing Limitation

Since LANTEC is not supplying the Motor and Brake Valve the hoist cannot be fully
tested at the factory. LANTEC will test the hoist, using a standard motor, and
standard test procedures. It is the responsibility of the customer to test the hoist
with the customer supplied Motor and Brake Valve installed.

Related Documents
LANTEC recommends understanding the contents of these related documents,
available from LANTEC upon request.
Technical Bulletin 30050 Selecting a Brake Valve
Sales Bulletin 50010 Personnel Handling Statement
End of Bulletin

Service
Selecting a Brake Valve
Bulletin
Brake Valves
(a.k.a. “Motor Control Valve”, “Counterbalance Valve”, “Holding Valve”)
Background
LANTEC LH Hoist Series and LW Winch Series employ a multi-disc brake for static
and emergency load holding, however, while lowering the load the dynamic braking
function is performed by the Brake Valve. The LANTEC Brake Valve has
undergone exhaustive testing to ensure the highest level of performance and
operational stability.
Customers may elect to purchase a LANTEC LH Series Hoist without the Hydraulic
Motor and Brake Valve normally supplied by LANTEC. In these cases the customer
accepts responsibility for the proper selection, supply, installation, testing, support
and warranty of the Motor and Brake Valve.
LANTEC provides this document to assist our customer in selecting a Brake Valve
by providing detailed specifications for the operating characteristics required of the
Brake Valve.
The proper selection of the Brake Valve is perhaps the most critical task leading to a
successful hoist installation. Great care must be exercised to ensure a stable
operating performance over the full range of operating conditions.
General
The Brake Valve must be mounted directly to the working pressure port of a
hydraulic motor. The motor drives a hoist which has a Friction Brake (multi-disc,
spring applied, hydraulic pressure released) and a multistage planetary reduction
gearbox. The Friction Brake is intended only as a static parking brake and
emergency-only dynamic brake. Due to the inclusion of an overrunning “sprag”

clutch, the friction brake is released only when lowering a load.
Brake Valve Experience

Brake Valves are recognized by most valve manufacturers and users as being
inherently unstable, often requiring field “tuning” and even system modifications in
order to provide suitable operating characteristics. This “trial and error” approach is
extremely undesirable and can be costly. The customer should put a very high
emphasis on working with a Brake Valve manufacturer that can demonstrate
considerable experience and success in the application of Brake Valves to
Hoists.
Load Conditions
This hoist application requires that a load be lowered smoothly through a full
spectrum of speeds and loads. The winch must operate smoothly from very slow
“creep” speed to full speed and with “no load” to “full load”. Therefore, the Brake
Valve must be stable from very low to full system flow, and with low to full pressure.
Mounting
Direct mounting to the hoisting (raising) pressure port of the hydraulic motor is
important to eliminate the risk of a line failure.
Pressure Rating
The selected Brake Valve must have a pressure rating suitable for the system
pressures expected.
Flow Rate
The selected Brake Valve must have a flow rating suitable for the system maximum
flow.
Customer systems will vary considerably depending on the hoist performance
required for a given application.

Check Valve Bypass

The selected Brake Valve must have a full flow check valve bypass so that during
hoisting (raising the load) operations the oil passes freely through the check valve to
the hoisting pressure port of the motor. Low pressure drop through the check valve
section is important to reduce overall pressure drop in the system.
Brake Valve Opening Pressure

The Brake Valve works in conjunction with the Hoist Friction Brake. The Friction
Brake is released by hydraulic pressure. The hydraulic pressure is developed when
the pump supplies oil to the reversing pressure port of the motor. Since the Friction
Brake is applied, the motor will not rotate. The pressure increases until the Friction
Brake is fully released, at which time the Brake Valve will hold the load. The
pressure will continue to increase until the Brake Valve opens and smoothly lowers
the load at a speed proportional to the supply of oil.
When the operator wants to stop the load he moves the main control valve to
neutral, reducing and stopping the supply of oil to the motor. The pressure thus
decreases, causing the Brake Valve to close. The Friction Brake then sets by spring
force.
The pressure required to fully release the Friction Brake is 700 psi. Therefore,
the Brake Valve must open at a 150-200 psi higher pressure (850-900 psi).
Related Documents
available from LANTEC upon request:
Technical Bulletin 30040 Customer Supply of Hydraulic

Motor and Brake Valve
End of Bulletin
Service
LANTEC Bulletin
106758
Motor Installation Guidelines Page 1 of 5
Date 2009 / 07 / 23 Rev Date

By / Approved DJM/DJM Rev Author
LANTEC reserves the right to change this bulletin without notice and without obligation.
Refer to our web site or contact LANTEC to verify the current revision level. Rev Level
Product Scope:
LANTEC winches and drives supplied less motor
Bulletin Scope:
This bulletin covers the typical checks and installation procedures to properly install a motor on a winch or
geardrive.
Advice:
! WARNING
The motor must be sized and fitted correctly to an input brake to
avoid overload, and or thrust loads.
Failure to ensure proper motor fit up as described in this
procedure could cause loss of control of the load, which could
result in property damage, personal injury or death.
1) Verify that your motor and hydraulic supply match the input specifications for input torque and speed
given in the specification page of the LANTEC manual that came with your product.
2) Inspect motor shaft (typically splined) for type and length to ensure suitability. It is important to be
certain that the motor installation will not cause end thrust within the drive. LANTEC provides
geometric data on motor fit up on installation drawings. This drawing can be found in your manual.
LANTEC Winch & Gear Inc. D R I V E N T O E X C E L L E N C E
5827 Production Way, Langley, BC V3A 4N5 Canada T 604-530-0737 F 604-530-2889 www.lantecgear.com [email protected]
Service
LANTEC Bulletin
106758
a. Typical motor spline cross section from a LANTEC installation drawing.
b. Spline length being measured on a motor with a straight edge and tape measure.
Service
LANTEC Bulletin
106758
3) Install a gasket or o-ring on your motor prior to assembly. LANTEC generally provides either a gasket or
o-ring to seal the motor to the gear drive. These items will be found in a bag either in the motor mount
spigot behind the shipping cover or taped to the drum with the manual.
a. Typical Packaging arrangements with a manual and Motor O-rings taped to the drum
b. Alternate location for shipping motor o-ring the shipping motor cover plate.
Service
LANTEC Bulletin
106758
4) If your product has a motor input brake then the brake hub must be centralized in the brake stack to
allow the motor to seat properly on assemblies where the brake hub is supported by the motor shaft.
On other LANTEC assemblies the brake hub is supported by bearings and this is not an issue. On new
units LANTEC assembles and delivers the brake hub pre-centralized with the use of a fitment jig at the
factory. If for some reason hydraulic pressure is applied to the brake release piston prior to motor
installation this alignment could be disturbed. If it is discovered that the hub is out of alignment then it
is a simple matter to release the brake stack with hydraulic pressure while the motor is being installed.
In this state the motor itself will align the brake stack as it is being installed.
a. Cross section of a classic series brake hub (bearing supported)
b. Cross section view of an LH brake hub (motor shaft supported)
Service
LANTEC Bulletin
106758
5) When installing the motor it is important to properly seat it into the geardrive mount. Ideally the motor
should be hand fitted and seated in place such that only small amount of draw in with the mounting
bolts is required to squeeze the o-ring. If the motor assembly is heavy then slinging and supporting the
motor during the process is advised. If there is a problem with the motor fit up this is the last chance to
detect it prior to it causing operational issues.
a. Motor being installed onto a winch drive while supported by a sling and overhead hoist.
End of Bulletin
4 3 2 1
REVISIONS
REV DESCRIPTION DRAWN BY APPROVED DATE
A Revised Dimensions to 'As Built' Condition jmc bdd 11/05/02

Fill / Drain Ports
SAE -16 O-Ring Boss B Added Auxiliary Views for Stowed & Operating Winch Positions jmc DJM 11/05/10
1 5/16-12 UN Thread
Brake Release Port (2 Places)
Pressure Roller
SAE -4 O-Ring Boss
7/16-20 UNF Thread (40 7/8)
500psi Zero Holding Torque Haul-In
Level Port
Spiral Grooving Cable Clamp
700psi MIN Full Release 23.475 for Ø7/8 Cable
SAE -16 O-Ring Boss
(6 Places)
3000psi MAX Allowable (7/8) (Root) 1 5/16-12 UN Thread
75psi MAX Back Pressure
B B
A
30 9/16
1 5/8 to Motor
Mounting Face
17
Design Ground Line 1 3/8
Encoder Drive
13 13/16 5 1/8 41 1/4 (See Sheet 2)
= = 48.540 0.010
20.000 0.010 Ø1 3/8 Mounting Holes 51 1/2
(4 Places)
26 1/8
3/4 37
A
SAE D Mount - 2 Bolt

(Hydraulic Motor and Counterbalance Valve Supplied by Others)
2.938 MAX
Shaft Length
CERTIFIED DRAWING Ø6.001 Free rotation of input is the
This drawing is certified to be dimensionally correct for Ø6.004 opposite of haul-in rotation
A installation purposes for the application identified below
Model Code: LHS430A-99.10-02-CC-D2-13D-X-X-X-DR-ED-GD-SP
A
Customer:
LANTEC
UNLESS OTHERWISE SPECIFIED
Model: 3/4-10 UNC x 1.44 Deep Imperial (in) MEAN SURFACE
Equally Spaced on 9.000 PCD SAE D Mount Spline ROUGHNESS Langley BC Canada
TOLERANCES
Serial Number: (2 Places) 8/16 Diametral Pitch 125
13 Teeth
Fractions: ±1/16
X.XX: ±0.020 Winch Installation
Certified By: 30° Pressure Angle X.XXX: ±0.005
X.XXXX: ±0.0005
ANGLES LHS430A-99.10-02-CC-D2-13D-X-X-X-DR-ED-GD-SP - C0.88
1.625 Pitch Diameter ±2°
REVISION
On acceptance, sign and date this DRAWN BY bdd 06/11/02 SIZE
sheet and return to LANTEC.
ANSI B92.1-1970 Class 5 DO NOT SCALE
CHECKED BY NH 06/11/03 205966 B
Approved By: APPROVED BY DJM 06/11/03 B WEIGHT 2,650 lbs. SCALE
1 = 12
SHEET
1 of 2
THIS DRAWING AND ALL INFORMATION HEREIN, BOTH IN PROPRIETARY AND NOVEL FEATURE, IS THE PROPERTY
OF LANTEC AND MAY NOT BE COPIED OR USED IN ANY WAY DETRIMENTAL TO THE INTERESTS OF LANTEC.
4 3 2 1
4 3 2 1
2.877
2.880
B B
0.500
1 3/16 MIN
A
2
Flat on Shaft
NEMA 34 Mount
1/4-20 UNC Thread x 0.35 Deep
Equally Spaced on 3.875 PCD
(4 Places)
135°
A A
LANTEC
Imperial (in) MEAN SURFACE
ROUGHNESS Langley BC Canada
TOLERANCES
Operating Position Stowed Position Fractions: ±1/16
X.XX: ±0.020
125
Winch Installation
SCALE 1 / 18 SCALE 1 / 18 X.XXX: ±0.005
X.XXXX: ±0.0005
±2°
DRAWN BY bdd 06/11/02 SIZE REVISION
DO NOT SCALE
CHECKED BY NH 06/11/03 205966 B
B B
APPROVED BY DJM 06/11/03 B WEIGHT 2,650 lbs. SCALE
1 = 12
SHEET
2 of 2
4 3 2 1
4 3 2 1
REVISIONS

9 4 10 Torque
B General Revision as per 107147 - ESN 55668 & jmc bdd 11/04/28 34 35 37 40 25 1 20 22 31
26 B 60 lb-ft dry
- Replaced 205578 with 107394 & 405537 with 406283 --- --- -----
8 32
23 28
- - 105596 Seal Kit
40 1 712847 Tube- 01.50 OD x 00.120W DOM - 002.94L 3 3
39 1 605091 Washer - Flat
38 4 605090 Capscrew - Hex A
37 2 605088 Capscrew - Hex
B Adjust Spring to 10
B
36 2 604937 Nut-Hex
35 4 604936 Washer-Flat After Cable Installed
34 2 604935 Nut-Hex Lock Nylon
6
32 1 604927 Spring-Tension
31 2 604921 Bearing Unit 15
36 39 7
30 1 604421 Bearing - SRB 29 30 17 19 5
29 1 604415 Seal - Oil SL B
Torque
28 1 604070 Gauge - Sight 2 20 22 75 lb-ft dry
27 8 602077 Washer-Flat Torque
27 33 38 12 14
1 24 lb-ft dry Haul-In
26 1 601933 Plug-Socket Head Black
25 2 601349 Plug - Socket Head
24 20 600997 Capscrew - Hex Free rotation of 13
23 1 600979 O-Ring input is opposite
to haul-in rotation
22 14 600816 Capscrew - Hex 11
21 20 600599 Washer - Flat
20 14 600597 Washer - Flat
19 1 406283 Drum-Winch Torque
265 lb-ft dry
18 1 405539 Drive Group
17 2 404737 Bar-Tie 21 24
16 1 404314 Housing - End - Drive Input Rotation
1
15
14
1
1
206517
205987
Housing - Bearing
Breather Kit
Notes:
13 1 205980 Shaft-Roller Apply Medium Strength Threadlocker Compound in Accordance with WI 4.4.1.1. 16
1
12 1 205979 Roller Assmebly
2 Lubricate All Seals on Assembly in Accordance with WI 106069.
11 1 205978 Bracket-Mounting - RH
10 1 205977 Bracket-Mounting - LH 3 Shim to Give 0.020 to 0.060 Drum End Float. Brake Release Port
A 9 1 205972 Lever-Spring Oriented as Shown 18 A
8 1 205971 Bracket-Mounting - Spring
7 1 205970 Housing-End-Bearing
LANTEC
6 1 205576 Adapter-Mount ISSUED Imperial (in)
TOLERANCES
MEAN SURFACE
5 1 205085 Placard Group
4 1 107394 Drive Kit-Encoder Date:
Fractions: ±1/16
X.XX: ±0.020
125
Winch Assembly
X.XXX: ±0.005
3 1 105265 Shim X.XXXX: ±0.0005
By: ±2°
2 1 105208 Adapter-Spring
Project:
DO NOT SCALE
CHECKED BY NH 07/01/15 205965 B
1
ITEM
6
QTY
105123
NUMBER
Clamp-Cable
DESCRIPTION WO/PO:
APPROVED BY jmc 07/01/15 B WEIGHT 2,650 lbs. SCALE
3 = 16
SHEET
1 of 1
MATERIAL / PARTS LIST OF LANTEC AND MAY NOT BE COPIED OR USED IN ANY WAY DETRIMENTAL TO THE INTERESTS OF LANTEC.
4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
D Revised Design - Replaced Brake Components with Brake Group jmc DJM 11/04/27
(1.36 MAX) 36 3
10 Notes:
37 18 14 27 17 12 21 1 Apply Medium Strength Threadlocker Compound in Accordance with WI 4.4.1.1.
D C D
2 2 Apply High Strength Threadlocker Compound in Accordance with WI 4.4.1.1.
A 4 3 See Detail A for Bearing Installation Orientation.

A
8 4 Lubricate All Seals on Assembly in Accordance with WI 106069.
3 43
32
33
39 34
47 15
C A
C C
DETAIL A
Bearing Snap Ring Orientation
SCALE 3 : 2
1 24 25 38 A
Torque
180 lb-ft dry
- - 107305 Seal Kit
47 3 605759 Ring-Retaining
46 1 605524 Ring - Retaining Spiral
5 43 1 604426 Bearing - CRB
41 12 604409 Stud
40 12 604399 Nut - Hex
39 1 604394 Seal - Oil SL
30 38 16 604393 Stud - Wheel
37 1 604369 Ring - Retaining
36 1 604263 O-Ring
33 6 604245 Washer - Axial Bearing
32 6 604243 Bearing - DC Needle Roller
30 1 603798 Retaining - Ring
29 3 603593 Bearing-SRB
B 26 3 601825 Ring-Retaining B
25 16 601562 Nut - Hex
24 16 600598 Washer - Flat
23 12 600597 Washer - Flat
22 20 600595 Washer - Flat
21 1 406085 Hub-Planet
20 1 405860 Housing - Gear
A 19 1 404623 Gear - Internal
18 1 404378 Hub - Planet
17 1 404376 Hub - Planet
16 1 207489 Brake Group
22 44 2
15 1 204538 Cap - End - Oil Holes
Torque 14 1 204515 Gear - Internal Assembly
45 lb-ft dry 13 1 204266 Gear - Sun
12 1 204265 Gear-Sun
31 19 11 11 1 204264 Gear-Sun
10 3 204263 Gear - Planet
8 3 204261 Gear-Planet
16
22 28 2 7 1 204260 Shaft - Drive
B D
6 3 204258 Pin-Planet
Torque 5 1 203543 Bearing - Thrust Washer
45 lb-ft dry
4 6 104367 Bearing - Needle Race
3 3 104266 Spacer-Bearing
1 3 103899 Spacer - Bearing
ITEM QTY NUMBER DESCRIPTION
45 7 13 46 42 1 20 MATERIAL / PARTS LIST
A A UNLESS OTHERWISE SPECIFIED A
9
26
ISSUED Imperial (in)
TOLERANCES
MEAN SURFACE
ROUGHNESS Langley BC LANTEC Canada
C
Date:
Fractions: ±1/16
X.XX: ±0.020
125
Drive Group
29 X.XXX: ±0.005
1 23 40 41 2 ANGLES LHS430A-99.10 - D2-13D - DDP
By: X.XXXX: ±0.0005
±2°
405539
SIZE REVISION
35 DO NOT SCALE
DRAWN BY bdd 06/11/22
Torque Project: CHECKED BY NH 07/01/15 D
120 lb-ft dry
WO/PO:
APPROVED BY jmc 07/01/15 D WEIGHT
765 lb.
SCALE
7=8
SHEET
1 of 1
8 7 6 5 4 3 2 1
4 3 2 1
6 Notes:
B A 1 CAUTION: Parts Under Spring Load
13
14 11 2 Apply Medium Strength Threadlocker Compound in Accordance with WI 4.4.1.1
16 17 18 1 3 See Drive Group Assembly for QTY of Studs -- See Sheet 2 for Position of Studs.
7 4 Lubricate All Seals on Assembly in Accordance with WI 106069
B B
- - 107225 Seal Kit

21 1 604583 O-Ring
B 20 5 604227 Disc-Divider
19 4 604226 Disc-Friction
18 1 604214 Ring-Retaining Spiral
17 1 603523 O-Ring Backup
10
15 12 603294 Spring-Die
14 1 602203 O-Ring
13 2 601213 O-Ring
9
12 4 601003 Capscrew - Soc
11 1 601000 O-Ring
10 1 600911 O-Ring
12 2 1 19 3 15 4 5 1
9 1 600752 O-Ring
Torque 20 8 1 600161 Plug-Socket Head
380 lb-ft dry SECTION A-A 7 2 600159 Plug-Socket Head
A 21 6 1 405858 Housing - Brake
5 1 404227 Plate-Pressure
8 4 1 404225 Piston-Brake
3 1 204807 Spacer-Brake
2 1 204575 Clutch-Sprag Assembly
1 1 105574 Adapter - Mount
A ITEM QTY NUMBER DESCRIPTION A
MATERIAL / PARTS LIST
LANTEC

TOLERANCES
MEAN SURFACE
125
Date:
Fractions: ±1/16
X.XX: ±0.020 Brake Group
X.XXX: ±0.005
X.XXXX: ±0.0005
ANGLES LH Series-A - D2-13D - DDP
By: ±2°
DRAWN BY JY 11/02/17 SIZE REVISION
Project:
DO NOT SCALE
CHECKED BY NH 11/03/08 207489
WO/PO:
SECTION B-B APPROVED BY DJM 11/04/28 B WEIGHT
115 lbs.
SCALE
3=8
SHEET
1 of 2
4 3 2 1
4 3 2 1
Stud Position Stud Position

Stud Position
B B
LHS110 LHS100/160/170 LHS240/330/430
A A
LANTEC
TOLERANCES
125
Fractions: ±1/16
X.XXX: ±0.005
X.XXXX: ±0.0005
±2°
DO NOT SCALE
CHECKED BY NH 11/03/08 207489
APPROVED BY DJM 11/04/28 B WEIGHT
---
SCALE
---
SHEET
2 of 2
4 3 2 1
2 1
Notes:
Item Identification - Metal Stamp, Engrave or Etch the following markings:
1 Mark the Part Number as shown with 1/8" high characters.
2 Mark the LANTEC WO or PO Number " " with 1/8" high characters.
3 Lubricate all parts with hydraulic oil on assembly
B B
2 6 8 4 7
1 2 3 5 1
8 1 604930 Bearing-Thrust Bronze

7 1 604792 Seal-Oil DL
6 2 604791 Bearing - Plain DU
5 1 600979 O-Ring
3 1 205575 Housing-Bearing
2 1 107400 Coupling-Clamp Jaw
A 1 1 107395 Shaft-Encoder Drive
A
LANTEC

TOLERANCES
MEAN SURFACE
125
Date:
Fractions: ±1/16
X.XX: ±0.020 Drive Kit-Encoder
X.XXX: ±0.005
X.XXXX: ±0.0005
ANGLES LHS-ED - 0.50 Shaft - Zero Backlash
By: ±2°
DRAWN BY jmc 11/04/29 SIZE REVISION
Project:
DO NOT SCALE
CHECKED BY NH 11/05/02 107394
WO/PO:
APPROVED BY bdd 11/05/04 A WEIGHT
1.2 lbs.
SCALE
3=4
SHEET
1 of 1
2 1
LANTEC
Continuing improvement and advancement of product design

may result in changes which are not reflected in this manual.
We reserve the right to change the data contained in this
manual without notice.
LANTEC
5827 Production Way
Langley, BC Canada V3A 4N5
Tel (604) 530-0737 – Fax (604) 530-2889
www.team-twg.com - [email protected]
LANTEC
LHS Winch Series
Installation and
Maintenance Manual
When ordering repair parts for LANTEC planetary winches

always quote the serial number of the unit.
Model Code LHS430A-99.10-02-CC-D2-13D-DR-ED-GD-SP
Serial No. 55743 to 55757
Date Shipped September 2011
Revision: D
Revision Date: 10/10
This winch is "power in/power out" and equal speed in both directions.
Model LHS430
Specifications Units
Prime Mover (Supplied by Others)
Gear Ratio 99.10 : 1
Input Speed 1,000 rpm
Input Torque 4,500 lbf-in
Drum Speed 10 rpm
Drum Torque 413,330 lbf-in
Line Pull -- 1st Layer 33,950 lb
Line Speed -- 1st Layer 64 fpm
Barrel Diameter 23.475 in
Barrel Length 40.06 in
Wire Rope Size 0.875 in
Minimum Dead Wraps 5 @ Each End -
Wire Rope Capacity (Dead Wraps + Active) 102 x 2 Ropes ft
Design Service Temperature (MIN) 0 °C
Oil Capacity 30 US gal.
Weight 2,750 lb
Brake Pressure – Minimum Full Release 700 psi
Brake Pressure – Maximum Allowable 3,000 psi

Configurations, Optional Equipment, and Accessories
The following table shows the configuration and options which are included in this manual. Consult
LANTEC for manuals and information on other configurations, options, and accessories.
Configuration / Option Included within this manual
Installation Drawing 205966
Assembly Drawing 205965
Motor Mounting Flange SAE D2 Bolt
Motor Mounting Shaft SAE D 13T Spline
Motor Type & Displacement Supplied by Others
Brake LANTEC Spring Applied / Hydraulic Release
Optional Accessories Drum Roller & Encoder Drive
Notes

Prior to performing any work on the winch please read and thoroughly
understand this Important Safety Information and observe all DANGER,
WARNING, and CAUTION safety notations, and informational callouts
used in this manual.
! DANGER
This emblem indicates a situation in which a hazard is
imminent and will result in a high probability of serious
injury or death.
! WARNING
which could result in some probability of serious injury or
death.
! CAUTION
which could result in minor injury or moderate injury and
product or property damage.
Notice
This emblem contains informational notes and tips related
to good work practice.
v

Operating Safety Tips torque or input speed stated in the winch
1. Be sure personnel are clear of work area specifications
BEFORE operating winch. 11. Do not weld on any part of the winch.
2. Read all danger warning and caution tag 12. Use only recommended gear lubricant
information provided for safe operation of and hydraulic oil.
winch.
13. Keep hydraulic system clean and free
3. Inspect winch at the beginning of each from contamination at all times.
work shift. Defects should be corrected
immediately. Wire Rope Safety Tips
4. An equipment warm-up procedure is 14. Inspect rigging at the beginning of each
recommended for all start-ups and work shift. Defects should be corrected
essential at ambient temperatures below immediately.
+40°F. Refer to "Warm-up Procedure" in 15. Leather gloves should be used when
section 3.2 of this manual. handling wire rope.
5. Operate winch line speeds to match job
16. Never attempt to handle wire rope when
conditions. Move heavy loads slowly.
the hook end is not free.
6. ALWAYS maintain the required number
17. When winding wire rope on the winch
indicated in the “Specification and drum, never attempt to maintain tension
Performance” section of this manual. by allowing wire rope to slip through
hands. Always use "Hand-Over-Hand"
Servicing Safety Tips technique.
7. Be certain equipment (boom, sheave 18. Never use wire rope with broken strands.
blocks, pendants, etc.) is either lowered Replace wire rope.
to the ground/deck or blocked securely 19. Use the correct wire rope anchor for the
before servicing, adjusting, or repairing wire rope in the drum pocket.
the winch.
20. Do not use knots to secure or attach wire
8. Read all danger warning and caution tag rope.
information provided for safe service of
the winch. 21. ALWAYS maintain the required number
9. Keep equipment in good operating indicated in the “Specification and
condition. Perform scheduled servicing Performance” section of this manual.
and adjustments listed in the "Preventive
Maintenance" section of this manual.
10. Do not exceed the maximum pressure Notice
(PSI) or flow (GPM) stated in the winch LANTEC Winches contain
specifications. For winches shipped NO Asbestos materials.
without motors, do not exceed maximum
vi
Table of Contents
1. Introduction ........................................................................................................................................1
1.1. Forward ......................................................................................................................................1
1.2. Product Identification and Serial Number ...................................................................................1
1.3. Personnel Handling Notice .........................................................................................................2
1.4. Configurations, Optional Equipment, and Accessories ..............................................................2
1.5. Theory of Winch Operation .........................................................................................................3
2. Installation..........................................................................................................................................4
2.1. General Requirements ...............................................................................................................4
2.2. Storage .......................................................................................................................................4
2.3. Winch Position ............................................................................................................................4
2.4. Foundation and Mounting ...........................................................................................................5
2.5. Lubricants ...................................................................................................................................7
2.6. Wire Rope Installation ................................................................................................................9
3. Operation of Winch ..........................................................................................................................10
3.1. Pre Operation Inspection ..........................................................................................................10
3.2. Warm-up Procedure .................................................................................................................10
3.3. Operating Tips ..........................................................................................................................11
4. Periodic Inspection and Testing.......................................................................................................12
4.1. General .....................................................................................................................................13
4.2. Internal (tear down) Inspection .................................................................................................13
4.3. Predictive Inspections ...............................................................................................................13
4.4. Wire Rope Inspection ...............................................................................................................14
5. Maintenance ....................................................................................................................................15
5.1. Oil Change ................................................................................................................................15
5.2. Vent Cleaning ...........................................................................................................................17
5.3. Mounting Bolts ..........................................................................................................................17
6. Trouble Shooting .............................................................................................................................18
6.1. Winch will not Haul In the rated load ........................................................................................19
6.2. Winch will not Pay Out the load ................................................................................................20
6.3. Brake will not hold the load when control valve is returned to neutral ......................................20
6.4. Winch runs hot ..........................................................................................................................21
6.5. Wire rope does not spool smoothly on the drum ......................................................................22
7. Reference ........................................................................................................................................23
7.1. Factory Limited Warranty .........................................................................................................23
7.2. Fastener Torque Chart .............................................................................................................23
7.3. Service Bulletins (if any) ...........................................................................................................23
7.4. Manual Supplements (if any) ....................................................................................................23
7.5. Installation Drawing ..................................................................................................................23
7.6. Assembly Drawing ....................................................................................................................23
7.7. Hydraulic Schematic (optional) .................................................................................................23
vii
Notes
viii
1. Introduction
1.1. Forward
This manual has been published to provide information on operation, installation, maintenance and periodic
inspection, troubleshooting, for this LANTEC Winch.
LANTEC strongly recommends that, prior to performing any work on the winch, the relevant sections of this
manual are read and understood.
LANTEC regularly implements product improvements, which may result in your winch differing from that
shown in this manual. Contact LANTEC Product Support directly to resolve any concerns regarding your
LANTEC winch or the content of this manual.
Prior to performing any work on the winch please read and thoroughly understand the Important Safety
Information shown at the front of this manual and observe all DANGER CAUTION, and WARNING safety
notations.
1.2. Product Identification and Serial Number
Notice
When information on the winch is needed, always reference
the Model and Serial Number of the winch. The
Identification Plate is normally located on the end of the
winch base, next to the drive group
1
1.3. Personnel Handling Notice

This LANTEC Winch is NOT intended and NOT approved for personnel handling.
1.4. Configurations, Optional Equipment, and

Accessories
LANTEC Winch are available in a wide variety of optional configurations and with optional attachments and
accessories. This manual is intended to cover only basic winch configurations and therefore some pictorials
and information may differ from your winch. Contact LANTEC Product Support directly to resolve any
concerns regarding your LANTEC winch or the content of this manual.
1.4.1. Hydraulic Motor and Brake Valve

The standard configuration of the LANTEC Winch is where the motor and brake valve are supplied and
installed by LANTEC. Winches can be supplied less motor and/or brake valve.
For winches supplied without motor and/or brake valve see Technical Bulletins 30040 (Customer Supplied
Motor and Brake Valve) and 30050 (Selecting a Brake Valve) included with this manual.
2
1.5. Theory of Winch Operation

The LANTEC Winch is made up of these basic assemblies:
1. Input adapter to suit hydraulic motor (Supplied by Others)

2. Friction Brake: Spring applied / hydraulic released multi-disc Friction Brake, and sprag type
Overrunning Clutch.
3. Multi-stage Planetary Gear Reduction.
4. Winch drum, winch base, outboard bearing.
5. Drum Roller & Encoder Drive
The hydraulic motor (supplied by others) is coupled directly to the input of the planetary reduction. The
output of the planetary reduction is coupled directly to the drum.
The coupling, which joins the hydraulic motor to the input of the planetary reduction, is also the inner
race of the sprag-type-overrunning clutch ("sprag clutch"). The outer race of the sprag clutch is
connected to the friction discs of the friction brake.
The friction brake is a static parking brake. The friction discs are held from rotation by the clamping
force of a spring-applied piston. The piston forms part of a hydraulic cylinder which, when pressurized,
retracts the spring applied piston permitting the friction discs to rotate.
The sprag clutch is a device which permits free rotation of its inner race in one direction (the haul in
direction), but when the inner race is rotated in the opposite direction the sprag cams lock the inner race
to the outer race.
While hauling in, the friction brake remains applied. As the motor rotates in the haul-in direction, the
sprag clutch allows free rotation of the inner race. The motor drives the input to the planetary reduction,
which in turns rotates the drum in the haul-in direction. When stopped, the sprag clutch locks up,
holding the load. To pay-out the load, hydraulic pressure is applied to fully release the friction brake.
While paying out, the dynamic braking is performed by the brake valve and hydraulic system (supplied
by others).
3
2. Installation
2.1. General Requirements
! CAUTION
Do not operate or perform any lubrication, maintenance or
repair on this product, until you have read and understood
the operation, lubrication, maintenance and repair
information.
2.2. Storage
LANTEC routinely ships winches with a small amount of vaporizing storage oil (oxidization inhibitor) in the
gear drive compartment to protect the components during shipping. This protection is sufficient for
temporary storage indoors of up to 4 weeks prior to startup.
When LANTEC products require storage for longer than 4 weeks please refer to our Service Bulletin 40060
“Term Storage of Winches and Drives”, available upon request, or from our website; www.lantecgear.com.
2.3. Winch Position

The position of the winch must provide access to motor ports and to fill and drain ports and the oil level
gauge/port.
The winch must be mounted with the centerline of the drum in a horizontal position. The mounting plane
can be rotated to any position around this centerline, with due consideration to various port and vent
locations, which may require repositioning. Unless otherwise ordered, winches are shipped from the factory
are arranged for mounting on a horizontal plane.
Make certain that the winch drum is centered behind the first sheave and that the fleet angle is between 0.5
degrees and 1.5 degrees to help insure even spooling. The winch axis should also be mounted
perpendicular to an imaginary line from the center of the drum to the first sheave to insure even spooling.
4
2.4. Foundation and Mounting

2.4.1. Bolting:
The mounting holes on a LANTEC winch are suitably designed for general purpose installations using
SAE grade 5 bolts.
The installer is responsible for overall connection design including bolt type and size specifications,
tightening specifications and any other mounting hardware that may be needed.
2.4.2. Qualifications:
LANTEC recommends that a qualified Millwright carry out mounting and installation of the winch.
2.4.3. Foundation:
It is important to note that LANTEC machines its winch base mounting pads so they are flat and planar
(all on the same plane). It is critical that internal alignment of bearings and gears in the winch not be
disturbed.
Ideally, the winch should be installed onto a foundation, which is within the tolerances specified in
Section 2.4.4. If the foundation is not completely flat and planar then a shimming or grouting process
must be used to ensure that the winch base is not twisted during installation.
2.4.4. Misalignment:
Misalignment can be caused by a combination of two elements; forced misalignment by inaccurate
mounting procedures, and misalignment caused by distortion or flexing of the foundation under load.
Both elements must be accounted for when determining a suitable mounting for the winch.
The total allowable operating misalignment, considering all sources, is stated as the distance that one
mounting pad is out of plane with the other three mounting pads. The maximum allowable distance is
dependent upon the dimension between mounting holes at the end of the winch.
The maximum permitted misalignment is 0.001" per inch of distance from mounting hole center
to mounting hole center at the end of the winch. Example: If the distance from mounting hole
center to mounting hole center at the end of the winch is 21.00" then the maximum misalignment
permitted is 0.021".
5
2.4.5. Mounting Procedure:

1. Sling the winch by the drum.
! CAUTION
The winch base is not structurally rigid. The winch
base could twist under its own weight, thus it is
important to support the weight of the winch during
installation by slinging the drum.
2. Carefully lower the winch until three of the four winch base pads just contact the foundation.
3. Install mounting bolts, nuts, and washers on the three pads in contact with the foundation and
torque them to 1/4 of their correct value.
Notice
Hardened flat washers should be used under the bolt
heads and nuts; LANTEC does NOT recommend the
use of lockwashers.
4. Measure any gap between the fourth pad and the foundation with a feeler gauge and shim the
gap.
5. Once the correct shims are in place, the remaining bolt(s) can be installed and all of the bolts
and nuts are torqued to their correct value.
6
2.5. Lubricants
! WARNING
Using the correct type and viscosity of lubricating oil
is critical to the proper function of this winch. The
sprag clutch is particularly sensitive to EP (extreme
pressure) additives.
Some gear lubricants contain large amounts of EP

(extreme pressure) and anti-friction additives, which
may contribute to sprag clutch slippage and damage
to brake friction discs or seals.

cause failure of the winch to hold the load and result
in property damage, personal injury or death.
! CAUTION
The winch is shipped WITHOUT Lubricating oil and
MUST be filled to the proper level with the
recommended lubricant prior to operation.
Failure to fill the winch with lubricant will cause

accelerated wear resulting in failure of the winch to
hold the load and may result in property damage,
2.5.1. Lubricants for Outboard Bearing

Lubricate outboard bearing group using Lithium Based Grease (NLGI-2).
7
2.5.2. Lubricants for Gear Drive.

The following table gives the recommended viscosity in relation to ambient temperature. Other brand products
may be acceptable, be certain that your lubricant supplier provides oil that is equivalent to those shown here.
Ambient Temperature
0° to +15° C 0 to +30°C +10° to +50° C
+14° to +59° F 32 to +86°F +50° to +122° F
ISO 100 ISO 150 ISO 220

Oil Grade / Type
AGMA 3EP AGMA 4EP AGMA 5EP
Texaco Products Meropa 100 Meropa 150 Meropa 220
Exxon Products Spartan EP 100 Spartan EP 150 Spartan EP 220
Mobil Products Mobilgear 627 Mobilgear 629 Mobilgear 630
Shell Products Omala 100 Omala 150 Omala 220
Note: cSt is the same as mm2/s.

For special conditions consult factory for recommendations.
The recommended working temperature of the sump should be between 50 and 70°C (122 to 158°F).
The intermittent peak temperature of the sump should be no greater than 95°C (203°F).
The winch is filled via the filler plug. Fill with gear oil until it reaches the oil level port. Refer to the
Installation Drawing included with this manual for port locations.
Notice
DO NOT OVERFILL as this may cause the winch to
overheat.
The Winch is supplied with a VENT, which must be kept clear at all times.
8
2.6. Wire Rope Installation
! WARNING
Check the wire rope. If wire rope is worn or frayed install a
new wire rope. Worn or frayed wire rope could cause
! CAUTION
When winding wire rope on the winch drum, never attempt
to maintain tension by allowing wire rope to slip through
hands. Always use "Hand-Over-Hand" technique.
! CAUTION
Wedge-Type Cable Ferrules are intended for use only with
new 6x19 or 6x37 Class, Right Regular Lay EIP or IWRC
Wire Ropes.
Notice
To optimize spooling characteristics and wire rope life it is
recommended that the wire rope have the proper tensioning
as it is installed on the drum.
2.6.1. Cable Anchor
Cable anchors should be properly secured and rechecked on a regular basis.
9
3. Operation of Winch
! WARNING
The winch wire rope anchor alone is not intended to hold
rated loads.
Operator of winch must always maintain the required

number of dead wraps on the drum as indicated in the
3.1. Pre Operation Inspection

A Pre-operation Inspection should be performed prior to each shift of use and periodically during extended
shifts.
1. Check for external oil leaks and repair as necessary. This is extremely important due to the
accelerated wear that can be caused by insufficient lubricating oil in the winch.
2. Check the lubricant level in the winch using sight glass. Top up as necessary.
3. Check the ratchet and pawl mechanism (if installed) for proper operation and for full engagement of
the pawl with the ratchet wheel. Adjust and/or repair as necessary.
4. Check hydraulic hose and fittings for damage, such as, chafed or deteriorated hoses and repair as
necessary.
5. Check for loose, missing, or corroded bolts, pins, keepers, and cotter pins and replace or tighten as
necessary.
3.2. Warm-up Procedure

A warm-up procedure is essential at ambient temperatures below +40°F (4°C). The prime mover should be
run at its lowest recommended RPM with the hydraulic winch control valve in neutral allowing sufficient
time to warm up the system. The winch should then be operated at low speeds, forward and reverse,
several times to prime all lines with warm hydraulic oil, and to circulate gear lubricant through the planetary
gear sets.
! WARNING
Failure to properly warm up the winch, particularly under
low ambient temperature conditions, may result in
temporary brake slippage due to high backpressures
attempting to release the brake, which could result in
property damage, severe personal injury or death.
10
3.3. Operating Tips

1. Be sure personnel are clear of work area BEFORE operating winch.
2. Read all warning and caution tag information provided for safe operation of winch.
3. Inspect winch at the beginning of each work shift. Defects should be corrected immediately.
4. An equipment warm-up procedure is recommended for all start-ups and essential at ambient
temperatures below +40°F. Refer to "Warm-up Procedure" in section 3.2 of this manual.
5. Operate winch line speeds to match job conditions. Move heavy loads more slowly.
6. ALWAYS maintain the required number of dead wraps of rope on the drum as indicated in the
7. In order to obtain smooth control during low speed pay out, it is recommended that the hydraulic
pump be operated at maximum speed.
11
4. Periodic Inspection and Testing
! WARNING
Before operating or servicing the LANTEC Winch ensure that
you have read and understand this entire set of instructions.
Failure to properly operate, maintain, and service a winch may

lead to loss of control of the load and result in property damage,
! DANGER
following:


adequate lubricant.


rated load.

12
4.1. General
LANTEC recommends adherence to the latest revision of any code and/or regulation that is applicable to
the specific use or application of this winch.
4.2. Internal (tear down) Inspection

Any machine will eventually be subject to fatigue (developing cracks as a result of a sufficient number of
load cycles) and potential failure. Depending on the duty cycle and typical load quantity, the winch owner
may determine that an inspection of load bearing parts is warranted.
Additionally, the winch must be immediately decommissioned and subject to Internal Inspection upon the
occurrence of any of the following:

2. Unusual noise emanating from within the winch. This indicates possible impending failure.
3. Substantial leakage of gear lubricant from the winch. This suggests that the winch may have operated
without adequate lubricant.
4. Unusual amounts of particulate and/or other contaminants in the gear lubricant.
5. An overload that could have been in excess of the rated load.
Internal "tear down" Inspection should be performed by a trained and qualified person.
Inspection should include; complete disassembly, cleaning, measurement of critical tolerances,
non-destructive crack detection inspection, appropriate replacement of parts, re-assembly,
painting, and final testing.
4.3. Predictive Inspections

Using predictive tools to monitor the condition of the Winch can reduce the risk of failure. The purpose of
predictive inspection is to evaluate the mechanical integrity of the winch by detecting unusual amounts of
wear. Periodic analysis of the lubrication oil and inspection for particulate on the magnetic plug are
recommended.
A Magnetic Plug can help separate iron particles from suspension and hold them for easy removal from the
lubrication oil. When looking at the material held by the magnet, the experience of the service personnel is
as important as the service history of the winch.
The following are general notes regarding material found on a magnetic plug;
• Large particles generally indicate that substantial damage exists within the drive and requires a
tear down to investigate.
• Smaller particles and “fines” require judgment from the service personnel as to whether the
condition is serious or not. A small quantity of fines in this type of drive after a suitable break-in
period would be considered normal, and the service personnel who examines and maintains these
winches will, over time, become knowledgeable in “reading” the material found on the plug.
13
4.4. Wire Rope Inspection

Although the wire rope is not part of the winch, a regular inspection will help to prevent potential accidents.
Inspect the wire rope according to the rope manufacturer instructions.
14
5. Maintenance
5.1. Oil Change
! WARNING
Using the correct type and viscosity of lubricating oil is
critical to the proper function of this winch. The sprag
clutch is particularly sensitive to EP (extreme pressure)
additives.

cause failure of the winch to hold the load and result in
property damage, personal injury or death.
5.1.1. Changing Oil for Cleanliness and Lubricating Properties
5.1.1.1. Break-in Period

In order to limit contaminants to an acceptable level in new or rebuilt winches more frequent oil
changes are required until the winch is through the break-in period. The initial oil change should
be at 50 hours of service and then every 250 hours of service until contaminant levels indicate
that extended intervals between oil changes are appropriate.
To maximize the life of a winch, metallic contamination levels at the time of oil change should
not exceed 500 PPM. Additionally, there should be no indication that the oil has lost its
lubricating properties.
5.1.1.2. After the Break-in Period

Following the break-in period, when contaminant levels indicate that extended intervals
between oil changes are appropriate, then follow the frequency as shown in the following table.
If there are significant changes to the ambient temperature then refer to “Changing Oil for
Correct Viscosity (Ambient Temperature Change) below.
15
5.1.1.3. Winch Usage/Duty and Oil Change Frequency
Hours usage per month

Crane Usage
based on the average usage Oil Change Requirement
Category
over a 3 month period
Infrequent Usage less than 10 hours

Annually
Light Usage 10-25 hours
(every 12 months)
Moderate Usage 25-50 hours
Semi-annually
Heavy Usage 50-200 hours
(every 6 months)
Operated at loads over 75% of

rated load for more than 75% of Quarterly
Severe Usage
lifts. And/or over 200 hours per (every 3 months)
month
If winch has not

been used for 3 0 hours Required
months
5.1.2. Procedure for Changing Oil
! WARNING
Hot oil and components can cause personal injury. Do not
allow hot oil or components to contact skin.
1. Before changing oil, consider taking an oil sample for analysis.

2. Run the winch to warm up oil and to ensure particles are suspended in the oil.
3. Place an oil pan or bucket beneath the drain port to collect the oil.
4. To allow oil to drain from the winch, loosen and remove the plug.
5. Remove the filler plug to allow air into the gear case.
5.1.3. Upon completion of oil draining:

1. Replace and tighten the drain plug.
2. Fill with the correct oil to the correct level.
3. Operate the winch for 30 seconds.
4. Stop the winch for 30 seconds then re-check for correct oil level.
5. Check that fittings and plugs are correctly tightened.
6. Dispose of used oil and clean up any spillage in an environmentally sound way.
16
5.2. Vent Cleaning

The location of the vent fitting is shown in attached Installation drawing in Appendix. It is very important to
keep this vent clean and unobstructed. Whenever gear oil is changed, remove vent fitting, clean in solvent
and reinstall. Do not paint over the vent and do not replace with a plug.
Winches fitted with optional Vent Filter / Breathers must be changed when the Desiccant color changes
from Blue to Pink.
5.3. Mounting Bolts

Tighten all winch base mounting bolts to recommended torque after the first one hundred (100) hours of
operation, then every 1000 operating hours or six (6) months, whichever occurs first.
17
6. Trouble Shooting
! WARNING
following:


adequate lubricant.


rated load.

This trouble-shooting guide is included to help an experienced mechanic maintain and repair the winch.
More information should be obtained from the hydraulic system supplier and the manufacturers of other
components in the system.
18
6.1. Winch will not Haul In the rated load

Check the following items:
a) Is the load within the rated load for the

winch (see Specification and
Performance).
b) Has the reduced pull of the winch when

Load may exceed the maximum operating above the 1st layer been
1
rated load for the winch. considered?
c) Have the friction losses in the sheaves

been considered? This can be as high as
3% per sheave.
d) Has the correct number of parts of line

been considered?
Sheaves and rigging may not be Perform rigging service as recommended by

2
operating efficiently. the crane manufacturer.

uneven surface and not shimmed Follow the mounting procedure as specified in
3 properly. This will cause distortion in Section 2.4 ensuring that miss-alignment is
the winch base and may cause within the tolerance specified.
binding in the gear train.
Winch mounting surface may distort Reinforce the mounting surface so that under
under load. This will cause full load the combined miss-alignment from
4
distortion in the winch base and mounting and distortion is within the tolerance
may cause binding in the gear train. specified in Section 2.4.
After all the causes listed above Disassemble winch referring to the assembly
have been investigated and it is drawing. Check that all gears turn freely. If
found that the winch will stall at gears and bearings are found to be
5
maximum pressure without satisfactory, inspect the hydraulic motor,
developing the rated pull, the according to the service instructions for the
trouble may be in the winch. hydraulic motor.
19
6.2. Winch will not Pay Out the load

Check for brake piston seal leakage as follows:
a) Connect a hand pump, with an accurate

pressure gauge (0-2000 psi) and a positive
Friction brake may not be releasing shut-off valve, directly to the brake release
due to a defective (leaking) brake port on the winch.
piston seal.
1 b) Apply 1000 psi to the brake. Close the
Note: If a brake piston seal is hand pump shut off valve and let stand for
defective you will usually find oil five (5) minutes.
leaking from the winch vent fitting.
c) A loss in pressure in five (5) minutes
indicates a damaged brake piston seal.
Disassemble winch referring to the
assembly drawing and repair as required.
Friction brake may not be releasing

Disassemble brake and inspect brake discs.
2 as a result of damaged friction
Replace as required.
and/or divider discs.
6.3. Brake will not hold the load when control valve is
returned to neutral
Remove all hoses from control valve and with
the spool in neutral, blow air through the work
Control valve is not correct type.
ports. The air should escape through the
The correct control valve must have
1 return port on the valve. If the motor ports in
all ports open to tank when the
the valve are blocked by the spool when the
spool is returned to neutral.
spool is in neutral, remove the valve and
replace with correct valve.
If back pressure is excessive (over 90 psi)

Excessive hydraulic system then corrective measures must be taken to
backpressure may result in reduced reduce to acceptable limits, such as:
friction brake holding capacity.
a) Increase hose sizes
This backpressure is usually caused
2
by the use of a control valve and b) Increase control valve size
hoses that are too small. It can also
be caused by a restriction in the Excessive system backpressure may occur
return line from the control valve to due to high oil viscosity on cold start-ups.
the reservoir. Always perform the warm-up procedure before
loading winch. (see section 3.2).
20

Refer to section 2.5 for gear oil
recommendation.
Incorrect type of gear oil. The sprag
clutch element may slip or engage
3 If unapproved gear oil with excessive additives
erratically if the incorrect gear oil is
has been used then complete disassembly
used.
and thorough cleaning is required. Brake
friction discs must be replaced.
4 Winch is being overloaded. Refer to Section 6.1 cause 1.
Disassemble the winch brake assembly

according to the disassembly instructions.
Friction brake may not hold load due Inspect the brake springs, friction and divider
5
to excessive wear or damage. discs, and sprag clutch assembly. Check that
the sprag clutch assembly will "lock up" in the
required direction of rotation.
6.4. Winch runs hot

uneven surface and not shimmed
properly. This will cause distortion in Follow the mounting procedure as specified in
1 the winch base and may cause section 2.4.5 ensuring that the miss-alignment
binding in the gear train, which in is within the tolerance specified.
turn increases the heat generated by
friction.
Winch mounting surface may distort

under load. This will cause distortion Reinforce the mounting surface so that under
in the winch base and may cause full load the combined miss-alignment from
2
binding in the gear train, which in mounting and distortion is within the tolerance
turn increases the heat generated by specified in Section 2.4.4.
friction.

3 Low gear lubricant level.
sight glass range.

4 Excessive gear lubricant level.
sight glass range.
Excessively worn or damaged Disassemble winch and inspect parts.

5
internal parts in the winch. Replace worn parts.
21
6.5. Wire rope does not spool smoothly on the drum

Check the mounting distance and
Winch may be mounted too close or too far
fleet angle. Reposition winch if
from the main sheave. Fleet angle (see
1 required. Consult LANTEC regarding
section 2.3) should be between 0.5 and 1.5
the benefits of grooved drum or
degrees.
grooved lagging.
Winch may not be mounted in line with the

main sheave (see section 2.3). The winch
2 axis must be mounted perpendicular to an Reposition winch if required.
imaginary line between the center of the wire
rope drum and the main sheave.
Wire rope type may be incorrect. Selecting Consult your wire rope manufacturer
3 the correct “lay” of wire rope is critical to for recommended type for your
achieve proper spooling. application.
Rope may be worn or may have been

Inspect wire rope frequently. Replace
4 overloaded, causing a permanent set in the
as required.
rope.
22
7. Reference
7.1. Factory Limited Warranty
7.2. Fastener Torque Chart
7.3. Service Bulletins (if any)
7.4. Manual Supplements (if any)
7.5. Installation Drawing
7.6. Assembly Drawing
7.7. Hydraulic Schematic (optional)
23
LANTEC
Effective 8/1/2008
SUPERSEDES ALL PRIOR WARRANTIES
LIMITED WARRANTY 50130-0
Seller warrants that each article (whether Gear Drive Products, Brake Products and/or Winch Products, all of which are covered
hereunder) sold under this order shall at the time of shipment (i) conform to applicable specifications, and (ii) be free from defects in
material and workmanship during normal and ordinary use and service (the "Warranty").
Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or
part thereof which has proven to be defective, or to refund the purchase price of such article or part thereof. Buyer acknowledges that
Buyer is knowledgeable concerning the articles covered by this Warranty and sold in connection therewith which are being purchased,
that Buyer has reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer.
This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach of this Warranty
must be given by Buyer to Seller within the applicable period. Such notice shall include an explanation of the claimed warranty defect
and proof of date of purchase of the article or part thereof for which warranty coverage is sought. No allowances shall be made by
Seller for any transportation, labor charges, parts, "in and out" costs, adjustments or repairs, or any other work, unless such items are
authorized in writing and in advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are
expendable.
If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications, Sell er will either
examine the article at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or
parts thereof which have been installed, used, or serviced otherwise than in conformity with Seller's applicable specifications,
manuals, bulletins, or instructions, or which shall have been subjected to improper installation, operation, or usage, misapp lication,
neglect, incorrect installation, overloading, or employment for other than normal and ordinary use and service. This Warranty shall not
apply to any article which has been repaired, altered or disassembled, or assembled by personnel other than those of Seller. This
Warranty shall not apply to any article upon which repairs or alterations have been made (unless authorized in writing and in advance
by Seller). This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer's specifications and/or furnished
by Buyer or acquired from others at Buyer's request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN THE WARRANTY
EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to torsional vi bration
issues and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is
installed. Buyer acknowledges, understands and agrees that this Warranty does not cover failures of the unit which result in any
manner from the operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in
such a way that damage may result. Buyer expressly agrees that Seller is not responsible for failure damage or accelerated wear
caused by machine or ambient vibration. Further, Buyer acknowledges and agrees that Buyer is always solely responsible for
determination and final approval of the “application factor” which may be used in Seller’s calculations and this application factor is 1.0
unless otherwise stated in Seller’s quotation specifications.
The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other remedies of
whatsoever kind. The limited remedies set forth above shall be deemed exclusive, even though they may fail their essential purpose.
No agreement varying or extending the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in writing
signed by an executive officer of Seller and Buyer. This Warranty is non-transferable. If a party who had purchased articles from
Buyer, or from persons in privity with Buyer, brings any action or proceeding against Seller for remedies other than those set forth in
this Warranty, Buyer agrees to defend Seller against the claims asserted in such action or proceeding at Buyer’s expense, including
the payment of attorneys’ fees and costs, and indemnify Seller and hold Seller harmless of, from and against all such claims, actions,
proceedings or judgments therein. Buyer also agrees to defend and indemnify Seller of, from and against any loss, cost, damage,
claim, debt or expenses, including attorneys’ fees, resulting from any claims by Buyer or third parties to property or injury to persons
resulting from faulty installation, repair or modification of the article and misuse or negligent operation or use of the article, whether or
not such damage to property or injury to persons may be caused by defective material, workmanship, or construction. ADVISORY:
Winches and hoists are not approved for lifting or handling personnel or persons unless specifically approved in writing from Seller for
the specific intended application.
Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted article or part
thereof, or (ii) for any special, indirect, incidental, or consequential damage or loss, even though such expenses, damages, or losses
may be foreseeable.
The foregoing limitations on Seller's liability in the event of breach of warranty shall also be the absolute limit of Sel ler's liability in the
event of Seller's negligence in manufacture, installation, or otherwise, with regard to the articles covered by this Warranty, and at the
expiration of the Warranty period as above stated, all such liabilities shall terminate. Buyer’s purchase of any article(s) covered by this
Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer’s representatives,
heirs and assigns. The laws of the Province of British Columbia shall govern Buyer’s rights and responsibilities in regard to this
Warranty and the transaction(s) subject thereto, and the Province of British Columbia shall be the exclusive forum and jurisdiction for
any action or proceedings brought by Buyer in connection herewith or any dispute hereunder. If any of the terms and conditions
contained within this Warranty are void, the remaining provisions thereof are and shall remain valid and enforceable.
Recommended Capscrew Torque Values

Values are for dry assembly
Coarse Threads
Capscrew Size
Grade 5 Grade 8
1/4 - 20 8 12
5/16 – 18 17 25
3/8 – 16 30 45
7/16 – 12 50 70
1/2 - 13 75 110
9/16 – 12 110 150
5/8 – 11 150 220
3/4 - 10 260 380
7/8 – 9 430 600
1–8 640 900
1 1/8 – 7 800 1280
1 1/4 - 7 1120 1820
1 3/8 – 6 1460 2380
1 1/2 - 6 1940 3160
Fine Threads
Capscrew Size
Grade 5 Grade 8
1/4 - 28 10 14
5/16 – 24 19 25
3/8 – 24 35 50
7/16 – 20 55 80
1/2 - 20 90 120
9/16 – 18 120 170
5/8 – 18 180 240
3/4 - 16 300 420
7/8 – 14 470 660
1 – 14 730 1020
1 1/8 – 12 880 1440
1 1/4 - 12 1240 2000
1 3/8 – 12 1680 2720
1 1/2 - 12 2200 3560
II

Service
Customer Supply of Hydraulic Motor & Brake Valve
Bulletin
Customers may elect to purchase a LANTEC LH Series Hoist or LW Series Winch without
the Hydraulic Motor and Brake Valve normally supplied by LANTEC. In these cases the
customer accepts responsibility for the proper selection, supply, installation, testing,
support and warranty of the Hydraulic Motor and Brake Valve.
Important Note for Hoists to be Rated for Personnel Handling
LANTEC LH (not LW) Series Hoists are rated for personnel handling only if the
hoist is an integral part of an Offshore Crane carrying a valid API Spec 2C
nameplate, and other conditions are met (see LANTEC Sales Bulletin 50010
“Personnel Handling Statement”, available upon request).
The Motor and Brake Valve are critical components of the hoist system. The
Brake Valve (Counterbalance Valve) fulfills the API Spec 2C requirement for a
secondary braking system. When the customer elects to supply the Motor and
Brake Valve, they take on the responsibility for declaring and authorizing the
hoist for Personnel Handling. In such cases LANTEC will NOT label the hoist as
rated for Personnel Handling. LANTEC will provide a “Statement of Conditional
Approval”, rating the hoist for Personnel Handling subject to satisfactory
integration with the customer supplied Motor, Brake Valve and other circuit
components and features as may be required to comply with API Spec 2C and
safe operation of the hoist. The customer will have the responsibility to label the
hoist as “Rated for Personnel Handling”, if required.
LANTEC provides this document to include the following items for customer’s
consideration.

Motor Selection
The customer must select the appropriate motor type and displacement giving due
consideration to the desired operating pressure, motor starting torque efficiency
versus running torque efficiency, and life expectancy.
LANTEC will provide, upon request, specifications for the motor performance
requirements and limitations such as motor shaft torque required for rated load and
the maximum motor shaft speed permitted.
The customer must order the hoist specifying the appropriate motor mounting flange
and shaft configuration to match the selected motor.
Brake Valve (Counterbalance Valve) Selection

LANTEC LH hoists employ a multi-disc brake for static and emergency load holding,
however, dynamic braking while lowering the load is a function performed by the
Brake Valve.
LANTEC will provide to the customer specifications for the operating characteristics
required of the Brake Valve (see LANTEC Technical Bulletin 30050 “Selecting a
Brake Valve”, available upon request). The proper selection of the Brake Valve is
perhaps the most critical task leading to a successful hoist installation. Great care
must be exercised to ensure a stable operating performance over the full range of
operating conditions.
Brake Pressure Limit

LANTEC LH hoists employ a multi-disc brake for static and emergency load holding.
The brake is spring force applied and hydraulic pressure released. The maximum
allowable pressure permitted in the brake cylinder is 3000 psi. This restriction must
be considered during the hydraulic circuit design.
Factory Testing Limitation

Since LANTEC is not supplying the Motor and Brake Valve the hoist cannot be fully
tested at the factory. LANTEC will test the hoist, using a standard motor, and
standard test procedures. It is the responsibility of the customer to test the hoist
with the customer supplied Motor and Brake Valve installed.

Related Documents
available from LANTEC upon request.
Technical Bulletin 30050 Selecting a Brake Valve
End of Bulletin

Service
Selecting a Brake Valve
Bulletin
Brake Valves
(a.k.a. “Motor Control Valve”, “Counterbalance Valve”, “Holding Valve”)
Background
LANTEC LH Hoist Series and LW Winch Series employ a multi-disc brake for static
and emergency load holding, however, while lowering the load the dynamic braking
function is performed by the Brake Valve. The LANTEC Brake Valve has
undergone exhaustive testing to ensure the highest level of performance and
operational stability.
Customers may elect to purchase a LANTEC LH Series Hoist without the Hydraulic
Motor and Brake Valve normally supplied by LANTEC. In these cases the customer
accepts responsibility for the proper selection, supply, installation, testing, support
and warranty of the Motor and Brake Valve.
LANTEC provides this document to assist our customer in selecting a Brake Valve
by providing detailed specifications for the operating characteristics required of the
Brake Valve.
The proper selection of the Brake Valve is perhaps the most critical task leading to a
successful hoist installation. Great care must be exercised to ensure a stable
operating performance over the full range of operating conditions.
General
The Brake Valve must be mounted directly to the working pressure port of a
hydraulic motor. The motor drives a hoist which has a Friction Brake (multi-disc,
spring applied, hydraulic pressure released) and a multistage planetary reduction
gearbox. The Friction Brake is intended only as a static parking brake and
emergency-only dynamic brake. Due to the inclusion of an overrunning “sprag”

clutch, the friction brake is released only when lowering a load.
Brake Valve Experience

Brake Valves are recognized by most valve manufacturers and users as being
inherently unstable, often requiring field “tuning” and even system modifications in
order to provide suitable operating characteristics. This “trial and error” approach is
extremely undesirable and can be costly. The customer should put a very high
emphasis on working with a Brake Valve manufacturer that can demonstrate
considerable experience and success in the application of Brake Valves to
Hoists.
Load Conditions
This hoist application requires that a load be lowered smoothly through a full
spectrum of speeds and loads. The winch must operate smoothly from very slow
“creep” speed to full speed and with “no load” to “full load”. Therefore, the Brake
Valve must be stable from very low to full system flow, and with low to full pressure.
Mounting
Direct mounting to the hoisting (raising) pressure port of the hydraulic motor is
important to eliminate the risk of a line failure.
Pressure Rating
The selected Brake Valve must have a pressure rating suitable for the system
pressures expected.
Flow Rate
The selected Brake Valve must have a flow rating suitable for the system maximum
flow.
Customer systems will vary considerably depending on the hoist performance
required for a given application.

Check Valve Bypass

The selected Brake Valve must have a full flow check valve bypass so that during
hoisting (raising the load) operations the oil passes freely through the check valve to
the hoisting pressure port of the motor. Low pressure drop through the check valve
section is important to reduce overall pressure drop in the system.
Brake Valve Opening Pressure

The Brake Valve works in conjunction with the Hoist Friction Brake. The Friction
Brake is released by hydraulic pressure. The hydraulic pressure is developed when
the pump supplies oil to the reversing pressure port of the motor. Since the Friction
Brake is applied, the motor will not rotate. The pressure increases until the Friction
Brake is fully released, at which time the Brake Valve will hold the load. The
pressure will continue to increase until the Brake Valve opens and smoothly lowers
the load at a speed proportional to the supply of oil.
When the operator wants to stop the load he moves the main control valve to
neutral, reducing and stopping the supply of oil to the motor. The pressure thus
decreases, causing the Brake Valve to close. The Friction Brake then sets by spring
force.
The pressure required to fully release the Friction Brake is 700 psi. Therefore,
the Brake Valve must open at a 150-200 psi higher pressure (850-900 psi).
Related Documents
available from LANTEC upon request:
Technical Bulletin 30040 Customer Supply of Hydraulic

Motor and Brake Valve
End of Bulletin
Service
LANTEC Bulletin
106758
Date 2009 / 07 / 23 Rev Date

By / Approved DJM/DJM Rev Author
LANTEC reserves the right to change this bulletin without notice and without obligation.
Refer to our web site or contact LANTEC to verify the current revision level. Rev Level
Product Scope:
LANTEC winches and drives supplied less motor
Bulletin Scope:
This bulletin covers the typical checks and installation procedures to properly install a motor on a winch or
geardrive.
Advice:
! WARNING
The motor must be sized and fitted correctly to an input brake to
avoid overload, and or thrust loads.
Failure to ensure proper motor fit up as described in this
procedure could cause loss of control of the load, which could
result in property damage, personal injury or death.
1) Verify that your motor and hydraulic supply match the input specifications for input torque and speed
given in the specification page of the LANTEC manual that came with your product.
2) Inspect motor shaft (typically splined) for type and length to ensure suitability. It is important to be
certain that the motor installation will not cause end thrust within the drive. LANTEC provides
geometric data on motor fit up on installation drawings. This drawing can be found in your manual.
Service
LANTEC Bulletin
106758
a. Typical motor spline cross section from a LANTEC installation drawing.
b. Spline length being measured on a motor with a straight edge and tape measure.
Service
LANTEC Bulletin
106758
3) Install a gasket or o-ring on your motor prior to assembly. LANTEC generally provides either a gasket or
o-ring to seal the motor to the gear drive. These items will be found in a bag either in the motor mount
spigot behind the shipping cover or taped to the drum with the manual.
a. Typical Packaging arrangements with a manual and Motor O-rings taped to the drum
b. Alternate location for shipping motor o-ring the shipping motor cover plate.
Service
LANTEC Bulletin
106758
4) If your product has a motor input brake then the brake hub must be centralized in the brake stack to
allow the motor to seat properly on assemblies where the brake hub is supported by the motor shaft.
On other LANTEC assemblies the brake hub is supported by bearings and this is not an issue. On new
units LANTEC assembles and delivers the brake hub pre-centralized with the use of a fitment jig at the
factory. If for some reason hydraulic pressure is applied to the brake release piston prior to motor
installation this alignment could be disturbed. If it is discovered that the hub is out of alignment then it
is a simple matter to release the brake stack with hydraulic pressure while the motor is being installed.
In this state the motor itself will align the brake stack as it is being installed.
a. Cross section of a classic series brake hub (bearing supported)
b. Cross section view of an LH brake hub (motor shaft supported)
Service
LANTEC Bulletin
106758
5) When installing the motor it is important to properly seat it into the geardrive mount. Ideally the motor
should be hand fitted and seated in place such that only small amount of draw in with the mounting
bolts is required to squeeze the o-ring. If the motor assembly is heavy then slinging and supporting the
motor during the process is advised. If there is a problem with the motor fit up this is the last chance to
detect it prior to it causing operational issues.
a. Motor being installed onto a winch drive while supported by a sling and overhead hoist.
End of Bulletin
4 3 2 1
REVISIONS
A Revised Dimensions to 'As Built' Condition jmc bdd 11/05/02

Fill / Drain Ports
SAE -16 O-Ring Boss B Added Auxiliary Views for Stowed & Operating Winch Positions jmc DJM 11/05/10
1 5/16-12 UN Thread
Brake Release Port (2 Places)
Pressure Roller
SAE -4 O-Ring Boss
7/16-20 UNF Thread (40 7/8)
500psi Zero Holding Torque Haul-In
Level Port
Spiral Grooving Cable Clamp
700psi MIN Full Release 23.475 for Ø7/8 Cable
SAE -16 O-Ring Boss
(6 Places)
3000psi MAX Allowable (7/8) (Root) 1 5/16-12 UN Thread
75psi MAX Back Pressure
B B
A
30 9/16
1 5/8 to Motor
Mounting Face
17
Design Ground Line 1 3/8
Encoder Drive
13 13/16 5 1/8 41 1/4 (See Sheet 2)
= = 48.540 0.010
20.000 0.010 Ø1 3/8 Mounting Holes 51 1/2
(4 Places)
26 1/8
3/4 37
A
SAE D Mount - 2 Bolt

(Hydraulic Motor and Counterbalance Valve Supplied by Others)
2.938 MAX
Shaft Length
CERTIFIED DRAWING Ø6.001 Free rotation of input is the
This drawing is certified to be dimensionally correct for Ø6.004 opposite of haul-in rotation
A installation purposes for the application identified below
Model Code: LHS430A-99.10-02-CC-D2-13D-X-X-X-DR-ED-GD-SP
A
Customer:
LANTEC
Model: 3/4-10 UNC x 1.44 Deep Imperial (in) MEAN SURFACE
Equally Spaced on 9.000 PCD SAE D Mount Spline ROUGHNESS Langley BC Canada
TOLERANCES
Serial Number: (2 Places) 8/16 Diametral Pitch 125
13 Teeth
Fractions: ±1/16
X.XX: ±0.020 Winch Installation
Certified By: 30° Pressure Angle X.XXX: ±0.005
X.XXXX: ±0.0005
1.625 Pitch Diameter ±2°
REVISION
On acceptance, sign and date this DRAWN BY bdd 06/11/02 SIZE
sheet and return to LANTEC.
ANSI B92.1-1970 Class 5 DO NOT SCALE
CHECKED BY NH 06/11/03 205966 B
Approved By: APPROVED BY DJM 06/11/03 B WEIGHT 2,650 lbs. SCALE
1 = 12
SHEET
1 of 2
4 3 2 1
4 3 2 1
2.877
2.880
B B
0.500
1 3/16 MIN
A
2
Flat on Shaft
NEMA 34 Mount
1/4-20 UNC Thread x 0.35 Deep
Equally Spaced on 3.875 PCD
(4 Places)
135°
A A
LANTEC
TOLERANCES
Operating Position Stowed Position Fractions: ±1/16
X.XX: ±0.020
125
Winch Installation
SCALE 1 / 18 SCALE 1 / 18 X.XXX: ±0.005
X.XXXX: ±0.0005
±2°
DO NOT SCALE
CHECKED BY NH 06/11/03 205966 B
B B
APPROVED BY DJM 06/11/03 B WEIGHT 2,650 lbs. SCALE
1 = 12
SHEET
2 of 2
4 3 2 1
4 3 2 1
REVISIONS

9 4 10 Torque
B General Revision as per 107147 - ESN 55668 & jmc bdd 11/04/28 34 35 37 40 25 1 20 22 31
26 B 60 lb-ft dry
- Replaced 205578 with 107394 & 405537 with 406283 --- --- -----
8 32
23 28
- - 105596 Seal Kit
40 1 712847 Tube- 01.50 OD x 00.120W DOM - 002.94L 3 3
39 1 605091 Washer - Flat
38 4 605090 Capscrew - Hex A
B Adjust Spring to 10
B
36 2 604937 Nut-Hex
35 4 604936 Washer-Flat After Cable Installed
6
32 1 604927 Spring-Tension
31 2 604921 Bearing Unit 15
36 39 7
30 1 604421 Bearing - SRB 29 30 17 19 5
29 1 604415 Seal - Oil SL B
Torque
28 1 604070 Gauge - Sight 2 20 22 75 lb-ft dry
27 8 602077 Washer-Flat Torque
27 33 38 12 14
1 24 lb-ft dry Haul-In
26 1 601933 Plug-Socket Head Black
25 2 601349 Plug - Socket Head
24 20 600997 Capscrew - Hex Free rotation of 13
23 1 600979 O-Ring input is opposite
to haul-in rotation
22 14 600816 Capscrew - Hex 11
21 20 600599 Washer - Flat
20 14 600597 Washer - Flat
19 1 406283 Drum-Winch Torque
265 lb-ft dry
18 1 405539 Drive Group
17 2 404737 Bar-Tie 21 24
16 1 404314 Housing - End - Drive Input Rotation
1
15
14
1
1
206517
205987
Housing - Bearing
Breather Kit
Notes:
13 1 205980 Shaft-Roller Apply Medium Strength Threadlocker Compound in Accordance with WI 4.4.1.1. 16
1
12 1 205979 Roller Assmebly
2 Lubricate All Seals on Assembly in Accordance with WI 106069.
11 1 205978 Bracket-Mounting - RH
10 1 205977 Bracket-Mounting - LH 3 Shim to Give 0.020 to 0.060 Drum End Float. Brake Release Port
A 9 1 205972 Lever-Spring Oriented as Shown 18 A
8 1 205971 Bracket-Mounting - Spring
7 1 205970 Housing-End-Bearing
LANTEC
6 1 205576 Adapter-Mount ISSUED Imperial (in)
TOLERANCES
MEAN SURFACE
5 1 205085 Placard Group
4 1 107394 Drive Kit-Encoder Date:
Fractions: ±1/16
X.XX: ±0.020
125
Winch Assembly
X.XXX: ±0.005
3 1 105265 Shim X.XXXX: ±0.0005
By: ±2°
2 1 105208 Adapter-Spring
Project:
DO NOT SCALE
CHECKED BY NH 07/01/15 205965 B
1
ITEM
6
QTY
105123
NUMBER
Clamp-Cable
DESCRIPTION WO/PO:
APPROVED BY jmc 07/01/15 B WEIGHT 2,650 lbs. SCALE
3 = 16
SHEET
1 of 1
MATERIAL / PARTS LIST OF LANTEC AND MAY NOT BE COPIED OR USED IN ANY WAY DETRIMENTAL TO THE INTERESTS OF LANTEC.
4 3 2 1
8 7 6 5 4 3 2 1
REVISIONS
D Revised Design - Replaced Brake Components with Brake Group jmc DJM 11/04/27
(1.36 MAX) 36 3
10 Notes:
37 18 14 27 17 12 21 1 Apply Medium Strength Threadlocker Compound in Accordance with WI 4.4.1.1.
D C D
2 2 Apply High Strength Threadlocker Compound in Accordance with WI 4.4.1.1.
A 4 3 See Detail A for Bearing Installation Orientation.

A
8 4 Lubricate All Seals on Assembly in Accordance with WI 106069.
3 43
32
33
39 34
47 15
C A
C C
DETAIL A
Bearing Snap Ring Orientation
SCALE 3 : 2
1 24 25 38 A
Torque
180 lb-ft dry
- - 107305 Seal Kit
5 43 1 604426 Bearing - CRB
41 12 604409 Stud
40 12 604399 Nut - Hex
39 1 604394 Seal - Oil SL
30 38 16 604393 Stud - Wheel
37 1 604369 Ring - Retaining
36 1 604263 O-Ring
33 6 604245 Washer - Axial Bearing
32 6 604243 Bearing - DC Needle Roller
30 1 603798 Retaining - Ring
B 26 3 601825 Ring-Retaining B
25 16 601562 Nut - Hex
24 16 600598 Washer - Flat
23 12 600597 Washer - Flat
22 20 600595 Washer - Flat
21 1 406085 Hub-Planet
20 1 405860 Housing - Gear
A 19 1 404623 Gear - Internal
18 1 404378 Hub - Planet
17 1 404376 Hub - Planet
16 1 207489 Brake Group
22 44 2
15 1 204538 Cap - End - Oil Holes
Torque 14 1 204515 Gear - Internal Assembly
45 lb-ft dry 13 1 204266 Gear - Sun
12 1 204265 Gear-Sun
31 19 11 11 1 204264 Gear-Sun
8 3 204261 Gear-Planet
16
22 28 2 7 1 204260 Shaft - Drive
B D
6 3 204258 Pin-Planet
Torque 5 1 203543 Bearing - Thrust Washer
45 lb-ft dry
4 6 104367 Bearing - Needle Race
1 3 103899 Spacer - Bearing
45 7 13 46 42 1 20 MATERIAL / PARTS LIST
A A UNLESS OTHERWISE SPECIFIED A
9
26
TOLERANCES
MEAN SURFACE
ROUGHNESS Langley BC LANTEC Canada
C
Date:
Fractions: ±1/16
X.XX: ±0.020
125
Drive Group
29 X.XXX: ±0.005
1 23 40 41 2 ANGLES LHS430A-99.10 - D2-13D - DDP
By: X.XXXX: ±0.0005
±2°
405539
SIZE REVISION
35 DO NOT SCALE
DRAWN BY bdd 06/11/22
Torque Project: CHECKED BY NH 07/01/15 D
120 lb-ft dry
WO/PO:
APPROVED BY jmc 07/01/15 D WEIGHT
765 lb.
SCALE
7=8
SHEET
1 of 1
8 7 6 5 4 3 2 1
4 3 2 1
6 Notes:
B A 1 CAUTION: Parts Under Spring Load
13
14 11 2 Apply Medium Strength Threadlocker Compound in Accordance with WI 4.4.1.1
16 17 18 1 3 See Drive Group Assembly for QTY of Studs -- See Sheet 2 for Position of Studs.
7 4 Lubricate All Seals on Assembly in Accordance with WI 106069
B B
- - 107225 Seal Kit

21 1 604583 O-Ring
B 20 5 604227 Disc-Divider
19 4 604226 Disc-Friction
18 1 604214 Ring-Retaining Spiral
10
15 12 603294 Spring-Die
14 1 602203 O-Ring
13 2 601213 O-Ring
9
12 4 601003 Capscrew - Soc
11 1 601000 O-Ring
10 1 600911 O-Ring
12 2 1 19 3 15 4 5 1
9 1 600752 O-Ring
Torque 20 8 1 600161 Plug-Socket Head
380 lb-ft dry SECTION A-A 7 2 600159 Plug-Socket Head
A 21 6 1 405858 Housing - Brake
5 1 404227 Plate-Pressure
8 4 1 404225 Piston-Brake
3 1 204807 Spacer-Brake
2 1 204575 Clutch-Sprag Assembly
1 1 105574 Adapter - Mount
A ITEM QTY NUMBER DESCRIPTION A
LANTEC

TOLERANCES
MEAN SURFACE
125
Date:
Fractions: ±1/16
X.XXX: ±0.005
X.XXXX: ±0.0005
By: ±2°
Project:
DO NOT SCALE
CHECKED BY NH 11/03/08 207489
WO/PO:
SECTION B-B APPROVED BY DJM 11/04/28 B WEIGHT
115 lbs.
SCALE
3=8
SHEET
1 of 2
4 3 2 1
4 3 2 1
Stud Position Stud Position

Stud Position
B B
LHS110 LHS100/160/170 LHS240/330/430
A A
LANTEC
TOLERANCES
125
Fractions: ±1/16
X.XXX: ±0.005
X.XXXX: ±0.0005
±2°
DO NOT SCALE
CHECKED BY NH 11/03/08 207489
APPROVED BY DJM 11/04/28 B WEIGHT
---
SCALE
---
SHEET
2 of 2
4 3 2 1
2 1
Notes:
Item Identification - Metal Stamp, Engrave or Etch the following markings:
1 Mark the Part Number as shown with 1/8" high characters.
2 Mark the LANTEC WO or PO Number " " with 1/8" high characters.
3 Lubricate all parts with hydraulic oil on assembly
B B
2 6 8 4 7
1 2 3 5 1
8 1 604930 Bearing-Thrust Bronze

7 1 604792 Seal-Oil DL
6 2 604791 Bearing - Plain DU
5 1 600979 O-Ring
3 1 205575 Housing-Bearing
2 1 107400 Coupling-Clamp Jaw
A 1 1 107395 Shaft-Encoder Drive
A
LANTEC

TOLERANCES
MEAN SURFACE
125
Date:
Fractions: ±1/16
X.XX: ±0.020 Drive Kit-Encoder
X.XXX: ±0.005
X.XXXX: ±0.0005
ANGLES LHS-ED - 0.50 Shaft - Zero Backlash
By: ±2°
DRAWN BY jmc 11/04/29 SIZE REVISION
Project:
DO NOT SCALE
CHECKED BY NH 11/05/02 107394
WO/PO:
APPROVED BY bdd 11/05/04 A WEIGHT
1.2 lbs.
SCALE
3=4
SHEET
1 of 1
2 1
LANTEC
Continuing improvement and advancement of product design

may result in changes which are not reflected in this manual.
We reserve the right to change the data contained in this
manual without notice.
LANTEC
5827 Production Way
Langley, BC Canada V3A 4N5
Tel (604) 530-0737 – Fax (604) 530-2889
www.team-twg.com - [email protected]
Bulletin 947019B
OILGEAR TYPE “PVG” PUMPS -

048/065/075/100/130
SERVICE INSTRUCTIONS
Figure 1. Typical Oilgear “PVG” Open Loop Pump
PURPOSE OF INSTRUCTIONS Become familiar with the construction, principle of

operation and characteristics of your pump to help
These instructions will simplify the installation, you attain satisfactory performance, reduce shut-
operation, maintenance and troubleshooting of down and increase the pump's service life. Some
Oilgear type “PVG” pumps. pumps have been modified from those described in
this bulletin and other changes may be made
without notice.
REFERENCE MATERIAL
Fluid Recommendations .....................................................................................Bulletin 90000
Contamination Evaluation Guide.........................................................................Bulletin 90004
Filtration Recommendations ...............................................................................Bulletin 90007
Piping Information ...............................................................................................Bulletin 90011
Pump Control Instructions
“P-1NN” Pressure Compensator ................................................................ Data Sheet 947541
“P-1NN/F” Pressure Compensator w/Load Sense ..................................... Data Sheet 947542
“P-1NN/H” Pressure Compensator w/H.P. Limited..................................... Data Sheet 947543
“P-1NN/G” Horsepower Limit w/Load Sense ............................................. Data Sheet 947544
“P-2 -” Dual Pressure Compensator .......................................................... Data Sheet 947545
“P-A” and “P-B” Electrohydraulic Proportional Pressure Compensator ..... Data Sheet 947546
“P-C -” Soft Starting ................................................................................... Data Sheet 947547
“V-S” Electrohydraulic Servo Valve w/o Amplifier....................................... Data Sheet 947719
“V-A” Electrohydraulic Servo Valve w/Amplifier .......................................... Data Sheet 947720
THE OILGEAR COMPANY

2300 South 51st Street
Revised Dec., 2003
Bulletin 947019B Milwaukee, Wisconsin
THE OILGEAR COMPANY 53219 1
Bulletin 947019B
Safety First
Read and understand this entire instruction sheet The cleanliness of working on this pump or
NOTE the hydraulic system is extremely
before repairing, or adjusting your Oilgear product.
important to the safety and reliability of the
Those who use and maintain this equipment must pump and the system. Always make sure
be thoroughly trained and familiar with the product. the fittings are clean on the outside before
If incorrectly used or maintained, this product and removing them from their connections, are
its equipment can cause severe injury. capped and plugged when removed and
placed in a clean rag or container until they
SAFETY SYMBOLS are reinstalled.
The following signal words are used in this

instruction sheet to identify areas of concern where ! WARNING
your safety may be involved. Carefully read the text Some service operations may require
and observe any instructions provided to ensure special tools or equipment. If you require
your safety. information on these items, please contact
Oilgear before attempting these repairs
! DANGER ! and service operations.
THIS SIGNAL WORD INDICATES AN IMMI-
NENTLY HAZARDOUS SITUATION WHICH, ! WARNING
IF NOT AVOIDED, WILL RESULT IN DEATH Read, understand, and follow the safety
OR SERIOUS INJURY. guidelines, dangers, and warnings
contained in this instruction sheet to
! WARNING promote reliable operation and prevent
serious personal injury.
This signal word indicates a potentially
hazardous situation which, if not avoided,
could result in death or serious injury. ! WARNING
DO NOT attempt to service this machinery
CAUTION in an environment where safety regulations
are not established and in place.
This signal word indicates that a potentially
hazardous situation exists which, if not
avoided, may result in damage to ! WARNING
equipment or minor personal injury. DO NOT operate the hydraulic system if a
leak is present. Serious injury may result.
While not directly relevant to the topic being
NOTE discussed, the NOTE is used to emphasize
information provided, or provide additional ! WARNING
information which may be of benefit. Hydraulic systems operate under very high
pressure. Hydraulic fluid escaping from a
! WARNING pressurized system can penetrate
unprotected body tissue. DO NOT inspect
This service information is designed for for hydraulic leaks with bare hands or other
the maintenance of your Oilgear product. exposed body parts. As a minimum, wear
It contains the information on the correct leather gloves prior to inspecting for leaks
procedures determined by Oilgear for the and use cardboard or wood. If leaks are
safe manner of servicing. Always keep present, relieve pressure and allow system
this instruction sheet in a location where it to cool prior to servicing. If injured by
is readily available for the persons who escaping hydraulic oil, contact a physician
use and maintain the product. Additional immediately. Serious complications may
copies of this instruction sheet are arise if not treated immediately. If you have
available through the Oilgear Company. questions regarding inspecting for
(Contact phone number.) Or visit our hydraulic leaks, please contact Oilgear
website: www.oilgear.com. Please contact prior to servicing.
us if you have any questions regarding the
information in this instruction bulletin.
2 © 1993 THE OILGEAR COMPANY

THE OILGEAR - ALL RIGHTS RESERVED
COMPANY Bulletin 947019B
Safety First
! WARNING ! WARNING
Hydraulic hoses and tubing must be Hydraulic cylinders can be holding a
inspected on a daily basis for leaks, cuts, function in a certain position when
abrasions, damage and improper thepump is OFF. An example of this is a
clearance along any mounting frame for function being held in the lift or partial lift
hidden damage before the unit is put into position by the cylinders. If a hydraulic
service. Replace damaged hoses or hoses line is removed or the hydraulic circuits or
you suspect are damaged before the controls are being worked on, gravity may
system is returned to service! Hoses must allow the function being held in position to
be replaced every two years. Failure to drop. All workers and personnel must
properly inspect and maintain the system remain clear of these areas when working
may result in serious injury. on or operating the hydraulic system.
Block and secure all devices and
functions which apply before beginning
! WARNING work or operation. Failure to comply with
Hydraulic systems are hot. DO NOT this can result in serious injury or death.
TOUCH! Serious personal injury may
result from hot oil. When you have
completed working on the hydraulic ! WARNING
system, thoroughly clean any spilled oil Any hydraulic pipe which is replaced must
from the equipment. Do not spill any conform to SAE J1065 specifications. If
hydraulic fluids on the ground. Clean any incorrect hydraulic pipe is installed, the
hydraulic fluids from your skin as soon as hydraulic system may fail, causing
you have completed maintenance and serious injury. Damaged or leaking
repairs. Dispose of used oil and system fittings, pipes or hoses must be replaced
filters as required by law. before the system is returned to service.
! WARNING ! WARNING
Use correct hoses, fittings, and adapters DO NOT heat hydraulic pipe. The carbon
with the correct SAE rating when content of this steel tube is such that if
replacing hoses to prevent possible heated for bending, and either water or air
serious injury. Always replace hoses, quenched, the pipe may lose its ductility
fittings, and adapters with replacements and thereby be subject to failure under
that have a proper, suitable, working high pressure or hydraulic chock
pressure rating. Replacement hoses must conditions. Serious injury can result.
be of the correct length and must comply Damaged or leaking pipes must be
with the hose manufacturer’s and replaced before the system is returned to
Oilgear’s installation guidelines and service. Please contact Oilgear if you
recommendations. require assistance or have questions.
! WARNING ! WARNING
Hydraulic hoses have the SAE ratings All hydraulic pressure must be relieved
marked on the hose to assist you in from the hydraulic system prior to removing
selecting the correct hose. The same manu- any components from the system. To
facturer must supply any replacement relieve the hydraulic pressure from the
hydraulic hoses and fitting assemblies. As hydraulic system, turn off the motor and
an example: Brand “X” hose and brand “Y” operate the control panel with the key in the
fitting will not normally be compatible. No ON position. Failure to comply can result in
“Twist” is allowed in the hydraulic hoses. serious injury. If you have any questions
“Twist” may result in premature hose concerning relieving the hydraulic pressure
failure. This can cause serious injury. from the system, please contact Oilgear.
Please contact Oilgear for assistance when
required.
Bulletin 947019B THE OILGEAR COMPANY 3

Safety First
! WARNING ! WARNING
Hydraulic components can be heavy. Use Any Oilgear pump safety decals must be
caution while lifting these components. replaced anytime they are damaged,
Serious personal injury can be avoided missing, or cannot be read clearly. Failure
with proper handling of the components. to have proper decals in place can result
in serious injury or death. (If you require
safety decals, please contact Oilgear for
! WARNING replacement safety decals, at no charge.)
Please contact Oilgear if you require
assistance, when performing hydraulic
test procedures, use the proper hydraulic ! WARNING
gauges. Installing an incorrect test gauge Be sure everyone is clear of the area
could result in serious injury if the gauge around the hydraulic system before
fails. Use properly rated hydraulic hoses operating after servicing. Remain attentive
to allow the test gauge to be read away at all times when operating to check your
from moving parts and functions. work until you are completely sure it is
safe to return to service. Failure to heed
this warning may result in serious
! WARNING personal injury or death.
Increasing hydraulic pressure beyond the
recommendations may result in serious
damage to the pump and system or ! WARNING
serious personal injury and may void the Wear the proper protective clothing when
Oilgear Warranty. If you have questions operating, servicing or maintaining the
concerning hydraulic pressures or testing hydraulic system or the Oilgear pump. Wear
procedures, please contact Oilgear before the correct protective gear, safety glasses,
attempting the test procedures or making gloves, and safety shoes. Serious injury
adjustments. can result without proper protective gear.
! WARNING ! WARNING
An Oilgear pump must not be modified in Make sure to keep hands and feet and
any way without authorization from other parts of your body clear of revolving
Oilgear. Modifications may not comply or moving parts. Failure to comply can
with safety standards, including ANSI cause serious injury.
safety standards, and may result in
serious personal injury. Please contact
Oilgear if you require assistance. ! WARNING
DO NOT wear watches, rings, or jewelry
while working with electrical and mechani-
! WARNING cal equipment. These items can be hazard-
DO NOT enter under hydraulic supported ous and can cause serious and painful
equipment unless they are fully supported injuries if they come into contact with elec-
or blocked. Failure to follow this procedure trical wires, moving parts, or hydraulic
can result in serious injury or death. equipment.
4 THE OILGEAR COMPANY Bulletin 947019B

Service Instructions
PREPARATION AND
! WARNING
INSTALLATION Running the pump in NEUTRAL position
(zero delivery) for extended periods
MOUNTING without a supercharge circuit can damage
Pump Without Reservoir - The pump can be the pump. The system and pump must be
mounted in any position. But, the recommended protected against overloads by separate
mounting position is with the drive shaft on a high pressure relief valves. Install bleed
horizontal plane and the case drain port 1 on the valve(s) at the highest point(s) in system.
top side. Secure the pump to a rigid mounting
surface. Refer to the referenced Oilgear Piping POWER
Information Bulletin 90011. Power is required in proportion to volume and
pressure used. Motor size recommendations for
Pump With Reservoir - These pumps are usually specific applications can be obtained from The
fully piped and equipped. It may be necessary to Oilgear Company. Standard low starting torque
connect to a super-charge circuit when used. motors are suitable for most applications.
Mount reservoir on level foundation with the
reservoir bottom at least six inches above floor
level to facilitate fluid changes. CAUTION
DO NOT start or stop unit under load
PIPING AND FITTINGS unless system is approved by Oilgear. It
Refer to the referenced Oilgear Piping Information may be necessary to provide delivery
Bulletin 90011 and individual circuit diagram before bypass in some circuits.
connecting the pump to the system. Inlet velocity
must not exceed 5 fps (1,5 mps). Inlet should be DRIVE
unrestricted and have a minimum of fittings. Verify rotation direction plate on the pump's housing.
Clockwise pumps must be driven clockwise and
DO NOT use an inlet strainer. counterclockwise pumps must be driven
NOTE
counterclockwise. Use direct drive coupling. Size
Arrange line from “case drain” so the case remains and install coupling per manufacturer's instructions.
full of fluid (non-siphoning). Case pressure must be
less than 25 psi (1,7 bar). For higher case CAUTION
pressures and the special shaft seals required,
DO NOT drive the coupling onto the pump
contact our Customer Service. Each drain line
drive shaft. If it is too tight, it may be
must be a separate line, unrestricted, full sized and necessary to heat coupling for installation.
connected directly to the reservoir below the lowest Refer to manufacturer's instructions.
fluid level. Make provisions for opening this line
without draining (siphoning) reservoir. Misalignment of pump shaft to driver's shaft should
not exceed 0.005 inches (0,13 mm) Total Indicator
Readout (TIR) in any plane.

FILTRATION FLUID, FILLING AND STARTING
RECOMMENDATIONS
Keep the fluid clean at all times to ensure long life
from your hydraulic system. Refer to the referenced Refer to instruction plate on the unit, reservoir,
Oilgear Filtration Recommendations bulletin 90007 machine and/or reference, Fluid Recommendations
and Oilgear Contamination Evaluation Guide bulletin. Fire resistant fluids and phosphate ester
Bulletin 90004. Oilgear recommends use of a filter fluids can be used in accordance with fluid
in the pressure or return line. Replace filter manufacturer's recommendations.
element(s) when the filter condition indicator
reaches change area at normal fluid temperature. 1. Pump all fluid into reservoir through a clean
Drain and thoroughly clean filter case. Use (beta 10 ratio of 4 or more) filter. Fill reservoir
replacement element(s) of same beta 10 ratio to, but not above, “high level” mark on the sight
(normally a ratio of 4 with hydraulic oils). gauge.
2. Remove case drain line and fill pump case
FLUID COOLING with hydraulic fluid.
3. Turn drive shaft a few times by hand with a
When the pump is operated continuously at the spanner wrench to make sure parts rotate.
rated pressure or frequently at peak load, auxiliary
cooling of the fluid may be necessary. Fluid Unit 048/065/075/100/130
temperature should not exceed limits specified in
the referenced Oilgear Fluid Recommendations Approximate Torque 9-24 ft•lb
Bulletin 90000. to turn drive shaft (12-32 N•m)
AIR BREATHER Table 1. Torque to Turn Shaft
On most installations, an air breather is mounted With pump under “no load” or with pump control at
on top of fluid reservoir. It is important for the NEUTRAL:
breather to be the adequate size to allow air flow in
and out of reservoir as fluid level changes. Keep 4. Turn drive unit ON and OFF several times
the breather case filled to the “fluid level” mark. before allowing pump to reach full speed. The
About once every six months, remove cover, wash system can usually be filled by running the
screen in solvent and allow screen to dry, clean pump and operating the control.
and refill case to level mark and install screen. 5. The fluid level in the reservoir should decrease.
Refer to the manufacturer's recommendations. Stop the pump. DO NOT allow the fluid level to
go beyond the “low level.” If the level reaches
“low level” mark, add fluid and repeat step.
With differential (cylinder) systems, the fluid

NOTE must not be above “high level” when the
ram is retracted or below “low level” when
extended. Bleed air from the system by
loosening connections or opening petcocks
at the highest point in the system. Close
connections or petcocks tightly when solid
stream of fluid appears.

CONSTRUCTION 6. The shoe retainer is held in position by the
fulcrum ball (103) which is forced outward by
See Figures 2, 8 and 9.
the shoe retainer spring (105).
1. A drive shaft (301) runs through the center line 7. The spring acts against the pump cylinder
of pump housing (001) and valve plate (401) barrel, forcing it against the valve plate while
with the pump cylinder barrel (101) splined to it. also forcing the piston shoes against the
2. A bearing (306) supports the outboard end of swashblock.
the drive shaft and a bushing supports the 8. The semi-cylindrical shaped swashblock limits
inboard end. (The bushing is part of valve plate the piston stroke and can be swiveled in arc
assembly.) shaped saddle bearings (204).
3. The pump cylinder barrel is carried in a 9. The swashblock is swiveled by a control
polymerous (journal type) cylinder bearing (included in referenced material). Refer to
(202). PRINCIPLE OF OPERATION.
4. The valve plate (401) has two crescent shaped
ports. SPECIFICATIONS
5. The pumping piston/shoe assemblies (102) in
the cylinder barrel are held against a Refer to reference material, pump control
NOTE material and individual application circuit
swashblock (201) by a shoe retainer (104).
for exceptions.
FLOW RATE at POWER

THEORETICAL RATED 1800 rpm rated INPUT at rated
MAXIMUM MAXIMUM
MAXIMUM CONTINUOUS continuous pressure continuous
Unit PRESSURE SPEED
DISPLACEMENT PRESSURE and 14,7 psia (bar abs) pressure &
inlet condition 1800 rpm
in 3/rev ml/rev psi bar psi bar gpm l/mi rpm hp kw
PVG 048 2.93 48,0 5000 344,8 5800 400,0 21.1 79,9 2700 73 54,5
PVG 065 3.98 65,0 5000 344,8 5800 400,0 28.8 108,9 2700 100 74,6
PVG 075 4.60 75,4 3750 258,6 4250 293,1 33.3 126,0 2700 89 66,4
PVG 100 6.00 98,3 5000 344,8 5800 400,0 42.4 160,5 2400 150 111,9
PVG 130 7.94 130,2 3750 258,6 4250 293,1 57.6 218,0 2400 150 111,9
Case pressure should be less than 25 psi (1,7 bar). For higher pressure, consult factory.
Higher speeds available - consult factory.
Table 2. Nominal Performance Data with 150--300 SSU viscosity fluids.
Length Width Height Weight

Unit Face Mounting
inches mm inches mm inches mm lbs. kg
PVG 048, 065, 075 12.0 303,0 6.9 174,5 6.3 160,4 68* 31 SAE “B” 2 and 4 bolt
PVG 100, 130 13.0 330,5 8.4 212,9 7.3 185,7 110* 50 SAE “C” 2 bolt
All dimensions (without controls) are approximate. For detailed dimensions, contact your Oilgear Representative.
* Weight with P Control and rear port valve plate
Table 3. Nominal Dimensions and Weights without controls.
Refer to installation drawings for more detailed dimensions and port configurations.

TROUBLESHOOTING
PROBLEM CAUSES REMEDY
Low control input (pilot) pressure for “R” and “V” volume type
Unresponsive or Refer to referenced control instruction material.
controls only.
Sluggish Control
Swashblock saddle bearings (204) worn or damaged. Inspect bearings. Replace.
Delivery limited by faulty control Refer to appropriate control instruction material.
Obstructed suction circuit or insufficient supercharge volume. Inspect for obstruction and verify supercharge.
Insufficient drive motor speed. Refer to appropriate power material.
Insufficient Pump Worn or grooved cylinder barrel (101) and/or valve plate (401)
Volume mating surfaces.
Worn piston/shoe assemblies (102) or piston bores in cylinder Inspect components. Replace.
(101).
Worn or damaged piston shoe or swashblock (201).
Faulty control. Inspect components. Replace.
Fluid level in reservoir is low or supercharge is insufficient. Verify fluid level and/or supercharge.
Irregular or Air entering hydraulic system. Inspect system for leak.
Unsteady Operation Worn axial piston pump. Inspect components. Replace.
Faulty output circuit components (cylinder, motors, valves or
Inspect components. Replace.
other related components).
Worn piston pump.
Worn or grooved cylinder barrel (101) and/or valve plate (401)
Loss of Pressure mating surfaces. Inspect components. Replace.
Worn piston/shoe assemblies (102) or piston bores in cylinder.
Faulty output circuit components.
Excessive or High
Faulty output circuit components. Check the relief valves.
Peak Pressure
Pump stopped or started incorrectly under load. Verify operation procedure of pump.
Low fluid level in reservoir or insufficient supercharge causing
Verify fluid level and/or supercharge.
cavitation.
Air entering hydraulic system. Inspect system for leak.
Excessive Noise Fluid too cold or viscosity too high. Verify fluid temperature and/or type.
Suction line problem i.e.; obstructions in line, line too long, line
Inspect line and for obstruction.
diameter too small or too many bends and/or loops in line.
Broken or worn piston/shoe assembly (102). Inspect components. Replace.
Pump rotating in wrong direction. Inspect operation direction of pump.
Operating pump above rated or peak pressure. Verify pump limitations.
Low fluid level in reservoir or insufficient supercharge. Verify fluid level and/or supercharge.
Air entering hydraulic system. Inspect system for leak.
Worn piston pump.
Excessive Heating Worn or grooved cylinder barrel (101) and/or valve plate (401)
mating surfaces. Inspect components. Replace.
Faulty output circuit components (continuous blowing relief valves
or "slip" through valves, cylinder or other components.
Insufficient cooling provision or clogged coolers. Inspect for obstruction.

PRINCIPLE OF OPERATION Position B, Pump During Full Delivery FROM
PORT B - Figure 3
The illustrations show the pump driven clockwise
(right hand) from the top (plan) view. Rotating the drive shaft (301) clockwise turns the
splined cylinder, which contains the pumping
pistons (102). When the cylinder rotates, the
pistons move in and out within their bores as the
shoes ride against the angled (C) swashblock
(201).
As the cylinder rotates, the individual piston bores
are connected, alternately, to the crescent shaped
upper (port A) and lower (port B) in the valve plate.
While connected to the upper side (suction) port A,
each piston moves outward OUT, drawing fluid
from port A into the piston bore until its outermost
stroke (D) is reached. At this point, the piston bore
passes from the upper crescent port A to the lower
crescent port B.
While rotating across the lower crescent, each
piston moves across the angled swashblock face
Figure 2. Cut-a-way of a Typical “PVG” and then each piston is forced inward IN. Each
Pump (92011R) piston then displaces fluid through the lower
crescent to port B until its innermost stroke (D) is
reached. At this point, the piston bore passes from
the lower to the upper crescent again and the cycle
is repeated.
Figure 3. Position B, Pump During Full Delivery From Port B

Position B/2, Pump During One Half Delivery Position N, Pump In Neutral, No Stroke, No
FROM PORT B - Figure 4 Delivery - Figure 5
This illustration shows that the angle (E) of the Neutral position results when the control
swashblock determines the length of the piston centers the swashblock. The swashblock
stroke (F), (the difference between outermost and angle (G) is now zero and swashblock face is
innermost position) which determines the amount parallel to the cylinder face. There is no
of delivery from the pump. In this case, the stroke inward or outward motion of the pump pistons
angle (E) is one-half of the stroke, which means the as piston shoes rotate around the swashblock
piston stroke is one-half and the pump delivery is face. With no inward and outward motion or
one-half. no stroke (H), NEUTRAL no fluid is being
displaced from the piston bores to the
crescents in the valve plate and there is no
delivery from pump ports.
Illustration reference numbers match the

NOTE part item number in the parts list.
IN B
OUT A
E F
OILG-0002
Figure 4. Position B/2, Pump During One Half Delivery From Port B
NEUTRAL B
NEUTRAL A
H
G OILG-0003
Figure 5. Position N, Pump In Neutral, No Stroke, No Delivery
Refer to SPECIFICATIONS

TESTING AND ADJUSTING DISASSEMBLY
The cleanliness of working on this pump or
! WARNING NOTE the hydraulic system is extremely important
Shut the pump OFF and release pressure to the safety and reliability of the pump and
from the system before disassembling the system.
components. Failure to comply with these
instructions could result in personal injury When disassembling or assembling the
or death. Blocking the pressure line pump, choose a clean, dry, dust and sand
between the pump and the system (or free area where no traces of abrasive
pump) high pressure relief valve will result particles are in the air which can damage
in damage and could result in serious the pump and system. DO NOT work near
personal injury. welding, sandblasting, grinding benches or
similar conditions.
PISTON PUMP
Always make sure the fittings are clean on
To check for a worn piston pump, make a leak the outside before removing them from
measurement test from the case drain while the their connections. Make sure they are
pump is under pressure. After the unit is warm, capped and plugged when removed. Place
either install a flow meter in the drain line or have them on a clean surface and in a clean rag
the flow from the drain line directed into a large or container until they are reinstalled.
container or reservoir. The pump case must remain When cleaning parts which have been
full of fluid during this test. disassembled, it is important to use
CLEAN cleaning solvents and parts are
allowed to dry. All tools and gauges should
CAUTION be clean prior to working with the system
DO NOT run a pump on stroke against a and use new, CLEAN lint free rags to
blocked output unless it is protected by a handle and dry parts.
high pressure relief valve and then run no
longer than necessary to check slip. Limit
discharge to prevent dropping reservoir ! WARNING
fluid below low level. DO NOT attempt to remove or install any
components or assembly while the pump
With an accurate high pressure gauge in the and system is running. Always stop the
pressure line, start the pump and stall (or block) pump, shut OFF the power and release
output device to raise system pressure to pressure from the system before servicing
maximum (as set by system relief valve). Read the or testing. Be sure provisions have been
measurement on the flow meter or time and made so the case drain line can be
measure the case drain flow used to fill a known disconnected from the unit without
size container and calculate the flow rate in terms causing the line to drain (siphon) the
of cubic inches per minute (cipm). The leakage reservoir.
should conform to Table 4.
(continued)
Additional leakage indicates wear, but
NOTE does not become critical until it impairs
performance.

DISASSEMBLY (Continued) CONTROL GROUP
Refer to the reference material for the information
1. Disconnect case drain line from port 1 or 1A. which applies to the control your pump is equipped
2. Drain pump case through the remaining (port 1 with. Some force is required to remove the control
or 1A) on the bottom of case. If plugs are housing.
inaccessible, it may be necessary to remove 1. Remove socket head cap screws.
the pump from the mounting and drive motor
before draining it. 2. Lift the control group assembly, with control pin,
straight up from the top of the pump assembly.
3. After removing the pump from the mounting The control pin may or may not remain in the
and before disassembly, cap or plug all ports swashblock (201).
and clean the outside of unit thoroughly to
prevent dust from entering the system. See 3. Remove control gasket and O-rings from the
Figures 9 and 10. pump housing.
Depending on what part or parts are to be VALVE PLATE GROUP
NOTE inspected, it may not be necessary to
completely take apart all assemblies. If another pump is coupled to thru-shaft pumps, it
will be necessary to remove coupling half before
removing valve plate.
1. Block the pump on a bench with the drive shaft
facing down.
2. Remove the valve plate (401) by removing four
hex head cap screws (403) and lifting it straight
up.
3. Remove valve plate gasket (411) and O-ring
(404).
Case Slip at Full Stroke and Indicated Pressure

Unit - Size 500 psi 1000 psi 2000 psi 3000 psi 3750 psi 4000 psi 5000 psi
cipm 130 195 455 760 1070 N/A N/A
048, 065, 075 lpm 2,1 3,2 7,5 12,5 17,5 N/A N/A
cipm 190 250 400 600 900 1200
100 lpm 3,1 4,1 6,5 9,8 14,7 19,7
cipm 300 400 600 1000 1400 N/A N/A
130 lpm 4,9 6,6 9,8 16,4 22,9 N/A N/A
Table 4. NOMINAL CASE SLIP versus High Pressure at 1800 rpm

(Viscosities of 90-110 SSU)

ROTATING GROUP DRIVE SHAFT GROUP
1. Remove the drive key (303), if used and the
! WARNING drive shaft bearing retainer ring (305).
The rotating group is heavy. Be careful not 2. Grasp outboard end of drive shaft (301) and
to damage cylinder wear surface which pull it out of the pump housing.
mates against the valve plate, bearing
diameters or piston shoes. Use proper 3. Remove the shaft seal retainer (302) and shaft
lifting techniques and assistance from seal (007) from the housing only if necessary.
others to prevent personal injury.
SWASHBLOCK GROUP
On thru-shaft pumps, the tailshaft bushing On 100/130 remove guide plate (203) and (206)
assembly (307, 308, 309) or a coupling will have to first. Reach inside the case and remove the
be removed (a “jacking” screw can be used) before swashblock (201) and saddle bearings (204).
the rotating group can be disassembled.
1. Place the pump in a horizontal position. INSPECTION
2. Remove the rotating group by turning shaft Clean all parts thoroughly and allow them to dry.
(301) slowly, while pulling the cylinder barrel Inspect all seals and O-rings for hardening,
(101) from the housing. cracking or deterioration. Replace if necessary or if
you suspect damage. Check all locating pins for
3. Identify (number) each pump piston shoe damage and springs for cracking or signs of
assembly (102) and its respective bore in the cracking or signs of wear.
cylinder barrel (101) and shoe retainer (104) for
easy reassembly.
! WARNING
4. See Figure 6. Lift out shoe retainer (104) with
Wear proper protective gear when using
pistons (102) and remove the fulcrum ball (103)
solvents or compressed air, servicing or
and shoe retainer spring (105).
maintaining the hydraulic system or the
Oilgear pump. Wear correct protective
gear, safety glasses, gloves, and safety
shoes. Serious injury can result without
proper protective gear.
104 CONTROL GROUP

102 Refer to the reference material on pump controls.
Be sure to carefully check the control pin for cracks
103 and/or signs of fatigue. Check fit of the pin in the
105 swashblock. It should be a slip-fit without side-play.
101 Replace if necessary or if you suspect damage.
OILG-0004
Figure 6. Rotating Group Disassembly (5V-12015-L).
5. Remove retaining ring (208) and pull the

hydrodynamic bearing (202) and roll pins, if
necessary, (205) from the housing. Note the
position of roll pin (205) inside of case.

VALVE PLATE GROUP
Inspect the valveplate (401) surface which mates
with the cylinder barrel (101) for excessive wear or A
scoring. Remove minor defects by lightly stoning
the surface with a hard stone which is flat to within
0.001 inches (0,03 mm).
Be sure to stone lightly. Any excessive

NOTE stoning will remove the hardened surface. B
If wear or damage is extensive, replace the OILG-0005
valve plate.
Figure 7. Piston and Shoe Inspection (5V-12015-L)
ROTATING GROUP
(A) All shoes must be equal within 0.001 inches
Inspect cylinder barrel (101) piston bores and the (0,025 mm) at this dimension.
face which mate with the valve plate for wear and (B) All shoe faces must be free of nicks.
scoring. Remove minor defects on the face by
lightly stoning or lapping the surface. End play should not to exceed 0.003
NOTE inches (0,076 mm) when new or 0.006
Inspect the cylinder bearing (202) for damage and inches (0,152 mm) when worn.
replace if necessary. Check all piston and shoe
assemblies (102) to be sure they ride properly on SWASHBLOCK GROUP
the swashblock.
Inspect the swashblock (201) for wear and scoring.
Be sure to stone lightly. Any excessive If defects are minor, stone the swashblock lightly. If
NOTE stoning will remove the hardened surface. damage is extensive, replace the swashblock.
If wear or damage is extensive and defects
cannot be removed, replace the cylinder Check the small hole in the face of the
barrel. swashblock. The hole provides “porting” for the
hydrostatic balance fluid of the piston/shoe
See Figure 7. Check each shoe face for nicks and assembly to be channeled through the swashblock
scratches, and the shoe for smooth pivot action on to the face of the saddle bearing, providing
the piston. pressure lubrication.
If one or more piston/shoe assembly needs Compare the saddle bearing (204) thickness in a
NOTE to be replaced, replace all the piston/shoe worn area to thickness in an unworn area. Replace
assemblies. When installing new piston/ saddle bearings if the difference is greater than
shoe assemblies or the rotating group, 0.015 inches (0,4 mm).
make sure the pistons move freely in their
respective bores. Check the mating surface of swashblock for cracks
or excessive wear. The swashblock movement in
the saddle bearings must be smooth. Replace if
necessary.
Be sure to stone lightly. Any excessive

NOTE stoning will remove the hardened surface.
If wear or damage is extensive and defects
cannot be removed, replace if necessary
or if you suspect them of being bad.

DRIVE SHAFT GROUP 6. Make sure the roll pin (205) is inserted into the
cylinder bearing (202). Position the cylinder
Check: bearing so the pin is located nearest the control
• the shaft seal (007) for deterioration or facing the outboard end of the drive shaft (301).
cracks. Replace if necessary (press-out). The bearing should be positioned with “scarf”
cuts (PVG 130 only) positioned top and bottom
• the shaft bearing (306) for galling, pitting, and with the pin (205) located on top of internal
binding or roughness. cast boss. The bearing should fit into place with
• the rear shaft bushing in valve plate. a little difficulty and be square to the axis of the
pump.
• the shaft and its splines for wear. Replace
any parts necessary. 7. Tap bearing into place if necessary using
extreme care not to damage the bearing.
ASSEMBLY 8. Insert retaining ring (208) to hold bearing in
place.
See Figures 8, 9 and 10. Follow the disassembly
procedures in reverse for re-assembling the pump. DRIVE SHAFT GROUP
During assembly, install new gaskets, seals and O- 1. Place the housing on its side with the axis
rings. Apply a thin film of CLEAN grease or horizontal.
hydraulic fluid to sealing components to ease
assembly. If a new rotating group is used, lubricate 2. Install the seal retainer (302).
thoroughly with CLEAN hydraulic fluid. Apply fluid
generously to all wear surfaces. 3. Lubricate the shaft seal (007) and shaft.
4. Insert the drive shaft (301) and bearing
SWASHBLOCK GROUP
assembly into the housing.
If removed,
5. Lock in place with the drive shaft bearing
1. Press shaft seal (007) into front of pump retainer ring (305).
housing.
ROTATING GROUP
2. Place housing on a bench with the mounting
flange side down. See Figure 6.
3. Press the two roll pins (207) (if they are 1. Place the cylinder barrel (101), wear surface
replaced or removed) into the pump housing so down, on a clean cloth.
the pins extend 0.050 to 0.065 inches (1,3 to 2. Place the shoe retainer spring (105) in the
1,6 mm) from the case. center of the barrel with the fulcrum ball (103)
4. Grease the back side of each saddle bearing on top of it.
(204) and place on the pin to locate the 3. Insert the identified pistons (102) into their
bearings in the pump case. Make sure the pins corresponding identified holes of the shoe
do not retainer (104). As a unit, fit the pistons into their
protrude. corresponding, identified bores in the cylinder
5. PVG 100 and 130, the swashblock is inserted barrel. DO NOT FORCE. If everything is
from the valve plate end. PVG 048, 065 and aligned properly, the pistons will fit smoothly.
075, the swashblock is inserted through the
control mounting face. Insert swashblock (201)
into the pump housing. Once in place, be sure
the swashblock swivels in the saddle bearings.
With new bearings, swiveling may be stiff and
not always smooth. PVG 110, 130; assemble
(203) and (206).

On thru-shaft pumps without another pump
! WARNING NOTE or device connected to them, slide
The rotating group weight is heavy. Be assembly onto the shaft (301) and secure
careful not to damage cylinder wear surface cap assembly (307, 309) in with socket
which mates against the valve plate, head shoulder screw (308).
bearing diameters or piston shoes. Use
proper lifting techniques and assistance VALVE PLATE GROUP
from others to prevent personal injury.
1. Place the pump housing on a bench with the
open end facing up.
The rotating group can now be carefully installed
over the tail of the drive shaft (301) and into the 2. Install new O-ring (411) and gasket (407) on
pump housing (001). the housing.
When installing the rotating group, support 3. Position the valve plate (401) on pins (005) and
NOTE the weight of the cylinder barrel (101), as housing. Make sure the tail end of shaft
cylinder spline is passed over the tailshaft, engages the bushing.
to avoid scratching or damage.
4. Hand-tighten the hex head cap screw (403)
4. Push cylinder forward until the cylinder spline closest to O-ring (404) first, then alternately
reaches the drive shaft spline and rotate tighten the other cap screws. On thru-shaft
slightly to engage shaft splines. Continue to units connected to another pump or device,
slide cylinder forward until it encounters the install coupling (half).
cylinder bearing (202). Lifting the tailshaft
slightly helps the cylinder (101) and the cylinder Refer to PREPARATION and INSTALLATION
bearing (202) engagement. Continue pushing when pump is ready to be returned to service.
the cylinder forward until the piston shoes
contact the swashblock, the back of the cylinder
should be located approximately 0.4 inches
(10,2 mm) outside the back of the pump
housing.
PVG Assembly Torques

Pump
Item no. 048/065/075 100/130
002 100 ft-lb 100 ft-lb
004 37 ft-lb 37 ft-lb
206 N/A 87 in-lb
308 57 in-lb 57 in-lb
403 100 ft-lb 100 ft-lb
408 45 in-lb 45 in-lb
409 45 in-lb 45 in-lb
410 120 in-lb 120 in-lb
503 cover plate 28 ft-lb 28 ft-lb
503 SAE A or A-A adapt 15 ft-lb 15 ft-lb
503 SAE B adapter 37 ft-lb 37 ft-lb
503 SAE C adapter N/A 74 ft-lb
507 28 ft-lb 28 ft-lb

PARTS LIST ordering replacement parts, be sure to include
pump type and serial number, bulletin number and
Parts used in these assemblies are per Oilgear item number. Specify type of hydraulic fluid to
specifications. Use only Oilgear parts to ensure assure seal and packing compatibility.
compatibility with assembly requirements. When
Item Qty. Description

HOUSING ASSEMBLY GROUP
001 1 Housing, Pump
003 1 Nameplate, Identification
004 1 Plug
005 4 Pin, Roll - 048, 065, 130
005 2 Pin, Roll - 100, 130
006 2 Pin, Roll - 100, 130
007 1 Seal, Shaft
008 2 Screw
010 1 Seal, O-ring
ROTARY ASSEMBLY GROUP
101 1 Barrel, Cylinder
102 9 Assembly, Piston/Shoe
103 1 Ball, Fulcrum
104 1 Retainer, Shoe
105 1 Spring, Shoe Retainer
SWASHBLOCK ASSEMBLY GROUP
201 1 Swashblock
202 1 Bearing, Cylinder
203 1 Guide Plate - 100, 130 only
204 2 Bearing, Saddle
205 1 Pin, Roll (2 for PVG 130)
206 2 Screw - 100, 130 only
207 2 Pin, Roll
208 1 Ring, Retainer
PARTS LIST drawings on pages 19, 20 and 30.

Parts are common between pumps. Only the differences are shown.
O-ring Sizes
ARP 568 Uniform Size number with
Durometer
Pump
Item Number 048, 065, 075 100, 130
010 916 - 70 916 - 70
404 012 - 90 013 - 90
405 902 - 90 902 - 90
406 903 - 90 903 - 90
407 904 - 90 904 - 90
413 138 - 70 138 - 70

Item Qty. Description
DRIVE SHAFT ASSEMBLY GROUP
301 1 Drive Shaft
302 1 Retainer, Seal Side
303 1 Key, Drive Shaft (keyed shafts only)
304 1 Ring, Retainer, External
305 1 Ring, Retainer, Internal
306 1 Bearing, Front
307 1 Bushing (used on thru-shaft w/ cover plate)
308 1 Screw (used on thru-shaft w/ cover plate)
309 1 Roll Pin (used on thru-shaft w/ cover plate)
VALVE PLATE ASSEMBLY GROUP
401 1 Valve Plate w/bearing
403 4 Screw, Socket Head Cap (048, 065, 075)
403 4 Screw, Hex Head Cap (100, 130)
404 1 Seal, O-ring
405 1 Seal, O-ring
406 1 Seal, O-ring (not required for all versions)
407 1 Seal, O-ring
408 1 Plug, #2 HP
409 1 Plug, #3 HP (not required for all versions)
410 1 Plug, #4 HP
411 1 Gasket, Valve Plate
PARTS LIST drawings on pages 19, 20 and 30.

Parts are common between pumps. Only the differences are shown.
Parts used in this assembly are per Oilgear specifications. Use only Oilgear
parts to ensure the compatibility with the assembly requirements. When
ordering replacement parts, be sure to include pump type and serial number,
bulletin number and item number. To assure seal and packing compatibility,
specify type of hydraulic fluid.

502
008 503
301 306 007 205 003 401 505
309
308
307
407 406
303 304 305 302 404 005 410 409 403
207 006 201 208 102 001 411
004 207 204 202 104 103 105 101

010
Figure 8. Cross section and plan view parts drawing, PVG 100/130 (516246 sheet 1 of 3).
Pins shown out of position. Hydrobearing

NOTE (202) to be assembled with scarf cuts
positioned top and bottom with pins (205),
which locate on top of internal cast boss
(PVG 130 only).

20
304 202
302 205 208
301 102
104
305
103
306 206
007 105
101
309 203
303
003
301
008
307 404 005

308 204
301
001 006 409
THE OILGEAR COMPANY

406 403
010
301 004 207 502
005 204
201
407 410
405 408
403
411
409 401 410
401
Figure 9. Exploded parts drawing, PVG 100/130 (516246 sheet 2 of 3).

406 407 401 503
403
505
410
407 OILG-0007
Bulletin 947019B
SERVICE KITS Document Number: 517105-SK
Revision: 0 (10-6-03)
PVG B Pump Service Kits
SERVICE KIT Drawings on pages 30 and 31.
Sheet 1 of 3
Design
Description Kit No. Series Items Included (quantity is 1 unless noted)
Housing Kits
Viton Seals L517105-604 All(A)
Nitrile Seals L517105-603 All(A) 001,002,003,004,005(4),007,008(2),010,011,207(2)
EPR Seals L517105-602 All(A)
Shaft & Bearing Kits

Viton or Nitrile seals
1" Dia. Keyed (Code Y) Std L517104-301 All 301B,302,303,304,305,306
13T, 16/32 Spline (Code K) Std L517104-305 All 301C,302,304,305,306
15T, 16/32 Spline (Code S) Std L517104-302 All 301A,302,304,305,306
1" Dia. Keyed (Code Y) T-S L517104-303 All 301D,302,303,304,305,306
13T, 16/32 Spline (Code K) T-S L517104-306 All 301E,302,304,305,306
15T, 16/32 Spline (Code S) T-S L517104-304 All 301E,302,304,305,306
EPR Seals
1" Dia. Keyed (Code Y) Std L517104-313 All 301B,302,303,304,305,306
13T, 16/32 Spline (Code K) Std L517104-315 All 301C,302,304,305,306
15T, 16/32 Spline (Code S) Std L517104-317 All 301A,302,304,305,306
1" Dia. Keyed (Code Y) T-S L517104-312 All 301D,302,303,304,305,306
13T, 16/32 Spline (Code K) T-S L517104-314 All 301E,302,304,305,306
15T, 16/32 Spline (Code S) T-S L517104-316 All 301E,302,304,305,306
Swashblock
All 516597-050 B2(B) 201
Saddle Bearing
Standard L517105-220 All
204(2)
High Temp L517105-221 All
Hydrodynamic Bearing Kit

All L517105-210 All 202,205,208
Rotating Group
PVG-048/065 L517104-103 B2(B)
101,102(9),103,104,105
PVG-075 L517105-103 B2(B)
Piston & Shoe Sub-Assembly

PVG-048/065 K407905-R65 B2(B)
102(9)
PVG-075 K407905-A75 B2(B)
Shoe Retainer & Fulcrum Ball

PVG-048/065 L319221-365 All
103,104
PVG-075 L319221-375 All

PVG B Pump Service Kits Document Number: 517105-SK
Reference: 517105 Ass’y Drwg Revision: 0 (10-6-03)
Sheet 2 of 3
Design
Valve Plate Kits
PVG-048/065 Rear Port LH
Viton Seals L517104-401 All
401A,403(4),404,405,406,407,408,409,410,411
Nitrile Seals L517104-411 All
EPR Seals L517104-408 All
PVG-048/065 Rear Port RH
401B,403(4),404,405,406,407,408,409,410,411
PVG-048/065 Side Port LH
401C,403(4),404,405,406,407,408,409,410,411
PVG-048/065 Side Port RH
401D,403(4),404,405,406,407,408,409,410,411
PVG-048/065 Side Port, Thru-Shaft LH
401E,403(4),404,405(2),407(2),408(2),410(2),411
PVG-048/065 Side Port, Thru-Shaft RH
401F,403(4),404,405(2),406,407,408(2),409,410,411
PVG-075 Rear Port LH
401A,403(4),404,405,406,407,408,409,410,411
PVG-075 Rear Port RH
401B,403(4),404,405,406,407,408,409,410,411
PVG-075 Side Port LH
401C,403(4),404,405,406,407,408,409,410,411
PVG-075 Side Port RH
401D,403(4),404,405,406,407,408,409,410,411
PVG-075 Side Port, Thru-Shaft LH
401E,403(4),404,405(2),407(2),408(2),410(2),411
PVG-075 Side Port, Thru-Shaft RH
401F,403(4),404,405(2),406,407,408(2),409,410,411

PVG B Pump Service Kits Document Number: 517105-SK
Reference: 517105 Ass’y Drwg Revision: 0 (10-6-03)
Sheet 3 of 3
Design
Basic Seal Kit
Viton Seals K517105-B11 All
Nitrile Seals K517105-B12 All 007,010,011,404,405(2),406,407(2),411 Control 313,330,341(2)
EPR Seals K517105-B13 All
Seal Kits for Options
Standard Cover Plate
Viton Seals 238270-138 All
505
Nitrile Seals 233370-138 All
EPR Seals 242080-138 All
SAE B Adaptor
505,506
SAE A Adaptor
505,506
SAE A-A Adaptor
505,508
Shaft Seal
Nitrile Seals 51155-7 All 007
EPR Seals L51155-3RP All
Cover Plate Kit
Nitrile Seals L319076-105 All 307,308,309,502,503(4),505
Rear Shaft Cover Kit
All L319263 All 307,308,309
SAE B Adaptor/Coupling Kit
Nitrile Seals L319076-107 All 501,502,503(2),504(2),505,506
SAE A Adaptor/Coupling Kit 9 tooth
Nitrile Seals L319076-109 All 501,502,503(2),504(2),505,506,507(4)
Nitrile Seals L319076-111 All 501,502,503(2),504(2),505,506,507(4)
SAE A-A Adaptor/Coupling Kit
Nitrile Seals L319076-113 All 501,502,503(2),504(2),505,507(4),508
Name Tag & Screws
All L50921 All 003,008(2)
Std = Rear ported or Side ported w/o thru-shaft, T-S = Side ported w/ thru-shaft
(A) Pump cases are interchangeable
A1 series has #12 SAE threaded case drain connection
B1 and B2 have #16 SAE threaded case drain connection
(B) Swashblock and Rotating group/piston and shoe assembly must have matching design series
B2 parts must all be same design series
A1, B1 parts can be intermixed between series

PVG C Pump Service Kits Document Number: 516246-SK
Revision: 0 (10-6-03)
Sheet 1 of 6
Design
Housing Kits
USA
Nitrile Seals L516275-603 All(A)
001,002,003,004,005(2),006(2),007,008(2),010,011,207(2)
Metric
Nitrile Seals L516679-602 All(A)
Shaft & Bearing Kits

Viton or Nitrile seals
1.50" Dia. Keyed (Code Z) Short L516175-301 All(B) 301D,302,303,304,305,306
1.50" Dia. Keyed (Code Y) Std L516175-307 All(B) 301D,302,303,304,305,306
14T, 12/24 Spline (Code K) Std L516175-305 All 301E,302,304,305,306
17T, 12/24 Spline (Code S) Std L516175-302 All 301E,302,304,305,306
1.50" Dia. Keyed (Code Z) T-S Short L516175-303 All(B) 301A,302,303,304,305,306
1.50" Dia. Keyed (Code Y) T-S L516175-308 All(B) 301A,302,303,304,305,306
14T, 12/24 Spline (Code K) T-S L516175-306 All 301B,302,304,305,306
17T, 12/24 Spline (Code S) T-S L516175-304 All 301B,302,304,305,306
EPR Seals
1.50" Dia. Keyed (Code Z) Short L516175-328 All(B) 301D,302,303,304,305,306
1.50" Dia. Keyed (Code Y) Std L516175-322 All(B) 301D,302,303,304,305,306
14T, 12/24 Spline (Code K) Std L516175-324 All 301E,302,304,305,306
17T, 12/24 Spline (Code S) Std L516175-326 All 301E,302,304,305,306
1.50" Dia. Keyed (Code Z) T-S Short L516175-327 All(B) 301A,302,303,304,305,306
1.50" Dia. Keyed (Code Y) T-S L516175-321 All(B) 301A,302,303,304,305,306
14T, 12/24 Spline (Code K) T-S L516175-323 All 301B,302,304,305,306
17T, 12/24 Spline (Code S) T-S L516175-325 All 301B,302,304,305,306
Swashblock
All 515794 All 201
Guide Plate Assembly

USA L516175-225 All
203,206(2)
Metric L516679-225 All
Saddle Bearing
Standard L516175-220 All
204(2)
High Temp L516175-221 All
Hydrodynamic Bearing Kit

PVG-100 L516175-210 All
202,205,208
PVG-130 L516275-210 All
Rotating Group
PVG-100 L516175-101 All
101,102(9),103,104,105
PVG-130 L516275-102 C2(C)

Revision: 0 (10-6-03)
Sheet 2 of 6
Design
Piston & Shoe Sub-Assembly
PVG-100 K407812-800 All
102(9)
PVG-130 K407837-800 All
Shoe Retainer & Fulcrum Ball

PVG-100 L318925-001 All
103,104
PVG-130 L318926 All
Valve Plate Kits

USA
401D,403(4),404,405,407,408,410,411
401D,403(4),404,405,406,407,408,409,410,411
401E,403(4),404,405,406,407,408,409,410,411
401E,403(4),404,405,406,407,408,409,410,411
401A,403(4),404,405(2),406,407,408(2),409,410,411
401A,403(4),404,405(2),406,407,408(2),409,410,411
Viton Seals L516275-401 C2(C)
401D,403(4),404,405,407,408,410,411
Nitrile Seals L516275-425 C2(C)
EPR Seals L516275-407 C2(C)
401D+D161,403(4),404,405,406,407,408,409,410,411
Viton Seals L516275-405 C2(C) 401E,403(4),404,405,406,407,408,409,410,411

Revision: 0 (10-6-03)
Sheet 3 of 6
Design
Description Kit No. Items Included (quantity is 1 unless noted)
Series
401E,403(4),404,405,406,407,408,409,410,411
401A,403(4),404,405(2),406,407,408(2),409,410,411
PVG-130 Side Port, Thru-Shaft RH 401A,403(4),404,405(2),406,407,408(2),409,410,411
Metric
401D,403(4),404,405,407,408,410,411
401D,403(4),404,405,406,407,408,409,410,411
401E,403(4),404,405,406,407,408,409,410,411
401E,403(4),404,405,406,407,408,409,410,411
401A,403(4),404,405(2),406,407,408(2),409,410,411
401A,403(4),404,405(2),406,407,408(2),409,410,411
401D,403(4),404,405,407,408,410,411
401D+D161,403(4),404,405,406,407,408,409,410,411
401E,403(4),404,405,406,407,408,409,410,411

Revision: 0 (10-6-03)
Sheet 4 of 6
Design
Series
401E,403(4),404,405,406,407,408,409,410,411
401A,403(4),404,405(2),406,407,408(2),409,410,411
401A,403(4),404,405(2),406,407,408(2),409,410,411
Basic Seal Kit

USA
Viton Seals K516175-C11 All
Nitrile Seals K516175-C12 All
EPR Seals K516175-C13 All
007,010,011,404,405(2),406,407(2),411 Control 330,313
Metric
Viton Seals K516678-C11 All
Nitrile Seals K516678-C12 All
EPR Seals K516678-C13 All
Seal Kits for Options

Standard Cover Plate
505
SAE C Adaptor
505
SAE B Adaptor
505,506
SAE A Adaptor
505,506
SAE A-A Adaptor
505,508
Shaft Seal
Nitrile Seals 51156-7 All 007
EPR Seals L51156-3RP All

Revision: 0 (10-6-03)
Sheet 5 of 6
Design
Series
Cover Plate Kit
USA
307,308,309,502,503(4),505
Metric
Viton Seals L319076-M01 All
Nitrile Seals L319076-M07 All
EPR Seals L319076-M08 All
Rear Shaft Cover Kit

All L319066-006 All 307,308,309
SAE C Adaptor/Coupling Kit

USA
Viton Seals L319076 All
501,503(2),504(2),505
Metric
SAE B-B Adaptor/Coupling Kit

USA
501,502,503(2),504(2),505,506
Metric
SAE B Adaptor/Coupling Kit

USA
501,502,503(2),504(2),505,506
Metric

USA
501,502,503(2),504(2),505,506,507(4)
Metric

Revision: 0 (10-6-03)
Sheet 6 of 6
Design
Series
USA
501,502,503(2),504(2),505,506,507(4)
Metric
SAE A-A Adaptor/Coupling Kit

USA
501,502,503(2),504(2),505,507(4),508
Metric
Name Tag & Screws

All L50921 All 003,008(2)
Std = Rear ported or Side ported w/o thru-shaft, T-S = Side ported w/ thru-shaft
(A) Pump cases are interchangeable
A1 series has #12 SAE threaded case drain connection
B1, C1, C2, D3, D4, E1 have #16 SAE threaded case drain connection
(B) Code "Y" shaft is length of Code "Z" shaft for Design Series "A1"
Parts are interchangeable between Design Series
(C) PVG130 Valve plate and Rotating group must be matched
A1, B1, C1 parts can be intermixed between series
C2, D3, D4, E1parts can be intermixed between series

205 003 008
306 007
301 401
405
408 304
305
302
005 404 403
208
005 201 102 001 411
409 207
406
407
410 207
101
204
002
202 104 103 105
205 202 208

301 102
104
304 103 105
302 101
404
305 005 003
008
306
007
301 207
301 001
303 002 011 405

004 010 005 408
301 204
201 403
406
405 411
410 409
407 408 410 401
408 406
309 410 407
301 405 401 403
307 308 502
503
OILG-0008
403 401 505
Figure 10. Cross Section and Exploded Parts Drawing for PVG 048, 065 and 075 (517105 sheet 1 and 2)
Cylinder bearing (202) to be held in

NOTE position with roll pin (205) which must be
located in the cast side slot of housing
(001).

401
502 503
505
307 309
308
COVER PLATE ASSEMBLY
401
508 OR 506
401 301 502
505 507
502 507 504 503
501
505 501
503 504
508
TO SAE A-A (SHOWN)
TO SAE A
401
505 502 504 503
401 506
505 301 501
502
506
501
503 504
TO SAE B
THRU-SHAFT OPTIONS OILG-0009
Available for PVG 048, 065, 075, 100 and 130

(Drawing 517105 sheet 6 and 7)
504 503 301 REF. 504

501 505 503
501 505
301
REF.
TO SAE C
OILG-0012
Available for PVG 100 and 130

(Drawing 516246 sheet 6, 7 and 8)
Figure 11. Cross Section and Exploded Parts Drawing

AFTER SALES SERVICES SERVICE SCHOOLS
At Oilgear we build products to last. It is the nature Oilgear conducts training to train your maintenance
of this type of machinery to require proper personnel. “General” hydraulic or electronic
maintenance regardless of the care we put into training is conducted at our Milwaukee, Wisconsin
manufacturing. Oilgear has several service plant on a regular basis. “Custom” training,
programs in place to help you. specifically addressing your particular hydraulic
and electro-hydraulic equipment can be conducted
STAY-ON-STREAM SERVICE at your facilities.
By signing up for Oilgear's Stay-On-Steam SPARE PARTS AVAILABILITY
program, you can prepare for problems before they
happen. Certain field tests such as fluid testing, Prepare for your future needs by stocking Oilgear
slip testing and electronic profile recording original factory parts. Having the correct parts and
comparisons can be performed by our field service necessary skills “in-plant” enables you to minimize
people or your own factory trained personnel. “down-time.” Oilgear has developed parts kits to
These tests can indicate problems before they cover likely future needs. Oilgear Field Service
become “down-time” difficulties. Technicians are also ready to assist you and your
maintenance people in troubleshooting and
repairing equipment.
THE OILGEAR COMPANY

2300 South 51st Street
Milwaukee, Wisconsin 53219
phone: 414/327-1700 fax: 414/327-0532
Revised
32 Dec., 2003 THE www.oilgear.com
OILGEAR COMPANY Bulletin 947019B
Series 40
Axial Piston
Motors
Technical
Information
Series 40 Axial Piston Motors
Revisions
Revisions Table of Revisions

Date Page Changed Rev.
September-2006 21-22 Corrections in model code examples Rev F

September-2005 Major Revision Rev E
© 2006 Sauer-Danfoss. All rights reserved.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to products
already ordered provided that such alterations aren’t in conflict with agreed specifications. All trademarks in
this material are properties of their respective owners. Sauer-Danfoss and the Sauer-Danfoss logotype are
trademarks of the Sauer-Danfoss Group.
Front cover illustrations: F101 220, F101 221, F101 222, F101 223, P100 651E
520L0636 • Rev F • September 2006

Contents
General description Basic design....................................................................................................................................................... 5

Key features....................................................................................................................................................... 6
Cross sections................................................................................................................................................... 7
System circuit diagram.................................................................................................................................. 8
M46 motor schematic . ................................................................................................................................. 8
Technical Overview............................................................................................................................................................ 9
specifications General................................................................................................................................................................ 9
Features and options..................................................................................................................................... 9
Specifications.................................................................................................................................................... 9
Operating parameters.................................................................................................................................10
Fluid specifications.......................................................................................................................................10
Hydraulic unit life..........................................................................................................................................10
Performance....................................................................................................................................................11
Bearing life and external shaft loading ................................................................................................12
Operating Fluids..................................................................................................................................................................14
parameters Viscosity............................................................................................................................................................14
Temperature....................................................................................................................................................14
Case pressure..................................................................................................................................................14
Pressure ratings..............................................................................................................................................15
Speed ratings..................................................................................................................................................16
System design Sizing equations............................................................................................................................................17

parameters Flow.........................................................................................................................................................17
Speed......................................................................................................................................................17
Torque....................................................................................................................................................17
Power......................................................................................................................................................17
Variables................................................................................................................................................17
Filtration...........................................................................................................................................................18
Bypass valve....................................................................................................................................................18
Loop flushing valve......................................................................................................................................19
Redundant braking system requirement.............................................................................................20
Reservoir...........................................................................................................................................................20
Overpressure protection............................................................................................................................20
Product coding Revised model code.....................................................................................................................................21

Name plate......................................................................................................................................................21
Model code modules...................................................................................................................................21
Fixed motor..........................................................................................................................................21
Variable motor.....................................................................................................................................22
Features and options Displacement limiters..................................................................................................................................23

Displacement limiter M35 MV..................................................................................................................23
Displacement limiter M46 MV..................................................................................................................23
Speed sensor option....................................................................................................................................24
Pulse pickup and connector......................................................................................................................25
Contents
Features and options Cross-section of speed sensor on cylinder kit....................................................................................25

Shaft options...................................................................................................................................................26
Through-shaft options................................................................................................................................26
Shaft options M25 MF.............................................................................................................................................................27

M35/44 MF.......................................................................................................................................................28
M35/44 MV......................................................................................................................................................30
M46 MV.............................................................................................................................................................31
Control options Direct displacement control (DDC).........................................................................................................32

Two-position hydraulic control................................................................................................................33
Installation M25 MF: axial ports, twin ports, loop flushing, speed sensor.........................................................34
drawings M25 MF: mounting flange,.........................................................................................................................35
M35/M44 MF: mounting flange...............................................................................................................35
M35/M44 MF: axial ports, twin ports, loop flushing, speed sensor..............................................36
M35/M44 MF: side ports, through shaft................................................................................................37
M35/M44 MV: twin ports............................................................................................................................38
M35/M44 MV: mounting flange, trunnion control............................................................................39
M46 MV: side ports, loop flushing............................................................................................................40
M46 MV: axial ports, loop flushing...........................................................................................................41
M46 MV: side ports, thru shaft twin ports, loop flushing.................................................................42
M46 MV: mounting flange..........................................................................................................................43
M46 MV: control ports.................................................................................................................................44
Schematics M25/M35/M44 fixed motor schematics (no loop flushing)...........................................................45

M25/M35/M44 fixed motor schematics................................................................................................45
M35/M44 variable motor schematics....................................................................................................45
M46 variable motor schematics...............................................................................................................45

General description
Basic design Series 40 is a family of hydrostatic pumps and motors for medium power applications
with maximum loads of 345 bar [5000 psi]. These pumps and motors can be applied
together or combined with other products in a system to transfer and control hydraulic
power.
Series 40 transmissions (pump plus motor) provide an infinitely variable speed range
between zero and maximum in both forward and reverse modes of operation. The
pumps and motors each come in four frame sizes: M25, M35, M44, and M46.
Series 40 pumps are compact, high power density units. All models use the parallel axial
piston / slipper concept in conjunction with a tiltable swashplate to vary the pump’s
displacement. Reversing the angle of the swashplate reverses the flow of fluid from the
pump, reversing the direction of rotation of the motor output.
Series 40 M35, M44, and M46 pumps may include an integral charge pump to provide
system replenishing and cooling fluid flow, as well as servo control fluid flow on M46
pumps. M25 pumps are designed to receive charge flow from an auxiliary circuit or
from a gear pump mounted on the auxiliary mounting pad. Series 40 pumps feature
a range of auxiliary mounting pads to accept auxiliary hydraulic pumps for use in
complementary hydraulic systems.
Series 40 M46 pumps offer proportional controls with either manual, hydraulic, or
electronic actuation. An electric three-position control is also available. The M25, M35,
and M44 pumps include a trunnion style direct displacement control.
Series 40 motors also use the parallel axial piston / slipper design in conjunction with
a fixed or tiltable swashplate. The family includes M25, M35, M44 fixed motor units and
M35, M44, M46 variable motor units.
The M35 and M44 variable motors feature a trunnion style swashplate and direct
displacement control. The M46 variable motors use a cradle swashplate design and a
two-position hydraulic servo control.

General description
Key features • 4 sizes of variable displacement pumps
• 4 sizes of tandem pumps
• 3 sizes of variable displacement motors
• 3 sizes of fixed displacement motors
• Efficient axial piston design
• Complete family of control systems
• Proven reliability and performance
• Compact, lightweight
• Worldwide sales and service

General description
Cross sections M25 fixed motor (MF) M35/M44 variable motor (MV)
Displacement limiter
Bearing
Piston Cylinder
Cylinder block Output shaf t
Output shaft
Lip seal
Bearing Lip seal
Piston Swashplate
M35/M44 fixed motor (MF) M46 variable motor (MV) (SAE flange)
Piston
Cylinder block
Output shaf t Piston Output shaf t
Bearing
Lip seal
Bearing Lip seal
Cylinder block
Swash plate Servo piston
P101738E

General description
System circuit
diagram
Heat exchanger Reservoir

bypass
Control
handle
Filter
Displacement Heat
control exchanger
valve
Fixed displacement
motor
Cylinder Cylinder
block block
assembly assembly
Charge relief
valve Bypass
valve
Output
shaft
Charge
pump Loop flushing
module
Input
shaft
Variable
displacement Suction flow
Check valves
pump w/ high pressure Charge pressure
relief valve
Servo pressure
High pressure
Case flow P100 586E
A Series 40 M35 fixed motor is shown in a hydraulic circuit with a Series 40 M46 variable pump. A loop flushing module
is included on the motor. The circuit features suction filtration and heat exchanger.
M46 motor schematic M1 X2 X1

A
L2
B
M2 L2
P101 869
The system ports (A and B) connect to the high pressure work lines. The motor receives pressurized fluid in its inlet port
and discharges de-energized fluid through the outlet port. Either port can act as inlet or outlet; flow is bidirectional.
System port pressure is gauged through ports M1 and M2. The motor has two case drains (L1 and L2). The motor may
include loop flushing. Loop flushing provides additional cooling and filtration capacity.

Technical Specifications
Overview Specifications and operating parameters are shown below. Not all hardware options are
available for all configurations. For additional information, see Operating parameters, page
14, System design parameters, page 17, Product coding, page 21, Features and options, page 23
and Control options, page 32.
Product line Series 40 motors

General
Product type In-line, axial piston, fixed and variable, positive displacement motors
Direction of rotation Clockwise (CW) and counterclockwise (CCW)
Installation position Discretionary, the housing must be filled with hydraulic fluid before operation
Filtration configuration Suction or charge pressure filtration
Other system requirements Independent braking system, circuit overpressure protection, suitable reservoir
and heat exchanger
Features and options Model M25 MF M35 MF M44 MF M35 MV M44 MV M46 MV
Type of mounting SAE B SAE B SAE B SAE B SAE B SAE B or
Side, Twin, Side, Twin, Side, Twin,

Port connections Twin, Axial Twin Twin
Axial Axial Axial
Splined Splined
Splined Splined
Output shaft options Tapered Tapered Splined Splined
Tapered Tapered
Straight Key Straight Key
Control options - - - DDC DDC Hyd. 2-pos.
Loop flushing Option Option Option Option Option Option
Displacement limiters - - - Option Option Option
Speed sensors Option Option Option - - Option
Model Unit M25MF M35 MF M44 MF M35MV M44MV M46 MV

Specifications
Model configuration Fixed Fixed Fixed Variable Variable Variable
Type of mounting SAE B SAE B SAE B SAE B SAE B SAE B
Displacement cm3/rev
25 [1.50] 35 [2.14] 44 [2.65] 35 [2.14] 44 [2.65] 46 [2.80]
[in3/rev]
Weight kg [lbf ] 11 [26] 11 [26] 11 [26] 21 [47] 21 [47] 23 [51]
Mass moment of inertia kg•m2 0.0018 0.0033 0.0032 0.0033 0.0032 0.0050
[slug•ft2] [0.0013] [0.0024] [0.0023] [0.0024] [0.0023] [0.0037]

Operating Model M25 MF M35 MF M44 MF M35 MV M44 MV M46 MV

parameters Case pressure bar [psi]
Continuous 1.7 [25]
Maximum 5.2 [75]

Speed limits min-1[rpm]
Rated @ max disp. 4000 3600 3300 3600 3300 4000
Maximum @ max. disp. 5000 4500 4100 4500 4100 4100
Rated @ min. disp. - - - 4200 3900 4500

Maximum @ min. disp. - - - 5300 4850 5000
System pressure bar [psi]
Continuous 210 [3000]
Maximum 345 [5000]
Fluid specifications Parameter Unit Minimum Continuous Maximum

Viscosity mm /sec (cSt) 7 12-60 1600
[SUS] [47] [70-278] [7500]
Ratings and data are based
Temperature °C [°F] -40 [-40] 82 [180] 104 [220]
on operation with premium
Cleanliness ISO 4406 Class 18/13 or better
petroleum-based hydraulic
Filtration efficiency suction filtration β35-44=75 (β10≥1.5)
fluids containing oxidation,
charge filtration β15-20=75 (β10≥10)
rust, and foam inhibitors.
Hydraulic unit life Hydraulic unit life is the life expectancy of the hydraulic components. Hydraulic unit life
is a function of speed and system pressure; however, system pressure is the dominant
operating variable affecting hydraulic unit life. High pressure, which results from high
load, reduces expected life.
It is desirable to have a projected machine duty cycle with percentages of time at various
loads and speeds. Sauer-Danfoss calculates appropriate design pressure from this
information. This method of selecting operating pressure is recommended whenever
duty cycle information is available.
10 520L0636 • Rev F • September 2006

Hydraulic unit life All pressure limits are differential pressures and assume normal charge pressure. Series
(continued) 40 motors will meet satisfactory life expectancy if applied within the parameters
specified in this bulletin. For more detailed information on hydraulic unit life see
BLN‑9884 Pressure and Speed Limits.
Performance This performance graph provides typical volumetric and overall efficiencies for Series 40
motors. These efficiencies apply for all Series 40 motors at maximum displacement.
Motor performance as a function of operating speed

100
Volumetric Efficiency - 170 bar [2500 psi]
95
Volumetric Efficiency - 345 bar [5000 psi]
Efficiency - %
90
Overall Efficiency - 170 bar [2500 psi]
Overall Efficiency - 345 bar [5000 psi]

85
80
0 25 50 75 100
Speed - % of Rated Speed P100 455E
The performance map provides typical motor overall efficiencies at various operating
parameters. These efficiencies apply for all Series 40 motors at maximum displacement.
Motor performance as a function of operating speed

bar psi
345 5000
85%
80%
%
88
89%
270 4000
System Pressure
210 3000
89%
140 2000
88%
85%
70 1000
80%
0 0
0 25 50 75 100
Speed - % of Rated Speed
P100 456E
520L0636 • Rev F • September 2006 11

Bearing life and Bearing life is a function of speed, pressure and swashplate angle, plus any external loads.
external shaft Other life factors include oil type and viscosity.
loading
In vehicle propulsion drives with no external loads, where the speed, pressure, and
swashplate angle are often changing, normal bearing ß10 (90% survival) life will exceed
the hydraulic unit life.
In non-propel drives, such as conveyors or fan drives, the operating speed and pressure
may be nearly constant leading to a distinctive duty cycle compared to that of a
propulsion drive. In propel applications, Sauer-Danfoss recommends a bearing life
review.
Series 40 motors are designed with bearings that can accept some incidental external
radial and thrust loads. However, any amount of external load will reduce the expected
bearing life.
The allowable radial shaft loads are a function of the load position, the load orientation,
and the operating pressures of the hydraulic unit. All external shaft loads have an effect
on bearing life. In motor applications where external shaft loads cannot be avoided,
the impact on bearing life can be minimized by orienting the load to the 180 degree
position (see Direction of external shaft load, next page).
The recommended maximum radial load (Re) is based on an external moment (Me) and
the distance (L) from the mounting flange to the load, (see table at below). The loads
in the table reflect a worst case external load orientation (0 degrees), a continuously
applied working pressure of 140 bar (2000 psi), 20 bar (285 psi) charge pressure,
1800 min-1(rpm), and a bearing life (ß10) of 2000 hours. Avoid thrust loads in either
direction.
The recommended maximum allowable radial load is calculated as: Re = Me / L
If continuously applied external radial loads exceed the recommended maximum

allowable, or thrust loads are known to occur, contact Sauer-Danfoss for an evaluation of
unit bearing life. Optional high capacity bearings are available.
Tapered output shafts or clamp-type couplings are recommended for applications

where radial shaft side loads are present.
Shaft loading parameters

Re Maximum radial side load
Me Maximum external moment
L Distance from mounting flange to point of load

FB Force of block (applies at center of gravity)
T Thrust load
Recommended maximum external shaft moments

M25 M35/44 M46
Me N•m [lbf•in] 29 [255] 25 [225] 24 [215]
12 520L0636 • Rev F • September 2006

Bearing life and External shaft loads

external shaft
loading L
(continued) FB
Re
P100 453E
Direction of external shaft load
0 Re
End view
of shaf t
90 Re 270 Re
Axis of swashplat e
rotation
180 Re
P100 454E
520L0636 • Rev F • September 2006 13

Operating parameters
Fluids Ratings and performance data are based on operating with premium hydraulic fluids
containing oxidation, rust, and foam inhibitors. These include premium turbine oils, API
CD engine oils per SAE J183, M2C33F or G automatic transmission fluids (ATF), DexronTM
II (ATF) meeting AllisonTM C-3 or CaterpillarTM T0‑2 requirements, and certain specialty
agricultural tractor fluids. For more information on hydraulic fluid selection, see Sauer-
Danfoss publications: 520L0463, Hydraulic Fluids and Lubricants, Technical Information,
and 520L465, Experience with Biodegradable Hydraulic Fluids, Technical Information.
Viscosity Maintain fluid viscosity within the Fluid viscosity limits

continuous range for maximum Condition mm2/s (cSt) SUS
efficiency and bearing life. Minimum Minimum 7 47
viscosity should only occur during Continuous 12-60 70-278
brief occasions of maximum ambient Maximum 1600 7500
temperature and severe duty cycle
operation. Maximum viscosity should
only occur at cold start: Limit speeds until
the system warms up. See Sauer-Danfoss
publication: 520L0463, Hydraulic Fluids
and Lubricants, Technical Information
Temperature Maintain fluid temperature within the Temperature limits

limits shown in the table. Minimum Minimum
- 40° C [- 40° F]
temperature relates to the physical (intermittent, cold start)
properties of the component materials. Continuous 82.2° C [180° F]
Cold oil will not affect the durability of Maximum 104.4° C [220° F]
the motor components. However, it may
affect the ability of the motor to transmit
power. Maximum temperature is based on material properties. Don’t exceed it. Measure
maximum temperature at the hottest point in the system. This is usually the case drain.
Ensure fluid temperature and viscosity limits are concurrently satisfied.
Case pressure Maintain case pressure within the limits Case pressure limits
shown in the table. Ensure housing is Maximum (continuous) 1.7 bar [25 psi]
kept filled with hydraulic fluid. Intermittent (cold start) 5.2 bar [75 psi]
C Caution
Operating outside of case pressure limits will damage the motor. To minimize this risk,
use full size inlet and case drain plumbing, and limit line lengths.
14 520L0636 • Rev F • September 2006

Pressure ratings The table, Operating parameters, page 10, gives maximum and continuous pressure
ratings for each displacement. Not all displacements operate under the same pressure
limits. Definitions of the operating pressure limits appear below.
System pressure is the differential pressure between system ports A and B. It is the
dominant operating variable affecting hydraulic unit life. High system pressure, which
results from high load, reduces expected life. System pressure must remain at or below
continuous working pressure during normal operation to achieve expected life.
Continuous working pressure is the average, regularly occurring operating pressure.

Operating at or below this pressure should yield satisfactory product life.
Maximum (peak) working pressure is the highest intermittent pressure allowed.

Maximum machine load should never exceed this pressure. For all applications, the load
should move below this pressure.
All pressure limits are differential pressures referenced to low loop (charge) pressure.
Subtract low loop pressure from gauge readings to compute the differential.
System pressure limits

Pressure Limits bar psi
Continuous 210 3000
Maximum 345 5000
520L0636 • Rev F • September 2006 15

Speed ratings The table, Operating parameters, page 10, gives rated and maximum speeds for each
displacement. Not all displacements operate under the same speed limits. Definitions of
these speed limits appear below.
Rated speed is the maximum recommended operating speed at full power condition.
Operating at or below this speed should yield satisfactory product life. In vehicle propel
applications, maximum motor speed during unloaded, on-road travel over level ground
should not exceed this limit.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed
reduces pump life and can cause loss of hydrostatic power and braking capacity. Never
exceed the maximum speed limit under any operating conditions.
W Warning
Unintended vehicle or machine movement hazard.
The loss of hydrostatic drive line power, in any mode of operation (forward, neutral, or
reverse) may cause the system to lose hydrostatic braking capacity. You must provide a
braking system, redundant to the hydrostatic transmission, sufficient to stop and hold
the vehicle or machine in the event of hydrostatic drive power loss.
Speed limits
Limit min-1(rpm) M25 MF M35 MF M44 MF M35 MV M44 MV M46 MV
Rated at max. displ... 4000 3600 3300 3600 3300 4000
Maximum at max. displ...
5000 4500 4100 4500 4100 4100
Rated at min. displ...

- - - 4200 3900 4500
Maximum at min. displ...

- - - 5300 4850 5000
16 520L0636 • Rev F • September 2006

System design parameters
Sizing equations Use the following equations to compute output power, torque, speed, and input
flow. Selecting the right motor starts with an evaluation of system requirements
such as speed and torque. Select a motor that will transmit the required torque, then
select a pump that will meet the flow and pressure requirements of the motor. For
more information on hydrostatic drive selection, refer to Sauer-Danfoss applications
guideline BLN-9885, Selection of Drive Line Components.
Based on SI units Based on US units
Flow Input flow Q = Vg • n (l/min) Input flow Q = Vg • n (US gal/min)

1000 • ηv 231 • ηv
Speed Motor speed n = Q • 1000 • ηv (min-1 ) Motor speed n = Q • 231 • ηv (min-1)

Vg Vg
Torque Output torque M = Vg • ∆p • ηm (N•m) Output torque M = Vg • ∆p • ηm (lbf•in)

20 • π 2•π
Power Output power P = Q • ∆p • ηt (kW) Output power P = Q • ∆p • ηt (hp)

600 1714
Variables SI units [US units]
Vg = Displacement per revolution cm3/rev [in3/rev]

pO = Outlet pressure bar [psi]
pi = Inlet pressure bar [psi]
∆p = pO - pi (system pressure) bar [psi]
n = Speed min-1 (rpm)
ηv = Volumetric efficiency
ηm = Mechanical efficiency
ηt = Overall efficiency (ηv • ηm)
520L0636 • Rev F • September 2006 17

Filtration To prevent damage to the system, including premature wear, fluid entering the motor
must be free of contaminants. Series 40 motors require system filtration capable of
maintaining fluid cleanliness at ISO 4406-1999 class 22/18/13 or better.
Consider these factors when selecting a system filter:

• Cleanliness specifications
• Contaminant ingression rates
• Flow capacity
• Desired maintenance interval
The filter may be located either on the inlet (suction filtration) or discharge (charge
pressure filtration) side of the charge pump. Series 40 pumps are available with
provisions for either suction or charge pressure filtration to filter the fluid entering the
charge circuit (see next page).
Typically, a filter with a beta ratio of β10 = 1.5 to 2.0 is adequate. However, open circuit
systems supplied from a common reservoir may have considerably higher requirements.
Because each system is unique, only a thorough testing and evaluation program can
fully validate the filtration system. For more information, see Sauer-Danfoss publication
520L0467, Design Guidelines for Hydraulic Fluid Cleanliness.
Bypass valve In some applications it is desirable to bypass fluid around the variable displacement
pump, for example; to allow a vehicle to move short distances at low speeds without
running the prime mover. This is done by opening a manually operated bypass valve.
This valve connects both sides of the pump/motor circuit and allows the motor to turn.
During normal operation, this valve must be fully closed .
Bypass valves are available in Series 40 pumps. See Sauer-Danfoss publication:

520L0635, Series 40 Pumps Technical Information.
Bypass valves are intended for moving a machine or vehicle for very short distances at
very slow speeds. They are NOT intended as tow valves.
18 520L0636 • Rev F • September 2006

Loop flushing valve Series 40 motors may incorporate an integral loop flushing valve. Installations that
require additional fluid to be removed from the main hydraulic circuit because of fluid
cooling or cleanliness requirements, will benefit from loop flushing. A loop flushing valve
will remove heat and contaminants from the main loop at a rate faster than otherwise
possible. Contact your Sauer-Danfoss representative for production availability on
specific frame size motors.
Series 40 loop flushing valves include a loop flushing relief valve with integral orifice. The
flushing flow is a function of the pump charge relief valve, and the orifice size.
Loop flushing flows of 3 to 7 l/min [0.75 to 2 US gal/min] are adequate for most
applications. Contact your Sauer-Danfoss representative for assistance.
W WARNING
Incorrect charge pressure settings may result in the inability to build required system
pressure and/or inadequate loop flushing flows. Maintain correct charge pressure under
all conditions.
Typical loop flushing flow as a function of Loop flushing valve

charge pressure
15.14
[4.00]
Flow l/min [US gal/min]
11.36
[3.00]
7.57
[2.00]
3.79 Loop flushing

[1.00] Loop flushing shuttle v alve
relief valve
0 with orifice P100 448E
8.62 12.07 15.51 19.96 22.41 25.86
[125] [175] [225] [275] [325] [375]
Charge pressure bar [psi] P100 643E
520L0636 • Rev F • September 2006 19

Redundant braking W Warning

system requirement Unintended vehicle or machine movement hazard.
The loss of hydrostatic drive line power, in any mode of operation (forward, neutral, or
reverse) may cause the system to lose hydrostatic braking capacity. You must provide a
braking system, redundant to the hydrostatic transmission, sufficient to stop and hold
the vehicle or machine in the event of hydrostatic drive power loss.
Reservoir The reservoir provides clean fluid, dissipates heat, and removes entrained air from the
hydraulic fluid. It allows for fluid volume changes associated with fluid expansion and
cylinder differential volumes. Minimum reservoir capacity depends on the volume
needed to perform these functions. Typically, a capacity of one half the charge pump
flow (per minute) is satisfactory for a closed reservoir. Open circuit systems sharing a
common reservoir will require greater fluid capacity.
Locate the reservoir outlet (suction line) near the bottom, allowing clearance for settling
foreign particles. Use a 100 - 125 µm screen covering the outlet port. Place the reservoir
inlet (return lines) below the lowest expected fluid level, as far away from the outlet as
possible. Use a baffle (or baffles) between the reservoir inlet and outlet ports to reduce
aeration and fluid surging.
Overpressure Series 40 motors (as well as other system components) have pressure limits. Relief valves
protection or pressure limiters should be present in the high pressure circuit to protect components
from excessive pressures.
Series 40 pumps are available with a range of high pressure relief valve settings. See
Sauer-Danfoss publication 520L0635, Series 40 Pumps Technical Information.
C Caution
High pressure relief valves are intended for transient overpressure protection and are not
intended for continuous pressure control. Operation over relief valves for extended peri
ods of time may result in severe heat build up. High flows over relief valves may result
in pressure levels exceeding the nominal valve setting and potential damage to system
components.
20 520L0636 • Rev F • September 2006

Product coding
Revised model code The model code is a modular description of a specific product and its options. To create
an order code to include the specific options desired, see the Series 40 Motor Model Code
Supplement or the Series 40 Price Book.
Name plate Name plate
Model-No/Ident-No. M46-2001 Model

Model Code MMV 046 C B A B A A number
Model R NN A A BLL DR A
FF A CNN
code
Serial-No A - 96 - 26 - 12345 Serial
number
Made in USA
Place of manufacture
P101 372E
Model code modules Fixed motor
Displacement
C D E F G T Z
M M V S 4 6 C - - - - - * * *
Product Type
P104 427E
C Seal group
D Output shaft/through shaft configuration
E Endcap configuration
F Cylinder block group
G Housing configuration
T Special hardware features
Z Special features (non-hardware) *** = None
520L0636 • Rev F • September 2006 21

Product coding
Model code modules Variable motor

(continued)
Displacement
C D E F G T Z
M M V S 4 6 C - - - - - * * *
Product Type
P104 427E
C Seal group
D Output shaft/through shaft configuration
E Endcap configuration
F Control features
G Housing configuration
T Special hardware features
Z Special features (non-hardware) *** = None
22 520L0636 • Rev F • September 2006

Features and options
Displacement limiters M35, M44, and M46 variable motors have minimum displacement limiters. Minimum
unit displacement is obtained with the adjuster screw at its maximum extension from
the end cap or displacement control piston cover. All motors are shipped with the
displacement limiter set for minimum motor displacement.
WWARNING
Undesirable output The M35 and M44 MV minimum displacement limiter is located in the end cap. The
speed hazard. M46 MV minimum displacement limiter is located in the displacement control piston
Take care adjusting cavity. The length and configuration of this limiter will depend upon the control option
displacement limiters. installed in the motor.
Too low of a minimum
displacement setting M46 MV units may have an optional mechanical maximum displacement limiter
can result in higher than located in the displacement control piston cover. The maximum displacement limit can
expected output speed. be adjusted by loosening the sealing lock nut, adjusting displacement by rotating the
Retorque the sealing screw with a screwdriver, then locking the adjuster by torquing the sealing lock nut.
locknut after every
adjustment to prevent Maximum unit displacement is obtained with the adjuster screw standing at its
an unexpected changes maximum height out of the displacement control piston cover. All motors are shipped
and to prevent external with the limiter set for maximum motor displacement.
leakage.
Displacement limiter M35/M44 MV Displacement limiter M46 MV

Sealing locknut Adjustable maximum
Fixed minimum
Displacement limiter displacement limiter
displacement limiter
Swashplate
Adjustable minimum P100 450E

displacement limiter
P100 449E
520L0636 • Rev F • September 2006 23

Speed sensor option Series 40 motors are available with a speed sensor option for direct measurement of
motor output speed. You can use this sensor may to sense the direction and speed of
motor rotation.
A special magnetic speed ring is pressed onto the outside diameter of the cylinder
block. A hall effect pulse pickup is located in the motor housing. The sensor accepts
supply voltage and outputs a digital pulse signal in response to the speed of the ring.
The output changes its high/low state as the north and south poles of the permanently
magnetized speed ring pass by the face of the sensor. The digital signal is generated at
frequencies suitable for microprocessor based controls.
This sensor will operate with a supply voltage of 4.5 to 15 Vdc, and requires a current of
12 mA at 5.0 Vdc (minimum) under no load. Maximum operating current is 20 mA at 5
Vdc (maximum). Maximum operating frequency is 15 kHz. Output voltage in High State
(VOH) is sensor supply voltage minus 0.5 Vdc, minimum. Output voltage in Low State
(VOL) is 0.5 Vdc, maximum. The sensor is available with a Packard Weather-PackTM or 4-
pin sealed connector.
Contact your Sauer-Danfoss representative for production availability on specific motor

frame sizes, or for special speed sensor options.
Speed sensor specifications Speed sensor cross section

Supply voltage 4.5 - 15 Vdc
12 mA @ 5 Vdc
Required current
(no load) Speed sensor
Magnetic ring
Maximum current 20 mA @ 5Vdc
Cylinder block
Maximum frequency 15 kHz
VOH Supply Vdc - 0.5 Vdc
VOL 0.5 Vdc maximum
Magnetic ring M25 M35 M44 M46

Pulses/revolution 43 46 46 51
Packard Weather-PackTM
Connector
3- pin, 4-pin
P100 452E
24 520L0636 • Rev F • September 2006

Pulse pickup and Speed sensor with directional signal

connector
Packard Weather-PackTM
4 pin tower connector
Red Supply voltage +
A
White
B Speed signal
Black
C Ground common
Green
D Direction
Mating parts kit part number K03379 (4 pin)
Speed sensor without directional signal
3 pin Weather-PackTM
shroud
Red A Supply voltage +
White B Speed signal
Black C Ground common
Mating parts kit part number K20582 (3 pin)

P100 451E
520L0636 • Rev F • September 2006 25

Shaft options Series 40 motors are available with a variety of splined, straight keyed, and tapered
shaft ends. Nominal shaft sizes and torque ratings for some available shafts are shown
in the accompanying table. Other shaft options may exist. Contact your Sauer-Danfoss
representative for availability.
Torque ratings assume no external radial loading. Continuous torque ratings for splined
shafts are based on spline tooth wear, and assume the mating spline has a minimum
hardness of Rc 55 to full spline depth and coupling has good lubrication.
Maximum torque ratings are based on shaft torsional strength and assume a maximum
of 200,000 load reversals.
Shaft availability and torque ratings

N•m [lbf•in] M25 MF M35 MF M44 MF M35 MV M44 MV M46 MV
Spline Continuous 80 [750] 73 [650] 73 [650] 73 [650] 73 [650] 73 [650]
13-tooth,
16/32 pitch Max 140 [1240] 226 [2000] 226 [2000] 226 [2000] 226 [2000] 226 [2000]
Spline Continuous - 153 [1350] 153 [1350] 153 [1350] 153 [1350] 153 [1350]
15-tooth,
16/32 pitch Max - 362 [3200] 362 [3200] 362 [3200] 362 [3200] 362 [3200]
Spline Continuous - - - - - 194 [1710]
19-tooth
16/32 pitch Max - - - - - 460 [4070]
Tapered
Max 140 [1240] 497 [4400] 497 [4400] - - 497 [4400]
1.00 inch
Straight
keyed Max - 226 [2000] 226 [2000] - - -
0.875 inch
Recommended mating splines for Series 40 splined output shafts should be in

accordance with ANSI B92.1 Class 5. Sauer-Danfoss external splines are modified Class
5 Fillet Root Side Fit. The external spline Major Diameter and Circular Tooth Thickness
dimensions are reduced in order to assure a clearance fit with the mating spline.
Through-shaft Optional through-shafts are available on Series 40 fixed and variable displacement motors
options (as noted in the accompanying table). Through-shafts are provided for use in secondary
(parking) braking systems. Through-shaft ends are not intended for continuous power
transmission.
Through-shaft availability and torque limitations

Frame size Shaft spline Max. torque limit
N•m [lbf•in]
M35 MF 13T 16/32 P 328 [2900]
M44 MF 13T 16/32 P 328 [2900]
M46 MV(SAE) 13T 16/32 P 328 [2900]
WWARNING
Potential loss of braking capacity.
Exceeding these torque limits could cause shaft breakage. Ensure your application never
exceeds maximum torque limits under any operating conditions.
26 520L0636 • Rev F • September 2006
Shaft options
M25 MF
Torque rating
Maximum torque Continuous torque
rating rating
Code Description N•m [lbf•in] N•m [lbf•in] Drawing
E 13-tooth 140 [1240] 80 [750] Coupling must not protrude
16/32 pitch beyond this surface
(ANSI B92.1 1970 - Class 5) 33.32 max.
[1.312]
Mounting 16.5 [0.65]
flange Full spline
(ref.) 18.8 max.
[0.74] 20.638 [0.8125] pitch dia.
30° pressure angle
13 teeth, 16/32 pitch
fillet root side fit
per ANSI B92.1 class 5
also mates with
21.717 dia. flat root side fit
[0.8550]
7.9 [0.31]
P104 428E
N Ø 25.4 mm [1.000 in] 140 [1240] — 42.8 [1.68]

1:8 taper 33.3 Gauge dim.
[1.311]
Coupling must not
Mounting protrude beyond
flange 25.4 max. [1.000]
(ref.)
27 [1.06]
6.30 x 22.22 dia. Woodruff key
[0.248x0.875]
0.25 [0.01] min. R on edges
3.81 max. [0.150]
22.22 Gauge dia.

[0.875]
0.750-16 UNF-2A thd.
38.1 [1.500] taper per foot

per SAE J5001
25.4 [1.000] nominal shaft dia.
P104 429E
Contact SAUER-DANFOSS Application Engineering for specific installation drawings. Dimensions in mm [in]
520L0636 • Rev F • September 2006 27

Shaft options
M35/44 MF
Torque rating
rating rating
A, C Splined output shaft (see 13 tooth 226 [2000] 13 tooth 73 [650] Coupling must not
table) protrude beyond
7.65 [0.301] this surface
S
Mounting W pitch dia.
flange U
30° pressure angle
F 15 tooth 362 [3200] 15 tooth 153 [1350] (ref.) Y teeth, Z pitch
per ANSI B92.1-1970 class no. 5
V dia. also mates with flat
root side fit
T dia.
P104 430E
M35 / M44 MF splined shaft option

No.
Shaft Shaft length Shaft diameter Full spline Major dia. Pitch dia. Pitch Thru
teeth
option S T U V W Z shaft
Y
20.638
A 33.55 [1.321] 18.8 [0.74] 16.5 [0.65] 21.72 [0.8550] 13 16/32 ---
[0.8125]
20.638
C 33.55 [1.321] 18.8 [0.74] 16.5 [0.65] 21.72 [0.8550] 13 16/32 13T
[0.8125]
23.812
F 33.55 [1.321] 21.98 [0.865] 18.5 [0.73] 24.89 [0.9800] 15 16/32 ---
[0.9375]
28 520L0636 • Rev F • September 2006

Shaft options
M35/44 MF (continued)
Torque rating
rating rating
N Ø 25.4 mm [1.000 in] 497 [4400] — 42.8 [1.68]
1:8 taper 33.3 gauge dim.
[1.311]
Coupling must not
Mounting protrude beyond
flange 25.4 max. [1.000]
(ref.) 27 [1.06] 6.30 x 22.22 dia. Woodruff key
[0.248 x 0.875]
0.25 [0.01] min. R on edges
3.81 max. [0.150]
22.22 gauge dia.

[0.875]
0.750-16 UNF-2A thd.
38.1 [1.500] taper per foot

per SAE J501
P104 431E
Y Ø 22.2 mm [0.874 in] 226 [2000] —

straight keyed
Coupling must not
protrude beyond
this surface
Mounting 7.65 [0.301] 6.35 [0.250] sq. key
flange 38.1 [1.500] long
(ref.) 0.38 [0.015] min. R
on edges
2.84 max.
[0.112]
22.2 dia.
63.73 [0.874]
[2.509]
9.4 [0.37] P104 432E
520L0636 • Rev F • September 2006 29

Shaft options
M35/44 MV
Torque rating
rating rating
A Splined output shaft (see 73 [650] 226 [2000] Coupling must not
table) protrude beyond
this surface
S
7.87
[0.310] W pitch dia.
U
30° pressure angle
Y teeth, 16/32 pitch
V dia. per ANSI B92.1 class no. 5
also mates with flat
root side fit
Mounting T dia.
flange
(ref.) P104 433E
M35 / M44 MV splined shaft option

Max.
Shaft Full spline
coupling
diameter length Pitch
Shaft engagement Major dia. Pitch dia. No. teeth Thru
T U
option S V W Y shaft
21.72 20.638
A 33.3 [1.31] 18.8 [0.74] 16.5 [0.65] 13 16/32 ---
[0.855] [0.8125]
30 520L0636 • Rev F • September 2006

Shaft options
M46 MV
Torque rating
rating rating
A, B, Splined output shaft (see 13 tooth 226 [2000] 13 tooth 73 [650] Coupling must not protrude
table) beyond this surface
S max.
U Full Spline
E, F, 19 tooth 460 [4070] 15 tooth 153 [1350]
T max. dia.
W pitch dia.
30° pressure angle
Y teeth, Z pitch
D 15 tooth 362 [3200] 19 tooth 194 [1710] fillet root side fit
per ANSI B92.1 class no. 5
V dia. also mates with flat
R root side fit
Mounting
flange
(ref.) 7.47 [0.294]
P104 434E
J 25.4 [1.000] — 497 [4400] Coupling must not protrude

tapered shaft beyond this surface
36.58 [1.440]
max. 6.30 x 22.22 dia. woodruff key
[0.248 x 0.875]
1/8 taper [1.500 per foot]
per SAE standard J501
3/4 - 16 Thd.
22.22 [0.875]
gauge dia.
26.97
[1.062]
9.17 gauge dim.

Mounting [0.361]
flange
(ref .) 37.62
[1.481]
5.05 [0.199]
P104 435E
M46 MV splined shaft option

Max.
Shaft coupling Shaft Full No.
Shaft extension engagement diameter spline length Major dia. Pitch dia. teeth Pitch Thru
option R S T U V W Y Z shaft
32.94 32 19.1 15.8 21.72 20.638
A 13 16/32 ---
[1.297] [1.26] [0.75] [0.62] [0.855] [0.8125]
32.94 32 19.1 15.8 21.72 20.628
B 13 16/32 13T
[1.297] [1.26] [0.75] [0.62] [0.855] [0.8125]
37.72 36.6 22.3 22.86 24.89 23.812
E 15 16/32 ---
[1.485] [1.44] [0.88] [0.90] [0.980] [0.9375]
37.72 36.6 22.3 22.86 24.89 23.812
F 15 16/32 13T
[1.485] [1.44] [0.88] [0.90] [0.980] [0.9375]
37.72 36.6 28.4 22.35 31.24 30.162
D 19 16/32 ---
[1.485] [1.44] [1.114] [0.88] [1.230] [1.1875]
520L0636 • Rev F • September 2006 31

Control options
Direct displacement The direct displacement control is available on either side of the M35 and M44 variable
control (ddc) motors. It provides a simple, positive method of displacement control. Movement of
the control shaft causes a proportional swashplate movement, thus varying the motor’s
displacement from full to minimum displacement.
WWARNING Neutral position is not factory set, nor is there any internal neutral return mechanism.
Unintended vehicle The application must include provisions for all control linkage and neutral return
movement hazard. functionality.
Internal forces may not
return the swashplate to External Control Handle Requirements
the neutral position under Maximum allowable trunnion torque is 79.1 N•m [700 lbf•in]. Minimum torque necessary
all operating conditions. to hold the swashplate per 70 bar of differential system pressure is 11.3 N•m [100 lbf•in].
Maximum trunnion angle is 16° for M35 and M44.
DDC on left side of M35 motor Motor displacement vs swashplate rotation

16° for M35
16° for M44 100%
Minimum
swashplate angle
t
or
en
ot
m
M
ce
la
sp
Min.
di
Trunnion rotation
P100 457E
P100 458E
DDC input specifications

Max. torque N•m [lbf•in] 79.1 [700]
Min. torque to hold (per 70 bar
[1000 psi] system pressure) 11.3 [100]
N•m [lbf•in]
Max. angle 16°
32 520L0636 • Rev F • September 2006

Control options
Two-position Series 40 M46 variable displacement motors are equipped with a hydraulically controlled
hydraulic control swashplate. The motor is spring biased toward maximum displacement. A hydraulic
piston is used to shift the swashplate from maximum to minimum displacement. A single
or two-line control can regulate the servo piston.
With the standard single-line control option, hydraulic pressure is supplied to the
control port (X1) to shift the motor to minimum displacement. The opposite end of the
displacement control piston internally drains to the motor case. The swashplate shifts
with a minimum pressure of 13.8 bar [200 psi]. The bias spring returns the motor to
maximum displacement when control pressure is removed.
The single-line control generally uses a customer supplied 2-position, 3-way control
valve. Hydraulic pressure on the control piston must not exceed 27.6 bar [400 psi].
In applications which encounter frequent shifting on-the-go as part of the normal duty
cycle, we recommend the optional two-line control. Applications with routine shifting
from work range to travel range may not require the two-line control. to command
minimum displacement, port control pressure to port X1 and drain port X2. To command
maximum displacement, port control pressure to port X2 and drain port X1.
The two-line control generally uses a customer supplied 2-position, 4-way control valve.
Hydraulic pressure on the control piston must not exceed 27.6 bar (400 psi).
Orifices in either (or both) the control valve supply and drain lines optimize the shift rate
for either the single or two-line control. Contact your Sauer-Danfoss representative for
additional information.
Input specifications bar [psi]

Single line control Two line control
Max. pressure on control 27.6 [400] 27.6 [400]
Min. pressure to shift 13.8 [200] 13.8 [200]
Control valve
2-position / 3 way 2-position / 4-way
(customer supplied)
M46 2-position hydraulic controls

Top
Port X2
Control pressure supply
(for maximum displacement)
Port X1
Control pressure supply
(for minimum displacement)
P100 459E
Single-line control Bottom Two-line control
520L0636 • Rev F • September 2006 33

Installation drawings
M25 MF: axial ports, Flow direction

twin ports, loop
flushing, speed Motor shaft rotation Port A Port B
sensor Clockwise (CW) In Out
Counterclockwise (CCW) Out In
Axial or twin ports

26.67 [1.050]
(2) Places 134.5
7/8 - 14* [5.29]
Port B 64.26 [2.530] (2) places
(2) Places 3/4 - 16 SAE*
(Twin port option) case outlet L1
7/8 - 14* 7/8 - 14*
Port A (Twin port 48.8
Port B [1.92] 64.8 [2.55]
(Axial port option) option) (2) Places
7/8 - 14*
Port A (Axial port
65.91 option)
[2.595] 25.4 [1.000]
64.97 min
[2.558]
101.57
[3.999]
78.9
[3.11]
9.4
[0.37]
9/16 - 18* 76.7
System pressure [3.02]
gauge ports M1 and M2 162.8
26.67 [1.050] 56.9 [6.41]
(2) Places [2.24]
(2) Places 3/4 - 16*
case outlet
(alternate) L2
With loop flushing

Packard Weather-packTM
4-way conn. (male)
mates with
Speed sensor PackardTMpart no. 12015797
option 4-way tower (female)
or
Sauer Danfoss
kit no. K03384
3.89
[98.9]
94.488
Loop flushing Loop flushing [3.72]
relief valve shuttle valve
143.0
[5.63]
P100 565E
*All ports are SAE straight thread o-ring ports per SAE J514, unless otherwise specified.
Shaft rotation is determined by viewing pump from input shaft end.
Dimensions in mm [in]
Contact SAUER-DANFOSS Application Engineering for specific installation drawings.
34 520L0636 • Rev F • September 2006

M25 MF: mounting

flange
87.2 73.02
[3.44] [2.875]
(2) places (2) places
CCW CW
14.27 [0.562] dia.

(2) places
P100 566E
M35/M44 MF: mounting

flange
66.55 [2.620]
Case drain - L1 and L2
both sides
Approx. center
of gravity
4.06
[0.16] CW
CCW
70.36 87.25
[2.77] [3.435]
(2) places (2) places
14.27 dia.
[0.562] (2) places
P100 569E
520L0636 • Rev F • September 2006 35

M35/M44 MF: axial Flow direction

ports, twin ports,
loop flushing, speed Motor shaft
Port A Port B
sensor rotation
Clockwise In Out
Counterclockwise Out In
Axial ports
186.8
[7.335]
185.4
[7.30]
9.4
[0.37]
Housing w/ optional
1-1/16 -12* speed sensing
(2) places
89.7
[3.53]
101.57
[3.999]
44.5
71.9 [1.75] 30.5
78.2 [2.83] [1.20]
[3.08]
23.9
[0.94] 105.6
7/8 -14* [4.16] Packard Weather-PackTM 4-way conn. (male)
Case drain - L3 mates with PackardTM par t no. 12015797
4-way tower (female)
7/16 -20* 7/16 -20* or Sauer-Danfoss kit no. K03384
System pressure 40.1 System pressure
gauge port - M2 [1.58] gauge port - M1 Speed sensor
(2) places option
Loop flushing
Loop flushing shuttle valve (option)
Relief valve (option)
Twin ports
186.3
77.7 [7.34]
[3.06] 154.6
(2) Places 1-1/16 -12* [6.08]
Port B (2) places 92.1
Port A [3.63]
12.8
[0.51]
79.5
77.1 [3.13]
[3.04]
71.9
78.2 [2.83]
[3.08]
23.9
[0.94]
(2) Places
7/8 -20*
7/8 -20* System pressure
System pressure gauge port - M1 Loop flushing 99.1
gauge port - M2 Loop flushing
shuttle valve (option) [3.90]
valve (option)
P100 567E
36 520L0636 • Rev F • September 2006

M35/M44 MF: side Side ports

ports, through shaft
77.7
[3.06]
(2) places 186.3
[7.34]
67.3 154.6
[2.65] [6.09]
(2) places Approx. center
of gravity 92.1
[3.63]
12.8
1-1/16 -12* [0.51]
7/8 -14*
(2) places
Case drain - L3
89.7
Port [3.53]
B
Port A
17.8
[0.70]
44.5
[1.75]
71.9
[2.83]
7/8 -14*
65.9 Case drain - L2
[2.60]
(2) places 99.1
[3.90]
161.3
[6.35]
184.9
[7.28]
Side ports with thru shaft
218.29
1-1/16 -12* [8.594]
(2) places 184.0
67.3 67.3 [7.25]
[2.63] [2.63] 92.1
65.91 [3.63]
[2.60] 21.1 [0.83] 12.8
Full spline [0.51]
length
29
[1.14]
(2) Places 89.7
[3.53] 21.72
[0.855]
Aux. shaft option

70.5
[2.77] Approx. center
71.9 of gravity
[2.83]
50.813 7/8 -14*
[2.000] 6.3 99.1 Case drain - L2
[0.25] [3.90]
7/8 -14* 1/2 -13 Thd.
36.8 max. 151.00
Case drain - L3 92 Min. Full Thd.
[1.45] [5.95]
[23.3]
(2) places 161.3
Auxiliary drive spline data: Coupling must not [6.35]
20.638 pitch diameter protrude beyond
[0.8125] this surface
30° pressure angle
13 teeth, 16/32 pitch
ANSI B92.1-1790 class no.5
also mates with flat
P100 568E
root side fit
520L0636 • Rev F • September 2006 37

M35/M44 MV: twin

ports
95
92.2 96.5 Displacement [3.74] 7.6
[3.63] [3.80] limiter [0.301]
9/16 -18*
System pressure
gauge Port M2 9/16 -18*
system pressure
gauge Port M1
101.57
[3.999]
80.5
[3.17]
min.
16° max. Disp.
Port B Port A Disp. 12.6
[0.50]
66.7
[2.63]
96.4
[3.80]
1-1/16 -12*
Case outlet
1-1/16 -12*
Port A
35
[1.38]
35
[1.38]
1-1/16 -12*
Port B
164.7
[6.48]
P100 570E
38 520L0636 • Rev F • September 2006

M35/M44 MV:
mounting flange,
trunnion control
125
[4.92] 70.4
111.8
[4.40] [2.77]
CCW CW
Control trunnion Control trunnion
left side right side
option L option R
87.25
[3.44]
73.03
[2.875]
14.5 dia.
[0.562]
(2) places
Trunnion control
45°
19.01 [0.750]
(2) places
19.84
[0 .781]
P100 571E
520L0636 • Rev F • September 2006 39

M46 MV: side ports, Flow direction

loop flushing
Motor shaft direction Port A Port B
Clockwise (CW) Out In
Counterclockwise (CCW) In Out
Radial (side) ports w/o loop flushing
1-1/16 - 12*
case outlets
ports L1 and L2
71.6 [2.82] 228
(4) places [8.98]
200.5
68.1 [2.68] 74.7 [2.94] [7.90]
(to L1) (2) places X2
(ref.)
case outlet L1
(opposite side)
30 [1.18]
(2) places
63.5 [2.50]
(4) places
72.6 min.
[2.86]
101.6 dia.
[4.000]
Case outlet L2 X1
71.1 [2.80] (alternate) (ref.) 22.61 [0 .890]
82.6 [3.25]
(2) places (to L2) 9.7 [0.38]
139.6 [5.50]
1-5/16 - 12* 1-5/16 - 12* (2) places
port A port B
Radial (side) ports w/ loop flushing
Loop flushing 7/16 - 20* 229.7

relief valve gauge ports M1 and M2 [9.04]
Loop flushing
shuttle valve
98.3
[3.87]
80.9
[3.19]
68.8 [2.71] 194.7

(2) places [7.66]
1-5/16 - 12* 1-5/16 - 12* P100 572E
Port A Port B
40 520L0636 • Rev F • September 2006

M46 MV: axial ports, Axial ports w/ loop flushing

loop flushing
Loop flushing 7/16 - 20* 229.7
relief valve gauge ports M1 and M2 [9.04]
Loop flushing
shuttle valve
98.3
89.7 [3.53] [3.87]
w/o loop
flushing
63.5
[2.50] 80.9
[3.19]
1-1/16 - 12*
port A 42.4 [1.67] 1-1/16 - 12*
(2) places port B
71.6 [2.82]
(2) places P100 573E
520L0636 • Rev F • September 2006 41

M46 MV: side ports,

thru shaft twin
ports, loop flushing
Side ports w/ thru shaft Radial (side) ported w/ loop flushing

w/ thru shaft
58.9 20.638 [0.8125] pitch dia.
[2.32] 30° pressure angle 25.4
(2) places 13 teeth, 16/32 pitch 7.7 [1.00]
1/2 - 13 Thd. fillet root side fit [0.303]
thru per ANSI B92.1, class no. 5
(2) places (also mates with flat
root side fit)
50.8
[2.00]
(2) places
50.813
ø [2.0005]
13.49 dia. thru

ø 21.717 [0.8550]
[0.531]
(2) places
21.1 [0.83] Full Spline

37.3 [1.47]
40.0 [1.57] max.
Radial (twin) ports w/ loop flushing
Loop flushing
relief valve 7/16 - 20* 229.7
gauge ports M1 and M2 [9.04]
Loop flushing
shuttle valve
98.3
[3.87] 89.7 [3.53]
w/o loop
flushing
68.5
[2.69]
1-1/16 - 12*
port A 1-1/16 - 12*
port B
29.7 [1.17] 199.6
(2) places [7.86]
P100 574E
42 520L0636 • Rev F • September 2006

M46 MV: mounting

flange
14.27 dia. thru
[0.562]
(2) places
89.1 73.02
[3.51] CCW CW [2.875]
(2) places
87.2
82 [3.44]
[3.23] (2) places
115.1 73.7
[4.53] [2.90]
P100 575E
520L0636 • Rev F • September 2006 43

M46 MV: control

ports Control w/ bottom pressure supply port and externally adjustable displacement limiters
Min. displacement
adjustment screw
(3/16 in. internal hex)
104.1
100.6 max.
[4.10]
[3.96]
89.1
[3.51]
(ref)
80.5
[3.17]
103.9
99.6 max.
[4.09]
[3.92]
Max. displacement
78.7
adjustment screw
[3.10]
9/16 - 18* (screwdriver slot)
Control pressure port X1
Control w/ top and bottom pressure supply ports
9/16 - 18*
80.5
[3.17]
80.5
[3.17]
78.7
[3.10]
9/16 - 18* Both sides
P100 576E
44 520L0636 • Rev F • September 2006

Schematics
M1 L2
M25/M35/M44 A
fixed motor
schematics
(no loop flushing)
B
M2 L1
P100 579E
M1 L2
M25/M35/M44
A
fixed motor
schematics
M2 L1
P100 580E
M1 L2
M35/M44
variable motor A
schematics
M2 L1
P100 581E
M1 X2 X1
M46
A
variable motor
schematics
L2
M2 L1
P100 582E
520L0636 • Rev F • September 2006 45

Notes
46 520L0636 • Rev F • September 2006

Notes
520L0636 • Rev F • September 2006 47

OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
Hydrostatic transmissions
Sauer-Danfoss is a comprehensive supplier providing complete
Hydraulic power steering
systems to the global mobile market.
Electric power steering
Sauer-Danfoss serves markets such as agriculture, construction, road
Electrohydraulic power steering
building, material handling, municipal, forestry, turf care, and many
Closed and open circuit axial piston others.
pumps and motors
Gear pumps and motors We offer our customers optimum solutions for their needs and
develop new products and systems in close cooperation and
Bent axis motors partnership with them.
Orbital motors
Sauer-Danfoss specializes in integrating a full range of system
Transit mixer drives components to provide vehicle designers with the most advanced
Planetary compact gears total system design.
Proportional valves Sauer-Danfoss provides comprehensive worldwide service for its

Directional spool valves products through an extensive network of Authorized Service
Centers strategically located in all parts of the world.
Cartridge valves
Hydraulic integrated circuits
Hydrostatic transaxles
Integrated systems
Fan drive systems
Electrohydraulics
Microcontrollers and software
Electric motors and inverters Sauer-Danfoss (US) Company
2800 East 13th Street
Joysticks and control handles
Ames, IA 50010, USA
Displays Phone: +1 515 239-6000, Fax: +1 515 239 6618
Sensors
Sauer-Danfoss GmbH & Co. OHG
Postfach 2460, D-24531 Neumünster
Krokamp 35, D-24539 Neumünster, Germany
Phone: +49 4321 871-0, Fax: +49 4321 871 122
Sauer-Danfoss ApS
DK-6430 Nordborg, Denmark
Phone: +45 7488 4444, Fax: +45 7488 4400
520L0636 • Rev F • September-2006
www.sauer-danfoss.com
Siemens Energy & Automation, Inc.
Motors and Drives Division
14000 Dineen Drive
Little Rock, Arkansas 72206
Installation • Operation • Maintenance

CLEANING
WARNING Instructions
Do not attempt to clean motor while it is operating.. Contact with rotating parts can cause severe
personal injury or property damage. Stop the motor and lock out switch before cleaning.
The motor exterior must be kept free of oil, dust, dirt, water, and chemicals. For fan cooled motors,
it is particularly important to keep the air intake openings free of foreign material. Do not block air
outlet or inlet.
On non-explosion-proof TEFC motors, a removable plug in the bottom center of the motor frame
or housing permits removal of accumulated moisture. Drain regularly.
VERTICAL MOTOR THRUST BEARINGS

Top bearings — high external thrust from the driven unit is usually carried by he top bearing or
bearings. If replacement is necessary, the new bearing must be the same size and type as the orig-
inal. Duplex bearings must also be the same type and mounted in an identical manner. When
angular contact type bearings are replaced, the new bearing must have the same thrust capacity.
Bottom bearings — grease lubricated lower bearings adequately lubricated at the factory for at
least three months operation. The relubrication procedure is the same as outlined above under
“Bearing Lubrication.” It is important to maintain the lower cavity full of grease at all times.
The correct replacement bearings are given on the nameplate by AFBMA (Anti-Friction Bearing
Manufacturers Association) number.
SERVICE
For immediate action on your motor problems call your certified service center or contact your
nearest Siemens District Office.

Industrial Products Division
14000 Dineen Drive
Induction Motors
© 2001 Siemens Energy & Automation, Inc. Bulletin NMIM-L1000 143-449 Frame NMIM-L1000
IM0606TI Printed in U.S.A.
BEARING LUBRICATION
CAUTION
Do not lubricate motor while in operation, since excess grease will be forced through the bearings
and into the motor before it will force its way out of the drain plug. Excess grease accumulation
TABLE OF CONTENTS on windings reduces insulation life.
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bearing life is assured by maintaining proper alignment, proper belt or chain tension, and good
lubrication at all times.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Prior to shipment, motor bearings are lubricated with the proper amount and grade to provide six
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 months of satisfactory service under normal operation and conditions.
VOLTAGE REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 For best results, grease should be compounded from a polyurea base and a good grade of petro-
leum oil. It should be of No. 2 consistency and stabilized against oxidation. Operating tempera-
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ture range should be from -15°F to +250°F for class B insulation, and to +300°F fir class F and H.
• BEARING LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Most leading oil companies have special bearing greases that are satisfactory.
• INSULATION RESISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
• CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Relubricate bearings every six months (more often if conditions require), as follows:
1. Stop the motor. Lock out the switch.
VERTICAL MOTOR THRUST BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. Thoroughly clean off pipe plugs and remove from housings.
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Remove hardened grease from drains with stiff wire or rod.
4. Add grease to inlet with hand gun until small amount of new grease is forced out of drain.
5. Remove excess grease from ports, replace inlet plugs, and run motor 1/2 hour before replac-
ing drain plug.
6. Put motor back in operation.
These instructions do not purport to cover all details or variations in equipment, nor to provide for
every possible contingency to be met in connection with installation, operation or maintenance.
Should further information be desired or should particular problems arise which are not covered suf- INSULATION RESISTANCE
ficiently for the purchaser’s purposes, the matter should be referred to the local Siemens Sales Office. Check insulation resistance periodically. Any approved method of measuring insulation resistance
may be used, provided the voltage across the insulation is at a safe value for the type and condi-
The contents of this instruction manual shall not become part or modify any prior or existing agree- tion of the insulation. A hand cranked megger of not over 500 volts is the most convenient and
ment, commitment or relationship. The sales contract contains the entire obligation of Siemens. The safest method. Standards of the Institute of Electrical and Electronics Engineers, Inc. (IEEE) rec-
warranty contained in the contract between the parties is the sole warranty of Siemens. Any state- ommended that the insulation resistance of stator windings at 75°C, measure at 500 volts DC, after
ments contained herein do not create new warranties or modify the existing warranty. one minute should not be less than:
Rated voltage of machine + 1000 = Insulation resistance in Megohms
1000
This formula is satisfactory for most checks. for more information, see IEEE Standard No. 43,
“Recommended Practice for Insulation Resistance Testing of AC Rotating Machinery.”
2 7
VOLTAGE REGULATION INDUSTRIAL MOTOR DIVISION
Motors will operate successfully under the following conditions of voltage and frequency varia-
tion, but not necessarily in accordance with the standards established for operation under rated
conditions:
a. When the variation in voltage does not exceed 10% above or below normal with all phases INTRODUCTION
balanced.
THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES, ROTATING PARTS AND HOT SURFACES.
b. When the variation in frequency does not exceed 5% above or blow normal. SEVERE PERSONAL INJURY OR PROPERTY DAMAGE CAN RESULT IF SAFETY INSTRUCTIONS ARE
NOT FOLLOWED. ONLY QUALIFIED PERSONNEL SHOULD WORK ON OR AROUND THIS EQUIP-
c. When the sum of the voltage and frequency does not exceed 10% above or below normal
MENT AFTER BECOMING THOROUGHLY FAMILIAR WITH ALL WARNINGS, SAFETY NOTICES, AND
(provided the frequency variation does not exceed 5%).
MAINTENANCE PROCEDURES CONTAINED HEREIN. THE SUCCESSFUL AND SAFE OPERATION OF
THIS EQUIPMENT IS DEPENDENT UPON PROPER HANDLING, INSTALLATION, OPERATION AND
MAINTENANCE MAINTENANCE.
Failure to properly maintain the equipment can result in severe personal injury and product
failure. The instructions contained herein should be carefully reviewed, understood and followed. QUALIFIED PERSON
The following maintenance procedures should be performed regularly: For the purpose of this manual and product labels, a qualified person is one who is familiar with the
1. Bearing lubrication installation, construction and operation of the equipment and the hazards involved. In addition, he
has the following qualifications:
2. Insulation resistance check
a) Is trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment in
3. Cleaning accordance with established safety practices.
b) Is trained in the proper care and use of protective equipment such as rubber gloves, hard hat,
This checklist does not represent an exhaustive survey of maintenance steps necessary to ensure safety glasses or face shields, flash clothing, etc., in accordance with established safety prac-
safe operation of the equipment. Particular applications may require further procedures. Should tices.
further information be desired or should particular problems arise which are not covered sufficient-
ly for the purchaser’s purposes, the matter should be referred to the local Siemens Sales Office. c) Is trained in rendering first aid.
Dangerous voltages are present in the equipment which can cause severe personal injury and
product failure. Always de-energize and ground the equipment before maintenance. Maintenance
should be performed only by qualified personnel. DANGER
The use of unauthorized parts in the repair of the equipment, tampering by unqualified personnel or
removal or alteration of guards or conduit covers will result in dangerous conditions which can cause For the purpose of this manual and product labels, DANGER indicates death, severe personal
severe personal injury or equipment damage. Follow all safety instructions contained herein. injury or substantial property damage will result if proper precautions are not taken.
WARNING
For the purpose of this manual and product labels, WARNING indicates death, severe personal
injury or substantial property damage can result if proper precautions are not taken.
CAUTION
For the purpose of this manual and product labels, CAUTION indicates minor personal injury or
property damage can result if proper precautions are not taken.
6 3
INSPECTION OPERATION
Care is taken at the factory to assure that the motor arrives at its destination in first class condition. Repeated trial starts can overhead the motor and may result in motor burnout (particularly for
If there is evidence of rough handling or damage in shipping, file a claim at once with the carrier across the line starting). If repeated trial starts are made, allow sufficient time between trials to per-
and notify your Siemens Sales Office. mit heat to dissipate from windings and rotor to prevent overheating. Starting currents are sever-
al times running currents, and heating varies as the square of the current.
Examine the outside of the motor carefully for damage, with particular attention to conduit box,
fans, and covers. Inspect and tighten all hardware and accessories which may have become loos- After installation is completed, but before motor is put in regular service, make an initial start as
ened during shipping and handling. Turn the shaft by hand to be sure that it rotates freely. If the follows:
motor has been mishandled sufficiently to break external parts, the end shield should also be 1. Check motor starting and control device connections against wiring diagrams.
removed to check for internal damage unless the motor is explosion-proof. See warning below on
2. Check voltage, phase and frequency of line circuit (power supply) against motor nameplate.
explosion proof motors.
3. If possible, remove external load (disconnect drive) and turn shaft by hand to ensure free
rotation. This may have been done during installation procedure; if so, and conditions have
not changed since, this check may not be necessary.
WARNING a. If drive is disconnected, run motor at no load long enough to be certain that no unusual
conditions develop. Listen and feel for excessive noise, vibration, clicking or pounding.
If present, stop motor immediately. Investigate the cause and correct before putting
Explosion-proof motors—these motors are constructed to comply with the U.L. Label Service motor in service.
Procedure Manual. When repairing and reassembling a motor that has an underwriter’s label,
it is imperative that the unit be reinspected and: b. If drive is not disconnected, interrupt the starting cycle after motor has accelerated to low
speed. Carefully observe for unusual conditions as motor coasts to a stop.
1. All original fits and tolerances be maintained.
2. All plugs and hardware be securely fastened. 4. When checks are satisfactory, operate at minimum load and look for unusual condition.
Increase load slowly to maximum. Check unit for satisfactory operation.
3. Any parts replacements, including hardware, be accurate duplicates of the originals.
Repair work on explosion-proof motors can only be done by the original manufacturing or U.L.
certified shops. Violations of any of the above items will invalidate the significance of the U.L.
Label.
CAUTION
STORAGE
Motors must be stored in a clean, dry, well ventilated location free from vibration and rapid or wide Guard against overloading. Overloading causes overheating and overheating means shortened
temperature variations. If the unit is to be stored longer than three months, consult factory. Ball insulation life. A motor subjected to a 10°C temperature rise above the maximum limit for the
bearing motors are shipped from the factory properly lubricated and ready to operate. When in insulation may cause the insulation life to be reduced by 50%. To avoid overloading, be sure
storage, the motor shaft must be turned several rotations every month and the bearing relubricat- motor current does not exceed nameplate current when nameplate voltage is applied.
ed every year. On non-explosion-proof TEFC motors, a removable plug in the bottom of the frame
or housing permits removal of accumulated moisture. Drain regularly if storage atmosphere
results in formation of condensation.
Electric motors operating under normal conditions become quite warm. Although some places
may feel hot to the touch, the unit may be operational within limits. Use a thermocouple to mea-
INSTALLATION sure winding temperature when there is any concern.
Installation must be handled by qualified service or maintenance personnel. The motor foundation
must rigidly support all four feet in the same plane. Place shims under the motor feet, as required, The total temperature, not the temperature rise, is the measure of safe operation. Investigate the
so they will not be pulled out of plane when mounting bolts are tightened. All wiring to the motor operating conditions if the total temperature measured by a thermocouple placed on the winding
and control must be in accordance with the National Electrical Code and all local regulations. exceeds:
Before drive is connected, momentarily energize motor to check that direction of rotation is proper.
For direct drive, accurate alignment is 0.004 inch/ft. (radius to dial indicator = one foot). 230°F (110°C) for class “B” insulation
275°F (135°C) for class “F” insulation
Any change in shims requires rechecking alignment. When alignment is within limits, dowel two
feet of each unit. When installing flat belt pulley, V-belt sheave, spur or helical pinion or chain dri- 302°F (150°C) for class “H” insulation
ves, be certain that they are within NEMA limitations. Refer to NEMA motor and general standards,
MG-1 14.07 and 14.42.
4 5
INSPECTION OPERATION
Care is taken at the factory to assure that the motor arrives at its destination in first class condition. Repeated trial starts can overhead the motor and may result in motor burnout (particularly for
If there is evidence of rough handling or damage in shipping, file a claim at once with the carrier across the line starting). If repeated trial starts are made, allow sufficient time between trials to per-
and notify your Siemens Sales Office. mit heat to dissipate from windings and rotor to prevent overheating. Starting currents are sever-
al times running currents, and heating varies as the square of the current.
Examine the outside of the motor carefully for damage, with particular attention to conduit box,
fans, and covers. Inspect and tighten all hardware and accessories which may have become loos- After installation is completed, but before motor is put in regular service, make an initial start as
ened during shipping and handling. Turn the shaft by hand to be sure that it rotates freely. If the follows:
motor has been mishandled sufficiently to break external parts, the end shield should also be 1. Check motor starting and control device connections against wiring diagrams.
removed to check for internal damage unless the motor is explosion-proof. See warning below on
2. Check voltage, phase and frequency of line circuit (power supply) against motor nameplate.
explosion proof motors.
3. If possible, remove external load (disconnect drive) and turn shaft by hand to ensure free
rotation. This may have been done during installation procedure; if so, and conditions have
not changed since, this check may not be necessary.
WARNING a. If drive is disconnected, run motor at no load long enough to be certain that no unusual
conditions develop. Listen and feel for excessive noise, vibration, clicking or pounding.
If present, stop motor immediately. Investigate the cause and correct before putting
Explosion-proof motors—these motors are constructed to comply with the U.L. Label Service motor in service.
Procedure Manual. When repairing and reassembling a motor that has an underwriter’s label,
it is imperative that the unit be reinspected and: b. If drive is not disconnected, interrupt the starting cycle after motor has accelerated to low
speed. Carefully observe for unusual conditions as motor coasts to a stop.
1. All original fits and tolerances be maintained.
2. All plugs and hardware be securely fastened. 4. When checks are satisfactory, operate at minimum load and look for unusual condition.
Increase load slowly to maximum. Check unit for satisfactory operation.
3. Any parts replacements, including hardware, be accurate duplicates of the originals.
Repair work on explosion-proof motors can only be done by the original manufacturing or U.L.
certified shops. Violations of any of the above items will invalidate the significance of the U.L.
Label.
CAUTION
STORAGE
Motors must be stored in a clean, dry, well ventilated location free from vibration and rapid or wide Guard against overloading. Overloading causes overheating and overheating means shortened
temperature variations. If the unit is to be stored longer than three months, consult factory. Ball insulation life. A motor subjected to a 10°C temperature rise above the maximum limit for the
bearing motors are shipped from the factory properly lubricated and ready to operate. When in insulation may cause the insulation life to be reduced by 50%. To avoid overloading, be sure
storage, the motor shaft must be turned several rotations every month and the bearing relubricat- motor current does not exceed nameplate current when nameplate voltage is applied.
ed every year. On non-explosion-proof TEFC motors, a removable plug in the bottom of the frame
or housing permits removal of accumulated moisture. Drain regularly if storage atmosphere
results in formation of condensation.
Electric motors operating under normal conditions become quite warm. Although some places
may feel hot to the touch, the unit may be operational within limits. Use a thermocouple to mea-
INSTALLATION sure winding temperature when there is any concern.
Installation must be handled by qualified service or maintenance personnel. The motor foundation
must rigidly support all four feet in the same plane. Place shims under the motor feet, as required, The total temperature, not the temperature rise, is the measure of safe operation. Investigate the
so they will not be pulled out of plane when mounting bolts are tightened. All wiring to the motor operating conditions if the total temperature measured by a thermocouple placed on the winding
and control must be in accordance with the National Electrical Code and all local regulations. exceeds:
Before drive is connected, momentarily energize motor to check that direction of rotation is proper.
For direct drive, accurate alignment is 0.004 inch/ft. (radius to dial indicator = one foot). 230°F (110°C) for class “B” insulation
275°F (135°C) for class “F” insulation
Any change in shims requires rechecking alignment. When alignment is within limits, dowel two
feet of each unit. When installing flat belt pulley, V-belt sheave, spur or helical pinion or chain dri- 302°F (150°C) for class “H” insulation
ves, be certain that they are within NEMA limitations. Refer to NEMA motor and general standards,
MG-1 14.07 and 14.42.
4 5
VOLTAGE REGULATION INDUSTRIAL MOTOR DIVISION
Motors will operate successfully under the following conditions of voltage and frequency varia-
tion, but not necessarily in accordance with the standards established for operation under rated
conditions:
a. When the variation in voltage does not exceed 10% above or below normal with all phases INTRODUCTION
balanced.
THIS EQUIPMENT CONTAINS HAZARDOUS VOLTAGES, ROTATING PARTS AND HOT SURFACES.
b. When the variation in frequency does not exceed 5% above or blow normal. SEVERE PERSONAL INJURY OR PROPERTY DAMAGE CAN RESULT IF SAFETY INSTRUCTIONS ARE
NOT FOLLOWED. ONLY QUALIFIED PERSONNEL SHOULD WORK ON OR AROUND THIS EQUIP-
c. When the sum of the voltage and frequency does not exceed 10% above or below normal
MENT AFTER BECOMING THOROUGHLY FAMILIAR WITH ALL WARNINGS, SAFETY NOTICES, AND
(provided the frequency variation does not exceed 5%).
MAINTENANCE PROCEDURES CONTAINED HEREIN. THE SUCCESSFUL AND SAFE OPERATION OF
THIS EQUIPMENT IS DEPENDENT UPON PROPER HANDLING, INSTALLATION, OPERATION AND
MAINTENANCE MAINTENANCE.
Failure to properly maintain the equipment can result in severe personal injury and product
failure. The instructions contained herein should be carefully reviewed, understood and followed. QUALIFIED PERSON
The following maintenance procedures should be performed regularly: For the purpose of this manual and product labels, a qualified person is one who is familiar with the
1. Bearing lubrication installation, construction and operation of the equipment and the hazards involved. In addition, he
has the following qualifications:
2. Insulation resistance check
a) Is trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment in
3. Cleaning accordance with established safety practices.
b) Is trained in the proper care and use of protective equipment such as rubber gloves, hard hat,
This checklist does not represent an exhaustive survey of maintenance steps necessary to ensure safety glasses or face shields, flash clothing, etc., in accordance with established safety prac-
safe operation of the equipment. Particular applications may require further procedures. Should tices.
further information be desired or should particular problems arise which are not covered sufficient-
ly for the purchaser’s purposes, the matter should be referred to the local Siemens Sales Office. c) Is trained in rendering first aid.
Dangerous voltages are present in the equipment which can cause severe personal injury and
product failure. Always de-energize and ground the equipment before maintenance. Maintenance
should be performed only by qualified personnel. DANGER
The use of unauthorized parts in the repair of the equipment, tampering by unqualified personnel or
removal or alteration of guards or conduit covers will result in dangerous conditions which can cause For the purpose of this manual and product labels, DANGER indicates death, severe personal
severe personal injury or equipment damage. Follow all safety instructions contained herein. injury or substantial property damage will result if proper precautions are not taken.
WARNING
For the purpose of this manual and product labels, WARNING indicates death, severe personal
injury or substantial property damage can result if proper precautions are not taken.
CAUTION
For the purpose of this manual and product labels, CAUTION indicates minor personal injury or
property damage can result if proper precautions are not taken.
6 3
BEARING LUBRICATION
CAUTION
Do not lubricate motor while in operation, since excess grease will be forced through the bearings
and into the motor before it will force its way out of the drain plug. Excess grease accumulation
TABLE OF CONTENTS on windings reduces insulation life.
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bearing life is assured by maintaining proper alignment, proper belt or chain tension, and good
lubrication at all times.
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Prior to shipment, motor bearings are lubricated with the proper amount and grade to provide six
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 months of satisfactory service under normal operation and conditions.
VOLTAGE REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 For best results, grease should be compounded from a polyurea base and a good grade of petro-
leum oil. It should be of No. 2 consistency and stabilized against oxidation. Operating tempera-
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ture range should be from -15°F to +250°F for class B insulation, and to +300°F fir class F and H.
• BEARING LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Most leading oil companies have special bearing greases that are satisfactory.
• INSULATION RESISTANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
• CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Relubricate bearings every six months (more often if conditions require), as follows:
1. Stop the motor. Lock out the switch.
VERTICAL MOTOR THRUST BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. Thoroughly clean off pipe plugs and remove from housings.
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3. Remove hardened grease from drains with stiff wire or rod.
4. Add grease to inlet with hand gun until small amount of new grease is forced out of drain.
5. Remove excess grease from ports, replace inlet plugs, and run motor 1/2 hour before replac-
ing drain plug.
6. Put motor back in operation.
These instructions do not purport to cover all details or variations in equipment, nor to provide for
every possible contingency to be met in connection with installation, operation or maintenance.
Should further information be desired or should particular problems arise which are not covered suf- INSULATION RESISTANCE
ficiently for the purchaser’s purposes, the matter should be referred to the local Siemens Sales Office. Check insulation resistance periodically. Any approved method of measuring insulation resistance
may be used, provided the voltage across the insulation is at a safe value for the type and condi-
The contents of this instruction manual shall not become part or modify any prior or existing agree- tion of the insulation. A hand cranked megger of not over 500 volts is the most convenient and
ment, commitment or relationship. The sales contract contains the entire obligation of Siemens. The safest method. Standards of the Institute of Electrical and Electronics Engineers, Inc. (IEEE) rec-
warranty contained in the contract between the parties is the sole warranty of Siemens. Any state- ommended that the insulation resistance of stator windings at 75°C, measure at 500 volts DC, after
ments contained herein do not create new warranties or modify the existing warranty. one minute should not be less than:
Rated voltage of machine + 1000 = Insulation resistance in Megohms
1000
This formula is satisfactory for most checks. for more information, see IEEE Standard No. 43,
“Recommended Practice for Insulation Resistance Testing of AC Rotating Machinery.”
2 7
Motors and Drives Division
14000 Dineen Drive
Installation • Operation • Maintenance

CLEANING
WARNING Instructions
Do not attempt to clean motor while it is operating.. Contact with rotating parts can cause severe
personal injury or property damage. Stop the motor and lock out switch before cleaning.
The motor exterior must be kept free of oil, dust, dirt, water, and chemicals. For fan cooled motors,
it is particularly important to keep the air intake openings free of foreign material. Do not block air
outlet or inlet.
On non-explosion-proof TEFC motors, a removable plug in the bottom center of the motor frame
or housing permits removal of accumulated moisture. Drain regularly.
VERTICAL MOTOR THRUST BEARINGS

Top bearings — high external thrust from the driven unit is usually carried by he top bearing or
bearings. If replacement is necessary, the new bearing must be the same size and type as the orig-
inal. Duplex bearings must also be the same type and mounted in an identical manner. When
angular contact type bearings are replaced, the new bearing must have the same thrust capacity.
Bottom bearings — grease lubricated lower bearings adequately lubricated at the factory for at
least three months operation. The relubrication procedure is the same as outlined above under
“Bearing Lubrication.” It is important to maintain the lower cavity full of grease at all times.
The correct replacement bearings are given on the nameplate by AFBMA (Anti-Friction Bearing
Manufacturers Association) number.
SERVICE
For immediate action on your motor problems call your certified service center or contact your
nearest Siemens District Office.

Industrial Products Division
14000 Dineen Drive
Induction Motors
© 2001 Siemens Energy & Automation, Inc. Bulletin NMIM-L1000 143-449 Frame NMIM-L1000
IM0606TI Printed in U.S.A.

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OPERATION and

PC-5-47 PipeCatTM LAYDOWN SYSTEM

Serial No.: DPH-092/DPH-093/DPH-094/

DOCUMENT NO. Rev.

All RIGHTS RESERVED

01 12.05.2012 Final Documentation MSH BMR/CJK IC

3. STORAGE AND PRESERVATION 11

6. RIG UP/RIG DOWN 28

7. START UP/POWER DOWN PROCEDURES 31

9. CONTROL LAYOUTS AND DESCRIPTIONS 37

10. MAINTENANCE AND LUBRICATION 49

11. GENERAL ROLLER CHAIN MAINTENANCE 55

13. TIGHTENING TORQUE GUIDE 68

14. SENSOR INFORMATION 72

15. SPARE PARTS 74

16. DRAWINGS 103

17. VENDOR INFORMATION 107

1.1 Manual Overview and Scope

1.2 Warranty Information

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

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

1.3 Warranty Limitations

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

1.4 Equipment Service Life

1.5 Content and Accuracy of Information

This manual is not intended as a textbook on mechanics, electronics, or hydraulics. The

Operators, maintenance personnel, and service technicians should study the

2.1 Safety Terms and Conventions

WARNING: A Warning provides a specific procedure or additional

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

2.2 Basic Safety Precautions

The PipeCatTM laydown system is designed to minimize mechanical dangers.

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

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

WARNING: Set up an exclusion zone to keep all personnel a safe distance

3. STORAGE AND PRESERVATION

3.1 Storage and Preservation

NOTE: Preservation done by National Oilwell Varco at the time of shipping is

4.1 General Information

4.2 Technical Specification

Technical Specification (Continued)

5.1 Major Components Overview

• Computer Control System (CCS)/ • HPU Power Pack

Refer to Figure #1 for further information.

5.2 Computer Control System (CCS)/ Local Control Station (LCS)

5.3 Power Control Cabinet (PCC)

5.4 Wireless Radio Control (WRC)

5.5.1 Safety Curtain

A safety curtain consisting of through-beam sensors is installed on the PipeCatTM

5.5.2 Pipe Racks

Refer to the “PipeCatTM” Operational Layout ~ Pipe Racks/Kickers/Indexers, drawing

There are two sets of indexers contained

5.6 HPU Power Pack

Refer to HPU Assembly – High Ambient/460V, drawing M231006892-ASM-001 and

The major components of the hydraulic tank assembly consist of:

The major components of each hydraulic pump assembly consist of:

5.7 V-Door Ramp

5.8 Trough Lift Winch

The major components of the winch assembly include:

When the winch is stopped, it is automatically locked in