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Manual TD GDS

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100% found this document useful (1 vote)
3K views417 pages

Manual TD GDS

Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 417

65 0 T O N T O P D R I V E

650/850 TON TOP DRIVE

Training Manual

GDS International 9841 Windmill Park Lane Houston, Texas 77064


www.globaldrillingsupport.com
1
GDM 650 Ton TOP DRIVE

OPERATIONS AND MAINTENANCE


MANUAL

2
G D M 5 0 0 / 6 5 0 T O P D R I V E

Table of Contents

Section 1 – General ....................................................................................................4


Using this Manual
Top Drive Specifications
Torque Data

Section 2 – Operations ...............................................................................................9


Top Drive Console
HMI Touch Screens

Section 3 – Maintenance and Inspection..................................................................33


Top Drive Maintenance Diagram
Maintenance
Inspection
Maintenance Checklist
Load Path Inspection Drawings

Section 4– Rig Up Procedure .............................................................................................. 63

Section 5 – Drawings and Parts.................................................................................74


5A - Assembly Drawings
5B – Electrical Schematics

Section 6 – OMRON ......................................................................................................... 166

Section 7 – HPU -WILSON .............................................................................................. 254

Section 8 – WAGO............................................................................................................. 381

3
G D M 650 / T O P D R I V E

1
Section

T he GDM (Global Drilling Machine) line of Top Drives solves many of the problems that
reduce the performance and reliability of conventional Top Drive models. The GDM line of
Top Drives offers a simple, robust mechanical design that minimizes failure points, provides
improved torque and RPM for increased performance, and allows easier access to maintenance
zones.

General
Contents
Using this Manual......................................................5
Top Drive Specifications..........................................6
Torque Data................................................................9

4
G D M 5 6 5 0 T O P D R I V E

Using this Manual


This manual is organized as follows:

Section Description

Contains an outline of this manual and defines precautionary terms; also describes
1 – General
Top Drive specifications, and how to find information.

2 – Operations Instructions for operating the Top Drive Console and HMI Touch Screens.

3 – Maintenance and
Describes maintenance and inspection requirements and routines.
Inspection

Contains assembly drawings and electrical, gear lube, and hydraulic schematics.
4 – Drawings and
Parts shown in drawings are outlined in their respectively allocated Bills of
Parts
Material.

5 – Certifications Certificate of Conformance and GDS’s API License and Certifications.

Important Safety Information


Throughout this manual, the following precautionary terms are used. It is imperative that their meanings
are fully understood before proceeding:

WARNING – This term immediately precedes or follows any procedural instruction or


information which, if not properly adhered to, poses the potential to cause personnel injury or
death.

CAUTION – This term refers to any technique or procedure which, if not properly adhered to,
poses the potential to cause damage to parts or equipment—up to and including catastrophic
failure.

NOTE – This term is used liberally to emphasize important information.

5
G D M 6 5 0 T O P D R I V E

Top Drive Specifications


GDM 500/650 AC

Static Hoist Rating 500 Short Tons 650 Short Tons


Drilling Electric Motor GEB20
Maximum Continuous Current 1185 Amps
Maximum Intermittent Current 1470 Amps (15 Seconds)
Maximum Voltage 575 Volts
Frequency Range 0 to 117 Hz
Cooling System 15 HP Local Blower 3900 CFM
Continuous HP Rating 800 HP 1150 HP
Gear Ratio 8.7059 : 1
Continuous Torque Rating 45,000 Ft-Lbs. 55,000 Ft-Lbs.
Maximum Torque Rating 75,000 Ft-Lbs. 65,000 Ft-Lbs.
Brake Capacity 50,000 Ft-Lbs.
Maximum Connection Break Out Torque 80,000 Ft-Lbs. 75,000 Ft-Lbs.
Pipe Clamp Capacity 110,000 Ft-Lbs.
Pipe Handler Orientation 360˚/Unlimited – Comes with Lock
Quill Connection 6-5/8” Reg. 7-5/8” Reg.
Mud Passage Diameter 3”
Mud Passage Maximum Circulating PSI 5,000 PSI (7,500 PSI Opt.)
Remote Actuated IBOP 10,000 PSI
Manual Actuated IBOP 10,000 PSI
Counterbalance Travel 7.25”
Hook Weight 34,000 Lbs.
Lubrication System 2HP 5GPM Flow

6
G D M 6 5 0 T O P D R I V E

Top Drive Specifications


GDM 500/650 DC

Static Hoist Rating 500 Short Tons 650 Short Tons


Drilling Electric Motor GE 752
Maximum Continuous Current 1185 Amps
Maximum Intermittent Current 1435 Amps (15 Seconds)
Maximum Voltage 750 Volts DC
Frequency Range 0 to 117 Hz
Cooling System 15 HP Local Blower 3900 CFM
Continuous HP Rating 800 HP 1150 HP
Gear Ratio 8.7059 : 1
Continuous Torque Rating 45,000 Ft-Lbs. 55,000 Ft-Lbs.
Maximum Torque Rating 75,000 Ft-Lbs. 65,000 Ft-Lbs.
Brake Capacity 50,000 Ft-Lbs.
Maximum Connection Break Out Torque 80,000 Ft-Lbs. 75,000 Ft-Lbs.
Pipe Clamp Capacity 110,000 Ft-Lbs.
Pipe Handler Orientation 360˚/Unlimited – Comes with Lock
Quill Connection 6-5/8” Reg. 7-5/8” Reg.
Mud Passage Diameter 3”
Mud Passage Maximum Circulating PSI 5,000 PSI (7,500 PSI Opt.)
Remote Actuated IBOP 10,000 PSI
Manual Actuated IBOP 10,000 PSI
Counterbalance Travel 7.25”
Hook Weight 34,000 Lbs.
Lubrication System 2HP 5GPM Flow

7
G D M 6 5 0 T O P D R I V E

Torque Data

8
G D M 650 / T O P D R I V E

Section

Operations
2
Contents
Top Drive Console..............................................................11
Figure 1-Top Drive Console
LED Indicator Lights (L1-L4)
Alarm Reset (PB1)
Top Drive Lockout (PB2)
Handler Bypass (PB3)
E-Stop (PB4)
Backup Wrench/BUW (PB5)
Hydraulic Power Unit Selection Switch (SW1)
Brake Switch (SW2)
Top Drive Enable Selection Switch (SW3)
Stand Jump Switch (SW4)
IBOP Switch (SW5)
Top Drive Mode Selection Switch (SW6)
Limit Selection Switch (SW7)
Limit Adjustment Switch (SW8)
Top Drive Handler Joystick (JS1).......................................19
Figure 2 – Top Drive Handler Joystick (JS1)
Link Tilt Joystick (JS2).......................................................19
Figure 3 – Link Tilt Joystick (JS2)
Top Drive Motor Control Joystick (JS3) ..........................20
Figure 4 – Top Drive Motor Control Joystick (JS3)
Top Drive Console Analog Gauges...................................20
Directional Controls ..........................................................21
Drill Mode
Torque Mode

9
G D M 650 / T O P D R I V E

HMI Touch Screens..........................................................23


HMI Main Screen
Figure 5 – Main Screen
HPU Pump Selection........................................................24
Top Drive HPU E-Stop
Additional Features...........................................................25
Bypass Pipe Handler Lock
Torque and Speed Settings and Limits............................26
Automatic Pipe Handler...................................................27
Top Drive Remote Motor Control via HMI.....................28
Drill Mode
Torque Mode
Top Drive Remote Pipe Handler via HMI......................31
Testing & Configuration Screen .....................................32
Switches
Push Buttons

10
G D M 650 / T O P D R I V E

Top Drive Console

Figure 1 – Top Drive Console

Following is a description of the Top Drive Console and its functional controls:

LED Indicator Lights (L1 – L4)

Green lamp illuminates when TD Enable switch is placed from OFF to the
Drill Enabled (L1)
DRILL position.

HPU Alarm (L2) Amber lamp illuminates when the HPU fluid level is low.

Lube Oil Alarm (L3) Red lamp illuminates when gear oil pressure drops below acceptable limit.

Amber lamp illuminates when main drilling motor temperature exceeds


Motor Temp (L4)
acceptable limit.

11
G D M 650 / T O P D R I V E

Alarm Reset (PB1)

Indicates that an alarm exists. PB1 is a spring-return, red translucent push button
Illuminated over an indicator lamp. Depressing the button will reset Top Drive alarms to
determine whether any faults still exist.

Indicates that there are no current Top Drive alarms. This can also be verified in
Extinguished the Active Status Summary block at the top right-hand corner of any HMI screen.

PB1 is also a tool that the Top Drive Console operator should use before
assuming ownership of the Top Drive. Push and hold the button for five
CAUTION seconds to test all indicator lamps and gauges for functionality. Failure to do so
may result in—for example—overlooking an inoperative lamp bulb that would
otherwise warn of potential equipment damage.

Top Drive Lockout (PB2)

Shuts off all electrical power to the Top Drive and disables all Top Drive
Depressed functions. PB2 is a red spring-return push button with a mechanical depression
device that allows a physical lock to be inserted so that button cannot be released.

Released Enables the VFD to allow ownership of the Top Drive.

12
G D M 650 / T O P D R I V E

Handler Bypass (PB3)

PB3 is a spring-return translucent red push button used for timed-override of


Handler Lock Proximity Sensor feedback control. This function is designed for
use in the event of a sensor or circuit malfunction. The button illuminates when
depressed and held for 3 seconds, and will remain illuminated during the 30-
Illuminated second window that the override is permitted. MAKE UP and BREAK OUT
functions are activated during this time, however this places responsibility in the
hands of the operator to ensure that the Handler is physically locked before
making or breaking connections. Use of the bypass is logged in case of incident.

Extinguished Indicates normal operation.

USE EXTREME CAUTION WHEN USING THIS FEATURE.


IT IS IMPERATIVE THAT THE OPERATOR ENSURES THROUGH
VERIFICATION THAT THE HANDLER IS PHYSICALLY LOCKED
WARNING BEFORE ATTEMPTING TO MANIPULATE ANY CONTROLS.
FAILURE TO DO SO MAY RESULT IN CATASTROPHIC
EQUIPMENT FAILURE, SEVERE INJURY, OR DEATH.

E-Stop (PB4)

PB4 is a 2-position (in/out) translucent red button with a steel shroud. When
depressed, the button illuminates and shuts off all electrical power to the Top
Drive—disabling all Top Drive functions by:
Depressed
► Tripping the VFD breaker on GDS supplied VFD units
► Tripping the feeder breaker at the GDP panel

Pulled Out Normal Top Drive operation.

13
G D M 650 / T O P D R I V E

Backup Wrench / BUW (PB5)

PB5 is a black spring-return push button, activated when the Mode Select switch
Depressed on the Top Drive console is in the TORQUE position. Push and hold PB5 to
engage the BUW clamp.

Released Retracts the BUW clamp piston.

Note The BUW function is NOT interlocked with the Drawworks.

CAUTION DO NOT OPERATE DRAWWORKS WITH BUW CLOSED.

Hydraulic Power Unit Selection Switch (SW1)

SW1 is a translucent green 3-position maintained switch (HPU1 / OFF / HPU2).


Selecting HPU 1 energizes the motor starter for HPU # 1, charging the main hydraulic
HPU 1 manifold on the Top Drive to allow hydraulic functions when enabled. Drill and Trip
screens on the HMI will indicate that HPU 1 is running.

Off De-energizes HPU 1 and 2 motor starters, removing available hydraulic power.

HPU 2 Energizes the motor starter for HPU # 2.

Only one HPU motor will run at a time. If HPU 2 is selected while HPU 1 is
Note running, HPU 1 will first shutdown before HPU 2 starts. Either HPU may run
continuously.

14
G D M 650 / T O P D R I V E

Brake Switch (SW2)

SW1 is a translucent red 2-position maintained switch (OFF / ON). In the


OFF position, it allows the Top Drive to rotate freely. Brakes are
Off hydraulically applied, spring released. The HPU must be on in order for
the brake to release when turned from ON to OFF.

On Brakes will engage.

Brakes will remain released during Torque and Spin operations; Brake
Note position is indicated on the HMI as ON or OFF in the Drill, Trip, and
Remote Operation screens.

Top Drive Enable Selection Switch (SW3)

The HMI’s Drill, Trip, and Remote Operation screens will indicate that
Trip Top Drive tripping is enabled; allows the operator to actuate all
hydraulic functions. Enables tripping and hydraulic functions.

The HMI’s Drill, Trip, and Remote Operation screens will indicate that
Top Drive drilling is enabled; allows the operator to utilize Drilling and
Drill Torque functions. Lube Pump motor will start. Top Drive Status
display will indicate Top Drive Enable Faulted if all drill enable
conditions are not met. Enables all Console functions.

The drill motor blower is automatically activated when motor reaches


Note 150˚F.
Lube Pump operates continuously while in Drill Mode.

15
G D M 650 / T O P D R I V E

Stand Jump Switch (SW4)

SW4 is a black 2-position maintained switch (OFF / ON) with a white position-
Off indicating stripe across the knob. In the OFF position, the Stand Jump function is
disabled.

On Enables the Stand Jump function only in Torque Mode.

IBOP Switch (SW5)

SW5 is a translucent amber 2-position maintained switch (OPEN / CLOSE).


Open Selecting OPEN will open the remote-actuated IBOP.

Close Closes the remote-actuated IBOP.

Valve status is indicated as OPEN or CLOSED on the HMI Drill and Trip
screens. Indicated valve status is based on both the IBOP switch position and the
Note HPU status. There is no positive feedback on actual valve status and visual
verification of valve position is recommended.

WARNING Do not start Mud Pumps with the IBOP in CLOSED position.

16
G D M 650 / T O P D R I V E

Top Drive Mode Selection Switch (SW6)

SW6 is a black 3-position maintained switch (REV / DRILL / TORQUE) with a


white position-indicating stripe across the knob. The REV position allows the
Reverse Top Drive to run in reverse (counterclockwise) to a maximum of 100 RPM, as
commanded through the operator’s TD Motor Control Joystick.

Drill Enables normal Drill operations (clockwise).

Torque Allows for BUW / Make & Break operations.

Limit Selection Switch (SW7)

SW7 is a black 3-position spring-loaded return-to-center switch (RPM / neutral or


centered / TORQUE) with a white position-indicating stripe across the knob.
RPM Holding the switch in RPM mode allows the operator to simultaneously
manipulate the Limit Adjustment Switch knob to set desired tool speed.

Holding the switch in TORQUE mode allows the operator to simultaneously


Torque manipulate the Limit Adjustment Switch knob to set desired torque.

Used in conjunction with Limit Adjustment Switch (SW8).


Switch Position Function
SW6-Drill, SW7 RPM = Drill Preset RPM
SW6-Drill, SW7 Torque = Drilling Max Torque
Note SW6-Torque, SW7 RPM = Spin in/Out RPM
SW6-Torque, SW7 Torque = Make-Up Torque
SW6-Rev, SW7 RPM = N/A
SW6-Rev, SW7 RPM = Reverse Torque

17
G D M 650 / T O P D R I V E

Limit Adjustment Switch (SW8)

SW8 is a black 3-position spring-loaded return-to-center switch (DEC / neutral or


centered / INC) with a white position-indicating stripe across the knob. While
holding the Limit Selection switch (SW7) in either RPM or TORQUE mode, the
Decrease operator can toggle or ‘bump’ SW8 between neutral center and the DEC position
repeatedly to decrease any previously set speed or torque limit by increments of
10. Holding SW8 in the DEC position while SW7 is enabled will quickly decrease
the desired set limit to zero.

While holding the Limit Selection switch (SW7) in either RPM or TORQUE
Increase mode, the operator can toggle or ‘bump’ SW8 between neutral center and the INC
position repeatedly to increase desired speed or torque limits by increments of 10.

Note Used in conjunction with Limit Selection switch (SW7).

18
G D M 650 / T O P D R I V E

Top Drive Handler Joystick (JS1)

Figure 2 – Top Drive Handler Joystick (JS1) function diagram

Link Tilt Joystick (JS2)

Figure 3 – Link Tilt Joystick (JS2) function diagram

19
G D M 650 / T O P D R I V E

Top Drive Motor Control Joystick (JS3)

Figure 4 – Top Drive Motor Control Joystick (JS3) function diagram

Top Drive Console Analog Gauges

The Top Drive Console RPM gauge may be one of two types:
► Traditional analog gauge, RPM from 0 – 250 in two-revolution increments,
with large tic marks in 10 RPM intervals and numerical values printed in
Tachometer increments of 20.
► Optimized analog gauge with backlit scale and a small digital display window,
RPM from 0 – 250 in five-revolution increments, with large tic marks and
numerical values in increments of 25.

The Top Drive Console Torque gauge may be one of two types:
► Traditional analog gauge, torque range from 0 – 100,000 Ft. Lbs. in 1,000#
Torque Meter increments, with bold tic marks in 5,000# intervals and numerical values printed
in increments of 10,000.
► Optimized analog gauge with backlit scale and a small digital display window,
torque range from 0 – 100,000 Ft. Lbs. in 1,000# increments, with large tic marks
in 5,000# intervals and numerical values displayed in increments of 10,000.

20
GDM 650 TON TOP DRIVE

Directional Controls
Drill Mode

Bumping the joystick UP will increase speed in increments of 1 RPM. Holding the
joystick in the upward position will increase speed until the maximum RPM limit is
reached.
Up
(Increase Releasing the joystick will not decrease speed. If the joystick is released, the speed
Speed) will be maintained at the value it was at before it was released.
With the Top Drive mode in Drill Reverse, the operation will be the same, but
rotation will be in the Reverse direction and limited to a maximum of 100 RPM.

Bumping the joystick DOWN will decrease speed in increments of 1 RPM. Holding
the joystick in the downward position will decrease speed until Zero speed is
reached.
Down
(Decrease If the joystick is released, the speed will be maintained at the value it was at before it
Speed) was released.
With the Top Drive mode in Drill Reverse, the operation will be the same, but
rotation will be in the reverse (counterclockwise) direction.

Moving the joystick RIGHT will enter the preset speed value (preset value is
Right displayed and modified on HMI) into the speed reference. The Top Drive speed
(Preset will ramp up or down, as applicable, until its preset value is achieved.
Speed)
When the joystick is released, speed will be maintained at its preset value.

Left Toggling the joystick LEFT will ramp the Top Drive speed down to Zero speed.
(Zero Operation is the same in both forward and reverse.
Speed)

21
GDM6 50 TON TOP DRIVE

Torque Mode

Make up should only be used once the joint is shouldered up with Spin In first.
Holding the Top Drive Motor Control Joystick UP (Make Up) with DRILL
Up enabled (SW3) and TORQUE mode selected (SW6) will rotate the Top Drive
(Make Up) forward at a maximum 5 RPM as long as you are holding the joystick UP.
The torque will be limited to the set Make Up limit, which is adjusted on the HMI
or console.

Proper sequence should be: (1) Hold the joystick DOWN (Break Out) until the
joint breaks, and then (2) move the joystick right (Spin Out or Spin Out Maintain)
until the joint has spun out.
Holding the Top Drive Motor Control Joystick DOWN (Breakout) with DRILL
Down enabled (SW3) and TORQUE mode selected (SW6) will rotate the Top Drive
(Break Out) reverse at a maximum 5 RPM as long as you are holding the joystick .
The torque will be limited to 80,000 Ft. Lbs.
There is no preset value available for Break Out Torque. The torque will continue
to ramp up until the connection breaks or the capacity of the equipment has
reached its limit.

Holding the joystick RIGHT (Spin Out) with DRILL enabled (SW3) and
TORQUE mode selected (SW6) will rotate the Top Drive at the preset spin speed
in the reverse direction (Spin Speed value is displayed and modified on HMI or
console).
Right When the joystick is released, the Top Drive will stop rotating.
(Spin Out)
Tap the joystick twice to the RIGHT within 2 seconds to maintain Spin Out. Top
Drive will be in Spin Out Maintain when joystick is released. Move joystick to
opposite position (spin in) to stop spin maintain rotation and allow the shaft to
coast to a stop.

22
GDM6 50 TON TOP DRIVE

HMI Touch Screens


Main Screen

Figure 5 –Main Screen

Upon power up of the system, the Main Screen (see Figure 5) appears first.

In the top right-hand of the screen, the date and time appear under the GDS logo, and an active
status summary is highlighted in green. Any active alarm lock-outs or interlocks would display here,
highlighted in red. This feature appears on every screen.

The Main Screen serves as a dashboard to the functional operation and troubleshooting of the Top
Drive.

23
GDM6 50 TON TOP DRIVE

HPU Pump Selection

The Hydraulic Power Unit (HPU) supplies hydraulic pressure to the Top Drive.
The HPU has two pumps; only one pump runs at any given time.
Either pump can be run continuously or on-demand (as hydraulic power is needed).

HPU 1 will start when the button is toggled.


The HMI will indicate if HPU 1 is running properly. If there is a problem
with HPU 1, a fault will be displayed on the HMI, such as:
HPU 1 ON
 HPU 1 not running (tripped).
 Low hydraulic oil level.
 High hydraulic oil temperature.

HPU 1 will stop when the button is toggled. If HPU 1 is running and HPU
HPU 1 OFF 2 is started, HPU 1 will shut off first.

HPU 2 Operation is the same as HPU 1.

Top Drive HPU E-Stop


When the HPU E-stop is pressed, this will prevent either HPU pump from operating under any conditions
and the HMI will indicate that the HPU E-Stop has been pressed.

24
GDM6 50 TON TOP DRIVE

Additional Features

Starts a 30-second timer after button has been depressed for 2 seconds. This
30- second window will allow TORQUE mode functions to be permitted,
even if the system cannot determine that the Handler is positively locked.
Normally this feature would only be used in the event of a Handler Lock
sensor failure. The Handler Lock HMI Fault indicator will turn on for 30
Bypass Pipe seconds. Normal Handler Lock operation will resume after 30 seconds. Use
Handler Lock of the Bypass is logged in case of incident.
WARNING: USE EXTREME CAUTION WHEN USING THIS
FEATURE TO ENSURE THAT THE HANDLER IS
PHYSICALLY LOCKED, OR DAMAGE, SEVERE INJURY OR
DEATH MAY RESULT.

25
GDM6 50 TON TOP DRIVE

Torque and Speed Settings and Limits

This feature is normally used when the Top Drive is stalled. Press the
Torque Ramp Down push button to unwind the torque.
When you first press this push button, the speed will be reduced to 15 RPM
and the torque will unwind (ramp down) to zero as long as the button
Torque Ramp remains pushed.
Down
When you release the push button, the torque will remain at the current
level.
You have two options now: 1) you can zero the speed reference and begin
normal drilling, or 2) you can press the Torque Restore push button.

This feature is normally used when the Top Drive is stalled.


After you use the Torque Ramp Down push button (to unwind torque), you
Torque Restore can press the Torque Restore button to restore the Torque Limit to the Drill
Limit Set Point. The speed reference will remain at 15 RPM until you
increase or use the preset with the joystick.

Drill Speed Preset adjustable from 0 to 200 RPM.


Speed Preset Can be adjusted on either the Drilling screen or the Remote Operation
screen.

Spin Speed adjustable from 5 to 40 RPM.


Spin Speed Can be adjusted on either the Drilling screen or the Remote Operation
screen.

Make up Torque Limit adjustable from 0 to 65,000 ft/lbs.


Make Up Can be adjusted on either the Drilling screen or the Remote Operation
screen.

Drill Torque Limit adjustable from 0 to 55,000 ft/lbs.


Drill Limit Can be adjusted on either the Drilling screen or the Remote Operation
screen.

Spin Torque Limit adjustable from 2,000 to 6,000 ft/lbs.


Spin Limit Can be adjusted on either the Drilling screen or the Remote Operation
screen.

26
GDM6 50 TON TOP DRIVE

Automatic Pipe Handler

This is intended to allow the driller to automatically move the Pipe Handler
to any one of four preset Pipe Handler positions, depending on which
positions are activated.

Automatic Mode can be turned on/off from the Drill, Trip, and Remote
Operation screens.

The Automatic Pipe Handler can be operated from the Drill, Trip, and
Remote Operation screens as well as from the Pipe Handler Joystick.

Set points can only be changed from the Trip screen, but all positions can
be activated or de-activated from the Drill or Trip screens.
Auto Mode
At 0, the Elevators should be pointing directly at the racking board. At
180, the Pipe Handler will be in Drill mode (Elevator handles pointed
towards the Drawworks).

To set the Pipe Handler position, use the joystick with the Pipe Handler in
Manual mode. Rotate the Pipe Handler to the Trip position (Elevators
pointed directly at the racking board) and press and hold the Zero PH
position PB for 2 seconds.

See the Pipe Handler Help Screen on the HMI for a detailed description of
each PB and display.

When the Automatic Pipe Handler is in Automatic mode, the Joystick Pipe
Joystick Operation Handler Unlock push button and LEFT and Right joystick movements
work the same as the HMI LEFT and RIGHT push buttons.

When the Automatic Pipe Handler is in Automatic mode, the Remote Pipe
Remote Operation Handler Unlock push button and LEFT and RIGHT Joystick push buttons
work the same as the HMI LEFT and RIGHT push buttons.

27
GDM6 50 TON TOP DRIVE

Top Drive Remote Motor Control via HMI

Activate
Activating Remote Motor Control will enable the HMI Remote Operation and
Remote Motor
disable the joystick from functioning.
Joystick

Toggling the Top Drive Motor Control Joystick Drill Reverse push button will
toggle the Top Drive Motor direction between Forward and Reverse; this button
PB1 is active only if the Top Drive Mode is selected to DRILL mode.
(Black -Drill
Reverse) The Top Drive Mode Indication on the HMI - Drill, Trip, and Remote
Operation Screens will indicate Top Drive In DRILL mode or Top Drive in
DRILL REVERSE.

Toggling the Top Drive Remote Motor Control BUW Close push button will
activate the BUW to Close. To lock the BUW, depress twice within one second.
PB2
(Red -BUW
Once the BUW is Closed, perform Torque function. When torque ft-lbs reaches
Close)
0, manually release BUW by depressing button again twice within one second.

Toggling the Top Drive Remote Motor Control Spin Maintain push button with
DRILL enabled and selected to TORQUE mode will give you a 2 second
PB3
window to toggle the joystick left or right (Spin In or Spin Out).
(Yellow -Spin
Maintain)
Spin In or Spin Out will be latched on to rotate the Top Drive in SPIN Mode
indefinitely until the joystick is moved in the opposite direction again.

Toggling the Top Drive Motor Control Joystick Torque/Drill push button will
toggle the Top Drive Motor Control Joystick Between DRILL and TORQUE
PB4 modes.
(Green -
Torque/Drill) This will change the functionality of the joystick. The Top Drive Mode
Indication on the HMI Drill, Trip, and Remote Operation Screens will indicate
Top Drive In TORQUE mode or Top Drive in DRILL mode.

28
GDM6 50 TON TOP DRIVE

Drill Mode

Pressing the Joystick UP will increase speed, as long as you keep the joystick button
pressed until maximum speed is reached.
Up
If the Joystick UP push button is released at any time, the speed will be maintained at
(Increase
the value it was at prior to release.
Speed)
With the Top Drive Mode in DRILL REVERSE, the operation will be the same but
rotation will be in the Reverse direction and limited to a maximum of 100 RPM.

Pressing the Joystick DOWN push button will decrease speed, as long as you keep the
joystick button pressed until Zero speed is reached.
Down
If the joystick is released at any time, the speed will be maintained at the value it was at
(Decrease
prior to release.
Speed)
With the Top Drive Mode in DRILL REVERSE, the operation will be the same but
rotation will be in the Reverse direction.

Pressing the Joystick RIGHT push button will enter the preset speed value into the
speed reference, and the Top Drive will ramp up speed until the preset value is
achieved.
Right
(Preset Speed)
If the preset value is lower than the actual speed when the Joystick RIGHT push
button is pressed to the right, the speed will ramp down to the preset value.

When the joystick is released, the speed will be maintained at the preset value.

Left Toggling the Joystick LEFT push button will ramp the Top Drive speed down to Zero
(Zero Speed) speed.

29
GDM6 50 TON TOP DRIVE

Torque Mode

Make Up should only be used once the joint is shouldered up with Spin in first.

Holding the Top Drive Motor Control Joystick UP PB (Make Up) with DRILL
Up enabled and selected to TORQUE mode will rotate the Top Drive forward at a
(Make Up) maximum 5 RPM as long as you are holding the Joystick UP PB.

The torque will be limited to the set Make Up limit, which is adjusted on the HMI
and Console Gauge.

Proper sequence should be: Break Out until the joint breaks, press the Joystick
RIGHT PB (Spin Out or Spin Out Maintain) until the joint has spun out.

Down Holding the Top Drive Motor Control Joystick DOWN PB (Breakout) with
(Breakout) DRILL Enabled and selected to TORQUE mode will rotate the Top Drive
Reverse at the Spin Speed as long as you are holding the joystick DOWN.

The torque will be limited to the maximum connection torque listed in the specs.

Holding the Top Drive Motor Control Joystick RIGHT PB (Spin Out) with
DRILL enabled and selected to TORQUE mode will rotate the Top Drive at the
Preset Spin Speed in the reverse direction (Spin speed value is displayed and
Left modified on HMI).
(Spin In)
When the Joystick PB is released, the Top Drive will stop rotating. If the Spin
Maintain push button is toggled first, and Spin Out is toggled within 2 seconds, the
Top Drive will be in Spin Out Maintain when Joystick PB is released.

Holding the Top Drive Motor Control Joystick LEFT PB (Spin in) with DRILL
enabled and selected to TORQUE mode will rotate the Top Drive at the Preset
Spin Speed in the forward direction (Spin speed value is displayed and modified on
Right HMI).
(Spin Out)
When the Joystick PB is released, the Top Drive will stop rotating. If the Spin
Maintain push button is toggled first, and Spin In is toggled within 2 seconds, the
Top Drive will be in Spin In Maintain when Joystick PB is released.

30
GDM6 50 TON TOP DRIVE

Top Drive Remote Pipe Handler via HMI

Activate
Activating Remote Pipe Handler will enable the HMI Remote Operation and
Remote Pipe
disable the joystick from functioning.
Handler

Toggling the Top Drive Remote Pipe Handler Pipe Handler Unlock push button will
activate the Pipe Handler Lock to UNLOCK.
PB3
(Yellow -
The Pipe Handler will stay unlocked for 3 seconds, unless the Pipe Handler is
Pipe Handler
rotated, in which case the Pipe Handler will remain unlocked as long as the
Unlock)
Handler is rotated.
When rotation has stopped, the Handler will automatically lock after 3 seconds.

Toggling the Top Drive Remote Pipe Handler Link Tilt Float push button will
PB4 activate the Link Tilt Cylinders to FLOAT if in Maintain, and MAINTAIN if in
(Green - Link Float.
Tilt Float)
Activating either EXTEND or RETRACT will unlatch Float.

UP
Pressing the Top Drive Remote Pipe Handler in the UP direction will activate the
(Link Tilt
Link Tilt Cylinders to EXTEND.
Extend)

Down
Pressing the Top Drive Remote Pipe Handler in the DOWN direction will activate
(Link Tilt
the Link Tilt Cylinders to RETRACT.
Retract

Left
(Pipe Toggle the Pipe Handler Unlock (PB3) first. Pressing the Top Drive Remote Pipe
Handler Handler in the LEFT direction will move the Pipe Handler in the Forward
Rotate (clockwise) direction.
Forward)
Right
(Pipe Toggle the Pipe Handler Unlock (PB3) first. Pressing the Top Drive Remote Pipe
Handler Handler in the RIGHT direction will move the Pipe Handler in the Reverse
Rotate (counter clockwise) direction.
Reverse)

31
GDM650 TON TOP DRIVE

Testing & Configuration Screen

Switches

Under normal conditions, the VFD uses encoder feedback for better torque
control. However, the Top Drive can be operating in Encoder Bypass mode,
in which the encoder feedback is ignored by the VFD.

At power up, the Bypass is deactivated. The Top Drive must be in OFF
position in order to switch between the two modes.
Encoder Bypass
The button must be held for 2 seconds before it will become functional.

WARNING: When in Bypass mode, the Top Drive torque will not be
accurate. If the Top Drive stalls while drilling, unexpected results may
occur.

Push Buttons

This feature is used for testing the third party RPM and Torque outputs.

In order to utilize this mode, the Top Drive must be in the OFF position.
Meter Test Mode When activated, whatever is entered in the Drill Limit will display on the
Torque Meter and be sent to the third party PLC Torque Analog Output.

Whatever is entered in the Drill Speed Preset will display on the RPM Meter
and be sent to the third party PLC RPM Analog Output.

Blower Restart If the Blower Motor trips while in in Auto mode, it can be restarted by this
push button, provided the OL has reset.

Lube Pump
If the Lube Pump Motor trips while in Auto mode, it can be restarted by this
Restart push button, provided the OL has reset.

32
3
Section
G D M 650 / T O P D R I V E

Maintenance and Inspection


Contents

Top Drive Maintenance Diagram .................................34


Figure 6 – Maintenance Points 1
Figure 7 – Maintenance Points 2
Figure 8 – Maintenance Points 3
Maintenance ..................................................................37
Lubrication
Hydraulic Oil
Filtration
Grease
Top Drive Gearbox
Top Drive Gearbox Oil Capacity
Figure 9 – Y Strainer
Figure 10 – Breather
Inspection ......................................................................42
Recommended Inspection Program
Quarterly or Upon Rig Move
Five Year Inspection
Inspection Following Periods of Severe Drilling
Conditions
Wear Limits
Main Bearing Pre-Load Inspection
Pinion Bearing Pre-Load Inspection
Washpipe Inspection Instructions
Top Drive Disc Brake Inspection
Manual Brake Bleeding
Maintenance Checklist...................................................49
Load Path Inspection Drawings ...................................50

33
G D M 650 / T O P D R I V E

Top Drive Maintenance Diagram


Figure 6 – Maintenance Points 1

NOTE:

See Maintenance
Checklist on Page
3-17

GDM500650 Rev. 2 34
G D M 650 / T O P D R I V E

Figure 7 – Maintenance Points 2

GDM500650 Rev. 2 35
G D M 650 / T O P D R I V E

Figure 8 – Maintenance Points 3

GDM500650 Rev. 2 36
G D M 650 / T O P DRIVE

Maintenance
Lubrication

Hydraulic Oil
Hydraulic oil that is of exceptional quality is vital to ensure acceptable performance of the GDM
500/650 Top Drive and promote long life of hydraulic system components.
Satisfactory results will be achieved in normal operating conditions when the oil in use has a
viscosity index of 100 or greater. A high viscosity index oil product will reduce cold-start issues and
minimize warm-up time. A high viscosity index will also minimize changes to viscosity that appears
with changes in temperature. Cold weather start-up viscosity should not exceed a maximum of 5000
SUS with a pour point of at least 20°F lower than the minimum ambient temperature.
It is recommended that anti-wear type hydraulic oils be utilized. These oils are generally developed
and evaluated on the basis of pump wear tests, such as ASTM-D2882. They offer superior
protection against pump and motor wear, provide resistance to emulsification, and offer corrosion
protection.

The temperature of the oil at any point in the system


must not exceed 180°F (during continuous operations).

Hydraulic Oil General Recommendations

Ambient Temperature
ISO Grade of Oil
(°C)
-45° to -15° 15
-20° to 15° 22
10° to 35° 32
20° to 45° 46
25° to 55° 68

GDM500650 Rev. 2 37
G D M 650 / T O P DRIVE

Filtration
Filtration is the key to overall purity of the hydraulic oil and helps extend the life of components.
To ensure optimal operation of the hydraulic system, maintain a minimum cleanliness level of:

9 To NAS 1638
6 To SAE
18/15 to ISO/DIS 4406

Check the bypass indicators daily. If indicator is RED, change the filter element.
The hydraulic element should be changed every 6 months. The lube oil element should be changed
during each oil change.

GDM500650 Rev. 2 38
G D M 650 / T O P DRIVE

Grease
Use multi-purpose lithium complex grease complying with N.L.G.I. classification No.1 or No.2 at
the following:

No. of
Location Application Frequency
Fittings
Washpipe 1 To excess Every 12 hours
Elevator Tilt Plate
8 To excess Daily
Pins
Load Collar 1 10 pumps per fitting Weekly
Back-up Wrench
2 10 pumps per fitting Weekly
Grabber Cylinder
Slewing Gear 2 10 pumps per fitting Daily
3 to 4 pumps per
Actuator 4 Every 12 hours
fitting
Back Up Wrench
1 To excess Weekly
Pin
 Refer to the Top Drive Maintenance Diagram on page 3-2 for the locations of grease points.

Motor
GE Motor See manufacturer’s documentation.
Use manufacturer recommended
Motor Coupling Kop-Flex High Performance Gear Coupling Grease
Frequency: 3-years
Motor Coupling Grease Procedure
Remove 2 set screws – Install grease zerk in one,
Pump grease until grease exits open set screw hole,
If grease appears dirty – Keep pumping until clean grease appears,
Remove grease zerk and reinstall 2 set screws.

GDM500650 Rev. 2 39
G D M 650 / T O P DRIVE

Top Drive Gearbox


GDM Top Drives are designed to be used with ISO Industrial EP (Extreme Pressure) Gear Oils.
EP oils are high quality, extreme pressure compounded type oils for use in all types of industrial gear
sets, except those with built-in variable speed type friction drive mechanisms.
The use of EP ensures increased life of your GDM Top Drive, especially during periods of heavy
jarring. The EP oils give superior corrosion protection to ferrous metal surfaces and are non-
corrosive to steel, copper, brass, bronze and other common bearing materials.

Ambient
A.G.M.A
Temperature GDS Top Drive Gear Oil
Number
(°C)

25°C & Up1 EP 9005-E02 Chevron ISO Meropa 220

1 Contact OEM for recommendations for other ambient temperature ranges.

Comparable products are available in the USA from the Exxon Corporation.
Oils meeting AGMA specifications and grades shown in the above chart could be used in the GDM
500/650 Top Drive.
For approval of specific oil, contact GDS Engineering Department.
Oil should be changed at planned intervals of 90 days.
Oil should never be permitted to become visibly contaminated with mud or water, which rapidly
causes bearing failure. If there is any doubt about the oil quality, it should be changed even if a
change is not due according to the maintenance schedule.

GDM500650 Rev. 2 40
G D M 650 / T O P DRIVE

Top Drive Gearbox Oil Capacity

The GDM 500/650 Top Drive Gearbox has a gear oil capacity of approximately 20 US Gallons.
When operating a GDM 500/650 Top Drive in humid climates, or when corrosive drilling fluids are
in use (e.g., high brine content), ensure that the lube oil is checked on a weekly basis for water
contamination. Samples should also be taken for a visual confirmation.
The gearbox can be drained by removing the drain plug in the bottom of the gearbox. The magnetic
plug is located in the Y-strainer to catch small metallic wear particles. A substantial accumulation of
such particles is often an indicator of an impending bearing failure. There is also a hose that drains
the remaining oil from the lower bearing. This will remove any contamination from the bearing.
Check the breather (located on the gearbox) on a daily basis to ensure that it is not plugged; replace
the breather as required. Seal damage may occur if pressure is permitted to build up in the gearbox.

Figure 9 – Y Strainer

Figure 10 - Breather

41
G D M 650 / T O P DRIVE

Inspection
Recommended Inspection Program

General Inspection

Pressure test the circulating path from the Lower Well Control Valve (LWCV) to 200psi to detect
obvious leaks before testing at rated pressure. The test intervals may be specified by regulatory
authorities, operator policies or contractor policies.

Monthly Inspection

1. Remove the LWCV and inspect the connections (including the quill rotary shoulder pin
connection) using magnetic particle techniques according to API RP7G.
2. Visually inspect the following for hoisting integrity:
 Bail Adapter
 Block Interface Beam
 Block Interface Pins
 Gearbox
 Side Load Plates
 Load Pins
 Load Collar
 Quill
 Landing Collar
 Elevator links
 Elevators (if applicable)
3. Visually check the welds on the Top Drive frame, guard, mounts and supports for cracks or
damage.
4. Visually check the Top Drive unit for loose bolts.
5. Visually inspect the electrical cables on the Top Drive Unit.
NOTE: Items 2, 3, 4, and 5 from the above list should also be checked after first week of
operation on a new Top Drive installation.

42
G D M 650 / T O P DRIVE

Quarterly or Upon Rig Move (whichever is first)

1. Visually check the complete track for any damage (i.e. bending or cracking).

2. Visually check all welds on the track system. If suspicious cracks are found, a full Dry
Magnetic Particle Inspection must be performed on all welds.

3. Check for loose bolts and mountings for the blower, mast junction box, cable trays and
hydraulic lines.

4. Visually check the service loop and service supports/mounts in the mast.

5. Visually check the blower and welds on the blower frame.

 Check the pre-load in the main Top Drive bearings and re-shim, if necessary, according to
the schedule and instructions in this manual.

 Check the gap between the brake disk and the caliper. The disc should be centered in the
caliper.

Five Year Inspection


The following major inspection is recommended every five years, as a minimum, or at alternate
intervals as specified by regulatory authorities, operator or contractor policies or following severe
drilling conditions:
1. Disassemble the Top Drive unit.

2. Inspect all of the following load path components using magnetic particle methods, as
specified on the Load Path Inspection Drawings at the end of this section:

 Block Interface Bail


 Block Interface Beam
 Block Interface Pins (2)
 Side Load Plates (2)
 Load Pins (4)
 Gearbox
 Gearbox Lid

GDM500650 Rev. 2 43
G D M 650 / T O P DRIVE

 Load Collar
 Quill
 Landing Collar (2)
 Landing Collar Retainer
3. Inspect all bearings, seals, seal running surfaces, gears and splines. Refurbish or replace as
necessary.

4. Remove the mudline and inspect the wall thickness using ultrasonic methods; check for
internal wear. Contact GDS for wall thickness tolerances.

5. Remove the motor and send to a qualified repair shop for inspection and repair, if necessary.

Inspection Following Periods of Severe Drilling Conditions


After periods of rough drilling, especially on surface hole, various Top Drive components may
became damaged or loose from vibration and jarring.
The following inspection procedure is recommended after periods of severe drilling conditions:
 Visually examine the Top Drive for any signs of damage.

 Visually inspect the mud inlet piping.

 Check all safety wires on bolts for damage. If broken wires are discovered, ensure bolts are
tight and re-wire / replace damaged wires. Be sure to torque all capscrews to their
recommended torque values.

 Check all external bolts that are not wired for tightness.

 Check all guards, vents, and covers for tightness.

 Ensure that all safety cables are attached properly and securely.

 Visually check the welds on the Top Drive guard and frame, blower frame and torque guide
system.

 Visually examine inside electrical junction boxes for loose components.

 Inspect the motor armature to ensure it has not dropped:

 If the brake disk is approximately in the center of the caliper, then this may be an
indication that the armature did not drop.

 If the brake disk is rubbing on the bottom of the caliper, this may be an indication
that the armature did drop.

44
G D M 650 / T O P DRIVE

Wear Limits
The load path components on the GDM 500/650 Top Drive are designed using safety factor
calculations described in API Specification 8C for particular load capacities.
As these components wear, the equipment may be subject to de-rating to sustain the proper API 8C
safety factors.
The following are the wear limits for the load path components:
 The nominal load rating is sustained if the wear is less than 5% for all load path components
of the Top Drive, with the exception of the load collar.

 The nominal load rating must be reduced by 5% if the wear is between 5% and 10% for all
load path components of the Top Drive, with the exception of the load collar.

 The wear limit for the load collar is 10% without the necessity to reduce the nominal load
rating. The load collar load rating must be reduced by 5% if the wear is found to be between
10% and 15%.

 GDS engineering must be contacted if the wear is above 10% for all load path components,
and above 15% on the load collar to obtain the correct load rating.

Conduct a Category IV inspection per API RP 8B to determine wear. Contact GDS Engineering
for baseline dimensions.

45
G D M 650 / T O P DRIVE

Main Bearing Pre-Load Inspection


Main bearings are preloaded from the manufacturer. To see if shimming is required, follow
instructions below:
1. Install dial indicator to read movement on quill.

2. Apply upward force to quill.

3. Read measurement on dial indicator. If no movement is recorded, shimming is not


necessary. If end play is present, use formula below to determine how much shim to remove.

End play + 0.010 inches = Shim to be added. *Note* preload not to exceed 0.005 inches

Pinion Bearing Pre-Load Inspection


Pinion bearings are preloaded from the manufacturer. To see if shimming is required, follow
instructions below:
1. Install dial indicator to read movement on pinion shaft.

2. Apply upward force to pinion shaft.

3. Read measurement on dial indicator. If no movement is recorded, shimming is not


necessary. If end play is present, use formula below to determine how much shim to remove.

End play + 0.010 inches = Shim to be added. *Note* preload not to exceed 0.005 inches

46
G D M 650 / T O P DRIVE

Washpipe Inspection Instructions

Packing Assembly

Instructions

1. Set magnetic base of dial indicator to quill or packing box.

2. Rotate sleeve 360° and record total indicator reading (TIR) at indicator positions A, B, C.

Recommended Tolerances

 Maximum allowable misalignment at gooseneck support bore = 0.008 inches TIR B.

 Maximum allowable misalignment at gooseneck pilot = 0.010 inches TIR

 Maximum allowable washpipe misalignment after complete assembly = 0.010 inches TIR

Inspection may indicate misalignment exceeding recommended limits.


Washpipe packing assemblies are designed to accommodate misalignments of quill to gooseneck and
will operate with some excessive misalignment.
However, to achieve maximum packing life, the alignment at the washpipe should be maintained
within recommended limits.

47
G D M 650 / T O P DRIVE

Top Drive Disc Brake Inspection

Check Brake Calipers

 Brake calipers should be checked weekly.

 A function test should be done at this time.

 In addition to premature wear, dragging brake pads can also cause excessive heat build-up in
the brake compartment.

 If the brake pads are dragging, the system may require bleeding to eliminate any trapped air.
See Brake Bleeding Procedure.

Manual Brake Bleeding

1. Activate brakes.

2. Place clear hose over into bucket bleeder.

3. Slightly loosen bleeder to remove air.

4. Re-tighten bleeder.

5. Repeat until air is no longer present.

48
G D M 650 / T O P DRIVE

Maintenance Checklist
GDM 500/650 Maintenance Checklist
For Week Ending: ________________

EVERY 12 HOURS Mon Tues Wed Thurs Fri Sat Sun


Grease Washpipe Packing
Grease Remote Actuator
Check Oil Level in Top Drive Gearbox
By:
DAILY Mon Tues Wed Thurs Fri Sat Sun
Grease Slewing Gear
Check Cooler Fins for Debris
Grease Link Tilt Elevator Plate Pins
Check Indicator on Hydraulic Filter
Check Indicator on Lube Oil Filter
Check Gearbox Breather
Check Top Drive for Loose or Leaking
Hydraulic Fittings or Components
Examine Top Drive for Loose Bolts, Etc.
Check Oil Level in HPU Reservoir
Check Indicator on HPU Pressure Filter
Check Indicator on HPU Return Filter
By:
WEEKLY Mon Tues Wed Thurs Fri Sat Sun
Grease Load Collar
Grease BUW Pin
Grease Stand Jump Pins
Check & Clean Lube Suction Y-Strainer
Examine Brake Pads & Calipers for Wear
By:
MONTHLY Mon Tues Wed Thurs Fri Sat Sun
Grease Motor per Manufacturer
Documentation
Remove & Check Lube Nozzles for Debris
@ Oil Change
By:
EVERY 3 MONTHS Mon Tues Wed Thurs Fri Sat Sun
Change Oil in Top Drive Gearbox
Date Due:

Form 257 Rev 0 Feb 2014

49
G D M 650 / T O P DRIVE

Load Path Inspection Drawings

50
Section

4
650/850 T O N T O P D R I V E MANUAL REV 0

Rig Up Procedure

Rig Up Procedure

Prior To Top Drive Installation Install All Rig Specific Equipment

Estimated Weights :
Top Drive Package 50,000 LBS (22,700 KG)
Top Drive with Slide Frame 37,300 LBS (19,900 KG)
Top Section of Track 4,500 LBS (2,040 KG)
Travel Stand 8,600 LBS (3,900 KG)

63
LIFT TOP DRIVE TO DRILL FLOOR. ENSURE ALL LIFTING
EQUIPMENT IS SUITIBLE FOR 50,000 LB (22,700 KG)
WORKING LOAD

1. ATTACH LIFTING EQUIPMENT TO PADEYES ON


TRAVEL STAND.
2. ATTACH SLINGS TO BACK UP LINE TO THE
BOTTOM OF THE TRAVEL STAND.

SHACKLES BACKUP LINE


1. FOLD UP RACKING BOARD FINGERS (IF POSSIBLE)
BEFORE RAISING THE HORIZONTAL TOP DRIVE AND
TRAVEL STAND INSTALLATION.
2. ATTACH SLINGS TO SHACKLES AT THE TOP OF THE
TRAVEL STAND.
3. ATTACH DUAL SLING BACK UP LINE TO THE BOTTOM
OF THE TRAVEL STAND.

NOTE: 50,000 LB ( 22,700 KG) WORKING LOAD WITH SUITIBLE


EQUIPMENT FOR ALL LIFTING.

BACKUP LINE

SHACKLES
1. WHILE RAISING TOP DRIVE TO FLOOR, USE
BACKUP LINE TO ASSIST IN CONTROLLING TOP
DRIVE FROM HORIZONTAL TO VERTICAL
POSITION.
2. PULL TOP DRIVE PACKAGE INTO POSITION
AND PREPARE TO REMOVE TOP DRIVE FROM
STAND.
1. WITH THE TOP DRIVE PACKAGE UPRIGHT ON
FLOOR, BRING TRAVELING BLOCK TO FLOOR
REMOVE SLINGS.
2. CONNECT TRAVELING BLOCK TO BAIL.
1. PUT A LITTLE TENSION ON TRAVELING
ASSEMBLY AND REMOVE LOWER TOP
DRIVE SHIPPING PINS FROM
TRACK/RUNNER AREA.
2. REMOVE BOLTS FROM SKID TO TRACK
THEN UNBOLT THE TRAVEL STAND GUIDES.
3. WITH UPPER TOP DRIVE SHIPPING PINS
REMAINING, LIFT TOP DRIVE AND TOP
PIECE OF TRACK OUT OF THE TRAVEL/RIG
UP STAND.
1. LIFT TOP DRIVE CLEAR OF THE TRAVEL STAND.
2. REMOVE TRAVEL STAND FROM THE DRILL FLOOR.

NOTE: TRAVEL STAND WEIGHS 8,600 LBS (3,900 KG)


1. USING WINCH, LIFT THE TRACK TO THE
DRILL FLOOR. 1 SECTION AT A TIME. TAG LINES
SUGGESTED TO PERVENT TOP DRIVE PACKAGE
FROM TWISTING.

NOTES:
• IDENTIFY BOTTOM SECTION AND INSTALL LAST
• TOP TRACK WEIGHT 4,500 LBS (2,040 KG)
• MID TRACK WEIGHT 5,450 LBS (2,470 KG)
• BOTTOM TRACK WEIGHT 4,500 LBS (2,040 KG)
TRACK HOOK

PIVOT PIN

ENGAGE

1. INTRODUCE THE TRACK HOOK TO THE PIVOT PIN.


2. ENGAGE THE HOOK AND PIVOT PIN.
LIFT

LOCKING PIN

LOCKING PIN

1. LIFT THE TOP DRIVE AND TRACK SECTION.


2. WITH LOCKING PINS HOLES ALIGNED, INSTALL
LOCKING PINS AND SAFETY BOLTS/NUTS.
1. REPEAT PREVIOUS STEPS UNITL ALL TRACK
SECTIONS ARE INSTALLED.
2. ATTACH TOP TRACK TO CROWN PER RIG
SPECIFIC INSTRUCTIONS.
3. INSTALL TORQUE REACTION ASSEMBLY
PER RIG SPECIFIC INSTRUCTIONS.
4. INSTALL MID MAST KITS PER RIG SPECIFIC
INSTRUCTIONS.
5. REMOVE UPPER SHIPPING PINS FROM
THE TOP OF THE TRACK AFTER CROWN
ASSEMBLY IS CONNECTED.
5
Section
650/850 T O N T O P D R I V E MANUAL REV 0

Drawings and Parts


Contents

5A Assembly Drawings ...................................................................75


Assembly Drawings Index...............................................................76
5B Schematics...................................................................................134
Electrical Schematics Index............................................................135

74
650/850 T O N T O P D R I V E MANUAL REV 0

5A Assembly Drawings

75
G D M 5 0 0 / 6 5 0 T O P D R I V E

5A – Assembly Drawings
Assembly Drawing Index

Drawing No. Revision Description

A500268 01 TOP DRIVE CORE, TOP DRIVE ASSY

A500373 01 GEARBOX ASSY, GDM500, 6/8 SINGLE

A500239 01 ASSY, IDLER GEARS, GEARBOX

A500226 01 IDLER GEARS ASSY

A500010 02 QUILL ASSY

A600003 01 QUILL ASSY, 650T, 7 5/8

A500279 01 ASSY, MOTOR, GDM 500

A500231 01 ASSY, MOTOR, DISC BRAKE

A500252 01 ASSY, BLOWER, 15HP, 575V, 3600

BLOWER ELIMINATOR 15 HP, 3600 RPM, 575V


P500001 03
STAINLESS STEEL

A500277 02 GUARD ASSY GDM 500

A500149 01 SERVICE PLATE ASSY, TOP DRIVE ASSY

A500110 01 PINION ASSY, SERVICE PLATE ASSY

A500101 02 PROXIMITY SENSOR MOUNT ASSY

M500105 01 IDLER GEAR ASSY, SERVICE PLATE ASSY

M500107 01 ENCODER ASSY, PINION ASSY

A500355 01 ASSY, LINK, TOP DRIVE, GDM 500

A500015 01 LINK COLLAR ASSY GDM 650/500

A500160 01 ROTATING PLATE ASSY, LINK ASSY

A500348 01 LOAD COLLAR, REAR ASSY, LINK ASSY

GDM500650 Rev. 8 76
G D M 5 0 0 / 6 5 0 T O P D R I V E

Drawing No. Revision Description

A500347 01 EVE. TILT PLATE CYL. ASSY

A500349 01 ELEVATOR TILT PLATE ASSY, LINK ASSY

A500162 01 LOAD COLLAR FRONT BRACKET ASSY

A500411 01 ELEVATOR LINK ASSY GDM

A500271 01 BUW ASSY, TOP DRIVE CORE

A500345 01 GRABBER ASSY, 500T

A500102 01 GDM 650/500 TON, GATE SIDE DIE BLOCK ASSY

GDM 650/500 TON, ROD SIDE 3 ½” DIE BLOCK


A500103 01
ASSY

GDM 650/500 TON ROD SIDE 5 1/2” DIE BLOCK


A500105 01
ASSY

GDM 650/500 TON GATE SIDE 6.625 -8.50 DIE


A500353 01
BLOCK ASSY

A500254 01 GRIPPER SPRING STABILIZER, GRABBER ASSY

A500175 01 GRABBER BOX ASSY, GDM

A500370 01 BONNET ASSY, GDM

A500230 01 ASSY, HYDRAULIC GDM 500

A500329 02 BLOCK INTERFACE ASSY, WITH SIDE PLATES

A500240 01 BLOCK INTERFACE ASSY

A500024 01 STAND JUMP ASSY

GDM500650 Rev. 8 77
       

 

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352+,%,7(' $ '21276&$/('5$:,1* 6&$/( :(,*+76+((72)
       
       

,7(012 3$57180%(5 '(6&5,37,21 47<


 $ *($5%2; *($56*($5%2;$66< 
 $ (/(&75,&027256833257$66< 
 $ $66<02725*'0 
' '
 $ *8$5'$66(0%/<*'0 
 $ 6(59,&(3/$7($66< 
 $ 723'5,9(/,1.$66<*'0 
 $ %8:$66<723'5,9(&25( 
 $ %211(7$66< 
 $ $66<+<'5$8/,&*'0 
 $ %/2&.,17(5)$&($66(0%/<:,7+6,'( 
3/$7(6*'0
1 $500024 STAND JUMP ASSEMBLY 2
& &

% %

*'6,QWHUQDWLRQDO
7,7/(
$ 723'5,9(&25( $

723'5,9($66<
6,=( ':*12 5(9

% $ 
6&$/( :(,*+7 6+((72)
       
8 7 6 5 4 3 2 1

11 62 26

D D

29 28
C C
63.25

54
56
28 29
71 20 64
C C
11 62
51.00

A
11 62 8

F
E E

B B
G G

101.69
F

D D

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 3/25/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/20/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 1/20/15
GEARBOX ASSY, A

A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
GDM500, 6-5/8 SINGLE
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500373
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 3/25/14 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

24 55 24 18 8 30 18 51 52 56 57 64 12 31 27 73 9 72 15 58

D D
26

68
41
67
70
16

35

14

C 22 C

75 23

37

10
B B
61
8
28 29

13

21

GDS International
TITLE:
A GEARBOX ASSY, A

GDM500, 6 5/8 SINGLE


44 42 53 17 25 25 44 42 33 47 40 34 69 34 46 1
SIZE DWG. NO. REV

SECTION A-A B A500373 01


SCALE 1 : 7 SCALE: 1:8 WEIGHT: SHEET 2 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

D D

48

C C
50

50

74

B B
4

43 32

49

GDS International
TITLE:
A GEARBOX ASSY, A

GDM500, 6 5/8 SINGLE


SECTION C-C
SCALE 1 : 8 SIZE DWG. NO. REV

B A500373 01
SCALE: 1:18 WEIGHT: SHEET 3 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

D D

69 34 40 56 33 43 60 21 59 28 29

59

29 28
65 66
36
C C
5

38 39

63
43 32

B B
42 44

SECTION D-D SECTION E-E

GDS International
TITLE:
A GEARBOX ASSY, A

GDM500, 6 5/8 SINGLE


SIZE DWG. NO. REV

B A500373 01
SCALE: 1:12 WEIGHT: SHEET 4 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

45 29 28 54 20 28 29 45

D 76 75 D

60
60

C C

B B

SECTION G-G
59 28 29 28 29 59 SCALE 1 : 12
19 19

GDS International
SECTION F-F TITLE:
A GEARBOX ASSY, A

GDM500, 6 5/8 SINGLE


SIZE DWG. NO. REV

B A500373 01
SCALE: 1:6 WEIGHT: SHEET 5 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY. ITEM NO. PART NUMBER DESCRIPTION QTY.
1 M100967 DOWEL PIN, 1/2'' x 2'' LONG 4 46 S101530 O RING, 6 1/4 X 6 1/2 X 1/8, 2- 259, 70 DUROMETER 1
2 M500024 PINION 1 47 S100079 O-RING, 8 3/4 x 9 x 1/8, NITRILE 1
3 M500243 FLANGE, IDLER GEARS, TOP 2 48 S100081 O-RING, 9 x 9 1/4 x 1/8,2-270 70 DUR 2
4 M500240 FLANGE, IDLER GEARS, BOTTOM 2 49 S500003 O-RING, 9.50 X 9.75 X .125, N-70 2
D D
5 M500245 COVER, IDLER GEARS, BOTTOM 2 50 S101439 O-RING,NITRILE,2-278 4
6 M500242 RETAINER, FLANGE, BOTTOM 1 51 S100123 O-RING, 10 1/2 x 11 x 1/4 1
7 A500239 IDLER GEARS ASSY 1 52 S500004 O-RING, 13.5 X 14.0 X .250, N-70 1
8 A500010 QUILL ASSY 1 53 S100129 O-RING, 15 x 15 1/2 x 1/4 1
9 M500305 13" DIA ROUND BAR 1 54 M500295 FLANGE, LUBE PIPE, GDM 500 1
10 M500239 FLINGER, LOWER BEARING, GEARBOX 1 55 M500297 SPACER CAGE SEAL, GEARBOX 1
11 230101.1000 WASHER,LOCK,HI COLLAR 5/8 36 56 A500011 GEARBOX ASSEMBLY MACHINING FINIAL 1
12 M500246 FLANGE, SEAL, PINION, TOP 1 57 S500005 ORING, 70 NITRILE, 2-276 1
13 M500247 FLANGE, PINION, BOTTOM 1 58 M500290 RE-WORK RENOLDS COUPLING, HUB COUPLING ASSY. 1
14 M500248 FLANGE, PINION, TOP 1 59 M500498 FLANGE, SUCTION DRAIN, GDM 500 2
15 M500249 COUPLING, RETAINER 1 60 A500095 KIT, GEARBOX VIEWPORTS, GDM 500 1
C
16 M500254 SPACER, SHAFT, PINION 1 61 M500257 SLEEVE, TAPER 1
C
17 M500255 FLANGE, QUILL, BOTTOM 1 62 026211.1028DH2 CAPSCREW,SOCKET HEAD, 5/8-11UNC X 1.75, DH2 28
18 M500256 SEAL, CAGE, TOP 1 63 M500294 LUBE PIPE GEAR BOX 1
19 S500014 O-RING, 2.406 ID x .139 4 64 026211.1032DH2 CAPSCREW,SOCKET HEAD, 5/8-11UNC X 2.00, DH2 8
20 M500259 FLANGE, FILLER CAP 1 65 220102.0400 WASHER,LOCK,NORDLOCK,1 PAIR 1/4 12
21 M500260 COVER, FLANGE, PINION, BOTTOM 1 66 026211.0412DH CAPSCREW,SOCKET HEAD, 1/4-20UNC X 0.75, DH 12
22 M500262 SHIMS, SET, PINION 1
67 A500272 RETAINER, MOTOR COUPLING ASSEMBLY 1
23 M102888 BEARING, TAPERED ROLLER 130X230X67.75MM 2
68 S101448 SEAL,ROUND EXTRUDED SILICONE CLOSED CELL FOAM 1
24 S101566 SEAL, OIL SEAL 8.5 X 10 X .625 2
69 M500611 BRACKET - LINK TILT CYLINDER HOSE 1
25 S101567 SEAL, OIL SEAL 10.5 X 12.5 X .625 2
70 M500261 SHIMS, KIT, QUILL 1
26 026211.1656DH2 CAPSCREW,SOCKET HEAD, 1-8UNC X 3.50, DH2 15
71 H100728 PLUG, HOLLOW HEX, 3/4'' NPT 1
27 208201.1200 WASHER,FLAT,Gr8, 3/4 1
72 S100124 O-RING, 11 1/2 X 12 X 1/4 1
B 28 026211.0824DH2 CAPSCREW,SOCKET HEAD, 1/2-13UNC X 1.50, DH2 26 B
73 S500008 O-RING, 11.375 X .250, N-70 1
29 230101.0800 WASHER,LOCK,HI COLLAR 1/2'' 26
74 M500264-250 SHIM, IDLER, 0.250 1
30 026211.0716DH2 CAPSCREW, SOCKETHEAD, 7/16-14UNC X 1 8
75 M500703 OIL RING, GDM 650, NEW 1
31 008122.1228DH2 CAPSCREW, HEXHEAD, 3/4-16UNF X 1-3/4 1
76 026211.0828DH2 CAPSCREW,SOCKET HEAD, 1/2-13UNC X 1.75, DH2 8
32 008121.1236DH2 CAPSCREW,HEX HEAD, 3/4-10UNC X 2.25,DH2 20
33 008121.1232DH2 CAPSCREW,HEX HEAD, 3/4-10UNC X 2.00,DH2 10
34 008121.0616DH2 HEX HEAD, 3/8-16 UNC x 1 IN, GR 8 WIRED 8
35 026211.1232DH2 CAPSCREW,SOCKET HEAD, 3/4-10UNC X 2.00, DH2 10
36 H102597 CLAMP, SADDLE, LUBE PIPE 6
37 M500253 FLINGER, BEARING, TOP, GEARBOX 1
38 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 10 GDS International
39 008121.0822DH2 SCREW, HEX HEAD, 1/2-13 X 1-3/8, GR8 10 TITLE:
A 40 220102.0600 WASHER,LOCK,NORDLOCK,1 PAIR 3/8 8 GEARBOX ASSY, A

41 M500059 FLANGE TOP QUILL, LOAD COLLAR ASSY 1 GDM500, 6 5/8 SINGLE
42 008121.1440DH2 CAPSCREW,HEX HEAD, 7/8-9UNC X 2.50,DH2 12
43 220102.1200 WASHER,LOCK,NORDLOCK,1 PAIR 3/4 30 SIZE DWG. NO. REV
44 220102.1400 WASHER,LOCK,NORDLOCK,1 PAIR 7/8 12 B A500373 01
45 S100419 O-RING,2-224,NITRILE, N70, 1.75 X 2.00 X 1/8 2 SCALE: 1:24 WEIGHT: SHEET 6 OF 6
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 A500226 IDLER GEARS ASSEMBLY 1
2 M500241 PL. 1" OR BAR ROUND 5" 2
3 M500234 BEARING, ROLLER 2

D
4 M500315 SLEEVE, WITHDRAWAL 2 D
5 026221.0824DH2 CAPSCREW,SOCKET HEAD, 1/2-20-UNF X 1.50, DH2 12

C
4 4

C C

SECTION C-C
5 2 3 1 3 2 5

B B

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DF 11/3/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 11/3/14 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 11/3/14
ASSY, IDLER GEARS, A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
GEARBOX
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500239
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/3/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500025 IDLER PINION, M12-19-HA8-X1=0.20-LH 1
2 M500026 IDLER GEAR, M10-38T-HA 15-X2=0.00 1
3 M500320 COVER, DOWEL PIN, IDLER GEAR 2
4 M100967 DOWEL PIN, 1/2" X 2" LONG 2 D
D
5 026221.1440DH2 CAPSCREW,SOCKET HEAD, 7/8-14-UNF X 2.50 DH2 18

1 2 E 3

C C

1
16 4 "

3
3
26 16 " E
B B

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES


ENSURE HOLE TOLERANCES:
DRAWN DF 10/31/14

ALIGNMENT FRACTIONAL 1/16 CHECKED DGW 10/31/14 TITLE:


A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 10/31/14
IDLER GEARS ASSEMBLY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
THIRD ANGLE
DETAIL A PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION
SCALE 1 : 2 4 SECTION E-E THE INFORMATION CONTAINED IN THIS
TOLERANCING PER: ASME Y14.5M
MATERIAL
SIZE PART/DWG NO. REV

B A500226
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR MANUFACTURE 10/31/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 517.53 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

13 14 18 6 7 1 10 9 1

D D

DETAIL C
SCALE 1 : 4
A
DETAIL B
SCALE 1 : 4
3 4 12
13
C C

B C
15

2
1

B 1 B
ITEM 16 APPLY BLUE LOCTITE
17

ITEM 15
APPLY WHITE ASSEMBLY GREASE (LUBRIPLATE) 6 11 5 15 2 8 10 16 9 1
TORQUE TO 1750 FT/LBS
SECTION A-A

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 11/4/13


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/7/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 1/7/15
QUILL ASSY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500010
DRAWING IS THE SOLE PROPERTY OF
02 UPDATED DRAWING TO REFLECT E2 1/7/15 DF
02
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/4/13 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1482.34 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500017 1
2 M500027 GEAR 1
3 M500019 LANDING COLLAR, 500T 1
4 M500020 14.5" DIAMETER BAR 1 D
D
5 M500060 3/16" PLATE 1
6 M500263 <Description> 1
7 M500284 9-1/4" OD X 1.0" W.T. PIPE 2
8 M100044 BRG, TPRD ROL, THRUST 1
9 M500281 SLEEVE SEAL, QUILL, LOWER 1
10 M102890 BEARING, CYLINDRICAL ROLLER 1
11 M102887 BEARING, TAPERED ROLLER 1
12 M102079 RING, RETAINING 1
13 R100364 LINER, UPPER STEM 1
14 S100413 SEAL 1
C C
15 026211.2072DH2 CAPSCREW,SOCKET HEAD, 1-1/4-7UNC X 4.50, DH2 20
16 312221.0610 SETSCREW, 3/8-24 UNF X 0.63 CUP POINT 6
17 312221.0816 SETSCREW, 1/2-20UNF X 1IN, CUP POINT 3
18 S101517 O-RING, 3 7/8 INCH ID 1

B B

GDS International
TITLE:
A QUILL ASSY A

SIZE PART/DWG NO. REV

B A500010 02
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

13 14 1 18 6 18 10 9 1

D D

DETAIL C
SCALE 1 : 4
A
DETAIL B
SCALE 1 : 4
3 4 12
13
C C

C
B

A
2

1
1
B 15 ITEM 16 APPLY BLUE LOCTITE
B

17

6 7 11 5 15 2 8 10 16
ITEM 15 1
APPLY WHITE ASSEMBLY GREASE (LUBRIPLATE)
TORQUE TO 1325 FT/LBS SECTION A-A

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 5/14/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/21/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/21/15
QUILL ASSY, A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
650T, 7 5/8
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A600003
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/21/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1476.31 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500570 QUILL, 650 TON, GDM 7 5/8 1
2 M500027 GEAR 1
3 M500019 LANDING COLLAR, 500T 1
4 M500020 14.5" DIAMETER BAR 1 D
D
5 M500060 3/16" PLATE 1
6 M500263 <Description> 1
7 M500284 9-1/4" OD X 1.0" W.T. PIPE 1
8 M100044 BRG, TPRD ROL, THRUST 1
9 M500281 SLEEVE SEAL, QUILL, LOWER 1
10 M102890 BEARING, CYLINDRICAL ROLLER 1
11 M102887 BEARING, TAPERED ROLLER 1
12 M102079 RING, RETAINING 1
13 R100364 LINER, UPPER STEM 1
14 S100413 SEAL 1
C C
15 026211.2072DH2 CAPSCREW,SOCKET HEAD, 1-1/4-7UNC X 4.50, DH2 20
16 312221.0610 SETSCREW, 3/8-24 UNF X 0.63 CUP POINT 6
17 312221.0816 SETSCREW, 1/2-20UNF X 1IN, CUP POINT 3
18 S101517 O-RING, 3 7/8 INCH ID 2
19 M100559 WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE 9
20 M100482 1/16'' ALUMINUM OVAL, WIRE ROPE CLIP 10

B B

GDS International
TITLE:
A QUILL ASSY A

SIZE DWG. NO. REV

B A600003 01
SCALE: 1:12 WEIGHT: SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 E100727 MOTOR, AC, VERT DRILLING,1150 HP 1
2 M500270-003 SHIM MOTOR MOUNT BTM - TOP DRIVE CORE 4
3 M500331 PLENUM, GE B20 GDM500 1
4 A500255 SEAL RING HOUSING ASSEMBLY, GE B20 1 D
D
5 A500231 ASSY, MOTOR, DISC BRAKE 1
6 A500252 ASSY, BLOWER, 15HP, 575V, 3600 1
52.00
7 M500289 HUB, GE20B-GF30DA MOTOR SIDE 1
8 M104035 SEAL RING, GE B20 1
6
9 M500335 SHAFT, MAIN ENCODER, GDM 1
A
10 M500530 GDM 500 - GEAR CASE VENT MOUNT 1
11 M500613 INSERT, AC PLENUM 2
12 N100495 1024 PULSE ENCODER WITH DOUBLE RECEPTICLE 1
13 312211.0608 SETSCREW, 3/8-16 UNC X 0.50 CUP POINT 2

C C
5
6

5
10
88.09
12

9 13
B 1 B

3 3

11
2 4
7 GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
8
A SECTION A-A DIMENSIONS ARE IN INCHES DRAWN DGW 12/18/13
TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/20/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/20/15
ASSY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
MOTOR
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION GDM 500
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500279
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/20/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 974.05 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

SEE BOM FOR


SPARE PARTS

D D

C C

16 2 SECTION B-B 1 14 13

30.00

14 15 7
6
8

11 12

B B

14.13
B B

10 11 5 4

GDS International
NAME DATE
4 16 9 3 2
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN INCHES DRAWN DGW 12/18/13
TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/21/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/21/14
ASSY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
MOTOR
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION DISC BRAKES
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500231
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/21/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 480.13 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500268 DISC, DISC BRAKE 1
2 M500238 HUB DISC 1

D 3 M500267 SHIMS, KIT, DISC BRAKE 1 D

4 M500274 DISC BRAKE HOUSING, DISC BRAKE ASSY 2


5 M500265 ADAPTER PLATE, DISC BRAKE 2
6 A500364 ASSY, CALIPER, BRAKE 2
7 M500275 DISC BRAKE COVER, DISC BRAKE ASSY 1
8 M500276 POST DISC BRAKE COVER, BRAKE ASSY 4
9 220102.1600 WASHER, NORD-LOCK, 1 IN, PAIR 4
10 016142.1650DH2 CAPSCR, SOCKETHEAD, M16 x 50, GR8.8, DH2 8
C 11 230101.1000 WASHER,LOCK,HI COLLAR 5/8 16 C

12 026211.1048DH2 CAPSCREW,SOCKET HEAD, 5/8-11UNC X 3.00, DH2 8


13 026211.1244DH2 CAPSCREW,SOCKET HEAD, 3/4-10UNC X 2.75, DH2 12
14 210202.1200 WASHER,LOCK,SPLIT,GR8, 3/4 16
15 026211.12124DH2 CAPSCREW, SOCKET HEAD, 3/4-10 X 7.75, DH2 4
16 008121.1656DH2 CAPSCREW,HEX HEAD, 1-8UNC X 3.50,DH2 4

SPARE M102872 BRAKE PAD, BRAKE CALIPER, SKD-80 4


SPARE S101565 SEAL KIT, BRAKE CALIPER, SKD80, STD-NITRILE 4
B B

GDS International
TITLE:
A ASSY A
MOTOR
DISC BRAKES
SIZE PART/DWG NO. REV

B A500231 01
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 P500001 BLOWER, ELIMINATOR, 15HP, 3600, 575V, STAINLESS STEEL 1
2 M500299 DUCT, BLOWER 1
3 008121.0824DH2 CAPSCREW, HEX HEAD, 1/2-13UNC X 1.50, DH2 6
4 101112.0800 NUT,HEX,STOVER C 1/2-13 6
D
5 206101.0800 WASHER,FLAT,HARDENED,F436 Plain, 1/2 12 D
6 008121.1056DH2 CAPSCREW,HEX HEAD, 5/8-11UNC X 3.5,DH2 2
7 008121.1032DH2 CAPSCREW,HEX HEAD, 5/8-11UNC X 2.00,DH2 2
8 M100506 QUICK LINK, 3/8 1
9 206101.1000 WASHER,FLAT,HARDENED,F436 PLAIN, 5/8 8
10 101112.1000 NUT,HEX,STOVER C 5/8-11 4
11 M100485 WIRE ROPE CRIMP, 3/16'' ALUMINUM 3
12 M100847 WIRE ROPE, 3/16" SS 7X19 WIRE STRAND 4

1 7
36 8 " 34 8 "
8
C 1 C

7 9 10
1
49 16 "

B B

6 10 9 1

3 4 5

2
2

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 12/18/13


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 10/14/14 TITLE:
A - - - - - ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 10/14/14
ASSY, A
- - - - - PROPRIETARY AND CONFIDENTIAL TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
BLOWER, 15HP
THIRD ANGLE
- - - - -
THE INFORMATION CONTAINED IN THIS
DRAWING IS THE SOLE PROPERTY OF INTERPRET GEOMETRIC PROJECTION 575V, 3600
GLOBAL DRILLING SUPPORT INTL. ANY TOLERANCING PER: ASME Y14.5M

-
REPRODUCTION IN PART OR AS A WHOLE MATERIAL
- - - - SIZE PART/DWG NO. REV

B A500252
WITHOUT THE WRITTEN PERMISSION OF

01
GLOBAL DRILLING SUPPORT INTL. IS
01
FINISH
RELEASE FOR MANUFACTURE DGW 10/14/14 - PROHIBITED.
125AA Unless stated otherwise

REV. DESCRIPTION INITIAL DATE ECN # DO NOT SCALE DRAWING SCALE: DNS WEIGHT: 161.78 SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

1. NOTES: ITEM NO. PART NUMBER DESCRIPTION QTY.


2. IMPELLER BUSHING BOLTED ON HUB WITH 3X 3/8-16 UNC BOLTS 3 1 P500001-02 BLOWER HOUSING 1
TORQUE HUB BOLTS TO 29 FT-LBS 2 P500001-04 MOTOR C-FACE WITH FEET 15 HP 3600 RPM 575 VOLT 1
3. IMPELLER & BOLTS ARE NOT SHOWN ITEM 4,7,10 3 P500001-01 INTAKE COVER 1
4. ALL BOLTS SHOULD BE TIE WIRED
5. ALL MATERIAL IS STAINLESS STEEL 4 P50000-03 IMPELLER 1
D 8 12X 5 210202.0800 WASHER,LOCK,SPLIT,GR8, 1/2 16 D

6 210202.0500 WASHER,LOCK, SPLIT, GR8 5/16 14


7 210202.0600 WASHER,LOCK,SPLIT,GR8 3/8 3
8 008121.0824DH2 CAPSCREW, HEX HEAD, 1/2-13UNC X 1.50" DH2 12
14X 9 3 9 008121.0516DH2 CAPSCREW,HEX HEAD, 5/16-18 UNC X 1.00 DH2 14
10 008121.0620DH2 CAPSCREW,HEX HEAD,3/8-16UNC X 1.25,DH2 3
11 008121.0832DH2 CAPSCREW,HEX,PLATED, GR8 1/2-13 UNC 4
12 108112.0800 NUT,HEX ,PLATED,GR8 1/2-13 16
13 108112.0500 NUT,HEX, PLATED, GR8 5/16-18 14

C 14X 6 C

3 1 5 16X

B B

11 4X 12 16X 13 14X
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 4/21/2014


GDS International
TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/21/2015 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/21/2015
BLOWER ELIMINATOR A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
15 HP, 3600 RPM, 575 V
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION STAINLESS STEEL
TOLERANCING PER: ASME Y14.5M
3 MODIFIED 3D MODEL TO ADD ALL THE BOLTS & WASHERS AND ADDED BOM 2/4/2015 HD THE INFORMATION CONTAINED IN THIS MATERIAL
DRAWING IS THE SOLE PROPERTY OF SIZE PART/DWG NO. REV
2 11/16" WAS 1/2" 7/28/2014 DGW SEE BOM
1 RELEASE FOR MANUFACTURING 4/21/2014 DGW
GLOBAL DRILLING SUPPORT INTL. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
FINISH
125AA UNLESS STATED OTHERWISE B P500001 3
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 125.40 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

9
41.00
D D

11
1 12

10
D
E
57.05

10 12
A
8 3
C C
5 5 11
12 10
1 14 15
F DETAIL D
SCALE 1 : 8
1
13

4
K
16
C
7
B 13 B
11 2 91.88
B
H H 12 5
9 8 12
DETAIL E
6 DETAIL K SCALE 1 : 8
SCALE 1 : 4
SECTION H-H
6 SCALE 1 : 24

1
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 12/18/2013


TOLERANCES:
FRACTIONAL 1/16 CHECKED JP 9/24/14 TITLE:
A 5 ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 ENG APPR. JP 9/24/14 GUARD ASSEMBLY, A

GDM 500
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 MFG APPR. XXX XX/XX/XX
PROPRIETARY AND CONFIDENTIAL INTERPRET GEOMETRIC Q.A.
TOLERANCING PER: ASME Y14.5M XXX XX/XX/XX
THE INFORMATION CONTAINED IN THIS

02
MATERIAL
ADDED WELDED HINGE PIN, PAGE 2 JP 9/24/14 DRAWING IS THE SOLE PROPERTY OF SIZE DWG. NO. REV

B A500277
GLOBAL DRILLING SUPPORT INTL. ANY

01 <REV DESC> DGW 12/18/13


REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GDS PART No.-Revision FINISH
02
REV. DESCRIPTION INITIAL DATE
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED. A500277-02 DO NOT SCALE DRAWING SCALE: 1:18 WEIGHT: 392.69 SHEET 1 OF 3
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

1
3

17
5
D D
4
8
AA

7
8
8
16
9
6 8

DETAIL A
G 8 G SCALE 1 : 4

C 1 C

DETAIL C
SCALE 1 : 4 1/2 ROUND BAR TYP
1/4
2 .25

CAGE HINGE

8
B DETAIL B 5 B
SCALE 1 : 12
1 DETAIL AA
2 7 SCALE 1 : 6
11 11

9
GDS International
DETAIL F TITLE:
A SCALE 1 : 8 GUARD ASSEMBLY, A

GDM 500
41.00 SIZE DWG. NO. REV

SECTION G-G B A500277 01


SCALE 1 : 12 SCALE: 1:1 WEIGHT: 392.69 SHEET 2 OF 3
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500401 GUARD FRAME 1
2 M500412 DOOR, DS, CAGE ACCESS, GDM 500 1
3 M500426 PLATFORM, UPPER CAGE, GDM 500 1
4 M500427 ROD, PLATFORM MOUNTING, GDM 500 1 D
D
5 M500434 DEFLECTOR PLATFORM, GDM 500 1
6 M500447 LATCH, BTM PLATFORM, GDM 500 2
7 M500448 DOOR, ODS, CAGE ACCESS, GDM 500 1
8 M500449 PIN W/HEAD, 3/8 x 1 3/4" 10
9 M500533 BRACE, FRONT CAGE, GDM 1
10 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 4
11 008121.0644DH CAPSCREW, HEX HEAD, 3/8-16UNC X 2.75, DRILLED 4
12 M500418 MOUNT, LOWER CAGE, GDM 500 2
13 M500425 CAPSCREW, 12-POINT, 1-8 UNC X 3-3/4", GR8 10
14 026211.1656DH2 CAPSCREW,SOCKET HEAD, 1-8UNC X 3.50, DH2 4
C C
15 101112.1600 NUT, HEX, STOVER 1-8 4
16 104112.1200 NUT, HEX, SLOTTED 3/4-10 UNC 4
17 M102322 COTTER PIN, 1/4" X 2" 2
18 M100734 NEW 1-1/2" DIA ROUND BAR, CUT TO 4-1/4" L 2
19 220102.1600 WASHER, NORD-LOCK, 1 IN, PAIR 10
20 208201.1200 WASHER,FLAT,Gr8, 3/4 2

B B

GDS International
TITLE:
A
GUARD ASSEMBLY, A

GDM 500
SIZE DWG. NO. REV

B A500277 01
SCALE: 1:1 WEIGHT: SHEET 3 OF 3
8 7 6 5 4 3 2 1
1 of 2
2 of 2
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500100 PRXIMITY MOUNT BRACKET 1
2 N500002 SENSOR, PROX INDUCTIVE, DC 1
3 N500003 CABLE, 5M, INDUCTIVE SENSOR 1
4 220102.1400 WASHER,LOCK,NORDLOCK,1 PAIR 7/8 2 D
D
5 008121.1424DH2 CAPSCREW,HEX HEAD, 7/8-9UNC X 1.50,DH2 2

1
58"

C C

1
B B
5 4

3
28"

1
88"

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN JAV 9/5/13


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 12/3/14 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 12/3/14
PROXIMITY SENSOR A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
MOUNT ASSEMBLY
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500101
DRAWING IS THE SOLE PROPERTY OF
02 MODIFIED FROM ORIGINAL VERSION 9/5/13 JAV
02
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 REFER TO TD125146 - ORIGINAL VERSION 7/18/12 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1.32 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
1 of 2
2 of 2
1 of 2
2 of 2
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 A500015 GDM 650/500 LINK COLLAR ASSEMBLY 1
12
2 A500160 ROTATING PLATE ASSY, LINKS ASSY 1
3 A500347 ELEV. TILT PLATE CYL. ASSY 2
D D
4 A500348 LOAD COLLAR REAR ASSY, LINK ASSY 1
5 A500349 ELEVATOR TILT PLATE ASSY, LINK ASSY 1
6 A500162 LOAD COLLAR FRONT BRACKET ASSEMBLY 1
7 A500411 ELEVATOR LINK, ASSEMBLY, GDM 2
8 M500145 SPRING POST, LOAD COLLAR ASSY 24
9 M500146 SPACER, SPRING POST, LOAD COLLAR ASSY 24
10 M500148 SPRING, LOAD COLLAR ASSY 24
11 206101.2000 WASHER,FLAT,HARDENED,F436 Plain, 1 1/4 48
9 12 M500054 ROTATING PLATE LINK ASSY 1
42" 12 2 44 16 "
C C

6
12
1

B B

1
92 8 "
5 9 10 11 8

7
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DF 1/21/15


TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 1/21/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 1/21/15 ASSY, LINK, A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 TOP DRIVE,
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION GDM 500
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500355
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/21/2015 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 3398.33 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

23 25 24 13 12

D D
21

DETAIL A 15 17
26
19 SCALE 1 : 2
DETAIL C
SCALE 1 : 1.5
C C

2
5 4 9 8
42"
3
B 37 16 " 3
7 20 21 22
10
18

B B

11
36 16 "
C

16 SECTION B-B
SCALE 1 : 12

14

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

B DIMENSIONS ARE IN INCHES DRAWN DF 1/22/15


TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 1/22/15 TITLE:
A
20 11
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 1/22/15 LINK COLLAR ASSEMBLY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 GDM 650/500
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL
3 TOLERANCING PER: ASME Y14.5M
42 4 " THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500015
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/22/2015 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 2834.84 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


20 M500021 LINK COLLAR FINAL MACHINING 500T 1
2 S500000 SEAL, SHAFT, RADIAL 9X11X.625 1
3 M500156 RETAINING RING, LOAD COLLAR SLEEVE, LINK ASSY 1
4 008121.0828DH2 HEX HEAD, 1/2-13 UNC x 1 3/4 IN, GR 8 WIRED 8 D
D
5 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 8
21 M500053 LINK COLLAR TOP PLATE CORE ASSY 1
7 M500304 ROTARY SEAL ASSY 1
8 008121.0424DH HEX HEAD CS, GR 8, 1/4- 20UNC x 1 1/2 DRILLED 8
9 220102.0400 WASHER,LOCK,NORDLOCK,1 PAIR 1/4 8
10 M500157 LOAD COLLAR SLEEVE 1
11 M100917 GREASE FITTING, 1/4 NPT, STRAIGHT 1
12 008121.0616 CAPSCREW, HEXHEAD, 3/8-16 X 1" GR. 8 3
13 220102.0600 WASHER,LOCK,NORDLOCK,1 PAIR 3/8 3
14 M500058 LATCH LOAD COLLAR, LOAD COLLAR ASSY 2
C C
15 M105001 LINCH PIN - WITH LOCKING RING 1/4" 2
16 M500636 PIN - 1'' X 3'' W/ 1''-8 THREADED END 2
17 108112.1600 NUT,HEX,PLATED,GR8 1-8 2
18 M100491 EYEBOLT, SHLD TYPE, 3/8-16UNC X 1-1/4in 2
19 H101598 CAP, 3/8 ORFS 9
20 M500165-060 SPACER PLATE, .060, CORE ASSY 2
21 M500165-134 SPACER PLATE, .134, CORE ASSY 1
22 M500165-250 SPACER PLATE, .250, CORE ASSY 1
23 M500314 PLATE 2-3/4", ASTM A572, Gr50 1
24 230101.1600 WASHER,LOCK,HI COLLAR 1'' 10
B B
25 026211.1672DH2 CAPSCREW,SOCKET HEAD, 1-8UNC X 4.50, DH2 10
26 M500394 PLATE, GUIDE, ANTI-ROTATION 1
27 M100482 1/16'' ALUMINUM OVAL, WIRE ROPE CLIP 8
28 M100559 WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE 20FT
29 M100485 WIRE ROPE CRIMP, 3/16'' ALUMINUM 4
30 M100847 WIRE ROPE, 3/16" SS 7X19 WIRE STRAND 4FT

GDS International
TITLE:
A LINK COLLAR ASSEMBLY A
GDM 650/500

SIZE PART/DWG NO. REV

B A500015 01
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500032 BRG, TURNTABLE, LINK ASSY 1
2 008121.1464DH2 CAPSCREW,HEX HEAD, 7/8-9UNC X 4.00,DH2 18
3 220102.1400 WASHER,LOCK,NORDLOCK,1 PAIR 7/8 18
D 1 4 M500159 BUSHING ROTATING PLATE SMALL, ROTATING PLATE ASSY 2 D
5 M500158 BUSHING ROTATING PLATE LARGE, ROTATING PLATE ASSY 2
6 026211.1464DH2 CAPSCREW, SOCKET HEAD, 7/8-9 UNC X 4.00 DH2 24
2 3
7 230101.1400 WASHER, LOCK, HI COLLAR 24
6 7 8 M500054 ROTATING PLATE LINK ASSY 1
9 M100635 GREASE FITTING, 1/8-27 NPT, STRAIGHT 1
10 M100491 EYEBOLT, SHLD TYPE, 3/8-16UNC X 1-1/4in 2
11 M100506 QUICK LINK, 3/8 2
A 12 220102.0600 WASHER,LOCK,NORDLOCK,1 PAIR 3/8 2
13 H500039 CLAMP, DOUBLE, 3/8 3
C 14 M100559 WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE 20FT C
15 M100847 WIRE ROPE, 3/16" SS 7X19 WIRE STRAND 3 FT
16 M103173 HOURGLASS SLEEVE ALUM, 3/16 IN (OVAL SLEEVE ALUM) 4
17 M100482 1/16'' ALUMINUM OVAL, WIRE ROPE CLIP 6

12 11 10 8

B B

5 9
13 13

DETAIL A
SCALE 1 : 4

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

4 DIMENSIONS ARE IN INCHES


TOLERANCES:
DRAWN DF 1/22/15

FRACTIONAL 1/16 CHECKED DGW 1/22/15 TITLE:


A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 1/22/15
ROTATING PLATE ASSY, A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
LINKS ASSY
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500160
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/22/15 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 151.42 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500563 LOAD COLLAR REAR BRKT WLDMT 1
2 M100131 BRG, SPHER. PLAIN RADIAL, 1.38 x 2.188 2
3 M100329 RETNG RING, INT, 2.188 BORE, 0.049 THK 2
4 M100635 GREASE FITTING, 1/8-27 NPT, STRAIGHT 2 D
D
5 220102.1600 WASHER, NORD-LOCK, 1 IN, PAIR 8
6 008121.1644DH2 CAPSCREW,HEX HEAD, 1-8UNC X 2.75,DH2 8
7 M500413 PIN W/HEAD 1.375 x 4.4375 2
8 008121.0632DH2 CAPSCREW, HEX HEAD, 3/8-16UNC X 2.75 2
9 206101.0600 WASHER,FLAT,HARDENED,F436 PLAIN, 3/8 4
6 5 10 101112.0600 3/8-16 STOVER NUT 2

C C

B B

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

7 8 9 10 4 1 DIMENSIONS ARE IN INCHES DRAWN DGW 1/22/15


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/22/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/22/15
LOAD COLLAR A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
REAR ASSY
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION LINK ASSY
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500348
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTUE 1/22/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

A ITEM NO. PART NUMBER DESCRIPTION Default/QTY.


1 H101555-1 CYLINDER, LINK TILT 1
2 H500112 CYLINDER ROD END, GDM LINK TILT 1
3 M100635 GREASE FITTING, 1/8-27 NPT, STRAIGHT 1
D 4 M100131 BRG, SPHER. PLAIN RADIAL, 1.38 x 2.188 1 D

1 5 M100329 RETNG RING, INT, 2.188 BORE, 0.049 THK 1


6 312211.0608 SETSCREW, 3/8-16 UNC X 0.50 CUP POINT 1
B 7 H100723 PLUG, SOC HEX, 1/8, 1
8 H101970 ELL90º, MALE 3/8" ORFS, 3/4" ORB 2
SPARE PARTS H101555-2 SEAL KIT,LINK TILT,1-3/4'' ROD,GDM -

8
C C
C

2
3 6

B B

DETAIL C
SCALE 1 : 4

4 5
DETAIL B
SCALE 1 : 4

DETAIL A
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

SCALE 1 : 4 DIMENSIONS ARE IN INCHES


TOLERANCES:
DRAWN MH 09/25/2014
FRACTIONAL 1/16 CHECKED JP TITLE:
A - - - - - ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. JP
ELEV. TILT PLATE CYL. ASSY A
- - - - - PROPRIETARY AND CONFIDENTIAL TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
THIRD ANGLE
THE INFORMATION CONTAINED IN THIS
- - - - - DRAWING IS THE SOLE PROPERTY OF
GLOBAL DRILLING SUPPORT INTL. ANY
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION

-
REPRODUCTION IN PART OR AS A WHOLE MATERIAL
- - - - SIZE PART/DWG NO. REV

B A500347
WITHOUT THE WRITTEN PERMISSION OF

01
GLOBAL DRILLING SUPPORT INTL. IS
01
FINISH
RELEASE FOR PRODUCTION MH 9/25/14 - PROHIBITED.
125AA Unless stated otherwise

REV. DESCRIPTION INITIAL DATE ECN # DO NOT SCALE DRAWING SCALE: DNS WEIGHT: SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


5 8 10 4 7 13 11 8 11 2 10 12 6 1 M500564 ELEVATOR TILT PLATE 500T TOP DRIVE 1
2 M500368 BUSHING PIVOT TILT PLATE, TILT PLATE ASSY 4
3 M500369 BUSHING MID TILT PLATE, TILT PLATE ASSY 4
4 M500370 BUSHING LINK TILT PLATE, TILT PLATE ASSY 4 D
D
5 M500143 PIN ELEVATOR TILT PLATE, LOAD COLLAR ASSY 2
6 M500147 PIN ELEVATOR TILT PLATE UPPER, LOAD COLLAR ASSY 2
7 M500151 SPACER TILT PLATE, ROD EYE 4
8 M100635 GREASE FITTING, 1/8-27 NPT, STRAIGHT 6
9 M500413 PIN W/HEAD 1.375 x 4.4375 2
10 206101.0600 WASHER,FLAT,HARDENED,F436 PLAIN, 3/8 12
11 101112.0600 3/8-16 STOVER NUT 6
12 008121.0636DH CAPSCREW,HEX HEAD, 3/8-16UNC X 2.25,DH 4
13 008121.0628DH CAPSCREW, HEXHEAD, 3/8-16 X 1.5" GR. 8 2
14 M100559 WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE 10
C C
15 M100482 1/16'' ALUMINUM OVAL, WIRE ROPE CLIP 6
9 8 12 10 3 11
49"

1
30 2 "

B B
13 5
8 16 "

6
9
5 1 9 1
6

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 9/22/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 9/23/14 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 9/23/14
ELEVATOR A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
TILIT PLATE ASSY
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION LINK ASSY
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500349
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 9/23/14 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500168 LOAD COLLAR FRONT BRACKET WLDMT 1
2 M500161 BUSHING LOAD COLLAR BRACKET 2
3 008121.1636DH2 CAPSCREW,HEX HEAD, 1-8UNC X 2.25,DH2 8
D 4 220102.1600 WASHER, NORD-LOCK, 1 IN, PAIR 8 D

5.50
4 3

C C

17.00
B B

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DF 6/17/14


17.75 TOLERANCES:
FRACTIONAL 1/16 CHECKED TITLE:
DGW 6/17/14
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 6/17/14
LOAD COLLAR A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
FRONT BRACKET
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION ASSY
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500162
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 6/17/14 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 71.06 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


3 1 M500481 ELEVATOR, LINK BRACKET, GDM 1
1
2 M100635 GREASE FITTING, 1/8-27 NPT, STRAIGHT 4
3 M100142 BRG, SPHERICAL, PLAIN RADIAL, 1.00 X 1.625 2
D 4 M500494 RETAINING RING, INTERNAL, 1.625 2 D

2
1 1
2

A A

C C

1.00

3
15.00
2

1 3
B
B B
3

SECTION A-A
SCALE 1 : 2
1

DETAIL B 4 UNLESS OTHERWISE SPECIFIED: NAME DATE


SCALE 1 : 1 DIMENSIONS ARE IN INCHES DRAWN MH 4/21/2014
GDS International
TOLERANCES:
FRACTIONAL 1/16 CHECKED TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 ENG APPR. JP 4/21/2014 ELEVATOR LINK, A

ASSEMBLY, GDM
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 MFG APPR. XXX XX/XX/XX
PROPRIETARY AND CONFIDENTIAL INTERPRET GEOMETRIC Q.A.
TOLERANCING PER: ASME Y14.5M XXX XX/XX/XX
THE INFORMATION CONTAINED IN THIS
MATERIAL
DRAWING IS THE SOLE PROPERTY OF SIZE DWG. NO. REV

B A500411
GLOBAL DRILLING SUPPORT INTL. ANY

01 RELEASE FOR PRODUCTION JP 4/22/14


REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GDS PART No.-Revision FINISH
01
GLOBAL DRILLING SUPPORT INTL. IS

REV. DESCRIPTION INITIAL DATE PROHIBITED.


DO NOT SCALE DRAWING SCALE: 1:4 WEIGHT: SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

14 15 16 17 29 11 19 12 1 12 13
11
24

D D
13

11
A A
29 10

14

C 12 C

21 29 10 3 4 12
B

14

B B

30 22

B 30 23

SECTION B-B
20

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 11/18/13


TOLERANCES:
21 20 5 6 9 2 7 18 8 4 FRACTIONAL 1/16 CHECKED DF 11/5/14 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 11/5/14
GRABBER ASSEMBLY A
SECTION A-A TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
500T
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500345
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/18/13 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1094.47 LBS SHEET 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION Default/ GRABBER CONFIGURATIONS


QTY. DIE BLOCKS
1 M500546 BODY, GRABBER, 500 T 1 GATE SIDE ROD SIDE OPTION
2 M500547 ROD, GRABBER 1 A500102 A500103 SMALLEST
3 M500548 PLUG, BORE, GRABBER, 500T 1 A500102 A500105 STANDARD
D 4 M500549 PLATE, RETAINER, PLUG, GRABBER 500T 4 A500353 A500105 650 TON LWCV ONLY D

5 S500016 WIPER, ROD, SNAP-IN, 6.000" 1


STABBING GUIDES
M500182 M500181 7 INCH
6 S500017 POLYPAK SEAL, TYPE B, 6.0" ID x 6.5" OD x .562" WIDE 1
M500723 M500722 9 INCH
7 S500018 SEAL, PISTON, CPS CAPPED T-SEAL, 9" OD 1
8 S500020 O-RING, 9-3/8" OD X 9" ID X 3/16" W 1
9 S500019 RING, WEAR, ROD, 6" ID X 6 1/4" OD X 1/2" W, 612F, ANGLE CUT 1
10 008121.0824DH2 CAPSCREW, HEX HEAD, 1/2-13UNC X 1.50, DH2 12
11 H500008 ELL 45deg, MALE 3/8" ORFS, MALE 1/2 ORB 2
12 H101400 PLUG, SOCKET HEX, 1/2'' ORB 4
13 M500581 PLATE, STRAP, RETAINER 1
C 14 M500209 GATE, GRABBER, 500 T 1 C
15 M500204 PIN GRABBER CLAMP 2
16 M500203 PIN LOCK, GRABBER ASSY 2
17 008121.0836DH2 CAPSCREW,HEX HEAD, 1/2-13UNC X 2.25,DH2 4
18 S500021 RING, WEAR, PISTON, 9" OD X 8 3/4" ID X 1/2" W, 612F, ANGLE CUT 1
19 H103771 2 X 7'' ISO LIGHT DIE SPRING 4
20 M500181 BELL GUIDE REAR 7 IN, GRABBER ASSY 1
21 M500182 BELL GUIDE FRONT 7 IN, GRABBER ASSY 1
22 008121.1236DH2 CAPSCREW,HEX HEAD, 3/4-10UNC X 2.25,DH2 2
23 008121.1224DH2 CAPSCREW, HEX HEAD, 3/4-10UNC X 1.50, DH2 2
B 24 A500254 GRIPPER SPRING STABILIZER, GRABBER ASSY 1 B
25 M100482 FERRULE, 1/16, OVAL, ALUMINUM 12
26 M100559 WIRE ROPE, 1/16" SS ,7X7 SAFETY CABLE 6
27 A500105 GDM 650/500 TON ROD SIDE DIE BLOCK ASSEMBLY 1
28 A500102 GDM 650/500 TON GATE SIDE DIE BLOCK ASSEMBLY 1
29 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 16
30 220102.1200 WASHER,LOCK,NORDLOCK,1 PAIR 3/4 5

GDS International
TITLE:
A GRABBER ASSEMBLY A
500T

SIZE PART/DWG NO. REV

B A500345 01
WEIGHT: LBS SHEET 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500578 BLOCK, DIE, GRABBER 1
2 R100030 BLOCK, DIE, GRABBER 2
3 M500579 BLOCK, DIE, RETAINER 2
4 008121.0816DH2 CAPSCREW,HEX HEAD, 1/2-13UNC X 1.00,DH2 4 D
D
5 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 4
3 6 M500553 PIN, BLOCK, DIE, GATE 1
38"
7 M100559 WIRE ROPE, 1/16" SS, 7X7 SAFETY CABLE 2
8 M100482 FERRULE, 1/16, OVAL, ALUMINUM 4

4 5 6
2 3 1
C C

7
68"

B B

5"

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DF 11/4/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 11/4/14 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 11/4/14
GDM 650/500 TON A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
GATE SIDE DIE
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION BLOCK ASSEMBLY
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500102
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/4/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 21.93 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


3 1 5 2 3 1 M500578 BLOCK, DIE, GRABBER- 4.000" X 6.625" OD 1
2 M500550 PIN, BLOCK, DIE, ROD 1
3 M500551 BLOCK, GUIDE, ROD, GRABBER, 500T 2
4 R100030 TONG DIE, 1/2 x 1 1/4 x 5 LONG 2
D
5 M500580 PLATE, RETAINER, DIE, ROD SIDE - 082-02-024 BLOCK 2 D
6 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 8
7 008121.0816DH2 CAPSCREW,HEX HEAD, 1/2-13UNC X 1.00,DH2 4
8 008121.0844DH2 CAPSCREW,HEX HEAD, 1/2-13UNC X 2.75,DH2 4
9 M100482 FERRULE, 1/16, OVAL, ALUMINUM 8
10 M100559 WIRE ROPE, 1/16" SS, 7 X 7 SAFETY CABLE 4

4
7 5 2
A 7
C C
3

8 6

1
7 16 "

B B

3
A 38"
SECTION A-A
15
10 16 "
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 1/27/15


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/27/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/27/15 GDM 650/500 TON A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 ROD SIDE 3 1/2"
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION DIE BLOCK ASSY
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500103
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURING 1/27/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500585 BLOCK, DIE, GRABBER 1
5
2 R100030 TONG DIE, 1/2 X 1-1/4 X 5 LONG TC DIE 2
3 M500567 PLATE, RETAINER, DIE ROD-SIDE FOR THE 8.5" OD DIE BLOCK 2
4 M500551 BLOCK, GUIDE, ROD, GRABBER, 500T 2 D
D
5 M500550 PIN, BLOCK, DIE, ROD 1
3
2 16 " 6 008121.0820DH2 CAPSCREW,HEX HEAD,1/2-13UNC X 1.25,DH2 4
7 008121.0844DH2 CAPSCREW,HEX HEAD, 1/2-13UNC X 2.75,DH2 4
8 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 8
9 M100559 WIRE ROPE, 1/16" SS, 7X7 SAFETY CABLE 4
10 M100482 FERRULE, 1/16, OVAL, ALUMINUM 8

2 3 6 8 1 4
A

C C

15 7 8
6 16 "

B B

A
SECTION A-A
15
10 16 "

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DF 11/4/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 11/4/14 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 11/4/14
GDM 650/500 TON ROD A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
SIDE 5 1/2 IN
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION DIE BLOCK ASSEMBLY
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500105
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 11/4/2014 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 21.30 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

BOM Table
1 2 ITEM NO. PART NUMBER DESCRIPTION QTY.
1 M500585 BLOCK, DIE, GRABBER, 6.625" - 8.500" 1
2 M500568 PLATE, RETAINER, DIE, GATE SIDE FOR 6-5/8" - 8-1/2" OD 2
3 R100030 TONG DIE, 1/2 x 1 1/4 x 5 LONG 2
D
4 M500553 PIN, BLOCK, DIE, GATE, GRABBER 500T 1 D
5 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 4
6 008121.0816DH2 CAPSCREW,HEX HEAD, 1/2-13UNC X 1.00,DH2 4
7 M100559 WIRE ROPE, 1/16 SS, 7X7 SAFETY CABLE 2
8 M100482 1/16" ALUMINUM OVAL, WIRE ROPE CLIP 4

5"

3
2 16 "
A 6 5
C 4 C

15
6 16 "

B B
NOTE:
LOWER WELL CONTOL VALVE (LWCV) USE ONLY.

2
A
SECTION A-A

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN DGW 1/28/15


TOLERANCES:
FRACTIONAL 1/16 CHECKED DF 1/28/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/28/15 GDM 650/500 TON A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 GATE SIDE 6.625-8.50
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION DIE BLOCK ASSY
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500353
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/28/2015 DGW 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 M500323 BASE STABILIZER, GRIPPER SPRING 1
2 M500321 STABILIZER SLIDE, GRIPPER SPRING 1
3 M500322 STABILIZER SLIDE INSERT, GRIPPER SPRING 1
4 M500324 CAP STABILIZER, GRIPPER SPRING 1 D
D
5 M500395 SPRING, COMPRESSION, GRIPPER 2
10 11 6 220102.0800 WASHER,LOCK,NORDLOCK,1 PAIR 1/2 2
5 1 10
11 7 008121.0820DH2 CAPSCREW,HEX HEAD,1/2-13UNC X 1.25,DH2 2
8 230101.1200 WASHER, LOCK, HI COLLAR 3/4" 2
1 9 026211.1244DH2 CAPSCREW,SOCKET HEAD, 3/4-10UNC X 2.75, DH2 2
2 10 208202.0800 WASHER,FLAT,Gr8, SAE, YZ, 1/2 2
5 11 101112.0800 NUT,HEX,STOVER C 1/2-13 2
12 M100559 WIRE ROPE, 1/16'' SS, 7 X 7 SAFETY CABLE 6
13 M100482 FERRULE, 1/16, OVAL, ALUMINUM 20
9
C
3
C

7 2
SECTION A-A
SCALE 1 : 3 INSERT OPTIONS
M500322 STANDARD
4 11
5 10 M500724 LARGE
4 7 6
4
3 A A

B B

10 11
3

2
1
9

8
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN JP 1/6/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 1/28/15 TITLE:
A 1 ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DGW 1/28/15
GRIPPER SPRING A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
STABILIZER,
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC PROJECTION GRABBER ASSY
TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500254
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/28/2015 JP 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
1 of 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


41.00 1 M500616 BONNET 500T TOP DRIVE JOLIET MOTOR 1
2 M100623 ADAPTER, S PIPE 1
3 M500310 SHIMS, S-TUBE ADAPTER, TOP DRIVE ASSY 1
2 4 230101.1000 WASHER,LOCK,HI COLLAR 5/8 8
D D
5 026211.1032DH2 CAPSCREW,SOCKET HEAD, 5/8-11UNC X 2.00, DH2 8
6 026211.1656DH2 CAPSCREW,SOCKET HEAD, 1-8UNC X 3.50, DH2 20
7 230101.1600 WASHER,LOCK,HI COLLAR 1'' 20

1
C C
2

A 4 5

B
35.50 B

6 7

A 34.27

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE
SECTION A-A
DIMENSIONS ARE IN INCHES DRAWN DF 1/27/15
TOLERANCES:
FRACTIONAL 1/16 CHECKED DGW 1/27/15 TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. DF 1/27/15
BONNET ASSY A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005
GDM
THIRD ANGLE
INTERPRET GEOMETRIC PROJECTION
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER: ASME Y14.5M
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500370
DRAWING IS THE SOLE PROPERTY OF

01
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
01 RELEASE FOR MANUFACTURE 1/27/15 DF 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 1000.93 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

D D

C C

B B

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN WJB 1/22/2015


TOLERANCES:
FRACTIONAL 1/16 CHECKED - - TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. - - ASSY, HYDRAULIC A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 GDM 500
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION -
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500230
DRAWING IS THE SOLE PROPERTY OF

1
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR DATABOOK 1/22/2015 WJB 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 A500240 BLOCK INTERFACE ASSY 1
2 M500098 PIN LOAD SIDE PLATES 500T TOP DRIVE CORE 4
3 M500228 KEEPER LOAD PIN, CORE ASSY 4
4 220102.1000 WASHER, LOCK, NORDLOCK, 5/8" 8 D
D
5 008121.1028DH2 CAPSCREW, HEX HEAD, 5/8-11 UNC X 1.75, DH2 8
6 M500069 SIDE LOAD PLATE, GDM 2
7 M500279 BUSHING, BLOCK INTERFACE ASSY 2
8 H100662 PLUG, SOCKET HEX, 1/2'' ORB 4

8 7
C C

6
A

B B

DETAIL A
B SCALE 1 : 4
5 4
DETAIL B
SCALE 1 : 4

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN JAV 1/2/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED - - TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. - - BLOCK INTERFACE A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 ASSEMBLY, WITH SIDE
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION PLATES
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500329
DRAWING IS THE SOLE PROPERTY OF
2 REDRAWN 1/21/2015 WJB
2
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE 1/2/14 JAV 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 3347.37 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 M500384 PIN BLOCK INTERFACE. BLOCK INTERFACE ASSY 2


500T
2 M500223 RETAINER, SIDE, BLOCK INTERFACE ASSY 500T 2
8 7 3 M500279 BUSHING, BLOCK INTERFACE ASSY 2
D D
4 M500070 COUNTER BALANCE BEAM 1
5 008121.1636DH2 008121.1636DH2 8
6 220102.1600 WASHER, NORD-LOCK, 1 IN, PAIR 8
7 101112.1200 NUT,HEX,STOVER C 3/4-10 2
8 008121.1280DH2 CAPSCREW,HEX HEAD, 3/4-10UNC X 5.00,DH2 2

C C
5 6
1 4
2

B B

3
GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN WJB 1/21/14


TOLERANCES:
FRACTIONAL 1/16 CHECKED - - TITLE:
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. - - BLOCK INTERFACE A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 ASSEMBLY
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION -
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500240
DRAWING IS THE SOLE PROPERTY OF

1
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR MANUFACTURE 1/21/2015 WJB 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 995.16 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

ITEM NO. PART NUMBER DESCRIPTION QTY.


1 H800000 CYLINDER, HYDRAULIC 5IN BORE X 10IN STROKE 1
2 M100635 GREASE FITTING, 1/8-27 NPT, STRAIGHT 2
3 M500413 PIN W/HEAD 1.375 x 4.4375 2
4 H101030 ELL 90°, MALE 1/2 ORFS, MALE 3/4 ORB 2
D 5 008121.0628DH CAPSCREW, HEX HEAD, 3/8-16UNC X 1.75, DH 2 D

6 101112.0600 NUT,HEX,STOVER C 3/8-16 2


SPARE PARTS M102871 PIN/CLEVIS SET, CYLINDER, COUNTERBALANCE -
SPARE PARTS H800000-1 GDM STAND JUMP CYLINDER SEAL KIT -
SPARE PARTS 312211.0608 SETSCREW, 3/8-16 UNC X 0.50 CUP POINT -

1 2 3 5 6

C C

B B

GDS International
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN WJB 1/21/15


TOLERANCES:
TITLE:
LOCATION OF ASSEMBLY
FRACTIONAL 1/16 CHECKED DF 1/27/15
A
ANGULAR: MACH .5 BEND 1
ONE PLACE DECIMAL .031 APPR. WJB 1/27/15 STANDJUMP A
TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 ASSEMBLY
THIRD ANGLE
PROPRIETARY AND CONFIDENTIAL
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
PROJECTION -
THE INFORMATION CONTAINED IN THIS MATERIAL
SIZE PART/DWG NO. REV

B A500024
DRAWING IS THE SOLE PROPERTY OF

1
GLOBAL DRILLING SUPPORT INTL. ANY
FINISH
REPRODUCTION IN PART OR AS A WHOLE
1 RELEASE FOR MANUFACTURE 1/21/2015 WJB 125AA UNLESS STATED OTHERWISE
WITHOUT THE WRITTEN PERMISSION OF
GLOBAL DRILLING SUPPORT INTL. IS
REV. DESCRIPTION DATE APPROVED ECN # PROHIBITED. DO NOT SCALE DRAWING WEIGHT: 3393.46 LBS SHEET 1 OF 1
8 7 6 5 4 3 2 1
650/850 T O N T O P D R I V E MANUAL REV 0

5B Electrical Schematics

134
G D M / 6 5 0 T O P D R I V E

5B Electrical Schematics
Electrical Schematics Index

Drawing No. Revision Description


05-MAIN-PWR 02 MAIN POWER DISTRIBUTION
09-PWR-GDP 01 120/24V POWER DISTRIBUTION GLOBAL
DRILLING PANEL
10-GDP-PLC 01 PLC RACK CONFIGURATION GLOBAL
DRILLING PANEL
17- ENC 01 ENCODER SCHEMATIC
18-PRO-INX 01 10C/12- INTERCONNECTION
19-PLC-TD-2 01 TOP DRIVE RACK 1 CONFIGURATION
20-PLC-TD-2 01 TOP DRIVE RACK 1 CONFIGURATION
21-OP-INT 01 OPERATOR INTERFACE TERMINAL
SCHEMATIC
22/PLC-AC- 02 CONSOLE RACK 3 CONFIGURATION
RACK-3
24-CON- 01 CONSOLE OUTPUTS SCHEMATIC
OUTPUT
25-CON-3RD 0 CONSOLE 3RD PARTY SCHEMATIC
30-E-STOP 02 E-STOP/LOCKOUT- AC/DC SCHEMATIC
31-HPU 01 HPU SCHEMATIC
32-OP-INT 01 LUBE CONTROL SCHEMATIC
33-BLOW 01 BLOWER CONTROL SCHEMATIC
34-TD-ENA 01 TOP DRIVE ENABLE SCHEMATIC
35-TD-ENC 01 TOP DRIVE SPEED CONTROL SCHEMATIC
39-BU-WRENCH 01 BACK UP WRENCH CONTROL
40-HANDLER 01 HANDLER CONTROL SCHEMATIC
41-LINK 0 LINK TILT CONTROL SCHEMATIC
42-IBOP 0 IBOP SCHEMATIC
43-BRAKE 0 BRAKE CONTROL SCHEMATIC
48-AC-TEMP 01 AC MOTOR TEMPRATURE SCHEMATIC
60-ELEV 01 ELEVATOR SCHEMATIC
61-ZONE 00 PLC RACK CONFIGURATION
62-SLIDER 00 SLIDER SCHEMATIC
DRIVER HOUSE 01 DRIVER HOUSE SCHEMATIC
101-SCR-DC 01 SCR HOUSE SCHEMATIC

GDM650 Rev. 8 135


SERVICE TOPDRIVE
500 MAST LOOP
GDP 600V MCC MAST AUX MTR J
501 Main Breaker BLOWER CAB 22
MS MS TB70 TB90
BLACK BLACK CAB 48
502 1 1
L1 T1 L3 T1 L1 T1 LOCAL BLOWER
WHITE 2 WHITE 2 15 HP
503 L2 T2 L2 T2 L2 T2 3550 RPM
RED RED
504 3 3 13.8 Amp
L3 T3 L1 THERMAL TRIP: 16 Amps T3 L3 T3
THERMAL TRIP: 100 Amps
MAGNETIC TRIP: 100 Amps
MAGNETIC TRIP: 450 Amps GREEN GREEN
4 4
505 LUBE PUMP
CB1 MCC BUS MS
ORANGE ORANGE
506 5 5
L3 T1 L1 T1 CAB 49 LUBE PUMP
BLUE BLUE
507 6 6 2 HP
LINE MONITOR L2 T2 L2 T2 1750 RPM
WHT-BLK WHT-BLK
508 TB11 7 7 2.7 Amp
NO 732 3015 L1 T3 L3 T3
1 THERMAL TRIP: 3.5 Amps
RED-BLK RED-BLK
Console MAGNETIC TRIP: 55 Amps
8 8
509
L1
2 E-stop
730 GRN-BLK
510 L2
C
918 9 9
L3
24V ORN-BLK
511 734A 10 10
NC
BLU-BLK
512 11 11
734 RL 1
SCR E-Stop BLK-WHT
513 TB23 12 12
705B
4 RED-WHT
514 UV Trip CB1 A1 A2 MOTOR 13 13 MOTOR
0030 HEATER GRN-WHT HEATER
TB 23:5 /936 14 14
515 Orange Brown
DC ONLY BLU-WHT
516 LUBE 15 15 LUBE
RL 1 HEATER BLK-RED HEATER
517 SCR E-Stop 16 16
TB14 Relay
518 3
205 CAB 23
11 14
519 3010
206
4
520 CAB 19
MTR5
521 L1 T1 L1 T1 T1

522 M
L2 T2 L2 T2 T2
523
HPU1
TB3
524 120 V (L) 650
L3 T3 L3 T3 T3 20 HP
1 TB20:1 907 1760 RPM
THERMAL TRIP: 25A
525 120 V (N)
2
651
TB21:1 924 MAGNETIC TRIP: 400A 19.3 A - 575V

526 3
CAB 20
527 GREEN
L1 T1 L1 T1 T1
MTR6

528 WHITE
M
BLACK L2 T2 L2 T2 T2
529
HPU2
530 CB ** TB4 L3 T3 L3 T3 T3 20 HP
120 V (L) BLACK L1 L1
1 SOLA THERMAL TRIP: 25A 1760 RPM
531 120 V (N) WHITE N UPS N MAGNETIC TRIP: 400A 19.3 A - 575V
2
532 GREEN G G
3
533 L2
L1 T1 L1 T1 HPU COOLER
534 M 2 HP
L2 T1 L1 T1 1750 RPM
535 L3 T1 L1
2.7 Amp
T1
536
537
901
902
903
904
905
TB 20
906 120V AC
10A
650 1F 600
TB3-1 120V AC (L) / 523 TB 20:1 / 1027 PLC PS1
907 1A POWER SUPPLY TB 22
#12 AWG 2F
120 VAC/24 VDC 24VDC(+)
908 3F 726 10A
700
C 1F
TD 24V PS1 / 1804
RDY
909 #12 AWG
10A
4F 606 606
L AC(L) NO
106
3027
10A
2F 702 TD 24V PS2 / 1805
10A
608 740 5A
910 5F
N AC(N) 24VDC + 746 3F

1A 10A
6F
G 24VDC - 741 4F
911 5A
2A
7F
744 5F 708 TB 22:5 /3102 HPU SENSORS
912 3027
5A
8F 2A
740 6F 710 TB 22:6 / 3151 HPU1 STATUS
2A
913 650 656 9F PS2 742
5A
7F 712
TB 22:7 / 3021 CONSOLE PLC
2A POWER SUPPLY 2A
10F
914 120 VAC/24 VDC #14 AWG 8F 714 TB 22:8 / 3163 HPU2 STATUS
#12 AWG #12 AWG 728
5A
11F C 1A
9F 716 TB 22:9 / 1735 ENCODER SELECT
915 5A 608
RDY
107 2A
12F L AC(L) NO
10F 718
TB 22:10 / 3269 LUBE STATUS
916 626
609
N AC(N) 24VDC + 742 2A
720
13 11F
TB 22:11 / 3369 BLOWER STATUS/ CT
743
917 658
G 24VDC - 2A
12F F12
TB 22:12 / MICROBOX
14 2A
142
918 13F
TB 22:13 / 3416 HEATER OPTION
5A
14F 730
15 E-STOP POWER
919 5A
15F

920 TB3-1 120V AC (L) / 523


650 605
120V AC (N) 926 726 726
16
903
RL3:43 / 3151 HPU2 STARTER
921 658
CB3
630A 605A 120V AC (N) 926 728 17
2 amp F 900
1 2 RL3:33 / 3143 HPU1 STARTER
922 18 908
RL3:63 / 3360 BLOWER STARTER
906
923 19 RL3:53 / 3260 LUBE STARTER
TB 21
120V AC(N) 651 20
924 651 TB3:2 / 526 GDP PLC M1
TB3-2 120V AC (N) / 524 1 106
601 1 I:1/0.0
925 TB11:6 / 3018
#12 AWG 1019 24V POWER SUPPLY #1
GDP PLC M1
926 / 920
605A 605
/ 920 107
2 I:1/0.1
2
603 607
927 PLC PS (N) / 1028 TB 23 1020 24V POWER SUPPLY #2
0V DC RETURN
928 609 741 705
RL6 - A2 / 3145
3 711 1 701
929 TB11:4 / 3023 TD RET PS1 / 1806

930 743 705


RL5 - A2 / 3117
4 2 703
705A
931 3143 TB9-4 / 1806
#14 AWG
932 705B 715
RL2 - A2 / 1732
932
5 3
933 RL8 - A2 / 3372
705 713
RL3 - A2 / 3011
6
934 705C 0030
3365 RL2 - A2 / 1732
4
935 3160
705E 621
TB21:11 / 3421

936 705D 705F


3260 TORQ,RPM
937 0030
5
UV/ 515
6
938
1001
1002
752

1003 753
ETHERNET PIN-OUT
1 - WHITE / GREEN
1004 M L+
MANAGED ETHERNET
SWITCH 2 - GREEN
3 - WHITE / ORANGE
CAB 30
1005 CAB 31
2119 4 - BLUE
5 - WHITE / BLUE
2119
6 - ORANGE
1006 1928 7 - WHITE / BROWN
1 8
6GK5310-0BA00-2AA3 8 - BROWN

1007
1008 754 754 754
24 VDC
1113

1009
RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP RACK 0 GDP

1010 GDP-PS GDP-CPU GDP-1 GDP-2 GDP-3 GDP-4 GDP-5


1011 DIGITAL INPUT 8 ANALOG INPUT 8 ANALOG OUTPUT
#1 #2 #3 #4 #5
1012
L1+ L1+ 754 L1
1 1 1 L1
1013 I-1/0.0 2 106 24V PS#1
924
O-1/0.0 2 135 TD VFD E-STOP/LOCKOUT
3011
O-2/2.0 2 181 HOUR METER
3421
754
2 (+) CH 0 1
754
754
HPU PRESSURE
AI-1/0 OPTION
1014 I-1/0.1 3 107 24V PS#2
926
O-1/0.1 3 134 BLOWER START
3362
O-2/2.1 3 SPARE 3
(-)
149
3 (+)164A
CH 0
PROFIBUS

1015
PORT
I-1/0.2 4 115 AUTO SLIDER REV O-1/0.2 4 139 LUBE PUMP START O-2/2.2 4 SPARE
C 4 (+) CH 1
AO-1/0
6
(-)
165A
TD TORQUE SIGNAL
THIRD PARTY 0
4202 3262 SPARE 3522
AI-1/2
1016 I-1/0.3 5 114 SLIDER ENABLE O/P O-1/0.3 5 137 HPU COOLER START O-2/2.3 5 SPARE 5
(-)
7 (+)164B
CH 1
4205 3162 149
AO-1/2 TD RPM SIGNAL
(-)
1017 I-1/0.4 6 112 BLOWER CT O-1/0.4 6 132 HPU #1 START O-2/2.4 6 SPARE 6 (+)
CH 2
SLIDER RPM SP
10 165B
THIRD PARTY 0
752 3369 3145 3529
L+ AI-1/4 3107
1018 I-1/0.5 7 105 HPU COOLER RUN O-1/0.5 7 133 HPU #2 START O-2/2.5 7 SPARE
(-)
11 (+)164C
SIEMENS 6ES7315-2EH14-0AB0
SIEMENS 6ES7307-1KA02-0AA0

7 CH 2
753 3164 3157 149

1019
M
ETHERNET
PORT I-1/0.6 8 100 TD HPU E-STOP O-1/0.6 8 138 SLIDER ENABLE O-2/2.6 8 SPARE
C 8 (+)
AO-1/4
14
(-)
165C
TD TORQUE SIGNAL
THIRD PARTY 1
3119 3422 CH 3 3522
AI-1/6 SLIDER TORQUE
1020 I-1/0.7 9 101 TD LUBE PUMP RUN O-1/0.7 9 136 HORN O-2/2.7 9 SPARE 9
(-) LIMIT 3107 15 (+)164D CH 3
3269 L1+ 3413 L1+ 149 TD RPM SIGNAL
754 754 AO-1/6
(-)
1021 L+ 10 10 10 11 18 165D
THIRD PARTY 1
3529
149
Comp + M - ana
I-1/1.0 12 102 TD BLOWER RUN O-1/1.0 12 900 SCR FORWARD O-2/3.0 12 SPARE
1022 M 3369 754
11
754
11 12 (+) CH 4
23 (+)
CH 4
AO-1/8 TD TORQUE SIGNAL
AI-1/8 INCLINEOMETER (-)
I-1/1.1 13 108 TD HPU OIL LEVEL O-1/1.1 13 901 SCR REVERSE O-2/3.1 13 SPARE THIRD PARTY 2
1023 3104 13
(-) 3107 26
149

1024 750
I-1/1.2 14 103 TD HPU#1 RUN
3150
O-1/1.2 14 902 SCR 40 AMP FIELD O-2/3.2 14 SPARE C 14 (+) CH 5
27 (+) CH 5
L+ L+ SPARE TD RPM SIGNAL
AO-1/10
SCR 15 AMP FIELD SPARE AI-1/10 (-) THIRD PARTY 2
1025 I-1/1.3 15 104 TD HPU#2 RUN
3162
O-1/1.3 15 903 O-2/3.3 15
(-) 30

SIEMENS 6ES7322-1BH01-0AA0
SIEMENS 6ES7322-1HH01-0AA0
SIEMENS 6ES7321-1BH02-0AA0

SIEMENS 6ES7322-5HF00-0AB0
751 15

SIEMENS 6ES7331-7KF02-0AB0
M M 149

1026 I-1/1.4 16 111 TD LOCKOUT / E-STOP


3035
O-1/1.4 16 SPARE O-2/3.4 16 SPARE
16 (+) 880 CH 6
31 (+) 882 CH 6
SCR
600 SCR TORQUE AO-1/12 TORQUE LIMIT
AI-1/12 (-)
1027 120V AC
907
L1 I-1/1.5 17 113 SCR FIELD LOSS O-1/1.5 17 SPARE O-1/3.5 17 SPARE
17
(-) FEEDBACK 34 0VDC REFERENCE
149
1028 120V AC (N)
925
603
N L+
754
I-1/1.6 18 SPARE O-1/1.6 18 SPARE O-2/3.6 18 SPARE B 18 (+) 881 CH 7
35 (+) 883 CH 7
SCR
755 SCR RPM AO-1/14 RPM LIMIT
AI-1/16 (-)
1029 GND M I-1/1.7 19 SPARE O-1/1.7 19 SPARE O-2/3.7 19 SPARE
19
(-) FEEDBACK 38 0VDC
REFERENCE

149
1030 M 20 M 20 M 20 M 20 M 20

1031
1032 755 755 755 755 755
0 VDC
1132

1033
1034
1035
1036
1037
1037
1001
1002
1003
1004
1005
1006
1007
1008
1009
RACK 0 GDP

1010 GDP-6
1011
#6
1012
754 L1+
24 VDC 21
1013 1009 3 197 WHITE
4844

1014 CH 0
GRID TEMP 1
4 196 RED
4842

1015 5 197

1016 6 198 RED


4843

1017 7 200 WHITE


4849

1018 CH 1 8 199 RED


GRID TEMP 2 4847

1019 9 200

1020 10 201 RED


4848

1021
SIEMENS 6ES7311-7PF01-0AB0

11 203 WHITE
1022 4854

CH 2 12 202 RED
1023 ROOM TEMP 4852

1024 13 203

RED
1025 14 204
4853

1026 15 556 WHITE

1027 CH 3
HPU TEMP
16 557 RED

1028 17

1029 18 557 RED

1030 M 40

1031
1032 0 VDC
755
1033

1033
1034
1035
1036
1037
1037
1700
1701
1702
1703
GDP
1704
1705 TD TB1
1 TB2:1
1706
2 TB2:2
1707
1708 3 TB2:3

1709 4 TB2:4

1710 5 TB2:5
1711
6 TB2:6
1712
7 TB2:7
1713
8 TB2:8
1714
1715 9 TB2:9

1716 10 TB2:10

1717
1718
VFD GDP TB2 MAST J BOX TD AUX BOX
1719 TD 309TB8 TD TB2 TD TB2 TD TB2
800
+VDC 1 1 1 1 RED
1720
+VDC CAB 33
801
1721 0VDC 2 2 2 2 BLACK

1722 3 3 3

1723 SIG(A)
802
YELLOW
11 4 4 4
TO VFD DRIVE
1724 CHANNEL A CHANNEL A
803
SIG(A\) 12 5 5 5 YELLOW/WHITE
TD ENCODER
1725 CAB 33
6 6 6
1726
804
1727 SIG(B) 13 7 7 7 BLUE
CHANNEL B CHANNEL B
805
1728 SIG(B\) 14 8 8 8 BLUE/WHITE

1729 9 9

1730
10 10
1731
1732
NOTE:
715A

1733 ***VFD TO GDP SHIELDS TO BE GROUNDED AT VFD***


***ISOLATED AT GDP***
1734
1735 ***NOTE : GDP TO ENCODER SHIELDS GROUNDED AT GDP / ISOLATED AT TD***
1736
1737
DRILL FLOOR MAST TOPDRIVE
SERVICE LOOP
1801
MAST CONTROL J-BOX TD PLC J-BOX
1802 GDP
700
TD TB9
TB71
D1 TB30
CAB13 BLACK CAB 43 BLACK 363 788
TD 24V S1 / 907 1 1 1
TD R1 13
1803 1 I-0.0
TD 24V S2 / 908
702 2
WHITE
2
WHITE 366
1804 D2
789
2
1805 TD R1 13
2 I-0.1
701 RED RED 3
TD RET S1 / 928 3 3
1806
703 GREEN GREEN 4
TD RET S2 / 929 4 4
1807 24 VDC
5
ORANGE
1808 5 TB70 / 516 5

1809 6
BLUE
TB70 / 517 6

7
1810
8
1811
9 0 VDC
1812 7
WHT-BLK
7
WHT-BLK

10
1813 RED-BLK RED-BLK
8 8

1814
9 GRN-BLK 9 GRN-BLK

1815
ORN-BLK ORN-BLK
10 10G
1816
1817 11

1818 12

1819
1820
1821
1822
1823
1824
1825
1826
1827
1828
1829
1830
1831
1832
1833
1834
1835
1836
1837
1838
MODULE #1 MODULE #2 MODULE #3 MODULE #4 MODULE #5 MODULE #6 MODULE #7
2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC
1900 RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE

1901
1902
ETHERNET
1903 24V 0V DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2

1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5
1904 HNDLR ROTATE
FORWARD
HNDLR ROTATE
REVERSE HNDLR UNLOCK STAND JUMP IBOP CLOSE IBOP OPEN BUW CLOSE BUW OPEN
LINK TILT
EXTEND
LINK TILT
RETRACT
LINK TILT
FLOAT
HYDRAULIC
OIL COOLER BRAKE BRAKE DUMP
Q8.0 Q8.1 Q9.0 Q9.1 Q10.0 Q10.1 Q11.0 Q11.1 Q12.0 Q12.1 Q13.0 Q13.1 Q14.0 Q14.1
320 322 334 316 314 312 310 308 326 328 324 332 304 306
1905
1906
+ + 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V
1907 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6

1908
1909
1910 - - 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V 0V

3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7
1911
321 323 335 317 315 313 311 309 327 329 325 333 305 307
1912
1913
PE PE PE PE PE PE PE PE PE PE PE PE PE PE PE PE
1914 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8

1915
1916
1917
WAGO 750-375 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508
1918
1919 TB30:7
0V MODULE #8 MODULE #9 MODULE #10 MODULE #11 MODULE #12 MODULE #13 MODULE #14
24V 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 2-DO 24V DC 16-DI 24V DC 4-AI 4-20mA
TB30:1 RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE
1920 DI1 DI2

1 2
1921 24V POWER 24V POWER
SUPPLY #1 SUPPLY #2

1922 363 366


DI3 DI4
DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 DO1 DO2 AI1 AI2
1923 1 5 1 5 1 5 1 5 1 5 AIR PRESSURE
3 4
PH LOCK 1 5
1MM MANIFOLD 2.5MM MANIFOLD ELEVATOR ELEVATOR SWITCH (AC ONLY) SENSOR
1924 TANK VENT
Q15.0
SPARE
Q15.1
COLD WEATHER
Q16.0
COLD WEATHER
Q16.1
OPEN
Q17.0
CLOSE
Q17.1
SPARE
Q18.0
SPARE
Q18.1
SPARE
Q19.0
SPARE
Q19.1 352 355
SPARE SPARE

344 1000 1002 330 332


DI5 DI6
1925 5 6
TD HEIGHT WEIGHT
PROX SWITCH PROX SWITCH
1926 24V 24V 24V 24V 24V 24V 24V 24V 24V 24V 375 M M

2 6 2 6 2 6 2 6 2 6 DI7 DI8 2 6
1927 7 8
PURGE PRESSURE
1928 SWITCH SPARE

1929 DI9 DI10

9 10
0V 0V 0V 0V 0V 0V 0V 0V 0V 0V AI3 AI4
1930 3 7 3 7 3 7 3 7 3 7
SPARE SPARE
3 7
HYDRAULIC
1931 DI11 DI12 SPARE SYS PRESS

345 1001 1003 331 333 11 12 409

1932 SPARE SPARE

1933 PE PE PE PE PE PE PE PE PE PE DI13 DI14 M M


13 14
1934 4 8 4 8 4 8 4 8 4 8
SPARE SPARE
4 8

0V
1935 DI15 DI16

1936 15 16

SPARE SPARE

1937 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 753-508 WAGO 750-1405 WAGO 753-455

1938
1939
1940
1941
MODULE #15 MODULE #16 MODULE #17 MODULE #18 MODULE #19 MODULE #20 MODULE #21
4-AI 4-20mA 4-AI 4-20mA 2/4 CHANNEL RTD 2/4 CHANNEL RTD INCREMENTAL ENCODER INTERFACE INCREMENTAL ENCODER INTERFACE END MODULE
2000 RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE RACK 1 TOP-DRIVE

2001
2002
2003 AI1 AI2 AI1 AI2 AI1 AI2 AI1 AI2 A A/ 24V 0V A A/ 24V 0V

1 5 1 5 1 5 1 5 1 5 1 5 1 5 1 5
2004 HYD RETURN
PRESS HYD TEMP
LUBE OIL
FLOW
ELEVATOR
SIGNAL CLOSED
LUBE OIL
TEMP
BRAKE
TEMP
MOTOR
RTD 1
MOTOR
RTD 3
PIPE HANDLER
ENCODER
TOP DRIVE
MOTOR RPM PROX

411 407 401 956 432 434 417 423 440 441 346 347
2005
2006
M M M M M M M M B B/ N1 N2 B B/ N1 N2
2007 2 6 2 6 2 6 2 6 2 6 2 6 2 6 2 6

2008 431 435 418 424 442 443

2009
2010 AI3 AI4 AI3 AI4 AI3 AI4 AI3 AI4 LTCH GATE LTCH GATE

3 7 3 7 3 7 3 7 3 7 3 7 3 7 3 7
2011 LUBE PRESS
AFTER FILTER
LUBE PRESS
B4 FILTER SPARE SPARE
AMBIENT
TEMP SPARE
MOTOR
RTD 2 SPARE

405 403 429 420


2012
2013
M M M M M M M M REF SHLD REF SHLD
2014 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8

2015 0V 0V
428 421

2016
2017
WAGO 753-455 WAGO 753-455 WAGO 750-464 WAGO 750-464 WAGO 750-637-000-0001 WAGO 750-637-000-0001 WAGO 750-600
2018
(DC Only)
2019 24V 24V
0V 0V

2020
2021
2022
2023
2024
2025
2026
2027
2028
2029
2030
2031
2032
2033
2034
2035
2036
2037
2101
2102 OPERATOR INTERFACE PANEL
2103
2104
2105
2106
2107
2108 SIEMENS HMI
2109 SIMATIC PANEL PC
2110 IPC 677C
2111
2112
2113 ETHERNET PROFI_BUS CDL DB15 L N G
2114
2115
2116
2117
2118
2119 ETHERNET / 1005

2120
ETHERNET / 1005
2121
2122
2123
2124
2125
2126 120V AC (L)

2127 120V AC (N)

2128
2129
2130
2131
2132
2133
2134
2135
2136
2137
2138
MODULE #1 MODULE #2 MODULE #3 MODULE #4 MODULE #5 MODULE #6
16-DI 24V DC 16-DI 24V DC 16-DI 24V DC 4-DO 24VDC 4-DO 24VDC 4-DO 24VDC
2200 RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE

1 2 1 2 1 2
2201 1 2 1 2 1 2
SLIDER SLIDER
E-STOP PRESSURE SW DRILL ENABLED TRIP ENABLED FORWARD REVERSE
2202 I2.0
3213 3211
I2.1 I4.0
3404 3215 3214
I4.1 I4.0
3404 8705 8706
I4.1

ETHERNET 3 4 3 4 4
2203 24V 0V
3 4 3 4 3 4
DO1 DO2 DO1 DO2 DO1 DO2

1 5 1 5 1 5 1 5
2204 ALARM RESET
I2.2
HNDLR BYPASS
I2.3
TORQUE / DRILL
I4.2
BUW CLOSE
I4.3
SPARE
I4.2
SPARE
I4.3 ALARM PL DRILL ENABLED PL HPU ON PL IBOP CLOSE PL BRAKE PL
ELEVATOR
CLOSED
3200 3203 3111 3107 Q4.0 Q4.1 Q5.0 Q5.1 Q6.0 Q6.1
3400 3300 3401 3500 3403 3650
2205 5 6 5 6 5 6

5 6 5 6 5 6
BRK-OUT / DEC MK-UP / INC
2206 HPU1 START
I2.4
HPU2 START
I2.5
JOYSTICK - DN
I4.4
JOYSTICK - UP
I4.5
SPARE
I4.4
SPARE
I4.5
+ + 3201 3202 3105 3104 24V 24V 24V 24V 24V 24V
2207 2 6 7 8 7 8 7 8 2 6 2 6 2 6
7 8 7 8 7 8
2208 IBOP CLOSE TD IBOP OPEN
SPIN-OUT / PRE
JOYSTICK - RT
SPIN-IN / ZERO
JOYSTICK - LT SPARE SPARE
I2.6 I2.7 I4.6 I4.7 I4.6 I4.7
3100 3216 3103 3102
2209 9 10 9 10 9 10

9 10 9 10 9 10
2210 - - LINK TILT EXT
JOYSTICK 3 - UP
LINK TILT FLOAT
JOYSTICK 3 - RT
REV / FWD
SWITCH 7 - LT RPM LIMIT SPARE SPARE
0V 0V 0V 0V 0V 0V

3 7 I3.0 I5.0 I5.0 3 7 3 7 3 7


2211 3114
11
3117
12
I3.1 3106
11
3205
12
I5.1
11 12
I5.1

2212 LINK TIL RET


11 12
HNDLR CCW
11 12 11 12

JOYSTICK 3 - DN JOYSTICK 2 - LT TORQUE LIMIT LIMIT DEC SPARE SPARE


I3.2 I5.2 I5.2
2213 3115 3112 I3.3 3206 3207 I5.3 I5.3

PE PE 13 14 13 14 13 14 DO3 DO4 DO3 DO4 DO3 DO4


2214 4 8 13 14 13 14 13 14
HNDLR BYP PL
4 8
HPU ALARM PL LUBE OIL PL
4 8
MOTOR TEMP PL SPARE
4 8
SPARE
HNDLR CW HNDLR UNLOCK
JOYSTICK 2 RT JOYSTICK 2 - UP LIMIT INC SPARE SPARE SPARE Q4.2 Q4.3 Q5.2 Q5.3 Q6.2 Q6.3
2215 I3.4
3113 3116
I3.5 I5.4
3210
I5.5 I5.4 I5.5
3402 3301 3302 3303
15 16 15 16 15 16
2216 15 16 15 16 15 16
ELEVATOR ELEVATOR
STANDJUMP TD BRAKE OPEN CLOSE SPARE SPARE
2217 I3.6
3204 3101
I3.7 I5.6
3550 3551
I5.7 I5.6 I5.7

WAGO 750-375 WAGO 750-1405 WAGO 750-1405 WAGO 750-1405 WAGO 750-504 WAGO 750-504 WAGO 750-504
2218
2219 0V MODULE #7 MODULE #8 MODULE #9 MODULE #10 MODULE #11
24V 4-DO 24VDC 4-AO 0-10V DC 4-AO 0-10V DC 4-AI 4-20mA END MODULE
RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE RACK 3 CONSOLE
2220
2221
2222
DO1 DO2 AO1 AO2 AO1 AO2 AI1 AI2
2223 1 5 1 5 1 5 1 5
RPM OUTPUT RPM OUTPUT SLIDER SLIDER
2224 SPARE
Q20.0
SPARE
Q20.1
RPM OUTPUT
PQW272
RPM SETPOINT
PQW274
3RD PARTY
PQW280
3RD PARTY
PQW282
RPM SETPOINT
PIW288
TORQUE SETPOINT
PIW290
3700+ 3701+ 3600+ 3602+ 8700 8702

2225
2226 24V 24V M M M M M M

2 6 2 6 2 6 2 6
2227
2228 3700- 3701- 3600- 3602+ 8702 8704

2229
0V 0V AO3 AO4 AO3 AO4 AI3 AI4
2230 3 7 3 7 3 7 3 7
TORQUE OUTPUT TORQUE OUTPUT
2231 TORQUE OUTPUT
PQW276
TORQUE SETPOINT
PQW278
3RD PARTY
PQW284
3RD PARTY
PQW286
SPARE
PIW292
SPARE
PIW294
3702+ 3703+ 3601+ 3603+

2232
2233 DO3 DO4 M M M M M M

4 8 4 8 4 8 4 8
2234 SPARE
Q20.2
SPARE
Q20.3
0V 0V 0V

2235 3702- 3703- 3601- 3603-

2236
2237 WAGO 750-504 WAGO 750-559 WAGO 750-559 WAGO 750-455 WAGO 750-600

2238
2239
2240
2241
2400 CONSOLE - TD MOTOR CONTROL JS 2441
2401 2442
DC R3 M4 DC R3 M8 RPM ANALOG
2402 3300 3300 0010 2443 3700+ WHITE
O-0.1 5 G 3005 O-7/0+ 1 A
DRILL ENABLED PL RPM OUTPUT
2403 2444 2211
DC R3 M4 Channel 0
2404 3301 3301 0010 2445 DC R3 M8 RPM ANALOG
O-0.3 8 A O-7/0- 2
3700- BLACK
B
2405 HPU ALARM PL 2446
RPM OUTPUT
2212
2406 DC R3 M5
3302 3302 0010
2447
2407
O-0.2 4 A 2448
LUBE OIL PL

2408 DC R3 M5 2449 DC R3 M8 RPM DIGITAL


3303 3303 0010 3701+ WHITE
2409 O-0.3 8 A 2450 O-7/2+ 5 A
MOTOR TEMP PL RPM SETPOINT
2410 2451 2214
DC R3 M4 Channel 1
3400 3400 0010 DC R3 M8 RPM DIGITAL
2411 O-0.0 1 R 2452 3701- BLACK
ALARM PL O-7/2- 6 B
2412 2453 RPM SETPOINT
DC R3 M5 2216
2413 3401 3401 0011 2454
O-0.0 1 R TB40:18 3035
2414 HPU ON PL 2455
DC R3 M4 TORQUE ANALOG
2415 3402 3402 0011 2456 DC R3 M8
O-0.2 4 R O-7/4+ 3
3701+ WHITE
A
2416 HANDLER BYPASS PL 2457 TORQUE OUTPUT
2218
2417 DC R3 M6 2458 Channel 2
3403 3403 0011 DC R3 M8 TORQUE ANALOG
2418
O-0.0 1 R 2459 3701- BLACK
TD BRAKE PL O-7/4- 4 B
2419 2460 TORQUE OUTPUT
DC R3 M5 2220
3500 3500 0011
2420 O-0.1 5 R 2461
IBOP CLOSED PL
2421 2462
DC R3 M6 DC R3 M8 TORQUE SETPOINT
2422 O-0.1 5
3650 3650
R
0011 2463 3700+ WHITE
O-7/6+ 7 A
ELEV CLOSED PL
2423 2464 TORQUE SETPOINT
2222
Channel 3
2424 2465 DC R3 M7 TORQUE SETPOINT
3700- BLACK
2425 2466 O-7/6- 8 B
TORQUE SETPOINT
2426 2467 2224

2427 2468
RPM GAUGE
2428 2469 F5 WHITE
24V 3032 A
2429 2470
2430 2471 0005 BLACK
OV 3037 B

2431 2472
2432 2473 TORQUE GAUGE
F5 WHITE
24V 3032 A
2433 2474
2434 2475 OV 3037
0006 BLACK
B

2435 2476
2436 2477
2437 2478
CONSOLE - 3RD PARTY RPM / TORQUE
4-20mA RPM
DC R3 M9 ISOLATOR 1
3600+ BLACK
O-7/0+ 1 1
RPM OUTPUT 0-10VDC
Channel 0
DC R3 M9
3600- BLACK
O-7/0- 2 2
RPM OUTPUT 0-10VDC
4-20mA TRQ
DC R3 M9 ISOLATOR 2
3601+ BLACK
O-7/0+ 3 1
TRQ OUTPUT 0-10VDC
Channel 2
DC R3 M9
3601- BLACK
O-7/0- 4 2
TRQ OUTPUT 0-10VDC

4-20mA TRQ
ISOLATOR 1
F6 BLACK
24V 24V 7

0V BLACK
OV 0V 8

4-20mA
ISOLATOR 2
F6 BLACK
24V 24V 7

0V BLACK
OV 0V 8

4-20mA RPM 3RD PARTY


ISOLATOR 1 TB
640 BLACK +
3 1

641 BLACK -
4 2

642 BLACK +
5 3

643 BLACK -
6 4

4-20mA TRQ
ISOLATOR 2
644 BLACK +
3 5

645 BLACK -
4 6

646 BLACK +
5 7

647 BLACK -
6 8
OPTIONAL
3000 GDP
DRIVE LOCKOUT
3001 GDP PLC M0
RL12
135 705
O-0.0 2
3002 3162
1025 E-STOP / L.O. SIGNAL A1 A2
24VDC
3003 CONSOLE
3004
E-STOP 0010
2402
3005 TD TB11 TB40 PB2
732 CAB 32 BLACK 732 734 0010
516 1 1 R 3034
3006 1 2 CP 3 4
DC ONLY E-STOP LIGHT
3007 SCR E-Stop CP 1 2 1 2 1 2
RL1 3 4 3033
3008 705B 734A WHITE 734
TB23:4 / 935 2 2
3009 A2 A1
TOP DRIVE LOCK-OUT
TD TB14 TD TB14 PB2 PB1
3010 LOCKOUT RELAY 3
205 206
4
744 742 740
RL3
DC R3 M1 1 2 1 2
3011 TB23:7 / 933
713 111A
3
RED
3
3213
1 I-2.0
111
CP 13 14 23 24 A2 A1 TD LOCKOUT/E-STOP
3012 24VDC
744
901 901 3 4
CP 33 34 43 44 GDP PLC M1
3013 901 901 I-1/1.4 16
111

3014 1025 E-STOP / L.O. SIGNAL


0V DC
711 0001
3015 TB23:6 / 931 4
GREEN
4

3016 24V DC
712 ORANGE 740
TB22:1 / 912 5 5
740
3017
3018 AC ONLY 6 BLUE
6

3019
FAULT RELAY WHITE/BLACK
7 7
3020 CR2A

3021 A1+ A2- 8 RED/BLACK


8

3022
GREEN/BLACK
TD TB12 9 9
3023 3
850
11 14
3024 851 10G ORANGE/BLACK
10G
4
3025
3026
3027 1F 2A FUSE F1 PLC 24V
2216
F2 ETHERNET
3028 2F
2A FUSE

3029
3030 3F 2A FUSE F3 INPUT 24V
3531
2A FUSE F4 INPUT 24V
3031 4F
3402
2A FUSE F5 GUAGE 24V
5F
3032 2470,2474
2A FUSE F6 SPARE
6F
3033
0002 0038
3034 0V DC
17
0010
PLC 0V 21 RPM METER 0V
3005 2218 3571
0011 0039
3035 18
0034
2413 22 TORQUE METER 0V
2225 3575
0035 0040
3036 19
0036
2225 23 ETHERNET SWITCH 0V
2225 3575
0037
3037 20 2225
GDP HPU J-BOX HPU
3100 3141 GDP PANEL

3101 TD TB 10 TB1 E-STOP 3142 RL3 RL5 RL6


HPU1
LOCKOUT HPU E-STOP HPU1
708 BLK CAB 82 RED PB1 STARTER
RELAY RELAY RELAY
3102 +24VDC TB22:5F / 910 1 1 3143 24 Vdc TB22:17 / 920
900 901 902 902A 705A
0 Vdc TB23:2 / 931
BLK 33 34 13 14 11 14 A1 A2
3103 RL5
HPU
3144
E-STOP GDP PLC M2
3104 3153
705 A2 A1 100A
2
WHT
2
3145 HPU1 START 6 O -0.4
132 A1 A2 705
TB23:3 / 930
705 705
1013
3105 TB23:2 / 931 3146 RL6 RL7 A2 / 3153
GDP PLC M1 HPU1 HPU1
100 BREAKER STARTER GDP PLC M1
3106 HPU E-STOP I-0.6 8 3147 710 710A 103 103
1013 24 Vdc TB22:6F / 912 33 34 13 14
14 I -1.2 HPU1 RUNNING STATUS
RED BLUE
3107 3 3 3148 1016

3108 HPU OIL LEVEL


3149
GDP PLC M1
108 GREEN BLK FS1
3109 HPU LEVEL I-1.0 13 4 4 4 3
3150 RL3 RL5 RL7
LEVEL SWITCH OPENS LOCKOUT HPU E-STOP HPU2 HPU2
SWITCH 1021 ON LOW LEVEL STARTER
3110 3151 903
RELAY
904
RELAY
905
RELAY
905A 705B
ORANGE 24 Vdc TB22:17 / 920 0 Vdc TB23:2 / 931
5 5
43 44 24 23 11 14 A1 A2
3111 3152 3160

GDP PLC M2
3112 6
BLUE
6
3153 133 A1 A2 705
HPU2 START 7 O -0.5 RL6 A2 / 3146
705
3113 3154 1014 RL7 RL8 A2 / 3363
HPU2 HPU1
556 WHT-BLK
BREAKER STARTER
3114 GDP PLC
7 7
HPU OIL TEMP 3155 714 714A 104 104
GDP PLC M1
WHT 24 Vdc TB22:8F / 914 33 34 13 14
15 I -1.3 HPU2 RUNNING STATUS
15
3115 557 RED-BLK RED 3156 1017
HPU TEMP M6 16 8 8
RED
3116 18 3157
557 GRN-BLK
3117 9 9 3158 RL11
HPU COOLER HPU COOLER
STARTER
3118 3159 905
RELAY
910 705E
ORG-BLK 24 Vdc 3152 0 Vdc TB23:2 / 935
10 10 11 14 A1 A2
3119 3160
3120 3161 GDP PLC M2
137 A1 A2 705
HPU COOLER START 5 O -0.3 RL10 A2 / 1736
705
3121 3162 1013 RL11 ISO 1 A
HPU COOLER HPU COOLER
3122 3163 BREAKER STARTER GDP PLC M1
710 710E 105 105
24 Vdc TB22:6F / 912 33 13
7 I -0.5 HPU COOLER STATUS
3123 3164 34 14
1018
MCC BUS
3124 3165 CAB 19
MTR5
L1 T1 L1 T1 T1
3125 TOPDRIVE 3166
TD PLC J-BOX M
3126 3167 L2 T2 L2 T2 T2
TD R1 M15 CH1
407 WHITE HPU1
3127 HYDRAULIC
- 5 SIGNAL - 3168 L3 T3 L3 T3 T3 20 HP
PT1 408 BROWN 24V
TEMPERATURE + TB30:3 1760 RPM
THERMAL TRIP: 25A
3128 3169 MAGNETIC TRIP: 400A 19.3 A - 575V
GND1
GND
3129 3170
CAB 20
TD R1 M14 CH3 MTR6
3130 409 BLK 3171 L1 T1 L1 T1 T1
HYDRAULIC - 7 SIGNAL -
SYSTEM PT1
3131 PRESSURE +
410 RED 24V
TB30:3 3172 L2
M
L2 T2 T2 T2
GND1
3132 GND 3173 HPU2
L3 T3 L3 T3 T3 20 HP
3133 TD R1 M15 CH0 3174 THERMAL TRIP: 25A 1760 RPM
411 BLK MAGNETIC TRIP: 400A 19.3 A - 575V
HYDRAULIC - 1 SIGNAL -
3134 RETURN PT1 3175
412 RED 24V
PRESSURE + TB30:3
3135 GND1
3176
L1 T1 L1 T1 HPU COOLER
GND
3136 3177 L2 T1 L1
M 2 HP
T1 1750 RPM
2.7 Amp
3137 3178 L3 T1 L1 T1
3200 3241
3201 3242
TOP DRIVE
3202 3243
3203 GEARCASE JBOX 3244
3204 3245
TD R1 M17 CH 0
3205 WHT
3246
WHT CAB 76 432
1 MEAS LEAD (-)
3206 LUBE OIL 3247
TEMP
3207 RED 431 RED
2 MEAS LEAD (+)
3248
RTD7
3208 3249
RED 433 LUBE OIL
3209 TEMP 3250
3210 3251
3211 3252
3212 3253
3213 TOPDRIVE 3254
3214 3255
3215 3256
TD R1 M16 CH0
3216 401 BLK 3257 GDP PANEL
- 1 SIGNAL -
LUBE OIL PT1
3217 +
402 RED 24V
TB30:4 3258 RL3 RL9
FLOW
L.O. AUX. LUBE LUBE PUMP
3218 GND1 3259 BLOCK RELAY STARTER
GND 705D
906 907 907 907A
3219 3260 24 Vdc TB20:18 / 920 0 Vdc / TB23:3 936
53 54 11 14 A1 A2
TD R1 M15 CH3
403 BLK
3220 LUBE PRESS - 7 SIGNAL - 3261
BEFORE PT2 404 RED 24V
3221 FILTER + TB30:4 3262 GDP PLC M2
GND2 139 A1 A2 705
3222 3263 LUBE START 4 O-2/0.2 RL8 / 3363
GND
1020 705
RL9 RL10/ 1736
3223 TD R1 M15 CH2 3264
405 BLK
LUBE PRESS - 3 SIGNAL -
3224 AFTER PT3 3265 LUBE PUMP LUBE PUMP
406 RED 24V BREAKER STARTER
FILTER + TB30:4 GDP PLC M1
3225 3266 718 718A 718A 101
9 I-1/0.7
GND3 24 V TB22:10F / 914 33 34 11 14 LUBE RUNNING STATUS
GND
3226 3267 1014

3227 3268
3228 3269
3229 3270
3230 3271
3231 3272
3232 3273
3233 3274
3234 3275
3235 3276
3236 3277
3237 3278
3300 3341
3301 3342
3302 3343
3303 3344
3304 3345
3305 3346
3306 3347
3307 3348
3308 OPTIONAL (SCR) 3349
3309 3350
FOR A DIFFERENTIAL
3310 TOPDRIVE PRESSURE SWITCH SET AT 4.5" OF
3351
WATER DECREASING
PLC J-BOX
3311 3352
FOR A PRESSURE SWITCH SET AT
3312 6" OF WATER DECREASING
TD R1 M13
3353
T.D LOW AIR PURGE
3313 PS2 352 WHITE 3354
3 I-0.2
3 4
3314 3355
3315 351 BLACK
24V 3356
3316 SWITCH OPENS ON T.D AIR PRESSURE PS 3357 GDP PANEL
LOW PRESSURE
3317 3358 RL3 RL8
L.O. AUX. BLOWER BLOWER
3318 3359 BLOCK RELAY STARTER
908 909 909 909A 705C
3319 3360 24 Vdc TB20:19 / 918 0 Vdc / TB23:4 / 935
63 64 11 14 A1 A2

3320 3361
3321 3362 GDP PLC M2
134 A1 A2 705
3322 3363 BLOWER START 3 O-0.1 RL7 A2 / 3154
1015 705
RL8 RL9 A2 / 3263
3323 3364
3324 3365 BLOWER BLOWER
BREAKER STARTER GDP PLC M1
3325 3366 720 720A 720A 102
12 I-1.0
24 Vdc TB22:11 / 915 33 34 13 14 BLOWER RUNNING STATUS
3326 3367 1015

3327 3368 BLOWER


CT RELAY GDP PLC M1
3328 3369 720 112
1 2
6 I-0.4 BLOWER CT RELAY STATUS
3329 3370 1026

3330 3371
3331 3372
3332 3373
3333 3374
3334 3375
3335 3376
3336 3377
3337 3378
3400 CONSOLE SW4 3441
TRIP
3401 3442
OFF DRILL
DC R3 M2
3402 3031
F4 3214 3214
2 I-0.1 3443
TRIP 1922
3403 DC R3 M2
3444
F4 3215 3215
3404 3543 1 I-0.0 3445
DRILL 1923
3405 3446
3406 3447
3407 3448
3408 3449
3409 3450
3410 3451
3411 3452
3412 3453
3413 3454
3414 3455
3415 3456
3416 3457
3417 3458
3418 3459
3419 3460
3420 3461
PLC_GDP_M3
3421 O - 0.0 2
181 621 HM A2 / 932 3462
A1 A2
1013 HOUR METER
3422 HOUR METER
3463
3423 3464
3424 3465
3425 3466
3426 3467
3427 3468
3428 3469
3429 3470
3430 3471
3431 3472
3432 3473
3433 3474
3434 3475
3435 3476
3436 3477
3437 3478
CONSOLE - TD MOTOR CONTROL JS
JS1-LEFT DC R3 M2 DC R3 M1
F4 F4 1 3 3102 3102 F4 1 3 3204 3204
3519 8 I-4.7 3404 8 I-3.6
SPIN-IN / DRILL ZERO STANDJUMP
F4 2212
3513
JS1-RIGHT DC R3 M2
F4 1 3 3103 3103
7 I-4.6
SPIN-OUT / PRESET
JS1-UP DC R3 M2
F4 1 3 3104 3104
6 I-4.5
MAKE-UP / INCREASE
JS1-DOWN DC R3 M2 GDP
F4 F4 1 3 3105 3105
5 I-4.4
BREAK-OUT / DECREASE
SW7-LEFT
DC R3 M2
4247
F4 F4 3106 3106
9 I-5.0 TD TB 13
TO DRILLING / MUDLOGGER
RECORDER RIG
GDP PLC M5
DRILL REV / FWD 164A MUDLOGGER +
F4 O-0+ 3 1
SW 5
DC R3 M2 TORQUE
F4 F4 3107 3107 Channel 0
3544 4 I-4.3
BUW CLOSE GDP PLC M5
F4 165A MUDLOGGER -
4242 O-0 - 6 2
TORQUE SUPPLIED BY CUSTOMER

SW 7
DC R3 M2
F4 F4 3111 3111 TD TB 13 RECORDER / MUDLOGGER RIG
3 I-4.2 GDP PLC M5
164B MUDLOGGER +
TORQUE / DRILL O-2+ 7 3
F4
3502 RPM
Channel 1
GDP PLC M5
165B MUDLOGGER -
SW 7 O-2 - 10 4
DC R3 M2 RPM SUPPLIED BY CUSTOMER
F4 F4 3205 3205
10 I-5.1
RPM LIMIT SELECT
SW 7 221
DC R3 M2
F4 3206 3206 TD TB 13
TO DRILLING / MUDLOGGER
RECORDER RIG
11 I-5.2 GDP PLC M5
164C MUDLOGGER +
TORQUE LIMIT SELECT O-4+ 11 5
SW 7 TORQUE
DC R3 M2 Channel 2
F4 3207 3207
12 I-5.3
GDP PLC M5
LIMIT DECREASE 165C MUDLOGGER -
SW 7 O-4 - 14 6
DC R3 M2 TORQUE SUPPLIED BY CUSTOMER
F4 3208 3208
13 I-5.4
LIMIT INCREASE
SW X
DC R3 M1
TD TB 13 RECORDER / MUDLOGGER RIG
F3 F3 3200 3200 GDP PLC M5
3028 3 I-2.2 164D MUDLOGGER +
O-6+ 15 7
ALARM RESET
SW 7 RPM
DC R3 M1 Channel 3
F3 3201 3201
5 I-2.4 GDP PLC M5
HPU1 START 165D MUDLOGGER -
O-6 - 18 8
SW 7 RPM
DC R3 M1 SUPPLIED BY CUSTOMER
F3 F3 3202 3202
4000 6 I-2.5
HPU2 START
CONSOLE
3900 BUW 3941
3901 CLOSED 3942
877 0VDC
3902 R3 MOD7 DO/1 TB 23 3943
3903 A1+ A2- 3944
3904 3945
3905 11 14 3946
3906 DRY CONTACTS 3947
3907 3948
3908 3949
3909 3950
3910 3951
3911 3952
3912 3953
3913 3954
3914 3955
3915 3956
3916 3957
3917 3958
3918 3959
3919 3960
3920 3961
3921 3962
3922 3963
3923 3964
3924 3965
3925 3966
TOPDRIVE
3926 PLC J-BOX 3967
BUW GRIPPER OPEN
3927 TD R1 M4 SOL10A 3968
308 CAB 54 BLACK 2-H
O-0.1 5
3928 + - 3969
309 WHITE
O-0.1 7
3929 GREEN 3970
3930 3971
BUW GRIPPER CLOSE
SOL10B
3931 310
3972
O-0.0 1 CAB 55 BLACK 2-H
+ -
3932 O-0.0
311 WHITE 3973
3
3933 GREEN 3974
3934 3975
3935 3976
3936 3977
3937 3978
CONSOLE - TD PIPE HANDLER CONTROL JOYSTICK
JS2-LEFT PLC J-BOX
4000 DC R3 M1 4041 PIPE HANDLER ENCODER
F3 3112 3112 24V
3536 12 I-1.3 TD R1 M18B
4001 PH LEFT
4042 346 CAB 74 RED 1024 PPR
I-5 1 + DUAL OUTPUT
4002 JS2-RIGHT DC R3 M1
4043 347 BLK
I-5 5 -
F3 3113 3113
4003 13 I-1.4 4044 0V
PH RIGHT TD R1 M18A
4004 4045 440 YEL
JS2-UP I-5 1 A
DC R3 M1
4005 F3 3116 3116
14 I-1.5
4046 441 YEL/WHT
I-5 5 /A
4006 UNLOCK 4047
4007 JS3-UP 4048 TD R1 M18A
DC R3 M1 BLU
442
F3 3114 3114 I-5 2 B
4302 9 I-1.0
4008 S1-1 S1-2 4049 443 BLU/WHT
ENCODER
LT EXTEND I-5 6 /B
4009 4050
JS3-DOWN DC R3 M1
4010 F3 3115 3115 4051
11 I-1.2
S2-1 S2-2 Z
LT RETRACT
4011 4052
JS3 - RIGHT /Z
DC R3 M1
4012 F3 3117 3117
4053
10 I-1.1
4013 LT FLOAT 4054 TD R1 M18B
13G
4014 DC R3 M1 4055 SHIELD 8 GND
F3 3203 3203 4
4015 I-0.3 4056
HANDLER BYPASS +
4016 4057
TOP DRIVE -
4017 PLC J-BOX 4058
TD R1 M13 HANDLER LOCK SENSOR
4018 HANDLER LOCK STATUS I-0.3 4 355 PROX2 4059
A
4019 TB30:9
356 0V 4060
BLK BRWN /A
354 24V
4020 TB30:3 4061
4021 4062
BLU B
4022 4063
/B
4023 4064
4024 TD R1 M2
HANDLER UNLOCK
SOL02B 4065
334 CAB 53 BLACK 2-H Z
HANDLER UNLOCK O-0.0 1
4025 - + 4066
/Z
4026 335 WHITE 4067
O-0.0 3
4027 GREEN 4068
4028 4069
HANDLER ROTATE FORWARD
4029 TD R1 M1 SOL09A
4070
320 CAB 60 BLACK 2-H
HANDLER ROTATE FORWARD O-0.0 1 +
-
4030 4071
321 WHITE
O-0.0 3
4031 4072
GREEN
4032 4073
HANDLER ROTATE REVERSE
4033 TD R1 M1 SOL09B 4074
5 322 CAB 61 BLACK 2-H
HANDLER ROTATE REVERSE O-0.1
4034 - + 4075
323 WHITE
4035 O-0.1 7 4076
GREEN
4036 4077
4037 4078
4100
4101
4102
CONSOLE
4103 CONSOLE - TD PIPE HANDLER CONTROL JS
LINK TILT
4104 FLOAT ENGAGED
4105 879 0VDC
JS3-UP DC R3 M1 R3 MOD7 DO/4 CONSOLE
4106 F3 1 3 3114 3114
4302 9 I-3.0 A1+ A2-
LINK TILT EXTEND
4107
JS3-DOWN DC R3 M1
4108 F3 1 3 3115 3115 11 14
11 I-3.2
4109 LINK TILT RETRACT
JS1-RIGHT
DRY CONTACTS
4110 1 3
DC R3 M1
F3 3117 3117
10 I-3.1
4111 LINK TILT FLOAT
4112
4113
4114
4115
4116
4117
4118 TOPDRIVE
PLC J-BOX
4119 TD R1 M5
LINK TILT RETRACT
SOL03B
328 CAB 64 BLACK 2-H
O-0.1 5
4120 + -

7
329 WHITE
0V DC
4121 GREEN
LINK TILT RETRACT
LINK TILT EXTEND
4122
TD R1 M5 SOL03A
326 CAB 63 BLACK 2-H
4123 O-0.1 1 + -

4124 0V DC 3 327 WHITE


LINK TILT EXTEND GREEN
4125
LINK TILT FLOAT
4126
TD R1 M6 SOL04A
324 CAB 62 BLACK 2-H
4127 O-0.0 1 + -

4128
325 WHITE
0V DC 3
4129 LINK TILT FLOAT GREEN
4130
4131
4132
4133
4134
4135
4136
4137
CONSOLE IBOP CONTROL VALVE
SW3
4200 4241
DC R3 M1
4201 4242 3514 F3 OPEN CLOSE 3216
8 I-2.7
A1 A2
4202 4243 IBOP OPEN SW

4203 4244
4204 4245
4205 4246
DC R3 M1
4206 4247 3511 F3 3100
7 I-2.6
B1 B2
4207 4248 IBOP CLOSE SW

4208 4249
4209 4250
4210 4251
4211 4252
4212 4253
4213 4254
4214 4255
4215 4256
4216 4257
4217 4258
4218 4259
4219 4260
4220 4261
4221 4262
4222 4263 TOPDRIVE
4223 4264
PLC J-BOX IBOP CONTROL VALVE
OPEN
4224 4265
SOLENOID "A"
TD R1 M3
4225 4266 5 312 CAB 56 BLACK 2-H (OPTIONAL)
O-0.2 + -
4226 4267 313
0V DC 7 WHITE
4227 4268 IBOP OPEN GREEN
IBOP CONTROL VALVE
4228 4269 CLOSE
SOLENOID "B" (OPTIONAL)
4229 4270 O-0.3 1 314 CAB 57 BLACK 2-H
+ -

4230 4271 315 WHITE


0V DC 3
4231 4272 IBOP CLOSE
GREEN
4232 4273
4233 4274
4234 4275
4235 4276
4236 4277
4237 4278
4300
CONSOLE TOP DRIVE BRAKE
4301 SW8
OFF ON
4302 DC R3 M1
F3 3101
4303 4008
1 2
16 I-3.7
T.D BRAKE SW
4304
4305
4306
4307
4308
4309
4310 TOPDRIVE
4311
4312 PLC J-BOX
4313 TOP DRIVE BRAKE

TD R1 M7 SOL01B
4314 304 BLACK 2-H
O-0.0 1
+ -
4315
305 WHITE
4316 0V DC 3
TOP DRIVE BRAKE GREEN
4317
4318
4319
4320 TOP DRIVE BRAKE DUMP

TD R1 M7 SOL01C
4321 306 BLACK 2-H
O-1/0.3 5
+ -
4322
307 WHITE
4323 0V DC 7
TOP DRIVE BRAKE GREEN
4324 DUMP VALVE

4325
4326
4327
TD R1 M17
4328 MEAS LEAD (-) 6
CAB 78 WHT 434
BRAKE
4329 TEMP
RED 435
4330 MEAS LEAD (+) 5

4331 BRAKE
TEMP
4332
4333
4334
4335
4336
4337
4800 4841
4801 PLC J-BOX MOTOR AC 5GEB20 4842
4802 4843
4803 TD R1 M18 CH0 WHT 4844
417
+AI 1 1
4804 WHT 4845
A
4805 TD R1 M18 CH0 RTD 4846
418 RED
-AI 1 2
4806 4847
4807 4848
WHT
4808 4849
4809 WHT
SPARE 4850
RTD
4810 RED 4851
4811 4852
4812 4853
TD R1 M18 CH1 WHT
4813 420 4854
+AI 3 3
WHT
4814 B 4855
TD R1 M18 CH1 RTD2
421 RED
4815 -AI 3 4 4856
4816 4857
4817 4858
WHT
4818 4859
WHT
SPARE
4819 4860
RTD
RED
4820 4861
4821 4862
4822 TD R1 M18 CH2 WHT 4863
423
+AI 2 5
4823 WHT 4864
C
TD R1 M18 CH2
4824 424 RED
RTD2 4865
-AI 2 6
4825 4866
4826 4867
WHT
4827 4868
4828 WHT 4869
SPARE
RTD
4829 RED 4870
4830 4871
4831 4872
4832 4873
4833 4874
4834 4875
4835 4876
4836 4877
4837 4878
CONSOLE ELEVATOR CONTROL VALVE
SW
4200 4241
TOPDRIVE DC R3 M2
4201 4242 F3 OPEN CLOSE 3550
15 I-5.6
A1 A2
4202 4243 ELEVATOR OPEN SW

4203 4244
TD R1 M13 WEIGHT SENSOR
4204 WEIGHT SENSOR SW I-0.5 6
375 LIMIT SWITCH 4245
4205 GND 376 GND 4246
BLU BLK
374 24V DC R3 M2
TB30:4
4206 4247 F3 3551
16 I-5.7
B1 B2
4207 4248 ELEVATOR CLOSE SW
GRN
4208 4249
4209 4250
4210 4251
4211 4252
4212 4253
4213 4254
4214 4255
4215 4256
4216 4257
4217 4258
4218 4259
4219 4260
4220 4261
4221 4262
4222 4263 TOPDRIVE
4223 4264
PLC J-BOX ELEVATOR CONTROL VALVE
OPEN
4224 4265
SOLENOID "A"
TD R1 M10
4225 4266 330 BLACK 2-H (OPTIONAL)
O-17.0 1 + -
4226 4267 331
0V DC 3 WHITE
4227 4268 ELEVATOR OPEN GREEN

4228 4269
4229 4270
4230 4271
4231 4272
4232 4273
4233 4274
4234 4275
4235 4276
4236 4277
4237 4278
2000
2001
2002
2003 MODULE #1 MODULE #2 MODULE #3 MODULE #4 MODULE #5
16-DI 24V DC 4-DO 24VDC 4-AI 4-20mA INCREMENTAL ENCODER INTERFACE END MODULE
2004 RACK 4 CONSOLE RACK 4 CONSOLE RACK 4 CONSOLE RACK 4 CONSOLE RACK 4 CONSOLE

1 2

2005 1 2
MUD PUMP DW ANTI COLLISON
RUN STATUS PROX SW
2006 3750 3751
ETHERNET 3 4
2007 24V 0V
3 4
DO1 DO2 AI1 AI2 A A/ 24V 0V

1 5 TD CALIBRATION UPPER LIMIT 1 5 1 5 1 5 1 5

2008 SW

3752 3753
OVER RIDE ANTI COLLISION
RELAY
CUT AND SLIP LT BAILS
INCLINOMETER
DRAWORKS
ENCODER 955
950 951
5 6
2009 5 6 954
ZONE MNGMT
2010 BYPASS
+ + 3754 0V 0V M M B B/ N1 N2

2011 2 6 7 8 2 6 2 6 2 6 2 6
7 8

2012 952 953

2013 9 10

9 10
2014 - - DO3 DO4 AI3 AI4 LTCH GATE

3 7 3 7 3 7 3 7 3 7

2015 11 12
UPPER LIMIT
INDICATION PL

11 12
2016
2017
PE PE 13 14 0V 0V M M REF SHLD

2018 4 8 13 14 4 8 4 8 4 8 4 8

2019 0V

15 16
2020 15 16

2021
WAGO 750-375 WAGO 750-1405 WAGO 750-504 WAGO 750-455 WAGO 750-637-000-0001 WAGO 750-600
2022 (OPTION)
2023 TB24/0V
2A FUSE F7
7F

2024
2025
954
2026 +VDC MOD1-B

955
0VDC MOD1-B
2027 RED
WHITE 24V
TB30:2 ZONE MNGMNT
TD R4 M3 CH0 BLACK BYPASS
WHITE SW
2028 DRAWORKS
SIG(A)
950
MOD1-A
SIGNAL 1
GREEN INCLINOMETER
W/ GATEWAY
F4 F4 3754 3754
DC R4 M1
5 I-0.5
ENCODER CHANNEL A BLACK
951 ZONE MGMT BYPASS
SIG(A\) MOD1-A
2029 YELLOW
BLUE
F4

2030 SIG(B)
952
MOD1-A
CHANNEL B
953
SIG(B\) MOD1-A
2031
2032
2033
2034
2035
2036
2037
CONSOLE - SLIDER RPM / TORQUE CONSOLE - TD MOTOR CONTROL JS SLIDER
JS1-LEFT DC R3 M2
4-20mA RPM 3RD PARTY 1 3 3102 3102
8 I-4.7
ISOLATOR 1 TB
SPIN-IN / DRILL ZERO
SLIDER TB
642 BLACK JS1-RIGHT 3900 3900
5 3 1
1 3

643 BLACK 3901


6 4 2
JS1-UP DC R3 M2
1 3 3104 3104 3902
4-20mA TRQ 6 I-4.5 3
ISOLATOR 2 MAKE-UP / INCREASE
JS1-DOWN 3901 3903
646 BLACK 4
5 7 1 3

647 BLACK
6 8 SW7-LEFT
DC R3 M2
3106 3106
9 I-5.0
DRILL REV / FWD
3902

TOP DRIVE BRAKE


SW8
OFF ON
DC R3 M1
3101 16 I-3.7
1 2
T.D BRAKE SW
3903
(OMRON) INVERTER CUBICLE GDP PANEL
TD TB8 TD TB2
790
+VDC 1 1

791
0VDC 2 2

SHIELD 3 3

820
SIG(A) 4 4
CHANNEL A
821
SIG(A\) 5 5

SHIELD 6 6

822
SIG(B) 7 7
CHANNEL B
823
SIG(B\) 8 8

SHIELD 9 9
734
10 10 LOCK-OUT
CR1A

0V TB 23

A1+ A2-
INPUT CUBICLE
TD TB3 TD TB6 TD TB12
852 852 BLK 852
1 1 1
11 14
853 853 WHT 853
2 2 2
744
TB12:3
FAULT RELAY
CR2A

A1+ A2-

TD TB5
850 850 RED 850
8 3 3
GDP CPU PROFIBUS PLUG
PROFIBUS PLUG VFD DRIVE 11 14
(NODE 3) 851 851 GRN 851
9 4 4
RED RED
SH RTD01
WHT ORG
GRN 5 5
ON SH OFF
1015 CAB006 GRN
SIEMENS CPU RED BLU
SH 6 6
RED
PROFIBUS PLUG
GRN BRAKING MODULE RED WHT/BLK
(NODE 4) 7 7
RTD02
RED WHT BLK/RED
8 8

RED BLK/GRN
SH ON 9 9

RED BLK/GRN
10 10
GRN
GDP (IDS) SCR HOUSE

Forward
RL13
900 0VDC
R0 MOD2 DO/12 TB 23
TB14 TB6
A1+ A2- BLACK H1 L1
1 1 39 PC1-44
3010 SCR ONLINE WHITE
2 2 40 TB8-5 600V CT
11 14
205 RED
3 3 41 PC1-38
H2 L2
Reverse E-STOP 206 GREEN
RL14 4 4 42 C-6
901 0VDC ORANGE
R0 MOD2 DO/13 5 5 730 PC1-36
A1+ A2- FORWARD 865 BLUE 708 FORWARD
6 6
REVERSE 866 WHITE-BLK 709 REVERSE FIELD SUPPLY
7 7
11 14 TB1 TB2
882 RED-BLK
TRQ LIMIT R0 MOD5 AO/31 8 8 128 128
200
40 Amp 15 5
883 GREEN-BLK
RL15 RPM REF R0 MOD5 AO/35 9 9 130 130
902 0VDC 880 ORANGE-BLK 0
R0 MOD2 DO/14 TRQ FDBK R0 MOD4 AI/16 10 10 161 PC1-7 (2.66V/1000A) 14 4

A1+ A2- BLUE-BLK


11 11 162 PC1-29 200
3
881 BLACK-WHT
RPM FDBK R0 MOD4 AI/18 12 12 156 156 (5.0V/1500V)
11 14 -
734 RED-WHT 3 2
TB 11:2 13 13 792 RL2-23
15 Amp 40AMP 873 GREEN-WHT 714 40AMP
14 14 +
RL16 4 1

903 0VDC 15AMP 874 BLUE-WHT 715 15AMP


R0 MOD2 DO/15 15 15
A1+ A2- BLACK-RED
16 16 716 FS TB1-5
120V WHITE-RED FIELD SETTINGS
17 17 706 RL1-24
11 14 113 ORANGE-RED DEFAULT 60A (TORQUE)
SCR FIELD LOSS R0 MOD1 DI/17 18 18 793 RL2-24 FIELD 1 40A (DRILL MODE)
FIELD 2 18A (HIGH SPEED) MOTOR
FIELD
120N BLUE-RED
TB 21:4 19 19 703 T4-14
COMMON RED-GREEN
TB 23 20 20 159 PC1-27

21 21
GDP
LOCK-OUT
TD TB1 POWER PLC 1 CR1A TD TB3
+VDC 1 TD TB9 003 853
BLK 700 2
+VDC 1 TD 24V S1 / 907 LOCKOUT A2- A1+
0VDC 2 TD TB12
WHT 702 TD 24V S2 / 908 BLK 734 852
2 1 1
3 14 11
RED 701 WHT
3 TD RET S1 / 928 2 FAULT RELAY
PR2 BLK / 1826 820 CR2A TD TB5
4
GRN 703 RED 0001 851
TO TOP DRIVE CHANNEL A 4 TD RET S2 / 929 3 9
PR2 WHT / 1827 821
5 A2- A1+
ORG GRN
5 4
744 850
6 8
BLU ORG 14 11
6 5
PR3 BLK / 1829 822
7
WHT/BLK BLU
CHANNEL B 7 6
823
PR3 WHT / 1830 8
RED/BLK WHT/BLK
8 7
9
GRN/BLK RED/BLK
9 8
PR4 BLK / 1832 10
ORG/BLK GRN/BLK
CHANNEL Z 10 9
NOT CONNECTED PR4 WHT / 1833 11
ORG/BLK
10
12

13 E-STOP
TD TB 10
14 BLK 708
1 RL5 +24VDC TB22:5F / 910 3rd Party
HPU TD TB13
15 E-STOP BLK 164A
WHT 100A A1 A2 705 1 3 O-4/0+
2 3153
1014 TORQUE
705 WHT 165A
TB23:2 / 931 2 6 O-4/0 -
***NOTE : GDP TO ENCODER SHIELDS GROUNDED AT GDP / ISOLATED AT TD***
GDP PLC M1
100 1015 TORQUE
2 I-1/0.0 HPU E-STOP RED 164B
3 7 O-4/2+
ENCODER VFD 1013
1016 RPM
TD TB2 GRN 165B
4 10 O-4/2 -
+VDC RED
1 3 1017 RPM
+VDC ORG 164C
5 11 O-4/4+
0VDC 2 1019 TORQUE
GDP PLC M1 BLU 165C
GRN 108 6 14 O-4/4 -
4 12 I-1/1.0 HPU LEVEL
3 1020 TORQUE
1021 SWITCH WHT/BLK 164D
7 15 O-4/6+
SIG(A) 4 ORG 1021 RPM
TO VFD DRIVE RED/BLK 165D
CHANNEL A 5 18
CAB 25 8 O-4/6 -
SIG(A\) 5 1022 RPM
BLU GRN/BLK
6 9
6
ORG/BLK
10
SIG(B) 7 WHT/BLK 556
7
CHANNEL B GDP PLC
SIG(B\) 8 15
RED/BLK 557
16 HPU TEMP
8 M6
Forward
9 18 RL10
0VDC 900
GRN/BLK 557 TB 23 MOD2 DO/12 R0
10 9 TB14
BLACK
A2- A1+
1
WHITE 3010
ORG/BLK 2
10 14 11
RED 205
3
GREEN 206 Reverse
4 RL11
TB3 ORANGE 0VDC 901
120 V (L) 650 5 MOD2 DO/13 R0
1 TB20:1 907
BLUE 865 FORWARD A2- A1+
120 V (N) 651 6
2 TB21:1 924
WHITE-BLK 866 REVERSE
7
3 POWER PLC 2 14 11
RED-BLK 882
TD TB11 8 MOD4 AO/3 R0 TRQ LIMIT
GREEN BLK 732 40 Amp
1 GREEN-BLK 883
9 MOD4 AO/7 R0 RPM REF RL12
WHITE
WHT 732 ORANGE-BLK 880 0VDC 902
2 10 MOD3 AI/16 R0 TRQ FDBK MOD2 DO/14 R0
BLACK
LOCKOUT RELAY BLUE-BLK A2- A1+
RL3 11
RED 111A
3 BLACK-WHT 881
744 12 MOD3 AI/18 R0 RPM FDBK
TB12:3
GRN 711 RED-WHT 734 14 11
4 TB23:6 / 931 0V DC 13 TB 11:2
TB4 0001
BLACK L1 L1 TB12:4 GREEN-WHT 873 40AMP 15 Amp
1 SOLA ORG 712 14 RL13
UPS 5 TB22:1 / 912 24V DC 15AMP
2
WHITE N N BLUE-WHT 874 0VDC 903
15 MOD2 DO/15 R0
GREEN G G BLU BLACK-RED A2- A1+
3 6 16
L2 WHITE-RED 120V
WHT/BLK 17
7
ORANGE-RED 113 14 11
18 MOD1 DI/17 R0 SCR FIELD LOSS
RED/BLK
GDP CPU 8
PROFIBUS PLUG
PROFIBUS PLUG VFD DRIVE BLUE-RED 120N
GRN/BLK 19 TB 21:4
HMI (NODE 3) 9
RED RED-GREEN
RED ORG/BLK 20
10
SH 21
GRN
ON SH OFF
1015 CAB006 GRN
SIEMENS CPU SH
RED
PROFIBUS PLUG
GRN BRAKING MODULE
(NODE 4)
RED

SH ON

GRN
6
650/850 T O N T O P D R I V E MANUAL REV 0
Section

OMRON

166
1
Drawing Package Index
Project Number 159105
Project Description 800HP Top Drive House
Drawing Package Version 11
Customer Name Global Drilling Support
Page Total Revision
No. Pages Name Description 1 Description 2 Doc Class Revision Description Number
1 1 Index Drawing Package
2 1 159105E020 DIAGRAM ‐ POWER SYSTEM ONE‐LINE ELECTRICAL INITIAL RELEASE A
3 1 159105E200 DIAGRAM ‐ LIGHTING PANEL ELECTRICAL Swaped 30 amp breaker to 15 amp breaker. B
4 14 159105E308 DIAGRAM ‐ STANDALONE A1000 VFD WITHOUT GEN CONTROLS ELECTRICAL REMOVED TB32 1,2 FROM SH 10 E
CHANGED CUSTOMER RTD CONNECTIONS TO
18 4 159105E309 DIAGRAM ‐ TOP DRIVE ELECTRICAL INTERNAL, 309TB8 TO TB8 C
22 1 159105M001 EQUIPMENT OUTLINE ‐ POWER CONTROL HOUSE MECHANICAL INITIAL RELEASE A
23 1 159105M002 ELEVATION ‐ LINE UP, 800HP TOP DRIVE MECHANICAL INITIAL RELEASE A
UPDATED DRAWING TO REFLECT CHANGES TO
24 3 001.028.112 HOUSE ‐ ACCESSORIES, TOP DRIVE MECHANICAL PLATE C
27 5 001.052.117. PLUG PANEL MAIN LEFT MECHANICAL INITIAL RELEASE A
32 2 001.029.006. PLUG PANEL ‐ TOP DRIVE, PRECABLE ASSEMBLY MECHANICAL INITIAL RELEASE A
34 3 001.039.194 CUBICLE ‐ MODEL 07010 INPUT, STAND ALONE DRIVE, 86.0 HIGH X 24.0 WIDE X 34.0 DEEP MECHANICAL REMOVED ITEM 321 E
37 2 001.039.195 CUBICLE ‐ MODEL 07103 CONVERTER/INVERTER, 3 POLE (1 FUTURE), SAD, 86.0 HIGH X 50.0 WIDE X 34.0 DEEP MECHANICAL REMOVED ITEM 266 AND ITEM 267 D

9/18/2014 166 Drawing Package Index


2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

NOTES:

1. THE MAIN PLUG PANEL IS REMOVABLE. IT IS TO BE INSTALLED USING 3/8-16 SS


HARDWARE, WHICH SHALL BE DRILLED AND TAPPED INTO THE WALL SIDING. THE
HOUSE AND PLUG PANEL ARE TO BE SEALED USING A CAULK SUITABLE FOR EXTERIOR
APPLICATIONS WITH MINIMAL SHRINKAGE AFTER CURING. THE COLOR OF THE CAULK
SHALL MATCH THE HOUSE.

2. THE LINE-UP SHALL BE SECURED BY WELDING THE BASE OF THE UNIT TO THE DECK
PLATE. THE TOP OF THE EQUIPMENT SHALL BE SECURED TO THE HOUSE WALL USING
AN ANGLE, 2 PLACES PER CABINET.

3. THE TRANSFORMER SHALL BE BOLTED TO THE MEMBERS ON THE PORCH AS SHOWN


USING SS HARDWARE.

4. THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.

5 CUSTOMER INSTALLED EQUIPMENT.

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
C 3/27/2014 STD-AC-ECN-20140327-01 JIMENEZ,M BRAATZ,J FRENCH,J
PHONE: (703)849-1900 TOP DRIVE
FAX: (713)849-4666

B 8/14/2013 STD-AC-ECN-20130814-02 BROWN,K BRAATZ,J FRENCH,J This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159105 SHEET NO:
1/ 3
A 7/16/2013 STD-AC-ERO-20130716-03 BROWN,K BRAATZ,J FRENCH,J of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.028.112 C
25

INPUT CONVERTER/ 240


5 INVERTER

61 X2

62 LF1 60 60 LF2

63 320 X2 61 321

5 344 1 10LDP1
PLAN VIEW

C B A D

100
320 321

320 700 321 240


A/C 1 A/C 2 GLAND PLATE
THIS SIDE
A/C 1 A/C 2

ADDED HOLE SIZES


5 TO TRANSITION PLATE

120 10T1

C 64 343 B A D 64 343

EAST ELEVATION
WEST ELEVATION SOUTH ELEVATION
(LESS CUST. EQUIP.)

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
PHONE: (703)849-1900 TOP DRIVE
FAX: (713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
FUO:
159105 SHEET NO:
2/ 3
PO#/CUSTOMER DRAWING NO: REV:
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.028.112 C
26

702 600

200

CONVERTER/ 240
INVERTER
323
100
INPUT CONVERTER/
INVERTER
120

201

SECTION A-A SECTION C-C

200

10DISC1,2 2X 80
321 320
INPUT 323 2X 340

2X 342 1

201

10RECPT1,2 2X 260
SECTION B-B SECTION D-D
2X 340

2X 341

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
PHONE: (703)849-1900 TOP DRIVE
FAX: (713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
FUO:
159105 SHEET NO:
3/ 3
PO#/CUSTOMER DRAWING NO: REV:
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.028.112 C
27

700 700

701

SEE PLUG
PANEL DETAIL

LEFT SIDE VIEW FRONT VIEW

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 PLUG PANEL - TOP DRIVE,
PHONE: ( 703) 849-1900 PRECABLE ASSEMBLY
FAX: ( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159286
SHEET NO:
1/ 2
A 1/10/2014 STD-AC-ERO-20140110-01 BAKER, M. BRAATZ, J. FRENCH, J. of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.029.006 A
28

ROW G

ROW F

ROW A
ROW D

ROW C

ROW B
ROW E
21

1
300

1
1
708
1

2
711
23

1
303 708

2
1 20

3
707
301 711

2
709
2

23

4
3
2
303 709
22 711
2

5
302

3
710
3

23

3
303
3

4
4

40 40

50 50

706 705 704 703 702

PLUG PANEL DETAIL

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 PLUG PANEL - TOP DRIVE,
PHONE: ( 703) 849-1900 PRECABLE ASSEMBLY
FAX: ( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159286
SHEET NO:
2/ 2
A 1/10/2014 STD-AC-ERO-20140110-01 BAKER, M. BRAATZ, J. FRENCH, J. of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.029.006 A
29
30
31
32
33
34
35
36

NOTES:

1. THE MAIN PLUG PANEL IS REMOVABLE. IT IS TO BE INSTALLED USING 3/8-16 SS


HARDWARE, WHICH SHALL BE DRILLED AND TAPPED INTO THE WALL SIDING. THE
HOUSE AND PLUG PANEL ARE TO BE SEALED USING A CAULK SUITABLE FOR EXTERIOR
APPLICATIONS WITH MINIMAL SHRINKAGE AFTER CURING. THE COLOR OF THE CAULK
SHALL MATCH THE HOUSE.

2. THE LINE-UP SHALL BE SECURED BY WELDING THE BASE OF THE UNIT TO THE DECK
PLATE. THE TOP OF THE EQUIPMENT SHALL BE SECURED TO THE HOUSE WALL USING
AN ANGLE, 2 PLACES PER CABINET.

3. THE TRANSFORMER SHALL BE BOLTED TO THE MEMBERS ON THE PORCH AS SHOWN


USING SS HARDWARE.

4. THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.

5 CUSTOMER INSTALLED EQUIPMENT.

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
C 3/27/2014 STD-AC-ECN-20140327-01 JIMENEZ,M BRAATZ,J FRENCH,J
PHONE: (703)849-1900 TOP DRIVE
FAX: (713)849-4666

B 8/14/2013 STD-AC-ECN-20130814-02 BROWN,K BRAATZ,J FRENCH,J This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159105 SHEET NO:
1/ 3
A 7/16/2013 STD-AC-ERO-20130716-03 BROWN,K BRAATZ,J FRENCH,J of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.028.112 C
37

INPUT CONVERTER/ 240


5 INVERTER

61 X2

62 LF1 60 60 LF2

63 320 X2 61 321

5 344 1 10LDP1
PLAN VIEW

C B A D

100
320 321

320 700 321 240


A/C 1 A/C 2 GLAND PLATE
THIS SIDE
A/C 1 A/C 2

ADDED HOLE SIZES


5 TO TRANSITION PLATE

120 10T1

C 64 343 B A D 64 343

EAST ELEVATION
WEST ELEVATION SOUTH ELEVATION
(LESS CUST. EQUIP.)

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
PHONE: (703)849-1900 TOP DRIVE
FAX: (713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
FUO:
159105 SHEET NO:
2/ 3
PO#/CUSTOMER DRAWING NO: REV:
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.028.112 C
38

702 600

200

CONVERTER/ 240
INVERTER
323
100
INPUT CONVERTER/
INVERTER
120

201

SECTION A-A SECTION C-C

200

10DISC1,2 2X 80
321 320
INPUT 323 2X 340

2X 342 1

201

10RECPT1,2 2X 260
SECTION B-B SECTION D-D
2X 340

2X 341

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
PHONE: (703)849-1900 TOP DRIVE
FAX: (713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property
of Omron. It may not be reproduced, in whole or in part, without the written
FUO:
159105 SHEET NO:
3/ 3
PO#/CUSTOMER DRAWING NO: REV:
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.028.112 C
39
40
41
42
43
44

700 700

701

SEE PLUG
PANEL DETAIL

LEFT SIDE VIEW FRONT VIEW

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 PLUG PANEL - TOP DRIVE,
PHONE: ( 703) 849-1900 PRECABLE ASSEMBLY
FAX: ( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159286
SHEET NO:
1/ 2
A 1/10/2014 STD-AC-ERO-20140110-01 BAKER, M. BRAATZ, J. FRENCH, J. of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.029.006 A
45

ROW G

ROW F

ROW A
ROW D

ROW C

ROW B
ROW E
21

1
300

1
1
708
1

2
711
23

1
303 708

2
1 20

3
707
301 711

2
709
2

23

4
3
2
303 709
22 711
2

5
302

3
710
3

23

3
303
3

4
4

40 40

50 50

706 705 704 703 702

PLUG PANEL DETAIL

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 PLUG PANEL - TOP DRIVE,
PHONE: ( 703) 849-1900 PRECABLE ASSEMBLY
FAX: ( 713) 849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
159286
SHEET NO:
2/ 2
A 1/10/2014 STD-AC-ERO-20140110-01 BAKER, M. BRAATZ, J. FRENCH, J. of Omron. It may not be reproduced, in whole or in part, without the written
PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.029.006 A
46
47
48
49
50
1
Drawing Package Index
Project Number 159286
Project Description 1200 HP Top Drive House
Drawing Package Version 13
Customer Name Global Drilling Support
Page Total Revision
No. Pages Name Description 1 Description 2 Doc Class Revision Description Number
1 1 Index Drawing Package
2 1 159286E020. DIAGRAM‐POWER SYSTEM ONE‐LINE ELECTRICAL INITIAL RELEASE A
3 1 159286E200. DIAGRAM‐LIGHTING PANEL ELECTRICAL Changed 200CB4 from 30A to 15A. B
Chng to rev D (sht. 1), chng tb5 5/6 to 6/7 (sht. 8),
4 14 159286E308. DIAGRAM‐STANDALONE A1000 VFD WITHOUT GEN CONTROLS ELECTRICAL rmv tb 47/tb63/tb16/tb32 (sht. 10) D

18 4 159286E309. DIAGRAM‐TOP DRIVE ELECTRICAL (Sheet 4) RTD dashed wires were changed to solid D
22 1 159105M001. EQUIPMENT OUTLINE ‐ POWER CONTROL HOUSE MECHANICAL INITIAL RELEASE A
23 3 001.034.527. HOUSE ‐ ACCESSORIES, TOP DRIVE, 1200 HP MECHANICAL ADDING ITEM 800 B
26 2 001.034.525. PLUG PANEL ‐ TOP DRIVE, PRECABLE ASSEMBLY MECHANICAL INITIAL RELEASE A
28 5 001.052.117. PLUG PANEL MAIN LEFT MECHANICAL INITIAL RELEASE A
33 3 001.039.194. CUBICLE ‐ MODEL 07010 INPUT, STAND ALONE DRIVE, 86.0 HIGH X 24.0 WIDE X 34.0 DEEP MECHANICAL REMOVED ITEM 321 E
36 2 001.024.995. CUBICLE ‐ MODEL 07103 CONVERTER/INVERTER, 3 POLE, SAD, 86.0 HIGH X 50.0 WIDE X 34.0 DEEP MECHANICAL ADDING LEXAN COVER D

9/18/2014 229 Drawing Package Index


2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

NOTES:

1. THE MAIN PLUG PANEL IS REMOVABLE. IT IS TO BE INSTALLED USING 3/8-16 SS


HARDWARE, WHICH SHALL BE DRILLED AND TAPPED INTO THE WALL SIDING. THE
HOUSE AND PLUG PANEL ARE TO BE SEALED USING A CAULK SUITABLE FOR EXTERIOR
APPLICATIONS WITH MINIMAL SHRINKAGE AFTER CURING. THE COLOR OF THE CAULK
SHALL MATCH THE HOUSE.

2. THE LINE-UP SHALL BE SECURED BY WELDING THE BASE OF THE UNIT TO THE DECK
PLATE. THE TOP OF THE EQUIPMENT SHALL BE SECURED TO THE HOUSE WALL USING
AN ANGLE, 2 PLACES PER CABINET.

3. THE TRANSFORMER SHALL BE BOLTED TO THE MEMBERS ON THE PORCH AS SHOWN


USING SS HARDWARE.

4. THE RESISTOR BOX SHALL BE BOLTED TO THE FRAME AS SHOWN WITH GLAND PLATE
FACING EAST USING SS HARDWARE.

5 CUSTOMER INSTALLED EQUIPMENT.

6 MODIFY PART 220.45.925 AS NEEDED IN INPUT CUBICLE.

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
PHONE: (703)849-1900 TOP DRIVE, 1200 HP
FAX: (713)849-4666
B 9/20/2013 STD-AC-ECN-20130920-01 BROWN,K BRAATZ,J ROYSE, M This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO: 159286 SHEET NO:
1/ 3
A 8/27/2013 STD-AC-ERO-20130821-02 BROWN,K BRAATZ,J FRENCH,J of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.034.527 B
801
24
X2 703

INPUT CONVERTER/ 240


5 INVERTER
6

61 X2
62 LF1 60 60 LF2
63 320 X2 61 321

5 344 1
PLAN VIEW
2 10LDP1

C B A D

100
320 321
320 700 321 240
A/C 1 A/C 2 GLAND PLATE
THIS SIDE
A/C 1 A/C 2

120 10T1

C 64 343 B A D 64 343

WEST ELEVATION SOUTH ELEVATION EAST ELEVATION


(LESS CUST. EQUIP.)

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
PHONE: (703)849-1900 TOP DRIVE, 1200 HP
FAX: (713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
159286 SHEET NO:
2/ 3
DRAWING NO: REV:
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.034.527 B
25

702 600

200

CONVERTER/ 240
INVERTER
323
100
INPUT CONVERTER/
INVERTER
120

201

SECTION A-A SECTION C-C

200

10DISC1,2 2X 80
321 320
INPUT 323 2X 340
2X 342 1
5

201

10RECPT1,2 2X 260
SECTION B-B SECTION D-D
2X 340
2X 341

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 HOUSE - ACCESSORIES,
PHONE: (703)849-1900 TOP DRIVE, 1200 HP
FAX: (713)849-4666
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
159286 SHEET NO:
3/ 3
DRAWING NO: REV:
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.034.527 B
26

700
700

701

SEE PLUG
PANEL DETAIL

LEFT SIDE VIEW


FRONT VIEW

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 PLUG PANEL - TOP DRIVE
PHONE: (703)849-1900
FAX: (713)849-4666
PRECABLE ASSEMBLY
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO: 159286 SHEET NO:
1/ 2
A 8/21/2013 STD-AC-ERO-20130821-02 BROWN,K BRAATZ,J FRENCH,J of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER DRAWING NO: REV:

REV DATE REVISION NOTE DRAWN CHKD APPR


consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.034.525 A
27

R R R R R R R
O O O O O O O
W W W W W W W
G F E D C B A

21
30 1
0
21 1 70
1 71 8
30 1
0 1 2
20 1 70
1 2 8
30 3 70
1 71 7
20 2 1
2 70
30 9
1 4
22 2 3
2 71 70
30 1 9
5
2 22 3
30 3 71
2 0
3
3 40
40
50
50
4 4

70 70 70 70 70
6 5 4 3 2

PLUG PANEL DETAIL

9510 N. HOUSTON ROSSLYN TITLE:


HOUSTON, TX 77088 PLUG PANEL - TOP DRIVE
PHONE: (703)849-1900
FAX: (713)849-4666
PRECABLE ASSEMBLY
This document contains Omron proprietary and confidential information. It is
transmitted to the recipient for limited purposes only, and remains the property FUO:
of Omron. It may not be reproduced, in whole or in part, without the written PO#/CUSTOMER
159286 SHEET NO:
2/ 2
DRAWING NO: REV:
consent of Omron, and must not be disclosed to persons not having
need of such disclosure consistent with the purpose of the transmittal.
STANDARD OMRON 001.034.525 A
28
29
30
31
32
33
34
35
36
37
7
Section
650/850 T O N T O P D R I V E MANUAL REV 0

HPU-WILSON

254
GDS International

Hydraulic Power Unit


Part Number 15H14028

7330 W Sam Houston Pkwy N – Houston, Texas 77040 – (832) 467-0001 – Fax (832) 467-0011
832-467-0001
832-467-0011 Fax

WILSON COMPANY
7330 W Sam Houston Pkwy N
Houston, TX 77040

To our Valued Customers

I want to thank you for buying your Fluid Power System from Wilson Company’s

Systems Division. This unit has been designed with high quality materials

and components and been carefully assembled by our experienced technicians.

With proper installation and maintenance, it should provide you with many

years of service.

If you have any question about this equipment before startup, contact

me or a member of our staff.

If you have other applications for fluid power or fluid connector

Products, please contact your local Wilson Company sales associate, or call

our Main Office at 832-467-0001.

Thank you again for electing Wilson Company as your source for

fluid power equipment.

Sincerely,

Gary Hanson
Systems Manager - Houston
DRAWINGS
Parts List, Schematics, & Specifications

LITERATURE
Hydraulic Motors, Pumps, & Valves

LITERATURE
Hydraulic Filters & Strainers

LITERATURE
Hydraulic Fittings & Hose

LITERATURE
Misc. Components

HYD. POWER UNITS


Maintenance & Installation

ELECTRIC MOTORS
Maintenance & Installation
WILSON COMPANY
WILSON COMPANY
P1/PD Series: 18cc to 140cc Medium
Pressure Axial Piston Pumps
Variable Displacement – Service Information
Bulletin HY28-2665-02/SVC/EN
Effective: January 1, 2014
The product information, specifications, and descriptions contained in this publication have been compiled for
the use and convenience of our customers from information furnished by the manufacturer; and we can not,
and do not, accept any responsibility for the accuracy or correctness of any description, calculation, specifica-
tion, or information contained herein. No such description, calculation, specification, or information regarding the
products being sold has been made part of the basis of the bargain, nor has same created or amounted to an
express warranty that the products would conform thereto. We are selling the goods and merchandise illustrated
and described on this publication on an “as is” basis, and disclaim any implied warranty, including any warranty of
merchantability or warranty of fitness for any particular purpose whatsoever, with respect to the goods and mer-
chandise sold. All manufacturer warranties shall be passed on to our customers, but we shall not be responsible
for special, indirect, incidental, or consequential damages resulting from the use of any of the products or informa-
tion contained or described on this publication. Further, we reserve the right to revise or otherwise make product
improvements at any time without notification.

WARNING - USER RESPONSIBILITY


FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH,
PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Parker-Hannifin Corporation, its subsidiaries and authorized distributors provide product or system options for further investigation
by users having technical expertise.

The user, through its own analysis and testing, is solely responsible for making the final selection of the system and components and assuring that all performance, endurance,
maintenance, safety and warning requirements of the application are met. The user must analyze all aspects of the application, follow applicable industry standards, and follow
the information concerning the product in the current product catalog and in any other materials provided from Parker or its subsidiaries or authorized distributors.
To the extent that Parker or its subsidiaries or authorized distributors provide component or system options based upon data or specifications provided by the user, the user is
responsible for determining that such data and specifications are suitable and sufficient for all applications and reasonably foreseeable uses of the components or systems.

OFFER OF SALE
The items described in this document are hereby offered for sale by Parker-Hannifin Corporation, its subsidiaries or its authorized distributor. This offer and its accepteance
are governed by the provisions stated in the detailed "Offer of Sale" elsewhere in this document.

2
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
General Information P1/PD Maintenance

MOUNTING These pumps are designed to operate in any position. The pump shaft must be in alignment
with the shaft of the source driver and should be checked with a dial indicator. The mating
pilot bore and coupling must be concentric. This concentricity is particularly important if the
shaft is rigidly connected to the driven load without a flexible coupling.

SHAFT INFORMATION Splined: The shafts will accept a maximum misalignment of 0.15mm, 0.005 inch, total
indicator reading. Angular misalignment at the external and internal spline axis must be less
than ± 0,002 mm per mm of shaft radius, ± 0.002 inches per inch of shaft radius. The coupling
interface must be lubricated. PARKER recommends lithium molydisulfide or similar grease.
The internal coupling should be hardened to Rc 27-34 and must conform to SAE-J498c,
class 5 flat root side fit.
Keyed: High strength heat treated keys must be used. Replacement keys must be hardened
to 27-34 Rc. The key corners must be chamfered 0.81-1.0 mm, 0.032”-0.040”, at 45° to clear
radii that exist in the keyway.

SIDE LOAD CAPABILITY The P1/PD series is designed for inline-drive. Side loading on the shaft is not recommended.
If this is unavoidable consult your nearest PARKER representative.

FLUID CONNECTIONS Connect inlet and outlet lines to the port block of the pump. The maximum case pressure is 2
bar (30 psi) continuous, 4 bar (60 psi) intermittent. The case pressure must never exceed inlet
pressure by more than .5 bar (7 psi). When connecting case drain line make certain that drain
plumbing passes above highest point of the pump before passing to the reservoir. The case
leakage line must be of sufficient size to prevent back pressure in excess of 2 bar (30 psi) and
returned to the reservoir below the surface of the oil as far from the supply inlet as possible.
All fluid lines, whether pipe, tubing, or hose must be adequate size and strength to assure
free flow through the pump. An undersize inlet line will prevent the pump from operating
properly at full rated speed. An undersize outlet line will cause back pressure and cause heat
generation and increased noise. Flexible hose lines are recommended. If rigid piping is used,
the workmanship must be accurate to eliminate strain on the pump port block or to the fluid
connections. Sharp bends in the lines must be eliminated wherever possible. All system piping
must be cleaned and flushed before installing pump. Make sure the entire hydraulic system is
free of dirt, lint, scale, or other foreign material.
Caution: Do not use galvanized pipe. Galvanized coating can flake off with continued use.

SYSTEM RELIEF VALVES Although the P1/PD series pumps have very fast off-stroke compensator response, system
relief valves are recommended in all cases for safety considerations.

RECOMMENDED FLUIDS The fluid recommended for use in these pumps has a petroleum base and contains agents
which provide oxidation inhibition and anti-rust, anti-foam and de-aerating properties as
described in PARKER standard HF-1. Where anti-wear additive fluids are specified, see
PARKER standard HF-0.

VISCOSITY INDEX 90 V. I. minimum. Higher values extend the range of operating temperature but may reduce
the service life of the fluid.

TEMPERATURE Determined by the viscosity characteristics of the fluid used. Because high temperatures
degrade seals, reduce the service life of the fluid and create hazards, fluid temperature
should not exceed 110°C (230°F) at the case drain.

MAINTENANCE The pump is self-lubricating and preventative maintenance is limited to keeping system fluid
clean by changing filters frequently. Keep all fittings and screws tight. Do not operate at
pressures and speeds in excess of the recommended limit. If the pump does not operate
properly, check the troubleshooting chart before attempting to overhaul the unit. Overhauling
may be accomplished by referring to the disassembly, rework limits of wear parts, and
assembly procedures as provided in this service manual.

FLUID CLEANLINESS Fluid must be cleaned before and continuously during operation, by filters that maintain a
cleanliness level of ISO 20/18/14. Better cleanliness levels will significantly extend the life
of the components. As contaminant generation may vary with each application, each must
be analyzed to determine proper filtration to maintain the required cleanliness level.

Parker Hannifin Corporation


Hydraulic Pump Division
4 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
General Information P1/PD Maintenance

STARTUP PROCEDURE FOR • Read and understand the instruction manual.


NEW INSTALLATIONS • Identify components and their function.
• Visually inspect components and lines for possible damage.
• Insure that all necessary ports are properly connected.
• Check reservoir for cleanliness. Drain and clean as required.
• Check fluid level and fill as required with filtered fluid to a minimum ISO cleanli-
ness level of 20/18/14.
• Fill pump case with clean oil prior to starting.
• If pump is mounted vertically with the shaft up, bleed the air out the D1 drain port
located near the mounting flange.
• Check alignment of drive.
• Check oil cooler and activate it, if included in circuit. Check fluid temperature.
• Reduce pressure settings of compensator and relief valve. Make sure accurate
pressure readings can be made at appropriate places.
• If solenoids in system, check for actuation.
• Jog the pump drive. Check for proper shaft rotation. Make sure pump fills properly.
• Start the pump drive.
• Bleed system of air. Recheck fluid level.
• Cycle unloaded machine at low pressure and observe actuation (at low speed, if
possible).
• Increase pressure settings gradually in steps. Check for leaks in all lines espe-
cially in pump and motor inlet lines.
• Make correct pressure adjustments.
• Gradually increase speed. Be alert for trouble as indicated by changes in sounds,
system shocks, and air in fluid.
• Equipment is operational.

Typical Ajustment Ranges and Initial Settings (unless customer specified at time of order)
Function Adjustment range Adjustment value Recommended or Initial Setting
Pressure compensators
"C0" 80-280 bar (1160-4060 PSI) 40 bar/turn (580 PSI/turn) Factory supplied at minimum
"C1" 20-80 bar (290-1160 PSI) 18.6 bar/turn (260PSI/turn) Factory supplied at minimum
"AM" 80-280 bar (1160-4060 PSI) 40 bar/turn (580 PSI/turn) Factory supplied at minimum
Load sense pressure
"L0" 8-35 bar (116-500 PSI) 28 bar/turn (410 PSI/turn) 24 bar (350 PSI)
Differential pressure
"AM" 37 bar (540 PSI) Adjustment not recommended Factory Set do not adjust
Maximum Volume stop
018 100-40% 9% per turn (1.6 cc/turn) 100%
028 100-40% 8.2% per turn (2.3 cc/turn) 100%
045 100-20% 7.5% per turn (3.4 cc/turn) 100%
060 100-30% 6.8% per turn (4.1 cc/turn) 100%
075 100-35% 6.2% per turn (4.65 cc/turn) 100%
100 100-50% 5.5% per turn (5.5 cc/turn) 100%
140 100-50% 4.8% per turn (6.72 cc/turn) 100%
Minimum Volume stop
018 0-68% 10% per turn (1.8 cc/turn) 0%
028 0-40% 9% per turn (2.6 cc/turn) 0%
045 0-40% 8.2% per turn (3.7 cc/turn) 0%
060 0-50% 4.6% per turn (2.76 cc/turn) 0%
075 0-45% 4.3% per turn (3.23 cc/turn) 0%
100 0-45% 3.9% per turn (3.9 cc/turn) 0%
140 0-25% 3.3% per turn (4.62 cc/turn) 0%

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 5
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Trouble Shooting P1/PD Maintenance

Component problems and circuit problems are often interrelated. An improper circuit may operate with apparent success but
will cause failure of a particular component within it. The component failure can be the effect, not the cause of the problem.
This general guide is offered to help in locating and eliminating the cause of problems by studying their effects.

Effect of Trouble Possible Cause Fault Which Needs Remedy


leak in inlet line
low fluid level
turbulent fluid
air in fluid return lines above fluid level
gas leak from accumulator
excessive pressure drop in the inlet line from a pressurized reservoir
inlet line strainer acting as air trap
fluid too cold
fluid too viscous
fluid too heavy
shaft speed to high
cavitation in
inlet line too small
rotating group
noisy pump inlet strainer too small
inlet strainer too dirty
operating altitude too high
inlet pressure too low
faulty installation
distortion in mounting
misaligned shaft axial interference
faulty coupling
excessive overhung loads
piston and shoe looseness or failure
bearing failure
mechanical fault in pump
incorrect port plate rotation
eroded or worn parts in the displacement control
air in fluid see noisy pump above
erosion on barrel ports
and port plate
cavitation see noisy pump above
cogging load mechanical considerations
worn relief valve needed repairs
worn compensator replace
pressure shocks slow response in check
replace or relocate
valves
excessive decompression
improve decompression control
energy rates
barrel blow-off rotating group worn, excessive case pressure
excessive line reduce line size or lengths
capacitance (line volume,
compensator instability
line stretch, acumulator
effects) eliminate hose

Parker Hannifin Corporation


Hydraulic Pump Division
6 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Trouble Shooting P1/PD Maintenance

Effect of Trouble Possible Cause Fault Which Needs Remedy


reduce pressure settings
excessive loads
reduce speeds
improper filter maintenance
filters too coarse
contaminant particles introduction of dirty fluid to system
in fluid reservoir openings
improper reservoir breather
improper line replacement
fluid too thin or thick for operating temperature range
high wear in pump breakdown of fluid with time/temperature/heating effects
improper fluid
incorrect additives in new fluid
destruction of additive effectiveness with chemical aging
incorrect parts
improper repair
incorrect procedures, dimensions, finishes
condensation
faulty breather/strainer
unwanted water in fluid heat exchanger leakage
faulty clean-up practice
water in makeup fluid
recheck case drain flow and repair as required
excessive pump leakage fluid too thin
improper assembly, port timing
set too low (compared to load or to compensator)
relief valve
instability caused by back pressure, worn parts
set too high (compared to relief)
compensator
worn parts
pump too large for
select smaller pump displacement
fluid needs
heating of fluid
water turned off or too little flow
water too hot
heat exchanger fan clogged or restricted
efficiency reduced by mud or scale deposits
intermittent hydraulic fluid flow
too little fluid
improper baffles
reservoir
insulating air blanket that prevents heat rejection
heat pickup from adjacent equipment

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 7
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
P1/PD 28cc, Model Ordering Code P1/PD Maintenance

028 P S 5 A 00
Pump Open Circuit Shaft Single Shaft Fluorocarbon Additional Adjustable Thru-Drive Special
Series Options Shaft Rotation Seal Material Control Displacement Mounting Features
Seal Design Control Options Stops Pad/Coupling
Displacement Mounting Configuration
Letter Options
28cc/rev. & Ports Port Port
(1.71 in³/rev) Orientation Type Paint

Pump Series Control Options Port Orientation


P1 Mobile Pressure limiter E End Ports
C0
PD Industrial 1160.30 - 4061.05 PSI (80 - 280 bar) R Side ported with ripple chamber
Pressure limiter T Side ported with through drive
C1
290.08 - 1160.30 PSI (20 - 80 bar)
Mounting & Ports
Load sensing 145.04-435.11 PSI ∆P
S
SAE B Pilot SAE Work Ports L0 (10-30 bar ∆P) with pressure limiter Adjustable Displacement Stops*
with SAE Aux Ports 1160.30 - 4061.05 PSI (80 - 280 bar) (For E & R Port Orientation Only)
SAE B Pilot Metric Work Ports Load sensing 145.04-435.11 PSI ∆P 0 None
A
with BSPP Aux Ports L2 (10-30 bar ∆P) with bleed & pressure limiter 1 Adjustable maximum displacement stop
ISO - 100MM Pilot Metric Work Ports 1160.30 - 4061.05 PSI (80 - 280 bar)
M 2 Adjustable minimum displacement stop
with Aux Ports
Pilot operated pressure limiter with
ISO - 100MM Pilot Metric Work Ports AN* Adjustable maximum and minimum
B ISO4401 interface & SAE 4 Vent Port 3
with BSPP Aux Ports displacement stop
Pilot operated pressure limiter with
AM *Not available with Thru-Drive
mechanical adjustment and SAE 4 Vent Port
Shaft Options Pilot operated pressure limiter with
01 Splined shaft - SAE B-B 15T
AE
mechanical and electrical adjustment 12 VDC
Port Type
0 Flange Ports
02 Keyed shaft - SAE B-B 1” Dia. Pilot operated pressure limiter with
AF 2 Threaded Ports
mechanical and electrical adjustment 24 VDC
04 ISO keyed 25MM Dia.
08 Splined shaft - SAE B 13T ## See chart below for electronic control options
*Not functional control as such Thru-Drive Mounting Pad/Coupling
0 No Thru-Drive
Shaft Rotation
Additional Control Options A SAE 82-2 (A), 16 (A), 9T coupling
R Clockwise
0 No other options H SAE 82-2 (A), 19 (--), 11T coupling
L Counterclockwise
2 Displacement sensor ** B SAE 101-2 (B), 22 (B) , 13T coupling
** mandatory with "W**", "X**", Q SAE 101-2 (B), 25 (B-B), 15T coupling
Configuration "Y**", "Z**" "*D*" and "*Y*"
M Mobile (P1)
S Industrial (PD)
Paint
00 No Paint
PB Black Paint

Electronic Control Options


# #

0 No ECU
D Proportional displacement control
Proportional pressure
Y
and displacement control

P Electronic valve with zero displacement default


T Electronic valve with max displacement default
S Electronic valve with zero displacement default and hydromechanical Pmax
U Electronic valve with max displacement default and hydromechanical Pmax
W Electronic valve with zero displacement default (CANBUS compatible)
Y Electronic valve with max displacement default (CANBUS compatible)
X Electronic valve with zero displacement default and hydromechanical Pmax (CANBUS compatible)
Z Electronic valve with max displacement default and hydromechanical Pmax (CANBUS compatible)
*** W, X, Y and Z only available with *D* and *Y*

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 9
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Typical Characteristics P1/PD Maintenance

Technical Data
Model P1/PD 018 P1/PD 028 P1/PD 045 P1/PD 060 P1/PD 075 P1/PD 100 P1/PD 140
Maximum Displacement, cm3/rev 18 28 45 60 75 100 140
cu.in./rev 1.10 1.71 2.75 3.66 4.58 6.01 8.54
Outlet Pressure – Continuous, bar 280
psi 4000
Intermittent*, bar 320
psi 4500
Peak, bar 350
psi 5000
P1 Maximum Speed (1.3 bar abs inlet), rpm 3600 3400 3100 2800 2700 2500 2400
P1 (1.0 bar abs inlet), rpm 3300 3200 2800 2500 2400 2100 2100
P1 (0.8 bar abs inlet), rpm 2900 2900 2400 2200 2100 1900 1800
PD Maximum Speed (1.0 bar abs inlet), rpm 1800
PD (0.8 bar abs inlet), rpm 1800
Minimum Speed, rpm 600
Inlet Pressure – Maximum, bar 10 (gage)
psi 145
Rated, bar 1.0 absolute (0.0 gage)
psia 14.5
Minimum, bar 0.8 absolute (-0.2 gage)
psia 11.6
Case Pressure – Peak, bar 4.0 absolute (3.0 gage)
and less than 0.5 bar above inlet pressure
Rated, bar 2.0 absolute (1.0 gage)
and less than 0.5 bar above inlet pressure
Fluid Temperature Range, °C -40 to +95
°F -40 to +203
Fluid Viscosity – Rated, cSt 6 to 160
Max. Intermittent, cSt 5000 (for cold starting)
Min. Intermittent, cSt 5
Fluid Contamination – Rated, ISO 20/18/14
Maximum, ISO 21/19/16
SAE Mounting – Flange 82-2 (A) 101-2 (B) 101-2 (B) 127-2 (C) or 127-4 (C) 127-4 (C) 152-4 (D)
ISO Mounting - Flange 80 mm 100 mm 100 mm 125 mm 125 mm 125 mm 180 mm
SAE Keyed Shafts 19-1, A 25-1, BB 25-1, BB 32-1, C 32-1, C 38-1, CC 44-1, D
ISO Keyed Shafts 20 mm 25 mm 25 mm 32 mm 32 mm 40 mm 50 mm
SAE Spline Shafts 9T, A 13T, B 13T, B
14T, C 14T, C 17T, CC 13T, D
11T, A 15T, BB 15T, BB
Weight – End Port, kg (lb) 13.4 (29.5) 17.7 (39.0) 23 (50) 29 (64) 30 (66) 51 (112) 66 (145)
Side Port, kg (lb) 14.2 (31.3) 18.1 (40.0) 24 (52) 30 (67) 31 (68) 53 (117) 67 (147)
Thru-Drive, kg (lb) — 22 (48) 27 (59) 34 (75) 35 (77) 55 (121) 82 (180)
Moment of Inertia kg·mm2 760 1555 3208 4548 5041 12027 21400
Moment of Inertia Thru-Drive kg·mm2 NA 1618 3268 4687 5207 12402 22343
*Intermittent pressure is defined as less than 10% of operation time, not exceeding 6 successive seconds.

Typical Control Reponse Times*


For max volume stops:
Typical Control
Response Time (ms) Pump Size % Stroke reduction per turn
P*060 6.76 P*018 9
Control Description Pump Operating Condition 018 028 045 060 075 100 140 P*075 6.2 P*028 8.2
Maximum Displacement to Zero 25 25 25 37 21 26 30 P*100 5.5 P*045 7.5
”C” Pressure Limiter P*140 4.8
Zero Displacement to Maximum 80 80 106 119 89 108 125
Control Adjustment Sensitivity:
Maximum Displacement to Zero 40 40 30 54 40 43 45 • Load Sense 28 Bar/Turn
”L” Load Sensing
Zero Displacement to Maximum 70 70 120 186 97 189 280 • Pressure Compensator 80 to 280
bar range (C0) = 40 Bar/Turn
”A” Pilot Operated Maximum Displacement to Zero 25 25 46 43 37 39 40
• Pressure Compensator 20 to 80
Control Zero Displacement to Maximum 80 80 131 125 115 123 130 bar range (C1) = 18.6 Bar/Turn
* Based on NFPA testing standards • Pressure compensator (AM) 10 to 40
bar range = 20 Bar/Turn
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA 15
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
18cc & 28cc Pump Exploded View P1/PD Maintenance

1
25

3
41 4
26
5

7
8
11 9
27 14

13

42 15

44

45
12 19
28
20

43
21
31 31
22
32
32
33 23

34 35

24
46 47 38

39
40

Parker Hannifin Corporation


Hydraulic Pump Division
16 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Parts P1/PD Maintenance

ITEM # QTY 018 PART # 028 PART # 045 PART # DESCRIPTION


1 4 210 x209 210 x 211 361-12229-0 Socket head cap screw
3 1 Contact Factory for port block ordering information Port Block
4* 1 2050V-7 2160V-7 675-00162-0 Port block O-Ring
5 2 108X2V 108X2V 108X2V Boss Plug (not shown)
7 1 299X67 324-30014-0 324-30014-0 Port Plate Pin
8* 3 605-10077-0 605-10077-0 605-10077-0 O-Ring
03E-94415-0 03E-94969-0 03E-94339-0 Port plate, clockwise, industrial (PD)
03E-94414-0 03E-94970-0 03E-94340-0 Port plate, counter clockwise, industrial (PD)
03E-94413-0 03E-94969-0 03E-94341-0 Port plate, clockwise, mobile (P1)
03E-94416-0 03E-94970-0 03E-94342-0 Port plate, counter clockwise, mobile (P1)
9 1
03E-94963-0 03E-94376-0 03E-95374-0 Port plate, CW, industrial (PD), ripple chamber
03E-94964-0 03E-94377-0 03E-95080-0 Port plate, CCW, industrial (PD), ripple chamber
03E-94965-0 03E-94378-0 03E-95374-0 Port plate, clockwise, mobile (P1), ripple chamber
03E-94966-0 03E-94379-0 03E-95375-0 Port plate, CCW, mobile (P1), ripple chamber
10* 2 ** ** 695-00912-0 Bias and control rod O-ring
11 1 03E-94427-0 03E-94390-0 03E-94355-0 Bias Guide
12 1 03E-94428-0 03E-94391-0 03E-94354-0 Bias Piston
13 1 03E-94430-0 03E-94393-0 03E-94356-0 Bias Spring
14 1 03E-94427-0 03E-94390-0 03E-94353-0 Control guide
15 1 03E-94426-0 03E-94389-0 03E-94352-0 Control piston
19 1 256X521 256X525 356-65144-0 Retaining ring, internal
20 1 787635 03E-94387-0 03E-94350-0 Barrel hold down spring
21 2 786996 03E-94388-0 03E-94351-0 Barrel hold down washer
22 3 787000 03E-94386-0 03E-95903-0 Barrel hold down pin
23 1 03E-94717-0 03E-94375-0 03E-94338-0 Barrel
24 1 787002 03E-94385-0 03E-94348-0 Spherical washer
25 1 786994 03E-94384-0 03E-94347-0 Retainer plate
26 9 789641 S2E-18415-0 S2E-18413-0 Piston and shoe assembly
03E-94409-0 03E-94372-0 03E-94335-0 01 shaft option, no thru drive
03E-94411-0 03E-94374-0 03E-94337-0 01 shaft option with thru drive
03E-94410-0 03E-94373-0 03E-94948-0 02 shaft option, no thru drive
03E-94806-0 03E-94900-0 03E-94908-0 02 shaft option with thru drive
03E-94800-0 03E-94903-0 03E-94923-0 04 shaft option, no thru drive
27 1
03E-94801-0 03E-94904-0 03E-94922-0 04 shaft option with thru drive
03E-94718-0 ** ** 06 shaft option, no thru drive
** ** ** 06 shaft option with thru drive
03E-94804-0 03E-95166-0 03E-94990-0 08 shaft option, no thru drive
03E-94762-0 03E-95492-0 03E-95197-0 08 shaft option with thru drive
28 1 S2E-19079-0 S2E-18414-0 S2E-18412-0 Cam
31 2 03E-94359-0 03E-94359-0 03E-94359-0 Bearing retainer Orifice
32 2 03E-94432-0 03E-94395-0 03E-94358-0 Cam bearing
33 1 ** ** ** Housing (not sold seperatley)
108X6 108X8 488-35055-0 Plug, SAE ORB
34 2 Consult Parker Rep. Plug, BSPP
Consult Parker Rep. Plug, ISO
35* 2 695-00908-0 695-00908-0 695-00910-0 SAE O-ring
38* 1 787140 P2-060-3304 620-82125-5 Shaft Seal
39 1 256X535 256X544 356-65158-0 Seal Retainer
40 1 see separate compensator ordering information Compensator
41 2 324-30024-0 324-30024-0 324-30014-0 Cover dowel pin
42 1 216-10013-0 789814 230-82227-0 Port block bushing
43 1 230-82514-0 789815 230-82516-0 Cylindrical roller bearing
44 1 256X222 256X222 356-65159-0 External retaining ring (shaft)
45 1 256X544 256X544 356-65144-0 Internal retaining ring (housing)
46 1 108X4 108X4 108X4 Boss plug
47* 1 695-00904-0 695-00904-0 695-00904-0 O-ring
* denotes Item is included in the seal kit

Parker Hannifin Corporation


Hydraulic Pump Division
18 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Electronic Control Exploded View P1/PD Maintenance

Torque to 5 ft-lbs (6.8 Nm)

Parker Hannifin Corporation


Hydraulic Pump Division
22 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Electronic Control Parts P1/PD Maintenance

RDEC Parts list


ITEM # QTY Part # DESCRIPTION
80 1 03E-95420-0 Rotary Position sensor
81 2 210X73 Socket head cap screw
82 2 234X7 Washer
83 1 03E-95249-0 Position sensor spacer
84 1 03E-95201-0 Shaft position connector 18 and 45 thru 75
03E-95545-0 Shaft position connector 28
03E-95205-0 Shaft position connector 100 and 140
85 1 789764 Seal
86 1 675-00904-0 O-Ring Seal
87 1 108X4V O-Ring boss plug
88 1 S13-40266-0 Check Valve
89 1 S2E-19182-5 External Servo Assembly*
90 1 03E-95347-0 External servo manifold
91 1 S2E-19174-5 Maximum pressure valve CCW
S2E-19173-5 Maximum pressure valve CW
92 12 605-10069-0 O-Ring Seal
93 1 517-00178-5 Proportional valve 0 disp default CW
517-00180-5 Proportional valve max disp default CW
517-00179-5 Proportional valve 0 disp default CCW
517-00181-5 Proportional valve max disp default CCW
94 8 350-10167-0 Lock Washer
95 4 361-07360-8 Socket head cap screw**
210x105 Socket head cap screw***
210x110 Socket head cap screw****
96 1 325-36002-0 Roll Pin
97 1 S13-40266-0 Check Valve
98 1 03E-94859-0 Cam pin
99 1 S2E-19190-0K Position sensor mating connector
100 1 S2E-19254-0 Electronic control unit (not shown)
101 1 S2E-19192-5K Pressure sensor kit UNC threads(not shown)
S2E-19523-5K Pressure sensor kit BSPP threads (not shown)
102 1 S2E-19191-0K Prerssure sensor mating connector (not shown)
103 1 S2E-19179-0 12 Pin cable assembly
104 1 S2E-19259-0 CAN communication cable
105 1 S2E-19180-0 Control communcation cable
106 1 1210694 Standard Coil
107 1 121459 Gasket
* Item 89 includes items 86, 87, 88, 90, 92 and 96
** Used on control options S/X/U/Z
*** Used on pumps without overcenter capability (P) and control options P/W/T/Y
*** Used on pumps with over center capability (X) and control options P/W/T/Y

Displacement Sensor Installation

After engaging
Aftershaft slot toshaft
engaging pin, slot to pin, After engaging
Aftershaft slot toshaft
engaging pin, slot to pin,
hold sensorhold
flushsensor
to pump padto pump pad
flush hold sensorhold
flushsensor
to pump padto pump pad
flush
and rotate toandalign screw slots
rotate to align screw slots and rotate toandalign screw slots
rotate to align screw slots
to screw holes. Secure
to screw withSecure
holes. screwswith screws to screw holes. Secure
to screw withSecure
holes. screwswith screws
& washers, & 2 places.
washers, 2 places. & washers, & 2 places.
washers, 2 places.

Final Position Final Position Final Position Final Position

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 23
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Case to Inlet Check Valve P1/PD Maintenance

198±8 Nm 50 51 52
(146±6 ft-lbs) 53

CASE TO INLET CHECK VALVE


Item No Qty 018, 028, 045 060, 075, 100, 140 Description
50 1 314-10002-0 314-10000-0 Hollow Set Screw
51 1 03E-94720-0 03E-93931-0 Check Valve Poppet
52 1 03E-94721-0 03E-93987-0 Spring
53 1 03E-94722-0 03E-93988-0 Check Valve Stop

Parker Hannifin Corporation


Hydraulic Pump Division
24 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Volume Stop Control P1/PD Maintenance

57 61

60
59 58 57 56
55
54

Minimum and Maximum Volume Stop


Item # Qty 018 028 045 060 075 100 140 Description
54 1 362-11045-0 Adjusting Screw
55 1 334-00013-0 334-00011-0 Locknut, Adjusting Screw
56 1 03E-93181-0 03E-93181-0 Volume Stop Plug
57 1 695-00908-0 695-00908-0 O-ring, Volume Stop Plug
58 1 618-15023-0 618-15023-0 Back Up Ring
59 1 695-00011-0 695-00011-0 O-ring, Volume Stop Rod
60 1 03E-94736-0 03E-95170-0 03E-93262-0 Volume Stop Rod
61 1 488-35018-0 488-35018-0 Plug(No Volume Stop)
Not Shown 1 03E-95217-0 03E-95358-0 03E-93262-0 ** Minimum Volume Stop Rod
KIT S2E-19203-5 S2E-19204-5 S2E-19114-5 S2E-18987-5K S2E-18988-5K Adjustable Volume Stop
KIT S2E-19608-5 S2E-19609-5 Use Above Kit Adjustable Minimum Volume Stop
Maximum and minimum volume stops use the same components except where noted.

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 25
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Seal Kits and Parts Kits P1/PD Maintenance

70

Thru Drive Pad Thru Drive Couplings


O-ring
Coupling #70 018 028 045 060 075 100 140
SAE A, 9 Tooth S2E-19538-0 S2E-19364-0 03E-94942-0 03E-93278-0 03E-93278-0 03E-94274-0 03E-93947-0 695-00237-0
SAE A, 11 Tooth S2E-19726-0 S2E-19391-0 03E-94943-0 03E-94724-0 03E-94724-0 03E-94657-0 ** 695-00237-0
SAE B, 13 Tooth ** S2E-19365-0 03E-94945-0 03E-93277-0 03E-93277-0 03E-94273-0 03E-93946-0 695-00243-0
SAE BB, 15 Tooth ** S2E-19409-0 03E-94361-0 03E-93279-0 03E-93279-0 03E-94272-0 03E-93945-0 695-00243-0
SAE C, 14 Tooth ** ** ** 03E-93276-0 03E-93276-0 03E-94271-0 03E-93944-0 695-00251-0
SAE CC, 17 Tooth ** ** ** ** ** 03E-94270-0 03E-93943-0 695-00251-0
SAE D&E, 13 Tooth ** ** ** ** ** ** 03E-93942-0 695-00259-0

018 028 045 060 075 100 140


Seal Kits
S2E-18709-5K S2E-19118-5K S2E-19066-5K S2E-18697-5K S2E-18004-5K S2E-18460-5K S2E-18158-5K
Note: Seal kits contain all the seals required for any pump configuration.

Parker Hannifin Corporation


Hydraulic Pump Division
26 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Parts Kits P1/PD Maintenance

Rotating Group
018 028 045 060 075 100 140
Kits
CW Mobile P1 S2E-18710-0K S2E-19119-0K S2E-19067-0K S2E-18698-0K S2E-18032-0K S2E-18485-0K S2E-18489-0K
CW Mobile P1 with
S2E-19205-0K S2E-19209-0K S2E-19235-0K ** ** ** **
Ripple Chamber
CCW Mobile P1 S2E-18711-0K S2E-19120-0K S2E-19068-0K S2E-18699-0K S2E-18033-0K S2E-18486-0K S2E-18490-0K
CCW Mobile P1 w/
S2E-19206-0K S2E-19210-0K S2E-19236-0K ** ** ** **
Ripple Chamber
CW Industrial PD S2E-18712-0K S2E-19121-0K S2E-19069-0K S2E-18700-0K S2E-18483-0K S2E-18487-0K S2E-18491-0K
CW Industrial PD w/
S2E-19207-0K S2E-19211-0K S2E-19126-0K ** ** ** **
Ripple Chamber
CCW Industrial PD S2E-18713-0K S2E-19122-0K S2E-19070-0K S2E-18701-0K S2E-18484-0K S2E-18488-0k S2E-18492-0K
CCW Industrial PD
S2E-19208-0K S2E-19212-0K S2E-19127-0K ** ** ** **
w/ Ripple Chamber
Rotating Group Kit includes barrel s/a, pistons, retainer, washer, pins, port plate

Torque Limiter Control Kits 045 060 075 100 140


Torque Limiter Kit for AMT Control S2E-19102-5 S2E-19033-5 S2E-18720-5 S2E-18888-5 S2E-18963-5
Torque Limiter Kit for ALT Control See Note ** ** **
Torque Limiter Kit for L0T ** ** S2E-18721-5 S2E-18759-5 S2E-18739-5
Torque Limiter Kits includes cartridge assembly, tubing and fittings.
Note: AM control can be converted to an AL control with conversion kit S2E-19117-0.
European customers will receive a solid spool in this kit. US customer will receive a set screw to plug orifice in spool.

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 27
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
“C” Compensator P1/PD Maintenance

Outer spring used C0 only.

Inner spring used for both


C0 and C1 versions.

NOTE: Individual parts are not available.


The compensator is sold as a complete assembly only.

Compensator Part Number


C0 C1
Rotation
80 - 280 bar (1150 - 4000 psi) 20 - 80 bar (300 - 1150 psi)
CW S2E-17904-5 T S2E-18285-5 T
CCW S2E-17905-5 T S2E-18286-5 T

Item
Quantity Description NOTES / Tightening Torque
no.
Compensator body CW rotation
1 1
Compensator body CCW rotation
2 1 Spool
3 1 Spring seat
4 1 Outer spring C0 versions only
5 1 Inner spring
6 1 Spring seat & piston
7 1 Seal piston o-ring
8 1 Spring cap o-ring
9 1 Spring cap 115 ± 7 N-m (85 ± 5 ft-lbs)
10 1 Adjusting screw
11 1 Adjusting screw locknut 7.9 ± 0.8 N-m (70 ±7 in-lbs)
12 1 Socket set screw (Loctite 242) 3.4 ± 0.4 N-m (30 ± 3 in-lbs)
13 4 Hex mounting screw 5.0 ± 0.3 N-m (45 ± 3 in-lbs)
14 1 SAE #2 o-ring
15 1 Hardened SAE #2 o-ring boss plug 4.0 ± 0.6 N-m (35 ± 5 in-lbs)
17 4 Teflon O-ring
18 1 Roll pin
19 1 Teflon O-ring

Parker Hannifin Corporation


Hydraulic Pump Division
30 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Compensator Procedures P1/PD Maintenance

COMPENSATOR DISASSEMBLY NOTES:


Access plugs on end of compensator spool bores are hardened plugs. Do not
interchange with other plugs in the control.
For rotation change, the complete compensator assembly will need to be
replaced.

Compensator Disassembly:
1. Measure and record the extension of the two pressure adjusting screws.
2. Carefully remove the main compensator spring cap. Remove the two
springs. Remove the seal piston and spring seat. Remove the o-ring
boss access plug on the opposite side of the compensator. Remove the
compensator spool. NOTE: the compensator spool and inner spring are
not interchangeable with the load sense compensator spool and spring.
3. For “L” series compensators: Carefully remove the load sense com-
pensator spring cap with spring seat/seal piston. Remove the spring.
Remove the spring seat. Remove the o-ring boss access plug on the
opposite side of the compensator. Remove the load sense compensa-
tor spool. NOTE: the load sense compensator spool and spring are not
interchangeable with the main compensator spool and inner spring of the
main compensator.
4. Remove all SAE o-ring boss access plugs.

COMPENSATOR INSPECTION NOTE: The compensator is supplied as an assembly. Individual parts


are not available. If there is significant damage to any of the parts, the
complete compensator will need to be replaced.

1. Inspect the main compensator spool and the load sense spool for
scratches or other damage.
2. Inspect the springs for proper free extension length (see chart below).
3. Inspect the spool bores for damage. Apply a light oil film on the
appropriate spool and check its fit in the bore. The spool should fit snugly
in housing and not have any radial play.

COMPENSATOR SPRING FREE LENGTH


Item
Type Component Tolerances
Number
C*/L* 5 Main compensator spring - inner Free height: 25.9±0.5mm (1.020±0.020 in.)
C0/L0/L2 4 Main compensator spring - outer Free height: 39±0.7mm (1.535±0.028 in.)
L* 17 Load Sense spring Free height: 14±0.4mm (0.551±0.016 in.)
R* 6 Bias spring
Reference item numbers on page 26.

Parker Hannifin Corporation


Hydraulic Pump Division
32 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Compensator Procedures P1/PD Maintenance
COMPENSATOR ASSEMBLY Carefully clean and dry all parts prior to assembly. Use caution to insure that
spools and other parts are not damaged during cleaning process. Use clean oil to
NOTE: instructions
COMPENSATOR are for load
ASSEMBLY lubricate seals and spools for easier assembly.
COMPENSATOR
COMPENSATOR
sense compensator. ASSEMBLY
ASSEMBLY
for other Carefully clean
Carefully clean and
and dry
dry all
all parts
parts prior
prior to
to assembly.
assembly. Use
Use caution
caution to
to insure
insure that
that
compensator types disregard steps spools
spools and other
and
1. Remove other parts
andparts areall
are
discard not
not damaged
damaged
o-rings. during
during
Install cleaning
newcleaning process.
process.
o-rings on SAE boss Useplugs
Use cleanand
clean oil to
oil to
NOTE:
relatedinstructions
NOTE:
NOTE: instructions
instructions are
to extra spoolare for
for load
load
assembly. lubricate
lubricate seals
seals and
and
seal pistons. spools
spools for
for easier
easier assembly.
assembly.
sense
sensecompensator.
compensator.For
compensator. for other
for other
compensator
compensator types
compensator types disregard
types disregard steps
disregard steps
steps 1.
1. Remove
2. Remove
Apply a lightand film
and discard
discard alltoo-rings.
of oilall o-rings. Install
Install
the o-ring on thenewmain
new o-rings
o-rings on SAE
on SAE boss
boss
compensator plugs
sealplugs and
and
piston.
related
related to
related to extra
to extra spoolassembly.
extra spool
spool assembly.
assembly. seal
seal pistons.
pistons.
Install the main compensator seal piston in the main compensator spring
cap.
2. Apply
2. Apply aa light
light film
film of
of oil
oil to
to the
the o-ring
o-ring on
on the
the main
main compensator
compensator seal
seal piston.
piston.
Install
Install the
the main
main compensator
compensator seal
seal piston
piston in
in the
the main
main compensator
compensator
3. Place inner compensator spring on seal piston. Install the outer compensator spring
spring
cap.
cap.
spring over the inner spring on the seal piston. Position the spring seat over
the springs. Insert this assembly into the main compensator housing bore.
3. Place
3. Place
Torque inner
inner compensator
the compensator
main springspring
spring
compensator on seal
on seal piston.
cappiston. InstallNm
Install
to 169-183 the (125-135
the outer compensator
outer compensator
ft.-lb.).
spring over
spring over the
the inner
inner spring
spring on
on the
the seal
seal piston.
piston. Position
Position the
the spring
spring seat
seat over
over
the
the springs.
springs. Insert
Insert this
this assembly
assembly into
into the
the main
main compensator
compensator
4. Apply a light film of oil on the main compensator spool (the longer of the 2housing
housing bore.
bore.
Torque
Torque the
spools).the main
main
Insert thecompensator
compensator
spool into thespring
spring
spoolcapcap to
boreto opposite
169-183 Nm
169-183 Nmmain
the (125-135
(125-135 ft.-lb.).
ft.-lb.).
compensator
spring assembly in the compensator body. The rounded end of the spool
Main Outer Spring 4. Apply
4. Apply
shouldaabelight
light film of
film
installed of oil
oil on
on
first the
sothe main
main
it will compensator
compensator
contact the spring spool
spool
seat. (the
(the longer
longer
Install of the
of
a new the 22
o-ring
spools).
spools). Insert
Insert the
the spool
spool into
into the
the spool
spool bore
bore opposite
opposite the
the main
on the hardened SAE boss fitting and place it into the port. Torque fitting to 4main compensator
compensator
spring
spring
± 0.5 Nmassembly
assembly
(37 ± 5in in the compensator
the
in-lb). compensator body. body. The
The rounded
rounded end end ofof the
the spool
spool
Main
Main Outer
Outer Spring
Spring should be
should be installed
installed first
first so
so itit will
will contact
contact the spring seat.
the spring seat. Install
Install aa new
new o-ring
o-ring
on
on the
the hardened
hardened SAE
SAE boss
boss fitting
fitting and
and place
place it
it into
into the
the port.
port.
5. Apply a light film of oil to the o-ring on the load sense seal piston. Install the Torque
Torque fitting
fitting to
to 44
±load
± 0.5 Nm
Nm (37
0.5sense (37 ±± 55 in-lb).
in-lb). seal piston seat in the load sense spring cap.
compensator
Install the load sense spring over the seal piston. Position the spring seat
5.
5. Apply
Apply
over the aa light
light film
spring. of
of oil
oil to
filmInstall to the
thisthe o-ring
o-ring on
assembly the
oninto load
thethe
load sense
sense
load seal
senseseal piston.
piston.
bore Install
of theInstall the
the
load
load sense
sense compensator
compensator compensator
housing. Torqueseal
seal piston
piston seat
seat
the load in
in the
sense load
load sense
thespring cap tospring
sense 35-38 cap.
spring cap.(26-28
Nm
Install
ft. lb.).the
Install the load
load sense
sense spring
spring over
over the
the seal
seal piston.
piston. Position
Position the
the spring
spring seat
seat
over
over thethe spring.
spring. Install
Install this
this assembly
assembly into
into the
the load
load sense
sense bore
bore ofof the
the
6. compensator
compensator
Apply housing.
a light film of oil Torque
housing. Torque
to the
the load load
load sense
thesense sense spring
spring cap
compensator cap to
to 35-38
spool 35-38 Nm
Nm (26-28
(the shorter (26-28
of
ft.
ft. lb.).
lb.).
the 2 spools). Insert the spool into the spool bore opposite the load sense
spring assembly. The spool should be installed with the rounded end in first
6.
6. Apply
Apply
so aa light
it will light film
contact of
of oil
filmthe oil to
loadto the
the load
senseload sense
sense
spring compensator
compensator
seat. Install a newspool
spool (the
(theon
o-ring shorter
the of
shorter of
the
the 2
2 spools).
spools). Insert
Insert the
the spool
spool into
into the
the spool
spool bore
bore opposite
opposite
hardened SAE boss fitting and place it into the port. Torque fitting to 4 ± 0.5 the
the load
load sense
sense
spring
spring assembly.
assembly. The The spool
spool should
should be be installed
installed with
with the
the rounded
rounded end end in in first
first
Nm (37 ± 5 in-lb).
so
so itit will
will contact
contact thethe load
load sense
sense spring
spring seat.
seat. Install
Install aa new
new o-ring
o-ring on on the
the
7. hardened
hardened
Install SAE
SAEon
o-rings boss
boss fitting
fitting and
remaining and
SAE place
bossititfittings
place into
into the port.
theand
port. Torque
install intofitting
Torque fitting to 44 ±± 0.5
to
housing. 0.5
Nm
Nm (37
(37 ±± 55 in-lb).
in-lb).
Torque SAE-2 fittings to 4 ± 0.5 Nm (37 ± 5 in-lb).
7.
7. Install
Install o-rings
o-rings on
on remaining
remaining SAE SAE boss
boss fittings
fittings and
and install
install into
into housing.
housing.
Torque
Torque SAE-2
SAE-2 fittings to 44 ±± 0.5
fittings to 0.5 Nm (37 ±± 55 in-lb).
Nm (37 in-lb).

Load Sense Spool


Load Sense Main Compensator
Spring Inner Spring
Load Sense
Load Sense Spool
Spool
Load
Load Sense
Sense Main
Main Compensator
Compensator
Spring
Spring Inner
Inner Spring
Spring

Main Compensator Spool

Parker Hannifin Corporation Main Compensator


Main Compensator Spool
Spool
Hydraulic Pump Division
Marysville, Ohio USA 33
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance

PUMP DISASSEMBLY Pump disassembly for inspection should be limited to the following cases:
a) Malfunction or oil leakage resulting from damage or wear and tear.
b) Trouble-shooting procedures previously listed do not solve the problem.

For rotation change or shaft conversion, disassembly should be done only as far
as necessary to completePump
conversion.
disassembly for inspection should be limited to the following cases:
a) Malfunction or oil leakage resulting from damage or wear and tear.
b) Trouble-shooting
Disassembly and reassembly procedures previously
should be performed in a clean listed do not solve the problem.
environment.
For rotation change or shaft conversion, disassembly should be done only as far
as necessary to complete conversion.
Caution: Spring assemblies in the pump are normally set under high
compression and bodilyDisassembly
injury mayand reassembly should be performed in a clean environment.
occur if caution is not taken during
disassembly.
Caution: Spring assemblies in the pump are normally set under high
compression and bodily injury may occur if caution is not taken during
disassembly.
It is usually not necessary to replace spring (20) fitted in cylinder barrel. Do not
replace the spring unless absolutely necessary.
It is usually not necessary to replace spring (20) fitted in cylinder barrel. Do not
After disassembly, the internal
replaceparts should
the spring beabsolutely
unless coated with a film of clean oil and
necessary.
protected from dirt and moisture.
After disassembly, the internal parts should be coated with a film of clean oil and
protected from dirt and moisture.
It is recommended that the length of the protruding portion of the compensator
adjusting screws, on the control 40 be measured
It is recommended andofnoted
that the length as thisportion
the protruding information
of the compensator
adjusting screws, on the control 38 be measured and noted as this information
will prove useful during assembly.
will prove useful during assembly.

Care must be taken to avoid


Caredropping, damaging
must be taken or contaminating
to avoid dropping, damaging or the machined
contaminating the machined
parts and the control valve.
parts and the control valve.

For complete overhaul, all o-rings and seals should be discarded and replaced.
For complete overhaul, all o-rings and seals should be discarded and replaced.
1. Identify the pump from information on the data tag. Figure 1
1. Identify the pump from information on the data tag. Figure 1

Figure 1

Parker Hannifin Corporation


Hydraulic Pump Division
34 Marysville, Ohio USA

Figure 1
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance
2. Drain fluid from housing. Fluid drained from pump should be disposed of
properly.

PUMP DISASSEMBLY 2. 3.
Drain fluidpump
Mount frominhousing.
fixture toFluid drained
prevent fromwhile
movement pump should main
removing be disposed
housing of
Continued properly.
bolts

3. 4.
Mount pumpbolts
Remove in fixture
holdingtothe
prevent movement
compensator whileonremoving
assembly the pump main housing
housing.
bolts
Additional fluid may drain out of the passages when the compensator is
removed. Set compensator aside for later disassembly and inspection
4. Remove bolts holding the compensator assembly on the pump housing.
Additional
5. Removefluid may attaching
the bolts drain outthe
of port
the passages
block to thewhen the compensator is
main housing.
removed. Set compensator aside for later disassembly and inspection
6. Carefully remove the port block. Use caution to avoid dropping the port
5. Remove
plate. the
Notebolts attaching
the location thebias
of the portspring
block- piston
to theassembly
main housing.
and the control
6. piston assembly.
Carefully remove the The control
port piston,
block. Usebias piston
caution toand biasdropping
avoid spring may
theremain
port
in pump when port block is removed. Remove and discard the three white
plate.
Teflon seals on the port block. These seals should be replaced each timecontrol
Note the location of the bias spring - piston assembly and the
piston
the assembly. The control piston, bias piston and bias spring may remain
pump is disassembled.
in pump when port block is removed. Remove and discard the three white
7. Remove
Teflon sealsthe
oncontrol piston
the port andThese
block. the bias piston
seals - spring
should beassembly.
replaced each time
the NOTE:
pump isFor rotation change only, do not disassemble further, proceed to
disassembled.
step 16.
7. Remove the control piston and the bias piston - spring assembly.
8. Remove
NOTE: the tapered
For rotation roller bearing
change only, docone
not and shim from the
disassemble end of
further, the shaft.
proceed to
step 14.
9. Position the pump horizontally and remove the rotating group. Avoid
8. Position the pump
separating horizontally
the pistons from theand remove
barrel the rotating
if possible. This will group.
assist inAvoid
identifying
separating thedamage
pistonsbetween
from thean barrel
individual piston and
if possible. borewill
This during
assistcomponent
in
inspection.
identifying damage between an individual piston and bore during component
inspection.
10. Remove the drive shaft.
NOTE: Forashaft
8a. If completing sealchange
changeonly, no further disassembly
or complete overhaul onisarequired.
045 pump Proceed
turn housing
to assembly procedure step 5.
over and remove the snap ring and shaft seal from the housing before moving
on to
11. step 9.the cam by rotating it 90 degrees and carefully extracting it from the
Remove
9. pump cam
Remove housing.
fromNote the large
housing. Seepocket under
Figure 2 the cam fits on the pressure
control side of the pump housing (same side as the three seals on the
housing flange). Figure 2

Large Pocket

Pressure control
side of pump
Figure 2

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 35
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance

PUMP DISASSEMBLY 10. Remove cam bushing screws and cam bushings from pump.
Continued
11. Remove snap ring in housing and shaft bearing assembly.
12. If completing a seal change or a complete overhaul turn the housing over
and remove the snap ring and shaft seal from the housing.
12a. If you are working on an 045 pump please omit this step as this
has already been completed in step 8a.
12b. Always use a new shaft seal. Do not reuse old shaft seal.
13. If there is excessive wear on the port block bushing; remove the bushing
from the port block.
14. If complete overhaul or rotation change, remove control piston and bias
piston guides. The Control piston and bias piston guides are installed with
Anaerobic thread lock. Place the port block in an oven at 163°C (325°F).
NOTE: to prevent annealing of heat treated surfaces DO NOT USE A TORCH
TO HEAT PISTON GUIDES. (45 Size only)

COMPENSATOR DISASSEMBLY NOTES: Access plugs on end of compensator spool bores are hardened plugs.
Do not interchange with other plugs in the control. For rotation change, the
complete compensator assembly will need to be replaced.
1. Measure and record the extension of the two pressure adjusting screws.
2. Carefully remove the main compensator spring cap. Remove the two
springs. Remove the seal piston and spring seat. Remove the o-ring boss
access plug on the opposite side of the compensator. Remove the
compensator spool. NOTE: the compensator spool and inner spring are not
interchangeable with the load sense compensator spool and spring.
3. Load sense compensator: Carefully remove the load sense compensator
spring cap with spring seat/seal piston. Remove the spring. Remove the
spring seat. Remove the o-ring boss access plug on the opposite side of the
compensator. Remove the load sense compensator spool. NOTE: the load
sense compensator spool and spring are not interchangeable with the main
compensator spool and inner spring of the main compensator.
4. Remove all SAE o-ring boss access plugs.

Proceed to inspection section of this manual.

Parker Hannifin Corporation


Hydraulic Pump Division
36 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance

PUMP INSPECTION PROCEDURES Carefully clean and dry all parts prior to inspection. Refer to chart 1 for dimensional
information regarding allowable tolerances.
1. Examine piston diameters for scratches or gouges. If any piston is severely-
damaged, note which piston bore it came out of. Extra attention should be
given to that bore in step 2. Check end play of piston shoe assembly. Check
the bottom surface of the shoes for damage. The shoe surface should be
square and flat. Measure the depth of the pocket of the shoe. Shoes may be
lapped as a set if the pocket depth is within allowable limits. Confirm pocket
depth after lapping to insure it is still within limits.
2. Examine bores in cylinder for scratches Check diameter of bores in 4different
locations, including near the bottom of the barrel where the piston does not
travel. If the dimensions vary by more than 0.0102 mm (0.0004 in.)or any di-
mension exceeds the allowable limit, the barrel needs to be replaced. Examine
the barrel face for scratches and gouges. The barrel canbe reworked if dimen-
sions are with specifications listed in chart 1.
3. The port plate can be lapped lightly if the face is only lightly scratched,
otherwise it should be replaced.
4. Examine the retainer plate in the area of contact with the piston shoes. Any-
marks beyond light polishing indicate that replacement is necessary. Check the
surface of the spherical area of the retainer plate and the spherical guide ball.
Inspect the back surface of the spherical guide ball where the load pins make
contact. If indentations are present replace the guide ball.
5. Examine cam on top and bottom surface. If scratches or gouges appear to
penetrate the surface treatment, the cam must be replaced.
6. The cam bearings cannot be reworked and should be replaced if worn through
the Teflon surface.
7. Both the bias piston and the compensator piston should move freely in their
respective bores. The pistons and bores should be free of scratches or gouges.
8. The seal area of the drive shaft should be smooth and not have marks due to
seal wear. Keyed shafts should be inspected for signs of brinelling and damage
to the key area. Splined shafts may have a contact wear pattern but should not
show excessive wear on the spline area.
NOTE: Spinning on shaft for P1/PD-018, 028 and 045 the cylindrical bearing
should not have any signs of roller spalling, brinelling or discoloration. The
bearing should be free to rotate without bind or rough feel.
COMPENSATOR INSPECTION NOTE: The compensator is supplied as an assembly. Individual parts are not
available. If there is significant damage to any of the parts, the complete
compensator will need to be replaced.
1. Inspect the main compensator spool and the load sense spool for scratches
or other damage.
2. Inspect the springs for proper free extension length (see chart on page 30).
3. Inspect the spool bores for damage. Apply a light oil film on the appropriate
spool and check its fit in the bore. The spool should fit snugly in housing and
not have any radial play.

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 37
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance

Chart 1
Rework Limits
Item Number Component 018 Part No 028 Part No 045 Part No Tolerances
13 03E-94430-0 03E-94393-0 03E-94356-0
Bias Spring Free Height +/- 0.2mm
Page 16 & 17 78.3 mm 87.5 mm 116.4 mm
20 787635 03E-94387-0 03E-94350-0
Barrel Spring
Page 16 & 17 41.4 mm 39.5 mm 48.3 mm Free Height +/- 0.2mm
Measure OD in 3 places,
789519 S2E-18415-0 S2E-184130-0
top, middle and bottom.
Max End Play Max End Play Max End Play
Measurement should
0.10 mm 0.07 mm 0.10 mm
not vary by more than
26
Piston 0.01 mm
Page 16 & 17 Min Shoe Min Shoe Min Shoe
Flange Flange Flange
End Play between piston
Thickness Thickness Thickness
and shoe should not
2.97 mm 3.98 mm 4.98 mm
exceed value shown
Measure piston bore ID
in 3 places , top, middle,
bottom. Measurement
should not vary by more
23
Barrel 03E-94717-0 03E-94375-0 03E-94338-0 than 0.01 mm.
Page 16 & 17
Max material to be
removed by lapping is
.0051 mm
P Max
4 03E-93158-0
Compensator Free Height : +/- 0.7mm
Page 28 & 30 39 mm
Spring-Outer
P Max
5 03E-93159-0
Compensator Free Height : +/- 0.5mm
Page 28 & 30 26 mm
Spring- Inner
17 Load Sense 03E-93825-0
Free Height : +/- 0.4mm
Page 28 Spring 14 mm

Parker Hannifin Corporation


Hydraulic Pump Division
38 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance

PUMP ASSEMBLY PROCEDURES For major overhauls, all plugs should be removed, and the seals replaced. Prior
to assembly, all parts should be thoroughly cleaned. Assembly should be
performed in a clean work environment.
Do not use bearing grease during installation. Grease does not dissolve in
hydraulic oil and may plug orifices or filters in the system. Clean petroleum jelly is
preferred to lubricate o-rings and seals, and to adhere parts for assembly.
NOTE: For fluids other than petroleum based hydraulic oil, insure that petroleum
jelly is compatible with the fluid. If not compatible, another product should be
used instead.
Inspect all bearing surfaces and seal areas to insure that they are free from
nicks, dings, scratches, and rust.
1. Turn housing over. Using installation tool T1, press the shaft seal in the
seal bore. Install the snap ring into the groove in the seal housing bore.
NOTE: Install shaft and bearing on 45 unit before installing shaft seal.
T1 tool not used on 45 unit, use T3 tool to insert shaft seal over input shaft.
2. Install cylindrical bearing on pump shaft (slip fit). Install external retaining ring
ASSEMBLY PROCEDUREto hold bearing in place on the shaft. Insert shaft assembly into the pump
CONTINUED 9. Repeat the procedure three times. Once recorded, take the average of the
housing with thethree
bearing sliding into the bearing diameter in the housing.
measurements.
Install internal retaining ring into the housing. (See drawing)
10. With the average, use chart 2 to determine the correct shim to install in the
3. If barrel hold down spring was removed during disassembly process, install
pump.
three pins to slots in barrel spline (45 Size only). Petroleum jelly can be used
to hold pins in
11.place while
If barrel holdinstalling
down spring remaining
was removedparts. (Figure
during 4) Place
disassembly barrelinstall
process,
on fixture with pinthree
sidepins to slots
down. in barrel
Install spline.washer
backup Petroleumandjelly can down
hold be used to holdand
spring pins in
second back up place
washer.while installing remaining
Compress spring in parts. (Figure
press and4)install
Place snap
barrel ring.
on fixture with
pin side down. Install backup washer and hold down spring. Compress
Caution: Make sure snap
spring ringand
in press is properly seated
install snap in groove
ring. Caution: Makeprior
suretosnap
removing
ring is
barrel from press. properly seated in groove prior to removing barrel from press.

Figure 4

4. Apply a light film of oil into the piston CHART


bores. 2Lightly lubricate the spherical
surface
Meof
asuthe
red guide
differenball.
tial Install the nine pistons into the bores in the hold
Shim
downminimum
plate. Install the spherical
maximum guide ball
thickness 018into
partthe
# hold028
down plate. While
part # 045 part #
holding the guide ball against the hold down plate, install the pistons into the
barrel.

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 39
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance

13. Apply a light film of oil into the piston bores. Lightly lubricate the spherical
PUMP ASSEMBLY PROCEDURES 5. Install the surface
locating pin
of the on ball.
guide theInstall
portthe
block face. into the bores in the hold
nine pistons
Continued down plate. Install the spherical guide ball into the hold down plate. While
6. For 045: Apply
holdingLoctite
the guidePrimer Grade
ball against T down
the hold to guide threads
plate, install and allow
the pistons into theto dry.
barrel.
Install unlubricated o-rings on the control guide and bias guide. Apply Loctite
271 to 14.
guide threads.
Install For
the locating pinleft hand
on the rotation
port block face. the bias guide is installed near-
est to the dowel pin (figure 5A.) For right hand rotation the control guide is
15. Apply Loctite Primer Grade T to guide threads and allow to dry. Install
installed nearest to o-rings
the dowel
on the pin (figure 5B.) Torque the Loctite
control and bias
Chart 2 Chart 3
unlubricated control guide and bias guide. Apply 271to
Pump Control and bias
guides as guide
specified
threads.inFor
Chart 2. rotation
left hand For 018, 028:
the bias The
guide guidesnearest
is installed are identical
to the and
Pump Control and bias dowel pin (figure 5A.) For right hand rotation the control guide is installed
guide torque press fit into the holes. (Not shown in picture below)
nearest to the dowel pin (figure 5B.) Torque the control and bias guides as
guide torque045 specified in Chart 3.
Locating pin
018 Press Fit Bias Piston 045 Picture
Guide
028 Press Fit
045 142 Nm (105 ft lbs)

Control Pistonfrom the chart (see step 11.) Install the


23. Install bearing spacer as determined
Guide
rear bearing on
Figure 5A the drive shaft. Figure 5B
Chart 4 Port Block with Left Port Block with Right
24 Confirm that compensator rotation, portHand
Hand configuration plateconfiguration
rotation, control and bias
Pump Housing bolt
piston location indicate same direction of rotation.
torque 16. Apply light oil film to control piston and install it in the control guide bore.
045 NOTE: The 140 had a lubrication hole in the piston. Confirm that the hole is
7. Apply 25 facing
light Carefully
oil film install
to
the port the
control
block. Theassembled
piston andport
control guide block
install
has iton
inthe
thepump
nonsymmetrical controlhousing.
guidePress
lubrication bore.the
port block
grooves. Thetoendcompress the bias
with the closest spring
grooves and
must beinstall housing
installed towards bolts.
the Tighten the
8. Apply lightport
oilblock.
boltsfilm
in ato the pattern
cross bias piston. Install
to insure theblock
the port biasdoes
spring notand the bias
get cocked on the
piston in the bias piston
housing. guide
When port bore.
block is seated on the housing, torque bolts in a cross
17. Apply lightas
pattern oilspecified
film to the bias piston.
in chart 4. Install the bias spring and the bias
9. piston
Apply a light in theof
layer bias piston guidejelly
petroleum bore. to the back surface of the port plate.

Install the
26. port
Installplate
o-ring on the
seals port
and block,
assembled lining
18. Apply a light layer of petroleum jelly to the backup the ofslot
compensator
surface on on the
theside
port port housing.
of pump
plate. plate
Pumpthe
with the locating
Install rotation
pin. is on
(Refer
port plate indicated
to port
the by arrow
Figure
block, liningon
6) upcompensator housing.
the slot on the port Torque bolts
plate with
the
to 5locating
0.25pin.
Nm (45 3 in-lb).
19. Install the large o-ring in the groove on the pump housing. Install the three
Teflon o-rings in the pressure communication ports on the pump housing.

20. Install the cam bearings in the cradle area of the housing. The chamfer on
the back of the bearing must face the outer wall of the housing. Use Loctite
Primer Grade “T” or other suitable primer on screws and mating threads in
Industrial port plates
housing. Apply Loctite #242 (use sparingly) to screw threads and install
orifice screws to hold bearings in place. Torque screws to 3.4 0.25 Nm (33
3 in-lb).

21. Place thin film of clean oil on cam bearing surfaces. Install cam in housing.
note slot length
The cam must be tilted to permit entry into the housing. (Figure 2) NOTE:
The large pocket on the bottom surface and quantity
of the cam must be on the same
side as the three pressure communication holes on the main housing. Pump
rotation does not affect the assembly of the cam.
Mobile port plates
22. Install the drive shaft into the pump housing. Position pump horizontally.
Install the rotating group over the pump shaft. Rotate the barrel to insure that
it is seated against the cam. Insure that the pump shaft is seated properly in
the front bearing.

CCW port plates CW port plates


Figure 6
Dowel
10. Install the large o-ring in the groove on the port block. Install the three teflon
o-rings on the pressure communication ports of the port block.

CCW CW compensator

Parker Hannifin Corporation


Hydraulic Pump Division
40 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Maintenance P1/PD Maintenance
23. Install bearing spacer as determined from the chart (see step 11.) Install the
rear bearing on the drive shaft.
Chart 4
PUMP ASSEMBLY PROCEDURES
11. 24 Confirm
Install that compensator
the cam bearings in the rotation,
cradleport plate
area ofrotation, controlThe
the housing. andchamfer
bias on
Continued Pump Housing bolt
piston location indicate same direction of rotation.
torque the back of the bearing must face the outer wall of the housing. Use Loctite
045 Primer Grade “T” or
25 Carefully install theother suitable
assembled portprimer onthe
block on screws
pumpand mating
housing. threads
Press the in
housing. Apply
port block Loctite #242
to compress (usespring
the bias sparingly) to screw
and install threads
housing bolts. and install
Tighten the
orifice screws
bolts to hold
in a cross bearings
pattern inthe
to insure place.
port Torque screws
block does to cocked
not get 3.4 ± 0.25
on the
Nmhousing.
(33 ± 3 When
in-lb).port block is seated on the housing, torque bolts in a cross
pattern as specified in chart 4.
12. Place thin film of clean oil on cam bearing surfaces. Install cam in housing.
For Install
26. 045, the cam
o-ring must
seals andbe tilted to permit
assembled entry into
compensator theofhousing.
on side (Figure 2)
pump housing.
NOTE:
Pump The largeispocket
rotation on by
indicated thearrow
bottom surface of the
on compensator cam must
housing. bebolts
Torque on the
sameto 5side as Nm
0.25 the (45
three3pressure
in-lb). communication holes on the main housing.
Pump rotation does not affect the assembly of the cam.
13. Install the drive shaft into the pump housing. Position pump horizontally.
Install the rotating group over the pump shaft. Rotate the barrel to insure
that it is seated against the cam. Insure that the pump shaft is seated
Industrial portproperly
plates in the front bearing.
14. Confirm that compensator rotation, port plate rotation, control and bias
Chart 3 piston location indicate same direction of rotation.
Pump Housing bolt noteblock
15. Carefully install the assembled port slot length
on the pump housing. Press the
torque and quantity
port block to compress the bias spring and install housing bolts. Tighten the
bolts in a cross pattern to insure the port block does not get cocked on the
018 51 Nm (38 ft lbs)
housing. When port block is seated on the housing, torque bolts in a cross
Mobile port plates
028 70 Nm (52 ft lbs) pattern as specified in chart 3.
045 85 Nm (63 ft lbs) 16. Install o-ring seals and assembled compensator on side of pump housing.
Pump rotation is indicated by arrow on compensator housing. Torque bolts
to 5 ± 0.25
CCWNm (45 ± 3plates
port in-lb). (See Figure 7)
CW port plates
Dowel

CCW CW compensator

Figure 7
CCW pump with CW pump with
compensator compensator
Parker Hannifin Corporation
Hydraulic Pump Division
Marysville, Ohio USA 41
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Assembly Tools P1/PD Maintenance

T1 Seal Installation Tool 133 mm


(5.250 in)
18.5 mm
(0.728 in)
D
8.0 mm
(0.3150 in)
3.0 mm RADIUS
(.12 in)

A B C 31.2 mm
DIA DIA DIA (1.250 in)
DIA.

U-CUT 1.5 mm x 45 ˚ TYP.


(.06 in X 45 ˚ )

T1 Seal installation tool A B C D


(018) 2.250 1.62 1.18 0.406

(028) 2.250 2.00 1.378 0.447

T3 Seal Guard B
C

30˚
D

E +/- 0.05mm F +0.05 / -0.00mm


DIA. (+/- 0.002 in) DIA BORE (+0.002 / - 0.000 in)

BLEND RADIUS
& POLISH O.D.

T3 SealModel
Pump Guard A B C D
D EE FF
018 (018 SAE) 76.20 mm 50.80 mm 19.05 mm 28.82 mm 20.45 mm
15°
“01”, “02”, “04” Shafts 3.00 in. 2.00 in. 0.75 in. 1.135 in. 0.805 in.
018 (018 ISO) 76.20 mm 50.80 mm 19.05 mm 28.82 mm 16.76 mm
15°
“06” Shaft 3.00 in. 2.00 in. 0.75 in. 1.135 in. 0.66 in.
(028 SAE)
028 / 045 76.20 mm 50.80 mm 19.05 mm 38.10 mm 26.00 mm
15°
“01”, “02”, “04” Shafts 3.00 in. 2.00 in. 0.75 in. 1.50 in. 1.024 in.
(028 ISO)
018/028/045 76.20 mm 50.80 mm 19.05 mm 28.82 mm 22.50 mm
15°
“08” Shaft
(045 SAE) 3.00 in. 2.00 in. 0.75 in. 1.135 in. 0.885 in.

(045 ISO)
Parker Hannifin Corporation
Hydraulic Pump Division
42 Marysville, Ohio USA
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Assembly Tools P1/PD Maintenance

T2 Front Bearing P1/PD45 Installation Tool


T2 Front Bearing P1/PD045 Installation Tool
mm
( in )
20.00 177.80
(0.787) (7.00)

89.75 29.92 50.80


( 3.53) ( 1.178) ( 2.00)

25.40
(1.00)

T5 Rear
T5Bushing Installation
Rear Bushing Tool
Installation Tool

mmmm
( in )
(in)
101.60
A 38 ( 4.00) 102
(1.5) (4.0)

19.05 25.40 50.80


38 B 29 25
(1.5) (1.14) B ( 0.75) ( 1.00) ( 2.00)
(1.0)

A
13
38.10
( 1.50)
(.5) Pump Size A B
12.7 3.71 mm 19.9 mm
018
( 0.5) 0.146 in. 0.772 in.
4.00 mm 21.6 mm
028
0.157 in. 0.85 in.
4.00 mm 24.1 mm
045
0.157 in. 0.95 in.

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 43
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028,TEST
PUMP 045PROCEDURE P1/PDoil
Pump Test ProcedureTest criteria based on hydraulic Maintenance
ISO 32 per Parker HF-0 specifications.
Oil temperature: 50°C ± 2°C (120°F ±10°F). NOTE: insure that the hydraulic
system does not overheat during this test procedure.
PUMP TEST
PUMP PROCEDURE
TEST PROCEDURE Operating
Test speed:
criteria based on0hydraulic
- 2300 rpm ± 3032rpm.
oil ISO per Parker HF-0 specifications.
OilCase pressure:
temperature: Maximum
50°C 14.5 psi
± 2°C (120°F (1 bar)
±10°F). NOTE: insure that the hydraulic
system does not overheat during this test procedure.
1. Mount
Operating pump
speed: on test
0 - 2300 rpmfixture. Insure that shaft alignment is within specified
± 30 rpm.
tolerances.
Case pressure: Maximum 14.5 psi (1 bar)

1. 2.Mount pumpwith
Fill case on test fixture.
clean Insure that
oil. Connect shaftdrain
upper alignment
port toisreservoir
within specified
with no
PUMP TEST PROCEDURE Testtolerances.
criteria based on hydraulic
restrictions. oil ISO drain
Insure other 32 per Parker HF-0properly
ports are specifications.
plugged.
Oil temperature: 50°C ± 2°C (120°F ±10°F). NOTE: insure that the hydraulic
2.system does not overheat during this test procedure.
3.FillConnect
case withinlet
clean oil.pressure
Connect upper drain port to reservoir with no
Operating speed: 0 - 2300and
rpm ± 30 rpm. lines. Insure that lines are filled with oil. Refer to
restrictions. Insure
circuit Maximum
Case pressure: below. For other
psidrain
14.5units bar)ports
(1 with are properly plugged.
“L” compensators, connect a suitable pilot line
from port “X” to the pump discharge pressure line, down stream of the
3.1. Connect
Mount pump inlet andfixture.
on test
non-compensating pressure lines.
Insure
flow Insure
that shaft
valve. that lines
alignment arespecified
is within filled with oil. Refer to
tolerances.
circuit below. For units with “L” compensators, connect a suitable pilot line
from port “X” to the pump discharge pressure line, down stream of the
2. 4. Fill Confirm direction
case with clean of rotation
oil. Connect for pump
upper drain and drive
port to reservoir withare
no correct.
non-compensating
restrictions. Insure otherflow valve.
drain ports are properly plugged.

4.3. 5.Confirm
Reduce
Connect inlet
the main
direction compensator
of rotation
and pressure for pump
lines. Insure
setting
andare
that lines
tofilled
drive minimum.
are correct.
with
For units with “L”
oil. Refer to
compensators,
circuit below. For units advance the load sense
with “L” compensators, connectcompensator adjustment
a suitable pilot line until it
5. frombottoms
port “X” toout, and
the pump lock into
discharge position.
pressure line, down stream of the
Reduce the main compensator setting to minimum. For units with “L”
non-compensating flow valve.
compensators, advance the load sense compensator adjustment until it
4. 6.bottoms
Set maximum
Confirm out, and
direction volume
lock into
of rotation stop
pump (if
andincluded)
for position. to full
drive are correct.displacement. If minimum
volume stop is included, back adjustment all of the way out.
Reduce
6.5. Set the main volume
maximum compensator
stopsetting to minimum.
(if included) Fordisplacement.
to full units with “L” If minimum
compensators, advance the load sense compensator
7.volume
If possible,
stop is gradually
included, increase
back adjustment
bottoms out, and lock into position.
all adjustment
pump speed to way
of the 1800until±it30 rpm with no load.
out.

7.6. 8.IfSetpossible,
Screw
maximumingradually increase
compensator
volume stop pump
to fullspeed
adjusting
(if included) screw to 1800
until
displacement. ± 30 rpmout,
itIfbottoms
minimum withwith
no load.
no pressure
on system
volume load-relief
stop is included, valve. all of the way out.
back adjustment
8. Screw in compensator adjusting screw until it bottoms out, with no pressure
7. If possible, gradually increase pump speed to 1800 ± 30 rpm with no load.
9.on Break-in
system load-relief
pump at valve.
times and pressures listed below. Adjust the load-relief
8. valve
Screw to the pressure
in compensator listed
adjusting screwfor
untilthe times out,
it bottoms indicated. After break-in,
with no pressure reduce
9. Break-in
on system pump at setting
load-relief
compensator times
valve. and pressures
to 280 listedpsi),
bar (4060 below.
andAdjust
adjustthe load-relief
system load relief to
valve to the
cause pumppressure
to listed for the
compensate timestimes
three indicated.
to After
verify break-in,
that pump reduce
compensates on
9. compensator
Break-in pump atsetting
times and pressures listed below. Adjust the load-relief
to 280 bar (4060 psi), and adjust system load relief to
and
valve off pressure
to the stroke properly.
listed for the times indicated. After break-in, reduce
cause pump to compensate three times to verify that pump compensates on
compensator setting to 280 bar (4060 psi), and adjust system load relief to
and
causeoff stroke
pump properly. three times to verify that pump compensates on
to compensate
Time 30properly.
and off stroke seconds 30 seconds 30 seconds
Time
Pressure30 seconds 30 seconds 30 seconds 30 seconds
Time 30 seconds 30 seconds
Time
Pressure
Pressure 3062-69
seconds
Bar 30 seconds
200-207 Bar 30 seconds269-276 Bar.
Pressure
TESTCIRCUIT
CIRCUIT 900-1000 psi 2900-3000 psi 3900-4000 psi
TEST
6
TEST CIRCUIT
TEST CIRCUIT
1. Test pump 6 6

1. Test1.pump
2. Test Test pump
stand prime mover 5
2. Test stand prime mover
3. Test
2. Pump pressure
stand prime gauge
mover
3. Pump pressure gauge
5
5
4. Pump
3. Non-compensating
4. pressure gaugeflow
Non-compensating control
flow control 4
4
4.
5. Non-compensating
Load
5. pressure
Load pressure flow
gaugegauge control 4
5.
6. Load 6.pressure
Load Load valve
relief relief valve
gauge
7.relief
Safety bypass relief valve 3
6.
7. Load
Safety valve 3
8. Main flow meter valve
bypass relief 8
3 8
7.
8. Safety
Main bypass
9. flowCasemeter relief
drain valvegauge
pressure 8
8.
9. Main10.flow
Case drain
Casemeter
pressure
drain gauge
flow meter 2 1
9. Case
10. 11. drain
Case Filterpressure
drain assembly
flow meter gauge
with bypass 2 1 7

10. 12. drain


Case Coolerflowassembly
meter with bypass 2 1 11
11. Filter assembly
13.assembly
Reservoir withwith bypass 7
11.
12. Filter
Cooler assembly with bypass
bypass EM “X”
7 11
12. CoolerNOTE:assembly with bypass 11
13. Reservoir Items 4 and 5 are required
13. Reservoirfor load sense pump test. EM
EM “X”
“X”
12
NOTE:Items
NOTE: Items44and
and5 5are
arerequired
required
for load sense pump test.
for load sense pump test. 13 12
12
9 10

Circuit 1
13 13
Parker Hannifin Corporation
9 9 10 10 Hydraulic Pump Division
44 Marysville, Ohio USA
Circuit
Circuit 1 1
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
018, 028, 045 Pump Test Procedure P1/PD Maintenance

PERFORMANCE SPECIFICATIONS
PUMP WITH PRESSURE COMPENSATOR
STEP
CONDITION 018 028 045
REFERENCE
1 Rated Speed 1800 1800 1800
32 lpm 49 lpm 80 lpm
4 Output Flow at minimum pressure
minimum minimum minimum
30 lpm 47 lpm 77 lpm
5 Output Flow at rated pressure of 280 bar
minimum minimum minimum
6 Case leakage at rated pressure of 280 bar 1.6 lpm 2.3 lpm 5.3 lpm
9* Case leakage when compensated at 280 bar 5.7 lpm 5.7 lpm 9.5 lpm
10 Input Torque when compensated at 280 bar 17.5 Nm 21.2 Nm 42 Nm
Output Flow when pressure reduced to 273 bar 30 lpm 47 lpm 77 lpm
11
with compensator set at 280 bar minimum minimum minimum
* When using the A series compensators increase compensated case leakage by 2.3 lpm

TEST PROCEDURE
PUMP WITH PRESSURE COMPENSATOR
STEP
CONDITION REQUIRED VALUE MEASURED VALUE
REFERENCE
1 Set the pump speed to 1800 RPM 1800 rpm
Increase pump pressure compensator adjustment to
2 n/a
maximum.
3 Record input oil temperature 43-54 ° C (110 – 130 °F)
Set output load pressure to minimum.
4 see performance chart
Record output flow
Set output load pressure to 280 ± 2 bar
5 see performance chart
(4060 ± 30 psi). Record output flow
6 Record case leakage see performance chart
7 Set output pressure to 290 ± 2 bar (4200 ± 30 psi) n/a
Set pressure compensator to
8 n/a
280 ± 2 bar (4060 ± 30 psi)
9 Record case leakage see performance chart
10 Record input torque see performance chart
Reduce output pressure to 273 ± 2 bar
11 see performance chart
(3960 ± 30 psi). Record output flow
12 Verify no external leaks No leakage permitted

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 45
Bulletin HY28-2665-02/SVC/EN Medium Pressure Axial Piston Pumps
Conversions & Formulas P1/PD Maintenance

CONVERSION FACTORS
DEFINITION & UNIT
displacement in3/rev x 16.387 = cm3/rev cm3/rev x 0.06102 = in3/rev
flow gpm x 3.78 = L/min L/min x 0.2642 = gpm
power hp x 0.7457 = kW kW x 1.341 = hp
torque lb-ft x 1.3567 = Nm Nm x 0.7376 = lb-ft
pressure lbs/in2 (psi) x 0.06895 = bar bar x 14.50 = lbs/in2 (psi)
lbs/in2 (psi) x 6.895 = kPa kPa x 0.1450 = lbs/in2 (psi)
weight lb x 0.4536 = kg kg x 2.205 = lbs
force lb x 4.448 = N N x 0.2248 = lbs
volume in3 x 16.387 = cm3 cm3 x 0.06102 = in3
area in x 6.452 = cm
2 2
cm2 x 0.1550 = in2
length in x 25.4 = mm mm x 0.03937 = in
temperature degree F-32 = °C 1.8 x C+32 = °F
1.8
viscosity cSt x 1.0 = mm2/sec mm2/sec x 1.0 = cSt
SSU = cSt x 4.25 + 14 20 cSt = 99 SSU

FLUID POWER FORMULAS


Pump input torque lbs. in. pressure(psi) x displacement (in3/rev)
2� x mech. eff.
Pump input power hp rpm x (in3/rev) x (psi)
395934 x overall eff.
Pump output flow U.S. gpm rpm x (in3/rev) x volumetric eff.
231
Fluid motor speed rpm 231 x flow rate(U.S. gpm) x volumetric eff.
displacement (in3/rev)
Fluid motor torque lbs. in. pressure(psi) x displacement (in3/rev) x mech. eff.
2�
Fluid motor power hp rpm x (in3/rev) x (psi) x overall eff.
395934
(metric)
Pump input torque Nm pressure(bar) x displacement (cm3/rev)
20� x mech. eff.
Pump input power kW rpm x (cm3/rev) x (bar)
600000 x overall eff.
Pump output flow Lpm rpm x (cm3/rev) x volumetric eff.
1000
Fluid motor speed rpm(min-1 ) (tr/mn) 1000 x flow rate (Lpm) x volumetric eff.
displacement (cm3/rev)
Fluid motor torque Nm pressure(bar) x displacement (cm3/rev) x mech. eff.
20�
Fluid motor power kW rpm x (cm3/rev) x (bar) x overall eff.
600000

Parker Hannifin Corporation


Hydraulic Pump Division
Marysville, Ohio USA 59
Check Valves DC Series

DC Series Check Valves are Rugged,


Cost-competitive.
The DC Series offers basic, workhorse check valves – ruggedly
built, readily available and reasonably priced. They are in-line
valves, available in sizes 1Ú4” to 2”, with a pressure rating
range up to 5000 psi, and flow capacities to 300 GPM.

Features
1. All-steel construction–no internal seals or gaskets to wear
out.
2. One-piece body eliminates threads and seals that may be
potential failure or leakage points.
3. Valve seats resist damage from shocks, surges and
contamination.
4. Poppet has an oil retention groove that lubricates the bore
2 3 4 and eliminates galling.
5
5. Poppet spring is isolated from the liquid flow stream,
minimizing turbulence.
6. Poppet is heat treated to help prevent damage from
shocks, surges and galling.
7. Close tolerance fit between poppet and poppet retainer
creates a cushion that protects valve from surge shock
damage.
8. Check valve body is shaped like an arrow to indicate flow
direction.
9. Available in a variety of standard and non-standard
crack pressures.

1 6 7 8 9

DC Series- Part Numbers


E Valves

Dimensions (In.)
Valve ** Std Crack Max Operating
Part Number Inlet Port Thread Wrench Outlet Port Thread
Size Length Pressure (psi) Pressure (psi)
Flats
1/4” DC-250-** 1/4 - 18 NPSF 2.44 0.81 1/4 - 18 NPSF 1, 5, 65 3000
1/4” DC-250-FOFO-** .438 - 20 UNF 2.44 0.81 .438 - 20 UNF 1, 5 3000
3/8” DC-370-** 3/8 - 18 NPSF 2.75 0.88 3/8 - 18 NPSF 1, 5, 65 3000
3/8” DC-370-FOFO-** .562 - 18 UNF 2.75 0.88 .562 - 18 UNF 5 3000
1/2” DC-500-** 1/2 - 14 NPSF 3.5 1.06 1/2 - 14 NPSF 1, 5, 65 3000
1/2” DC-500-FOFO-** .750 - 16 UNF 3.5 1.06 .750 - 16 UNF 5, 65 3000
3/4” DC-750-** 3/4 - 14 NPSF 3.88 1.37 3/4 - 14 NPSF 1, 5, 65 3000
3/4” DC-750-FOFO-** 1.062 - 12 UN 3.88 1.37 1.062 - 12 UN 5, 65 3000
1” DC-1000-** 1 - 11.5 NPSF 4.88 1.62 1 - 11.5 NPSF 5, 65 3000
1” DC-1000-FOFO-** 1.312 - 12 UN 4.88 1.62 1.312 - 12 UN 5, 65 3000
1-1/4” DC-1250-** 1-1/4 - 11.5 NPTF 5.94 2.00 1-1/4 - 11.5 NPTF 5, 65 3000
1-1/4” DC-1250-FOFO-** 1.625 - 12 UN 5.94 2.00 1.625 - 12 UN 5, 65 3000
1-1/2” DC-1500-** 1-1/2 - 11.5 NPTF 6.37 2.38 1-1/2 - 11.5 NPTF 5, 65 3000
1-1/2” DC-1500-FOFO-** 1.875 - 12 UN 6.37 2.38 1.875 - 12 UN 5, 65 3000
2” DC-2000-** 2 - 11.5 NPTF 7.00 3.00 2 - 11.5 NPTF 5, 65 3000
2” DC-2000-FOFO-** 2.500 - 12 UN 7.00 3.00 2.500 - 12 UN 65 3000

E-12 Parker Hannifin Corporation


Quick Coupling Division
Minneapolis, MN
www.parker.com/quickcouplings
Check Valves DC Series

Flow Data DC Series (1/4") DC Series (3/8", 1/2" & 3/4")


Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS

80 120

70 3/8" 1/2" 3/4"


100 DC-370 DC-500 DC-750

60
Pressure Drop in PSID

Pressure Drop in PSID


80
50 1/4"
DC-250

40 60

30
40

20

20
10

0 0
0 2 4 6 8 10 0 10 20 30 40 50 60

Flow - USGPM Flow in USGPM

DC Series (1", 1-1/4", 1-1/2" & 2")


Test Fluid: Oil - 200 SUS

120

110

100

90 1-1/2"
Pressure Drop in PSID

1-1/4" DC-1500
80 DC-1250
1"
70 DC-1000 2"
DC-2000
60

50

40

E Valves
30

20

10

0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300
Flow in USGPM
Ordering Information

DC-✱✱✱-✱✱✱✱-✱✱
Crack Pressure:
1 = 1 PSI
5 = 5 PSI
65 = 65 PSI
Other crack pressures up to 100 PSI (in 5 PSI increments)
are available. Contact the Division for price and delivery
on non-standard crack pressures.
Fitting Style:
Size Blank = Female pipe inlet to Female pipe outlet
250 = 1/4” FOFO = Female O-ring Boss inlet to Female O-ring Boss outlet
370 = 3/8”
500 = 1/2”
750 = 3/4”
1000 = 1”
1250 = 1-1/4”
1500 = 1-1/2”
2000 = 2”
Series

E-13 Parker Hannifin Corporation


Quick Coupling Division
Minneapolis, MN
www.parker.com/quickcouplings
Inserta® Products, Inc.
CHECK VALVES
4-BOLT
FLANGE TYPE
INSERTA® ICFT Check Valves, Flange Type, pro-
vide an effective way to install a Check Valve or Fixed
Orifice Flow Control Valve in a piping system that
uses SAE 4-Bolt flange ports. These flange bodies
include the INSERTA® ICT Thread-In Type Check
Valves. The free flow direction is always from the
surface with the seal to the surface without the seal.
The nominal size INSERTA® ICT Thread-In Type
Check Valve, matches the nominal flange size to
meet most flow requirements for the given flange
size. The INSERTA® ICFT Check Valves, Flange
Type, 6132 and 6232 are also available with -24
size Check Valves for those applications that do
not require the flow capacity of the -32 size.

For those applications where one requires the free


flow from the plain surface to the surface with the
seal, the INSERTA® ICF Check Valve Body or
INSERTA® ICFS Check Valve Body with Sup-
port Member, Flange type, should be used with
the INSERTA® ICS Check Valve, Slip-In Type.
The INSERTA® ICS Check Valve, Slip-In Type,
can be inserted from either end to permit free flow
through the body in either direction. The ICF bodies
use a larger nominal size INSERTA® ICS Check
Valve, and is the check valve of choice in higher
flow applications. PATENT 5,338,075
INSERTA® ICFT Check Valves, Flange Type, are
all steel construction.

ORDERING INFORMATION
ICFT – A – 61 32 (24) – N 015 – RØ
INSERTA®
FLOW CONTROL OPTION
CHECK VALVE R = FIXED RESTRICTIVE ORIFICE
FLANGE TYPE Ø = DIAMETER (INCH) OF THE FIXED
(w/ICT CHECK) ORIFICE. CUSTOMER MUST SPECIFY
THE ORIFICE DIAMETER.
DESIGN CODE SEE “RØ” ON DATA SHEET FOR
ORIFICE DATA.
MOUNTING PATTERN
CRACKING PRESSURE
61 = SAE CODE 61 003 = 3 PSI
62 = SAE CODE 62 007 = 7 PSI
015 = 15 PSI (STANDARD)
NOMINAL SIZE (USED WHEN ICT 030 = 30 PSI
08 = 1/2 24 = 1-1/2 CHECK SIZE IS
12 = 3/4 32 = 2 SMALLER THAN THE SEAL COMPOUND
16 = 1 40 = 2 1/2 NOMINAL SIZE) N = BUNA–N (STANDARD)
20 = 1 1/4 48 = 3 OMIT WHEN THE SAME V = VITON
CHECK VALVE
Inserta Products, Inc. 4-BOLT ø 1 ø 1
Blue Bell, Pa. 19422 FLANGE TYPE
© 2010 ADACONN® + INSERTA® All rights reserved. www.adaconn.com / www.inserta.com
CHECK VALVES
FACE SEAL
*Seal Protector must be retained
by the mating standard SAE Face
Seal groove’s inner support area.

**See Page 17 for Flow Control


Option Orifice data.
L Ø 1
CAUTION - Care must be
exercised when installing check
valve to insure the free flow path is
correct for the system in which it is
installed.

* SEAL PROTECTOR
W H
CODE 61
MOUNTING NOMINAL NOM. FLOW W H L O-RING THREAD-IN
PATTERN– SIZE RATE (GPM) SIZE NO. CHECK VALVE
SIZE PART NO.

6108 1/2 12 1.37 1.00 2.12 210 ICT–B–08–***


6112 3/4 25 1.75 1.25 2.50 214 ICT–B–12–***
6116 1 35 2.00 1.50 2.75 219 ICT–B–16–***
6120 1 1/4 63 2.25 2.00 3.00 222 ICT–B–20–***
6124 1 1/2 80 2.75 2.25 3.75 225 ICT–B–24–***
6132 (24) 2 80 3.00 2.00 4.00 228 ICT–B–24–***
6132 2 135 3.25 3.50 4.00 228 ICT–B–32–***
6140 2 1/2 155 3.50 3.75 4.50 232 ICT–B–40–***
6148 3 175 4.00 4.00 5.00 237 ICT–B–48–***
CODE 62
MOUNTING NOMINAL NOM. FLOW W H L O-RING THREAD-IN
PATTERN– SIZE RATE (GPM) SIZE NO. CHECK VALVE
SIZE PART NO.

6208 1/2 12 1.50 1.00 2.25 210 ICT–B–08–***


6212 3/4 25 1.87 1.25 2.75 214 ICT–B–12–***
6216 1 35 2.25 1.50 3.00 219 ICT–B–16–***
6220 1 1/4 63 2.50 2.00 3.50 222 ICT–B–20–***
6224 1 1/2 80 3.00 2.25 4.25 225 ICT–B–24–***
6232 (24) 2 80 3.50 2.00 5.00 228 ICT–B–24–***
6232 2 135 4.00 3.50 5.00 228 ICT–B–32–***
6240 2 1/2 155 4.25 4.00 6.00 232 ICT–B–40–***
6248 3 175 5.00 4.00 8.00 237 ICT–B–48–***
REFERENCE DATA TEMPERATURE RANGE: -22 F (-30 C) TO 175 F (80 C)
NOMINAL FLOW RATINGS ARE WITH A Δ P OF 30 TO 40 PSI. In applications where the valve is subject OPERATING MEDIUM: HYDRAULIC FLUID
to sudden shock opening or closing (e.g. Accumulator System), the nominal rated flow must not be ex- VISCOSITY RANGE: 50 SSU TO 2000 SSU
ceeded and a minimum cracking pressure of 15 PSI is required. THE PRESSURE RATING OF THESE VALVE CRACKING PRESSURE: 3 PSI, 7 PSI, 15 PSI
ASSEMBLIES MAY BE LIMITED BY THE ICT CHECK INSERT. REFER TO THE ICT DATA SHEET. (STANDARD) & 30 PSI.

CHECK VALVE
Inserta Products, Inc. ø
4-BOLT 1 ø 1
Blue Bell, Pa. 19422
FLANGE TYPE
© 2010 ADACONN® + INSERTA® All rights reserved. www.adaconn.com / www.inserta.com
Catalog HY15-3502/US
Technical Tips Pressure Control Valves
CV
INTRODUCTION
This technical tips section is designed to help familiarize you with the Parker line of Pressure Controls. In this
Valves
Check

section we highlight new products to this catalog as well as some design features of our pressure control line. In
addition we present common options available to help you in selecting products for your application. Finally we
SH
give a brief synopsis of the operation and applications of the various product offered in this section.
Shuttle
Valves

NEW PRODUCTS
LM There are several new additions and product improvements to our Pressure
Controls product line.
Load/Motor
Controls

Here are just some of the design features and advantages


to the “Winner’s Circle” product line.
FC
Controls

Variety of Adjustments
Flow

Pressure controls are offered


in screw adjust, knob adjust,
PC fixed and tamper resistant
configurations.
Pressure
Controls

Yellow Zinc Coating


Steel adapters are
coated with yellow zinc
LE di-chromate for protection
from salt spray.
Elements
Logic

DC
Directional
Controls

“D”-Ring
MV Standard 4301 Polyurethane Seal
High Pressure Design eliminates the need for backup rings
Pilot operated valves are rated providing easier manifold installation.
to 350 Bar (5000 PSI) for use (For more information on “D”-Ring
Manual
Valves

at elevated pressure. see Technical Data Section)

SV
Solenoid
Valves

PV Crimp Design Guided Pilot


Proportional

Fold over crimp provides Pilot is fully guided providing


secure holding and a more consistent reseat.
Valves

eliminates the need


for adhesive.

CE
Electronics

Internal Screen
Coils &

A small internal screen


protects the pilot orifice and
spring chamber from debris.
BC
Bodies &
Cavities

TD High Rate Bias Spring Low Profile Adapter


Pilot operated reducing and sequence The low profile shape of the pilot
Technical

valves are designed with a high rate operated pressure controls reduces
bias spring pressure, enhancing stability. the manifold clearance required.
Data

PC1 Parker Hannifin Corporation


Hydraulic Cartridge Systems
Catalog HY15-3502/US
Technical Tips Pressure Control Valves
CV
COMMON OPTIONS
As you will see, Parker offers a variety of Pressure

Valves
Check
Control products. As such, some of the options
mentioned below may not be available on all valves.
SH
Consult the model coding and dimensions for each
valve for specifics. Here are some of the common

Shuttle
Valves
options available.

LM

Load/Motor
Adjustment Types: Parker offers four primary types Tamper Resistant - The tamper

Controls
of adjustments for most of the pressure control pro- resistant option is a screw adjustable
ducts. Samples of these types are shown below. Please valve with a steel cap installed to
note all options may not be available for all valves. conceal the adjustment. The cap is FC
Consult the individual catalog pages for more details. designed so that the internal edges
clamp into the groove of the valve

Controls
adapter. Once the cap is installed,

Flow
Screw Adjustment - Valve can be it cannot be removed without damaging
adjusted with an allen wrench. Lock the cap and the valve. When a valve is ordered with PC
nut included to maintain desired the tamper resistant option, it will be preset at the

Pressure
Controls
setting after adjustment. This is the factory, and the cap will be included in a separate
most common adjustment option plastic bag to allow for fine tuning at the customer site.
available on most Parker products. Parker offers tamper resistant cap conversion kits for LE
most pressure control valves. For kit numbers consult

Elements
individual valve pages.

Logic
Knob Adjustment - An aluminum
knob is added to the standard screw
DC
adjustment. A lock knob is provided Seals: The Winner’s Circle products feature a

Directional
to help maintain the desired setting standard 4301 Polyurethane “D”-Ring. The “D”-Ring

Controls
after adjustment. Parker offers knob eliminates the need for backup rings. The majority of
conversion kits for most pressure the products are available in Nitrile or Fluorocarbon
control valves. For kit numbers consult Seals. You should match the seal compatibility to the MV
individual valve pages. temperature and fluid being used in your application.

Manual
Valves
Pressure Range: Parker offers a range of spring SV
Fixed Style - In most cases, the settings for the Pressure Control product line. You
Fixed Style product is a screw want to choose the setting that best meets the

Solenoid
Valves
adjustable product with a steel collet operating range. The model callout is equivalent to the
threaded over the screw adjustment. maximum setting (in psi) of the spring divided by 100
These valves are preset at the (i.e. 50 = 5000 psi). PV

Proportional
factory.

Valves
CE
Electronics
Coils &

BC
Bodies &
Cavities

TD
Technical
Data

PC2 Parker Hannifin Corporation


Hydraulic Cartridge Systems
Catalog HY15-3502/US
Technical Tips Pressure Control Valves
CV
PRODUCT TYPES / APPLICATIONS
Valves
Check

Direct Acting Relief Valves


Direct acting relief valves are designed
SH for fast response in intermittent duty Tank (2)
applications. They are often used as an Pressure
Shuttle
Valves

economical solution to clip pressure spikes. (1)

The poppet design allows for low leakage.


LM
OPERATION - The valve poppet is held against the seat by the
Load/Motor
Controls

spring force. Inlet pressure on the nose (port 1) of the poppet acts
against the spring force to unseat the poppet at the valve setting and allow flow to pass to tank. Since the
pressure is working directly on the spring, this valve is very fast responding. It is not the best choice for system
FC
pressure regulation as it is slightly noisier than pilot operated relief valves and has higher pressure rise.
Note: Any backpressure on port 2 would be additive to the spring setting.
Controls
Flow

PC
Differential Area Relief Valves
Differential area relief valves also are
Pressure
Controls

Pressure
(2)
also best suited for intermittent appli-
cations where fast response is critical. Tank
(1)
LE These valves are often used as cross-
over relief valves to chop pressure spikes.
Elements

Due to their design, they generally can handle a larger flow


Logic

rate and have a lower pressure rise than the standard directing
DC acting relief. The poppet design allows for low leakage.
Directional

OPERATION - Pressure on the inlet (port 2) of the valve acts on the differential area of the poppet (difference
Controls

between the O.D. of the poppet and the seat diameter) to produce a force which is opposed by the spring force.
When pressure reaches the valve setting, the poppet is pushed off its seat, permitting flow to tank.
MV Note: Any backpressure on port 1 would be additive to the spring setting.
Manual
Valves

Pilot Operated Relief


SV
Pilot operated relief valves are designed
for continuous duty applications. Due to Tank (2)
Solenoid
Valves

their stability and low pressure rise, the Pressure


pilot operated relief is the best option for (1)

PV setting the pressure of a hydraulic system.


Proportional

OPERATION - When inlet pressure at the nose (port 1) exceeds


Valves

the valve setting, the pilot ball unseats. The pilot flow creates a pressure
CE
imbalance across the main spool causing the spool to move and allowing flow from
inlet (port) 1 to tank (port 2.) Note: Any backpressure on port 2 would be additive to the spring setting.
Electronics
Coils &

BC
Bodies &
Cavities

TD
Technical
Data

PC3 Parker Hannifin Corporation


Hydraulic Cartridge Systems
Catalog HY15-3502/US Differential Area Relief Valve
Technical Information Series RDH083
CV
General Description
Differential Area Relief Valve. For additional
Valves
Check

information see Technical Tips on pages PC1-PC6.


SH
Shuttle

Features
Valves

• Hardened, precision ground parts for durability


LM • Spherical poppets for low leakage

Load/Motor

High flow capacity


Controls

• Internal mechanical stop limits poppet travel eliminating


spring solidification
FC • All external parts have yellow zinc dichromate. This
coating is ideal for salt spray applications.
(2) (1)
Controls
Flow

(2)

PC
(1)
Pressure
Controls

Specifications
LE Rated Flow 45 LPM (12 GPM) Performance Curve
Elements

Maximum Inlet 380 Bar (5500 PSI)


Flow vs. Inlet Pressure
Logic

Pressure (Pressure rise through cartridge only)


PSI Bar Hydraulic Oil 150 SSU @ 100°F (32 cSt)
DC Maximum 350 Bar (5000 PSI) 6000 414
Pressure Setting
Directional
Controls

5000 345
Maximum Tank 350 Bar (5000 PSI)
Pressure 4000 276
Pressure, PSI

MV
Reseat Pressure 75% of crack pressure 3000 207
Manual
Valves

Leakage at 10 drops/min. (.67 cc/min.)


2000 138
150 SSU (32 cSt) @75% of crack pressure
SV
1000 69
Cartridge Material All parts steel. All operating
Solenoid

parts hardened steel.


Valves

0
LPM 8 15 23 30 38 45 53
Operating Temp. -40°C to +93.3°C (Nitrile) 0
GPM 2 4 6 8 10 12 14
PV Range/Seals (-40°F to +200°F) Flow (Q)
Proportional

-31.7°C to +121.1°C (Fluorocarbon)


(-25°F to +250°F)
Valves

Fluid Mineral-based or synthetic with


CE Compatibility/ lubricating properties at viscosities
of 45 to 2000 SSU (6 to 420 cSt)
Electronics

Viscosity
Coils &

Filtration ISO Code 16/13,


SAE Class 4 or better
BC
Approx. Weight .19 kg (.43 lbs.)
Bodies &
Cavities

Cavity C08-2
(See BC Section for more details)
TD
Form Tool Rougher None
Technical

Finisher NFT08-2F
Data

PC27 Parker Hannifin Corporation


Hydraulic Cartridge Systems
Catalog HY15-3502/US Differential Area Relief Valve
Technical Information Series RDH083
CV
Dimensions Millimeters (Inches)

Valves
Check
SH
25.4 (1.00)
Dia. Knob

Shuttle
Valves
LM
72.8 75.3 74.6
71.7

Load/Motor
(2.86) (2.96) (2.94)
(2.82)

Controls
FC

Controls
Flow
* 3/4
16UNF-2A Thread 22.4 (.88) Hex. PC
31 N.m. 27.7
(276 In.-Lbs.) (1.09)

Pressure
Controls
(2) Torque
* For applications over 210 Bar
(3000 PSI), Thread Lock
Compound is recommended.
(1) Ø 12.7 LE
(.50)

Elements
Logic
THIRD-ANGLE Screw/Knob Version Fixed Cap/Tamper Resistant Version
PROJECTION

DC

Directional
Controls
Ordering Information

RDH083 MV

08 Size Adjustment Pressure Seals Optional Body Port

Manual
Valves
Differential Area Style Range Pressure Material Size
Relief Valve Setting
SV
Code Adjustment Style / Kit No. Code Seals / Kit No. Code Body Material

Solenoid
Valves
F Fixed style, preset at factory. Omit Nitrile / (SK08-2N) Omit Steel
K Knob Adjust (717784-10) V Fluorocarbon / (SK08-2V) A Aluminum
S Screw Adjust
PV
T Tamper Resistant Cap (718083)

Proportional
Optional Pressure Setting Code Port Size Body Part No.
Pressure ÷ 10 Omit Cartridge Only

Valves
Code Pressure Range i.e. 235 = 2350 PSI 4P 1/4″ NPTF (B08-2-*4P)
(Omit if standard setting is used) 6P 3/8″ NPTF (B08-2-*6P)
15 6.9 - 103 Bar (100 - 1500 PSI) Setting Range:
Standard Setting: 4T SAE-4 (B08-2-*4T) CE
100 to 5000 PSI
Electronics
51.7 Bar (750 PSI) @ crack pressure All settings at crack pressure, 6T SAE-6 (B08-2-*6T)
approximately .95 LPM (.25 GPM)
Coils &

approximately .95 LPM (.25 GPM) 6B 3/8″ BSPG (B08-2-*6B)


30 69 - 207 Bar (1000 - 3000 PSI) * Add “A” for aluminum, omit for steel.
Standard Setting:
103 Bar (1500 PSI) @ crack pressure BC
approximately .95 LPM (.25 GPM)
Bodies &

50 138 - 345 Bar (2000 - 5000 PSI)


Cavities

Standard Setting:
172.4 Bar (2500 PSI) @ crack pressure
approximately .95 LPM (.25 GPM)
TD
Technical
Data

PC28 Parker Hannifin Corporation


Hydraulic Cartridge Systems
PT Series
Tank Top Filters

9
PT Series
Applications

Together we can…

Preserve the environment. The new PT series filter is available


in two diameters and three lengths
Typical Applications
Minimize waste and promote
energy efficiency. for flow ranges from 5-50 gpm. • Turf Maintenance
The PT2 and PT4 filter cartridges • Material Handling
utilize Microglass media in 2, 5, 10
Achieve worldwide filtration
and 20 microns for the industry’s • Aerial Lifts
solutions.
Build global confidence. best particle removal efficiency
and retention. • Fan Drive
Redefine new limits.
This unique design simply threads
Forge ahead with advanced
technology. into a ported weld ring or flange,
which can be bolted to a metal
reservoir.
Keep contamination under
control. The disposable filter cartridge is a
Reduce maintenance costs. single-piece construction, which
incorporates the nylon cover
Enhance total system reliability. and integral 25 psi bypass valve.
Focus on customer The flow path is inside-out and
satisfaction. requires no special tools for
service.
Reach optimum potential.
Drill to greater depths. This concept assures minimal
installation costs with the least
…engineer your success. space requirements for return line
applications.

The PT Series filter combines high


efficiency Microglass filtration with
low cost installation featured in a
new patented element design.

10
1

PT Series
Features
2

1 Easy element assembly removal


4
2 Unique high flow top end cap

3 Lightweight cast aluminum head

4 Patented filter element assembly

5 Bowl-less, inside-out flow 5

6 Downstream element support with “no aeration” design

7 Solid bottom endcap with integrated bypass valve

8 Low profile tank top design

8 6

11
PT Series

Patented Filter Element

Premium original equipment


performance every time

Tank Top, Bowl-Less Design


Reduces weight

Significant cost savings over filters


with bowls

Bottom Endcap Integrated


Bypass Valve
New bypass valve with every
element change

Insures reliable performance

Inside-Out Element
Flow Path
Contamination contained
within the element

No system contamination during


element servicing

No Aeration Design High Flow, Low Pressure Premium Microglass


Oil cascades down the Drop Top Endcap Design Media
perforated outer support core Long element life Superior dirt holding
capacity and efficiency

No system aeration Lower maintenance costs Less maintenance and downtime

12
PT Series
PT4-3 Element Performance

:[[^X^ZcXn Capacity
7ZiVGVi^c\ :[[^X^ZcXn PSID BAR
&%%%% 100

'F
6
*F
*F
80
2Q
&%%% ..#. 5Q 5
&%F 10Q
20Q
60 4
'%% ..#*
&%% ..#%
'%F 3
40
'% .*#% 2

20
1
' *%#%
0 0
% ) - &' &+ '% 0 20 40 60 80 100 120
B^XgdcH^oZX Capacity grams

Flow vs. Pressure Loss*


LPM
0 40 75 110 150 190

15 1.0

10
PSID

BAR

0.5

0 0.0
0 10 20 30 40 50
GPM

Results typical from Multi-pass tests run per test standard ISO 16889 @ 45 gpm to 100 psid terminal - 10 mg/L BUGL.
Refer to Appendix on pages 264-265 for relationship to test standard ISO 4572.

*Note: Pressure drop calculations are based on SAE-16 porting.

17
PT Series
Specifications - PT4

Maximum Allowable Operating Pressure


(MAOP): 150 psi ( 10.3 bar)
Element Burst Rating: 150 psid
Operating Temperatures:
Buna: -40°F (-40°C) to 225°F (107°C)
Materials:
Tank Flange: aluminum
Endcaps: nylon

Drawings are for reference only.


Contact factory for current version.
1/8-27 PTF
2 PLC'S
REF.
Ø4.06
3.500-10 BUTTRESS

PORT OPTIONS -
SEE TABLE
2.41
1.11
2.70
15/16 (24MM) HEX
TORQUE 200-240 IN-LBS 941664
Ø3.33
O-RING
THRU. HOLE

6.20± .060 SINGLE


2.045
A A 9.79± .060 DOUBLE
14.55 `.060 TRIPLE
.90 DIA FLAT
5 PLC'S
36°

n.345 ON A
Ø5.50 B.C. 1/8-27 PTF
5 PLC'S 2 PLC'S
EQ. SPACED

.400 MIN CLEARANCE


FROM TANK BOTTOM

Ø3.09

SECTION A-A

19
PT Series
PT4 Parts List

INDEX PART DESCRIPTION PART NUMBER


1 PT4-1-02Q-25 psid bypass 936742
PT4-1-05Q-25 psid bypass 936743
PT4-1-10Q-25 psid bypass 936744
PT4-1-20Q-25 psid bypass 936745
PT4-2-02Q-25 psid bypass 936746
PT4-2-05Q-25 psid bypass 936747
PT4-2-10Q-25 psid bypass 936748
PT4-2-20Q-25 psid bypass 936749
PT4-3-02Q-25 psid bypass 936876
PT4-3-05Q-25 psid bypass 936877
PT4-3-10Q-25 psid bypass 936878
PT4-3-20Q-25 psid bypass 936879
2 PT4 DIE CAST SAE-16 (1.312-12 UN-2B) 941417
PT4 DIE CAST SAE-20 (1.625-12 UN-2B) 941448
PT4 DIE CAST 1” NPT (1.000-11.5 NPTF-1) 941449
PT4 DIE CAST 1 1/4” NPT (1.250-11.5 NPTF-1) 941450
PT4 DIE CAST G1” BSPF 941905
1
PT4 DIE CAST G1 1/4” BSPF 941906
3 O-RING 941664
4 1/8-27 PIPE PLUG 900782
5 1/8-27 PRESSURE GAUGE 936912

4
1.51
38.4
.36
9.1

5
3
1/8 NPT
THREAD
1.58
40.1

Linear measure = inches


mm

Pressure Switch (926923)

21
PT Series
How to Order
Select the desired symbol (in the correct position) to construct a model code.
Example:

BOX 1 BOX 2 BOX 3 BOX 4 BOX 5 BOX 6 BOX 7 BOX 8


PT2 1 10Q B G G S16 1
BOX 1: Filter Series1 BOX 4: Seals BOX 7: Ports
Symbol Description Symbol Description Symbol Description
PT2 Tank top filter B Nitrile (NBR) PT2
PT4 Tank top filter V Fluorocarbon (FKM) G12 G¾” BSPP
G16 G1” BSPP
BOX 2: Element Length N12 ¾” NPT
Symbol Description
BOX 5: Indicator N16 1”NPT
1 Single Symbol Description S12 SAE-12
2 Double P Port plugged S16 SAE-16
3 Triple (Avail. on PT4 only) G Pressure Gauge, 25 psi PT4
Consult factory for additional element G16 G1”BSPP
lengths S Pressure Switch
G20 G1¼” BSPP
BOX 3: Media Code N16 1”NPT
Symbol Description N20 1¼”NPT
BOX 6: Bypass
02Q Microglass III, 2 micron Symbol Pressure Setting S16 SAE-16
05Q Microglass III, 5 micron G 25 PSI (1.7 bar) S20 SAE-20
10Q Microglass III, 10 micron
20Q Microglass III, 20 micron BOX 8: Options
Symbol Description
1 None
2
W Steel weld ring

Notes:
1. The filters include the element you
select already installed.
2. When “W” is selected in Box 8, the
PT2 port options are “N12” and
“S12”; the PT4 port options are
“N16” and “S16”.

Please note the bolded options


reflect standard options with a
reduced lead-time. Consult factory
on all other lead-time options.

Global products as identified are offered


worldwide through all Parker locations and
utilize a common ordering code.

22
HYDRAULIC
World Pressure Filters - 7000 psi

WPF Series
A New Standard in 7,000 psi Pressure Filters

Features:
High strength ductile iron filter head with integral indicator port

Steel bowl with standard drain port

Proprietary element end cap assembly includes bypass and reverse flow valves

Patented deformable tangs secure element in bowl

Coreless element assembly

Re-usable element support core

Corporate Office: Toll Free: (800) 331-3118 [email protected]


310 2725 Commerce Parkway Fax: (248) 377-3172 www.tfsi1.com
Auburn Hills, MI 48326
HYDRAULIC
World Pressure Filters - 7000 psi

WPF Series
Specifications
Maximum Allowable Operating T-Port
Pressure (MAOP):
7000 psi (483 bar)

Rated Fatigue Pressure:


6000 psi (414 bar)
Design Safety Factor: 3:1

Operating Temperatures:-
15°F (-26°C) to 250°F (135°C)

Element Collapse Rating:


Standard: 300 psi (21 bar)
High Collapse: 2000 psi (138 bar)

Materials:
Head: SG Iron
Bowl: Steel
Indicator: Stainless Steel
with Plastic Connectors
Weights:
WPF1 9 lbs. (4.1 kg)
WPF2 13 lbs. (5.9 kg)
WPF3 21 lbs. (9.5 kg)
WPF4 45 lbs. (20.4 kg)
WPF5 67 lbs. (30 .4 kg)

Drawings are for reference only.


Contact factory for current version.

T-PORT DIMENSIONS mm (inch)


Filter
A B C D E F G H I J K L M
Model
WPF1 70 (2.76) 180 (7.09) 69.5 (2.74) 23 (.91) 15 (.59) 27 (1.06) 60 (2.36) 30 (1.18) 90 (3.54) 92 (3.62) 46 (1.81) 30 (1.18) 15 (.59)
WPF2 79 (3.11) 293 (11.53) 75 (2.95) 32 (1.26) 26 (1.02) 30 (1.18) 80 (3.15) 40 (1.57) 98 (3.86) 110 (4.33) 55 (2.17) 40 (1.57) 20 (.78)
WPF3 88 (3.47) 345 (13.58) 93 (3.66) 40 (1.57) 29 (1.14) 35 (1.38) 90 (3.54) 55 (2.17) 120 (4.72) 126 (4.96) 63 (2.48) 45 (1.77) 27.5 (1.08)
WPF4 100 (3.94) 445 (17.52) 128 (5.04) 49 (1.93) 39 (1.54) 48 (1.89) 120 (4.72) 50 (1.97) 160 (6.30) 163 (6.42) 81.5 (3.21) 60 (2.36) 25 (.98)
WPF5 100 (3.94) 561 (22.09) 128 (5.04) 61 (2.40) 51 (2.01) 48 (1.89) 140 (5.51) 80 (3.15) 160 (6.30) 183 (7.20) 91.5 (3.60) 70 (2.76) 40 (1.57)

Corporate Office: Toll Free: (800) 331-3118 [email protected]


2725 Commerce Parkway Fax: (248) 377-3172 www.tfsi1.com 311
Auburn Hills, MI 48326
HYDRAULIC
World Pressure Filters - 7000 psi
WPF Series
Specifications

Maximum Allowable Operating Manifold


Pressure (MAOP):
7000 psi (483 bar)

Rated Fatigue Pressure:


6000 psi (414 bar)

Design Safety Factor: 3:1

Operating Temperatures:-
15°F (-26°C) to 250°F (135°C)

Element Collapse Rating:


Standard: 300 psi (21 bar)
High Collapse: 2000 psi (138 bar)

Materials:
Head: SG Iron
Bowl: Steel
Indicator: Stainless Steel
with Plastic Connectors

Weights:
WPF2 18 lbs. (8.2 kg)
WPF4 63 lbs. (28.6 kg)
WPF5 70 lbs. (31.7 kg)

Drawings are for reference only.


Contact factory for current version.

MANIFOLD DIMENSIONS mm (inch)


Filter
A B C D E F G H I J K L M N O P
Model
WPF2 79 (3.11) 343 (13.50) 75 (2.95) 24 (.94) 39 (1.53) 95 (3.74) 116 (4.57)50 (1.97) 6 (.24) 110 (4.33) 80 (3.15) 40 (1.57) 110 (4.33) 121 (4.76) 17 (.67) 30 (1.18)
WPF4 100 (3.94) 532 (20.94) 128 (5.04) 38 (1.50) 57 (2.24) 140 (5.51) 150 (5.91)75 (2.95)13 (.51)142 (5.59) 100. (3.94)50 (1.97)166.5 (6.56) 161 (6.34) 21 (.83)31.7 (1.25)
WPF5 100 (3.94) 627 (24.69) 128 (5.04) 38 (1.50) 57 (2.24) 140 (5.51 150 (5.91)75 (2.95)13 (.51)142 (5.59) 100. (3.94)50 (1.97)166.5 (6.56) 161 (6.34) 21 (.83)31.7 (1.25)

Corporate Office: Toll Free: (800) 331-3118 [email protected]


312 2725 Commerce Parkway Fax: (248) 377-3172 www.tfsi1.com
Auburn Hills, MI 48326
HYDRAULIC
World Pressure Filters - 7000 psi

WPF Series
Service & Maintenance Instructions

1 Stop system power and vent captive pressure.


2 Drain filter assembly.

3 Remove bowl and element assembly.

Push down to squeeze tangs and lift element.

Twist to remove core.

Retain reusable core.

7 Discard used element.

Insert reusable core into new element until it snaps.

Push element assembly into bowl, snap tangs.

10 Inspect o-ring and anti-extrusion ring.

Install bowl with new element.

12 Torque bowl, vent and drain plugs.

13 Power up and inspect.

Corporate Office: Toll Free: (800) 331-3118 [email protected]


2725 Commerce Parkway Fax: (248) 377-3172 www.tfsi1.com 313
Auburn Hills, MI 48326
HYDRAULIC
World Pressure Filters - 7000 psi

WPF Series
How to Order
Select the desired symbol (in the correct position) to construct a model code.
Example:
BOX 1 BOX 2 BOX 3 BOX 4 BOX 5 BOX 6 BOX 7 BOX 8
WPF 2 10QE V M2 K S12 1

BOX 1: Filter Series BOX 5: Indicator BOX 7: Ports


Symbol Description Symbol Description Symbol Description
WPF High Pressure Filter P Plugged Indicator Port WPF1
M2 Visual Automatic Reset S08 SAE-8 Ports
BOX 2: Model E2 Electrical/ Visual WPF2
Symbol Description (DIN43650 style connection) S12 SAE-12 Ports
1 1/2” Nomial ports Note: When the “M2” or “E2” option is Y12 3/4” SAE Code 62 Flange
2 3/4” Nomial ports selected, the indicator port is plugged face
3 1” Nomial ports and the indicator is shipped as a loose X12 Manifold
4 1 1/4” Nomial ports part. WPF3
5 1 1/2” Nomial ports S16 SAE-16 Pots
BOX 6: Bypass Y16 1” SAE Code 62 Flange
BOX 3: Media Code Symbol Description face
Symbol Description K 50 PSID (3.5 bar) WPF4
02QE Ecoglass III (bypass only) No Bypass and No S20 SAE-20 Ports
X
05QE Ecoglass III (bypass only) Indicator (port plugged) Y20 1 1/4” SAE Code 62
10QE Ecoglass III (bypass only) Note: When an indicator and no bypass Flange face
High Collapse (“2” in Box 8) is selected, the X20 Manifold
02QH Microglass III (no bypass indicator setting is 50 psid WPF5
only) (3.5 bar). S24 SAE-24 Ports
10QH Microglass III (no bypass Y24 1 1/2” SAE Code 62
only) Please note the bolded options reflect Flange face
standard options with a reduced lead-time. X24 Manifold
BOX 4: Seals Consult factory on all other lead-time
Symbol Description options.
BOX 8: Options
B Nitrile (NBR) Symbol Description
E Ethylene Propylene 1 With Bypass
V Fluorocarbon (FKM) (for use with standard
element only)
2 No Bypass
(for use with high
collapse element only)

Replacement Elements:
Media WPF1 WPF2 WPF3 WPF4 WPF5
Ecoglass III, 02QE 941029Q 941032Q 941035Q 941038Q 941041Q
Standard Collapse
Ecoglass III, 05QE 941030Q 941033Q 941036Q 941039Q 941042Q
300 psid/21 bar)
Ecoglass III, 10QE 941031Q 941034Q 941037Q 941040Q 941043Q
High Collapse Microglass III, 02QH 941044Q 941046Q 941048Q 941050Q 941052Q
(2000 psid/138 bar) Microglass III, 10QH 941045Q 941047Q 941049Q 941051Q 941053Q

Global products as identified are offered


worldwide through all Parker locations and
utilize a common ordering code.

Corporate Office: Toll Free: (800) 331-3118 [email protected]


314 2725 Commerce Parkway Fax: (248) 377-3172 www.tfsi1.com
Auburn Hills, MI 48326
Suction Strainers
Internally Mounted Tank Filters - your front-line defense against particle contamination

Features:
- Die cast aluminum end covers.
- By-Pass valve available on most models(see tables).
- End caps are designed to provide a positive interlock with
epoxy bond to prevent leakage.
- Rated flow capacity at 5 ft/sec.
- Suitable with all petroleum base oils and fire retardant
hydraulic fluids, coolants and lubricants.

A B C D Rated Flow
Part Number
Outlet Port Wrench Flat Overall Length Outside Diameter @ 5 ft/sec
SS-003P006-1-01 3/8” NPT 1.20” 3.00” 2.75” 3 GPM
SS-005P008-1-X1
SS-008P012-1-X1
1/2” NPT
3/4” NPT
1.20”
1.50”
3.25”
3.25”
2.75”
2.75”
5 GPM
8 GPM
5
SS-010P100-1-X1 1” NPT 1.75” 5.50” 2.75” 10 GPM
SS-023P104-X-X 1 1/4” NPT 2.25” 6.60” 3.20” 23 GPM
SS-032P108-X-X 1 1/2” NPT 2.35” 8.60” 3.20” 32 GPM
SS-053P200-X-X 2” NPT 3.00” 7.20” 4.20” 53 GPM
SS-075P208-X-X 2 1/2” NPT 3.50” 9.30” 4.20” 75 GPM
SS-116P300-X-X 3” NPT 4.00” 12.50” 4.20” 116 GPM

1 - Standard 100 Mesh, contact factory for other Mesh sizes.


How to Order: SS-003P006-1-0
Code By-Pass Valve Setting
Model Code 0 No By-Pass Valve
003P006 3 3 PSI
5 5 PSI
005P008
008P012
014P100 Code Wire Cloth Mesh
023P104 1 100 Mesh (Std)
032P108 2 200 Mesh
053P200 3 30 Mesh
075P208 6 60 Mesh
116P300

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 155
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
8 7 6 5 4 3 2 1

ITEM NO. QTY. DESCRIPTION


16 6 12
1 1 PLATE 3/16", 304 SS
12
2 4 PLATE 3/16", 304 SS
12 3 2 P/N P100190, 1 1/4" NPT COUPLING, 3000 PSI, 304SS
D 9 4 1 P/N P100192, 1" NPT HALF COUPLING, 3000 PSI, 304SS D
1 6
5 1 P/N P100196, 2" NPT HALF COUPLING, 3000 PSI, 304SS
10
6 2 P/N P100193, 3/4" NPT HALF COUPLING, 3000 PSI, 304SS
17
7 1 P/N P100195, 1 1/2" NPT HALF COUPLING, 3000 PSI, 304SS
2 8 3 P/N P100194, 1/2" NPT HALF COUPLING, 3000 PSI, 304SS
2.48 9 1 PLATE 2", 304 SS
9 6 10 1 L1.5x1.5x0.25, 304 SS

7.50 13 6 11 1 ANGLE, 6" X 6" X 1/4"


VIEW - 6 12 1 PLATE 3/16", 304 SS
SCALE 1 : 20
12 6 13 1 PLATE 3/16", 304 SS
C C
12 11 14 1 PLATE, 1/4" AISI 304 SS
15 2 ANGLE, 1" X 1" X 1/8"
6 16 6 FLATBAR 1"x3/4", 304 SS
17 1 ANGLE 1 1/4"x 1 1/4"x 1/16"
6 18 2 ELBOW 90, 1 1/4" x 1 1/4"
15 F 6 8 D
8

7 8

E E
6 6
B 17 B
23.55 13
28.74 40.36
14
12
12 5
4 3
F D 2
6
31.00 44.00
UNLESS OTHERWISE SPECIFIED: NAME DATE

DIMENSIONS ARE IN INCHES DRAWN JA 7/17/2013


GDS International
TOLERANCES:
TITLE:
HPU TANK,
FRACTIONAL 1/16 CHECKED JP 2/5/13
ANGULAR: MACH .5 BEND 1
A ONE PLACE DECIMAL .031 ENG APPR. XXX
A
XX/XX/XX
06 UPDATED ACCORDING TO CURRENT REQUIREMENTS MH 3/3/14 TWO PLACE DECIMAL .015
THREE PLACE DECIMAL .005 MFG APPR. PN XX/XX/XX GDM 120 GAL
05 CHANGED COOLER MOUNT PLATE TO FLAT BAR JP 8/20/13 PROPRIETARY AND CONFIDENTIAL
THE INFORMATION CONTAINED IN THIS
INTERPRET GEOMETRIC
TOLERANCING PER: ASME Y14.5M
Q.A. XXX XX/XX/XX

04
MATERIAL
ITEM 15 DETAIL CHANGE JP 8/09/13 DRAWING IS THE SOLE PROPERTY OF
AISI 304
SIZE DWG. NO. REV

B M104178
GLOBAL DRILLING SUPPORT INTL. ANY

07 UPDATED PRINT TO AS BUILT SHOP REVISIONS CZ 8/1/14


REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
GDS PART No.-Revision FINISH
7
REV. DESCRIPTION INITIAL DATE
GLOBAL DRILLING SUPPORT INTL. IS
PROHIBITED. M104178-7 DO NOT SCALE DRAWING SCALE: 1:16 WEIGHT: 394.72 SHEET 1 OF 7
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

5.50 3.83 NOTES:


4.82
1. WELD ALL COUPLINGS, FLANGES, AND TANK ENDS FULLY SEAL WELDED INSIDE AND OUT.
2. DRILL TANK FOR ITEM 12 AFTER WELDED TO TANK. THEN TAP TO 3/8-16 UNC.
8.82 3. NOTE POSITION OF ITEM 12 TO TANK EDGES.
3.38 4. DRILL HOLES IN FEET AFTER WELDING TO TANK FOR PROPER ALIGNMENT.
5. BAFFLE INSIDE TANK STITCH WELD TO BOTTOM AND SIDES.
D D

12.00

16.00
3x, .75

TOP VIEW
12 3.00 6.00
30.36
C C

42.50
23.36 18

10.00
2x, .56 21.25
A
R.38 INSIDE
TYP
6.00 4.18
B 4.00 18 B
4x, 12.50 6x, .56

2x, 25.00 3.00

2x, 2.28
2.45 BOTTOM VIEW OF ASSEMBLY
1.22
40.00

1.78 GDS International


TITLE:
A
5.82 HPU TANK, A

GDM, 120 GAL


4.18
DETAIL A SIZE DWG. NO. REV
30.36 SCALE 1 : 4 B M104178 7
BOTTOM VIEW SCALE: 1:16 WEIGHT: 394.72 SHEET 2 OF 7
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

7.00
.13
5.50
BOLT CIRCLE
B
5x, 90° 3.38 2.00
D D
THRU
1/8 x 45 CHAMFER 6X .31 THRU ALL
C 3/8-16 UNC - 2B THRU ALL
5X .31
45°
.75
DETAIL C 4.5
SCALE 1 : 2
2.50 1.00
54°

B 2.00 .18
90° 4.23
SECTION B-B
SCALE 1 : 4 ITEM 16 DETAIL
C C

ITEM 9 DETAIL ITEM 2 DETAIL


10 17.50
2x, .75
3.00
.315
2.30
.50
1.25
.09
B TYP B
.125 1.25
EQ SPACE
8x, 2.625

ITEM 17 DETAIL
15.000
10.500

12.00 13.50 12.50

20x, .344
16.00
GDS International
TITLE:
A HPU TANK, A

3/8-16 Tapped Hole 8x, 3.625 2x, .75


1.25 GDM, 120 GAL
4x, 2.25 1.50
EQ SPACE
SIZE DWG. NO. REV
4x, 2.250 14.500 ITEM 10 DETAIL B M104178 7
19.000 SCALE: 1:16 WEIGHT: 394.72 SHEET 3 OF 7
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

5X .31 1.06
3/8-16 UNC - 2B .75
10 NOTE CLOCKING POSITION OF BOLT HOLES
BEVEL SIDE TO TANK.

D D

9.00 3/16
2X
8.12

11.00 2.88
2X
G
4.15
14.60 3.26
5.50 5.00
4.5 2.75 10 4.11
9 DETAIL G 16
C C
9 3X 3X SCALE 1 : 6
8.00 1.50
3/16
3/8-16 Tapped Hole 3X TYP
3/16
SECTION E-E
SCALE 1 : 12
1.06
14.91
INSIDE 7
9
2.00
1
8 3/16
6 TYP
.63 3/16
B B
8 7 18
2.45
3/16 FLUSH INSIDE
TYP 1.24
6 3/16

8 3/16 3/16

3/16 3/16 3
6
.98
SECTION F-F
4 SCALE 1 : 8 GDS International
1/8 1-4 TITLE:
A 5 HPU TANK, A

GDM, 120 GAL


SIZE DWG. NO. REV

SECTION D-D B M104178 7


SCALE 1 : 8 SCALE: 1:16 WEIGHT: 394.72 SHEET 4 OF 7
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1

TYP
1/8" 1.00
12.00

D
16 D
5.63 INSIDE 7.62 H
12.00 9

.25 15

7
TYP 6"X6" J-BOX
16.56 1/8
MOUNT 17

PRESSURE FILTER
C
MOUNT
3.33 C
11
45°
6.00 6.00 5
5.00
4.75 1.25 .13 2x, .31
R.75 1.00 2
4x, .438 .25
6.00 1.00
.59
1.00

4.13
1.00
DETAIL ITEM 15
2x, 2.188 DESC: ANGLE, 1" X 1" X 1/8"
REQD: 2
REFERENCE HOLE
2x, 1.00 DIMENSIONS 15
B 2.05 B
DETAIL ITEM 11
2x, 1.23 DESC: ANGLE, 6" X 6" X 1/4"
REQD: 1
40.00 4x, .31
2x, 1.25
2x, 3.54 2x, R.25

15.00
.25 .63

1.71
45.00° 2x, 6.81
5.25 28.00
GDS International
DETAIL ITEM 1 TITLE:
A
DESC: PLATE 3/16"
REQD: 1 HPU TANK, A

3.00 2.00 GDM, 120 GAL


DETAIL ITEM 14
DESC: PLATE, 1/4" SIZE DWG. NO. REV

B M104178
MATL: ASTM A 572
REQD: 1
2x, 4.00 DETAIL H 7
SCALE 1 : 6
SCALE: 1:16 WEIGHT: 394.72 SHEET 5 OF 7
8 7 6 5 4 3 2 1
3.00
2x .56 3.82

10.00 13
23.18 30.00

2x 2.28 40.00

1.78

ITEM 13 DETAIL
GDS International
TITLE:

30.22 HPU TANK,


GDM, 120 GAL
SIZE DWG. NO. REV

A M104178 7
SCALE: 1:16 WEIGHT: 394.72 SHEET 6 OF 7
5 4 3 2 1
TAG X LOC Y LOC SIZE
B1 B3 C1
A1 5.00 9.82 3.00 THRU
B2 D1
B1 5.75 25.37 1.13 THRU
C2 B2 7.56 21.37 1.13 THRU
28.55 B3 9.38 25.37 1.13 THRU
A1
C1 13.63 25.37 1.41 THRU

2x3.50 3.50 C2 27.25 16.99 1.41 THRU


2xR1.50
Y .95 D1 22.38 20.74 2.56 THRU

X
6x .56
2x3.00
2x12.50

12.50 4.05 ITEM 12 DETAIL


3.38 16.50
GDS International
TITLE:

5.38
9.13 HPU TANK,
GDM, 120 GAL
5.82 1.45 SIZE DWG. NO. REV
31.00
A M104178 7
SCALE: 1:16 WEIGHT: 394.72 SHEET 7 OF 7
5 4 3 2 1
M
C McDANIEL
Liquid Filled, Stainless Steel Case
Utility Gauges
“For the price-conscious buyer . . .
McDaniel utility gauges are designed for the price-
conscious buyer and user who have an emphasis on
maintaining quality and accuracy in a general
purpose gauge.

Our utility line offers trusted McDaniel quality in an


economical package. Special consideration given to
rigorous McDaniel standards for durability, accuracy,
and quality of construction.

Our Series 6: Glycerin filled, stainless steel case


utility gauges with brass internals. Designed for
applications with a corrosive atmosphere and where
pulsation and/or vibration are present.

Standard features include a restrictor screw


(removable) in the inlet port for pulsation dampening.

. . . and quality user.”

SPECIFICATIONS
Accuracy: Temperature Utilization:
ASME B40.1 standard (Grade B) (3 – 2 – 3%) -4 + 176 degrees Farenheit.
-20 + 80 degrees Celsius.
Dial:
White enameled aluminum. Black figures. Pressure Utilization:
Static: 75% maximum scale.
Case: Dynamic: 66% maximum scale.
304 Stainless steel.
Stem and Socket:
Pointer: Brass. Restrictor screw standard.
Black enameled aluminum. J6 = 1/4” NPT (1/8” special order available)
T6 = 1/4” or 1/8” NPT available
Lens:
Polycarbonate. Dial Sizes / Ranges Available
2” - (T6) / Vac, Comp, Rec 3-15, up to 5,000 psi
Precision Movement 2 1/2”- (J6) / Vac, Comp, Rec 3-15, up to 15,000 psi
Brass.
Configurations Available:
Bourdon Tube: Bottom connected standard
(L) = Center-back connected
Copper alloy (C Form 600 PSI & below). (U) = U-Clamp mounted, Center-back connected
Phosphorous bronze (Spiral 800 PSI & above). (P) = Front flange, Center-back connected

McDaniel Controls, Inc.


P. O. Box 187, Luling, LA 70070 • 14148 Highway 90, Boutte, LA 70039 U.S.A.
(985) 758-2782 • New Orleans (504) 467-1333 • Fax (985) 758-1688
www.mcdanielcontrols.com
WARNING
Read before 1nstalling or using gauge. Mis-
use ot trlis product may cause explOSIOn and
personal injut¥
Pressure gauges must be correctly selected
and installed to avoid possible inJury or
I CAN BE damage caused by misuse. Please note:

DAMAGED BY ... OXYGEN SERVICE Gauges must be


spec1ally cleaned tor oxygen service QY. the
manutacturer and labeled tor oxygen service.
~ use any gauge on oxygen service that
has been used on any other service.
PRESSURE Gauge dial range should be
IWice the Intended operating pressure range..
Do not apply pressure beyond top of scale.
VIBRAnON Isolate gauge from sources of
vibration to avo1d wear to movement which
results in decreased accu~·
TEMPERATURE Gauge temperature
should not exceed 150°F (65°C).
CORROSION Materials of pressure-<an-
taming parts must be res1stant to process
ftuid used.
PULSAnoN Excess1ve pressure pulsation
may cause pressure element !allure or sub-
stantial movement wear"
LIQUID·F1LLED GAUCiES Never use
for applications involvmg strong ox1c!1Zin<J
agents including !but not lim1ted to) oxygen.
chlonne. nitnc ac1d, and hydrogen perox1de.
These substances can comb1ne explosively
With liQuid filling.
Always wear safety gl~ses when workmg
w1tt1 pressuriZed eQuipment
For additional application data. refer to AN()E:
B40.1 or consult manufacturet
'LiQUid-filled gauges or pulsat1on-dampemng
dev1ces may be necessary tor some appli-
ca!lonS.

I CAN EXPLODE!
... and can injure you
WARNING
and those around you.

~~~0~~8i7e·IL~~~!~~~~~A17~0~;
(504] 758-2782 • FAX (504) 758-1688
www.mcdanielcontrols.com
Model Gauge Selecta·on Guide

Hlllllllll.llll 1/s" 304 316


OTHER FEATURES
'- Full blow-out protection " Repairable

s * 1/4 11
STAINLESS
STEEL
Fillable
STAINLESS
STEEL
12)
1.5°/o
Grade A
Up to
10,000 psi
Lexan Lens
Compensating diaphragm
M_!IUNTING STYLES:
" Weather Tight Case

Bottom, Center-back 111, U-Ciamp, Panel mount


304 '- Util1ty Gauge
lfs"
1~" R7 * /4"
1
STAINLESS
STEEL
Non-Fillable
en
en
<( 3-2-3o/o Up to
'- Polycarbonate Lens
'- Economical McDaniel Duality
(40mm)
lfs"
BLACK a: Grade B
5,000 psi Restrictor screw for pulsation dampening
m
RB * lf4"
ENAMELED
STEEL
Non-Fillable
13) MOUNTING STYLES:
Bottom, Center-back, U-Ciamp, Panel mount

304 316 ., Laminated Safety Glass Lens " Repairable


lfs" 1o/a
Q3 1/4 11
STAINLESS
STEEL
Fillable
STAINLESS
STEEL
(2)
Grade 1A
Up to
15,000 psi
:- Weather Tight Case
MOUNTING STYLES:
_, Blow-out disc

Bottom, Center-back , U-Ciamp, Panel mount

1/s" 304

T6 lf4"
STAINLESS
STEEL
Filled** en
,_ Utility Gauge

' Polycarbonate Lens

en ·• Economical McDaniel Quality

2" T7 1/s" 304


STAINLESS <( 3-2-3% Up to
%" STEEL a: Grade B 5,000 psi ,, Restrictor screw for pulsation dampening

(SO mm) Non-Fillable m


1/s" BLACK (3) MOUNTING STYLES:

TB %"
ENAMELED
STEEL
Non·Fillable
Bottom, Center-back, U-Ciamp (except T71,
Panel mount

* lfs" 304 316 -- Laminated Safety Glass Lens

K 1(4"
STAINLESS
STEEL
Fillable
STAINLESS
STEEL
12)
Up to
20,000 psi
_,_ Repairable
-:- Weather Tight Case
Restrictor screw for pulsation dampening
_,_ Solid Front Blow out Back Case Available
* lfs" 304
Up to

J en
STAINLESS MOUNTING STYLES:
STEEL 1o/o 6,000 psi Bottom, Lower-back, U-Ciamp, Panel mount, Rear Flange,
%"
. en Grade 1A CElllter-Back available by spec1al order,
Fillable <(
* lfs" a: Laminated Safety Glass Lens " Repairable

u %"
CAST
BRASS

Fillable
m
131
Up to
10,000 psi
One-piece case and stem
MOUNTING STYLES:
Bottom, Center-back , U-Ciamp
_, Heavy-duty

* Ifs" 304 316 '- Polycarbonate Lens _, Restrictor Screw

2~" K9
STAINLESS
STEEL
STAINLESS
STEEL
2-1-2% Up to ,_ Rolled Threads " Welded Case and Stem
%" Grade A 10,000 psi MOUNTING STYLES:
Fillable 121 Bottom, Lower-back, U-Ciamp, Front Flange, Rear Flange

(63 mm) * 1/s" 304

J6 1/4"
STAINLESS
STEEL
Filled** en
Up to
15,000 psi
Ut1l1ty Gauge

Polycarbonate Lens

* 1/s" 304 en _,_ Economical McDaniel Quality


<( 3-2-3%
J7 1/4 11
STAINLESS
STEEL
Non-Fillable
a:
m
Grade B
Inches of
Water
&
_, Restrlctor screw for pulsation dampening

* 1/s" BLACK 131 Up to MOUNTING STYLES:

JB 1/4 11

SPECIAL
ENAMELED
STEEL
Non-Fillable
FILLED ACCURACY
15,000 psi
RANGE
Bottom, Center-back, U-Clamp, Panel mount

l11 Model S 1/4 NPT only 1n Back connect1on


NON-STOCK GLYCERIN ASME Includes, Vacuum, ("I 316 SS Tube, Tip and Socket
840.1 Compound, and l21 Brass Socket, Copper Alloy I Phosphorous Bronze Tube and Tip
Receiver 3-15
McDaniel Controls, Inc.
P. 0. BOX 187 • LULING, LOUISIANA 70070
(504) 758-2782 • FAX (504) 758-1688
www.mcdanielcontrols.com

(' 1 K =To avoid duplicate part numbers, use 1K when specifying 0-1000 range on models J6 and T6)
(' 4K = 4,000 psi range, non-stock, special order for: Models A, B, C, D, E, F, G, H, MPB, S, Y, z
To order mercury, FT of Sea water, or special ranges, describe the desired range, after the MODEL type.

How To ORDER BY CoDE Adder Codes Special Configuration


l. Select the model. B psi/bar (dual scale)
2. Select the pressure range K psi/kPa (dual scale)
3. Specify mounting code if other than standard bottom connection. M Monel® Internals
4. Add special configurations if needed- either by code or written description. N Non-standard internals (316 SS tube/tip/socket)
Models: L, M, N, P, Y, Z
5. Add choice of filling, if appropriate.
(GF = Glycerin Filled, SF = Silicone Filled, or FF = Flourolube Filled) 0 02 (cleaned for oxygen service).
EXAMPLE:
s Solid Front I Blow-out Back case
Mounting Codes
Range Special Type of
Code Configuration Filling c Center-back Connected (use for models Q3, E9, G9)
L Lower-back or Center-back
n p GF p Panel mount. Front Flange
Order: A 2'h'' sealed gauge with a scale of 0 to 100 psi, panel-mounted I front flange, 1f4' NPT u U-clamp, Panel Mount
lower-back connection, filled at factory with glycerin (KDP-GF). R Rear Flange
INSTRUCTIONS

Series 1201 Orange Research Inc.


140 Cascade Boulevard, Milford, Connecticut 06460
DIFFERENTIAL PRESSURE INSTRUMENTS 203 877-5657 800 989-5657 Fax: 203 783-9546
www.orangeresearch.com

Your new Orange Research Differential Pressure Instrument is a this instrument may need attention. Erratic pointer or switch
rugged instrument featuring simplicity of design to provide action may indicate that cleaning is required. For cleaning:
dependable and efficient service. Because it is an instrument it
should be handled with care. Read all instructions carefully
before attempting to install the instrument.
CAUTION: Do not exceed nameplate maximum operating
pressure. Use only fluids compatible with wetted parts.

HOW IT WORKS
The instrument operates on the difference between two pressures
(delta-P). The sensing element is a spring biased piston which
moves linearly in proportion to the difference between two basic
pressures. A magnet on the HI pressure side of the piston
assembly moves with the piston and rotates a follower magnet
located adjacent to the pressure cavity. The gauge pointer is
located at the end of the rotary magnet shaft and rotates with the 1. Remove the unit from service.
magnet to provide gauge readings proportional to differential 2. Remove both end caps with a 1” spanner wrench.
pressure variations. There are no mechanical seals between the 3. Remove the range spring and the piston/magnet assembly.
pressure side of the instrument and the gauge mechanism side. BE CAREFUL NOT TO LOSE STACKING SPACERS.
This is accomplished by coupling the forces between two adjacent 4. Clean parts in a solvent solution after removing O-Ring seals
magnets through a solid wall. from the end caps since some solvents will attack the seal
material.
SWITCH UNITS: On switch and indicating switch models, reed
5. It is good to practice to replace the O-Ring seals while the
switches are located adjacent to the pressure chamber and are
instrument is dismantled. DO NOT ATTEMPT TO MOVE
actuated when the piston magnet field interacts at a preset point
THE TEFLON PISTON SEAL FROM THE PISTON. If piston
with the reed switch armature. Reed switch set points are
seal is damaged order a new piston/magnet assembly.
adjustable.
To reassemble:
1. Lubricate the piston bore lightly with petroleum jelly, light oil
INSTALLATION or silicone grease.
Check instrument and identify the HI and LO markings. HI 2. Install the HI end cap first and tighten.
identifies the high pressure port; LO the low pressure port. If 3. Install the piston/magnet assembly (magnet facing HI
instrument is installed backwards, it will neither operate nor be pressure port).
damaged. Reverse connections if installed backwards. The 4. Insert stacking spacers in bottom of piston spring pocket and
instrument can be line mounted, bracket mounted or panel insert range spring.
mounted depending upon the model purchased. 5. Reassemble LO end cap making certain that spring is seated
Under normal conditions Series 1201 Instruments are designed in the end cap spring pocket.
for line pressure to 3000 psig and can sustain a continuous 3000 6. Tighten LO end cap and the instrument is now ready for
psig forward or reverse overpressure. service.
IMPORTANT: Magnet end of piston/magnet assembly
It is recommended that the instrument be located above the MUST be facing the HI pressure port of the instrument;
pressure source to allow drainage of the unit. otherwise, the instrument will not operate.
LENS REPLACEMENT: To replace a broken lens, check to see if
IMPORTANT: Because of the magnetic movement, this the lens is held on by a bezel or a snap-ring. To remove a bezel,
instrument should never be mounted in direct contact with a steel
twist off by hand (watch out for the broken glass).To remove a
surface; otherwise, a calibration shift will occur. Mount the snap-ring, pry out the ring with a small screwdriver. Remove all
instrument so that the pressure body is at least 1” away from glass chips, insert new lens and re-insert the bezel or snap. With
metal surfaces with non-magnetic spacers or an aluminum- snap-rings, locate the ring joint at the bottom of the gauge.
mounting bracket. Flush panel mounted instruments will not be
affected by contact with aluminum panels. However, 2” and 2½” POINTER REPLACEMENT: (Probably damaged when lens was
gauges flush mounted in a steel panel may require resetting of broken). Remove bezel or snap-ring as previously described and
the pointer at zero. This should be done at time of manufacture clean out glass chips. Remove old pointer with pointer puller or
but can be reset in the field with a small loss of accuracy. two small screwdrivers opposite each other under pointer hub. Pry
off evenly being careful not to bend the pointer shaft. Install new
pointer dead on zero. Re-install lens, as described under lens
replacement.
MAINTENANCE
Other than replacing broken lens there is only one area where

GN128-1201 Rev. E Orange Research Inc. Page 1 of 2


SWITCH ADJUSTMENT
Reed switch set points are field adjustable. On indicating switches, the reed
switches can be adjusted over the top 80% of the gauge range. On switch
models the reed switches can be adjusted over the range shown on the
nameplates.
To change the reed switch setting, a source of pressure will be needed with the
instrument. Loosen the screw holding the reed switch. To increase the set
point, slide the switch tube toward the LO port. To decrease the set point, slide
the switch tube toward the HI port. Repeat as required until new setting is
reached. Tighten the screw holding the switch tube in place and recheck the
new actuation point. CAUTION: Do not over tighten the switch holding screw-
this is a cone point set screw and digs into the tube with light pressure. (in
some cases, it might be necessary to reverse the switch tube end for end to
locate the new actuation point-this is normal procedure.
HI PRESS LO PRESS
SWITCH WIRE COLOR
PORT PORT
-A SPST white and white
-B SPST green(N/C); blue(common)
-C SPDT green(N/C); red(N/O); blue(common)

REPLACEMENT PARTS
GAUGE GLASS PLASTIC POINTER SST BEZEL
DIA. LENS LENS (press-fit)
2” GG1-1 GG2-1 AF15-1 M1-5
2 ½” GG1-2 GG2-2 AF15-2 M2-5
3 ½” GG1-3 GG2-3 AF15-3 M4-5
4 ½” GG1-4 GG2-4 AF15-4 M5-5
6” GG1-5 GG2-5 AF15-5 ---

END CAP “O”-RING


Buna N BB1-1A
Viton BB1-1B
Fluorosilicone BB1-1C
Teflon BB1-1F
EPDM BB1-1E

PISTON/MAGNET ASSEMBLY
Aluminum SD12-1
316 SST SD12-3
PVC SD12-4
Naval Brass SD12-5

RECALIBRATION
Recalibration of this instrument is not required. However, if the range spring is damaged or a new dial is required, the instrument must
be returned to the factory for the parts and recalibration.
NOTE: When ordering replacement parts, identify instrument SO# or WO# from the nameplate. Identify parts required and quantity.

GN128-1201 Rev. E Orange Research Inc. Page 2 of 2


MODEL 1201PG (1/4" NPT)
DIAL CASE STYLES *.78 FOR "F"-STYLE GA. CASE
[19.8]
2.5" "B" & 2.5" "F" STYLE *.69 1.00
DIAL CASE [17.5] [25.4]
2.5" "F"
STYLE ONLY
.50
PANEL CUTOUT: [12.7]
2.98
2 MTG. HOLES
3.38 .187 EQUALLY CL .75
3.19 SPACED ON VERTICAL 2.92 GA. [19.1]
[85.9] CL OF DIAL [74.2] 2.00
CL
[81.0] [50.8]
.04 PORT
[1.0]

"B"-STYLE "E"
DIAL CASE "D" 1.00 DIAL CASE SIZES & DIMENSIONS
[25.4]
CL .50
GA. [12.7] 3.5" 4.5" 6.0"
"C" A 4.25[108.0] 5.25[133.4] 6.68[169.7]
B 3.94[100.1] 4.94[125.5] 6.44[163.6]
"B"
2.00 C .25[6.4] .62[15.7] 1.35[34.3]
"A" [50.8] D .13[3.3] .13[3.3] .13[3.3]
CL
E .72[18.3] .72[18.3] .75[19.1]
PORT
.75
[19.1]

"F"-STYLE "E"
DIAL CASE SIZES & DIMENSIONS
DIAL CASE "D" 1.00
[25.4]
3.5" 4.5" 6.0"
CL .50 5.00[127.0]
A 6.00[152.4] 7.62[193.5]
GA [12.7] 3.94[100.1]
B 4.94[125.5] 6.44[163.6]
C.25[6.4] .62[15.7] 1.35[34.3]
"C"
D.13[3.3] .13[3.3] .13[3.3]
"B"
2.00 E.72[18.3] .72[18.3] .75[19.1]
[50.8] PANEL CUTOUT: PANEL CUTOUT: PANEL CUTOUT:
"A" CL 4.00 5.00 6.50
PORT F 3 MTG. HOLES 3 MTG. HOLES 3 MTG. HOLES
.187 EQUALLY .218 EQUALLY .218 EQUALLY
SPACED ON A SPACED ON A
.75 4.56 B.C.
SPACED ON A
5.38 B.C. 7.00 B.C.
[19.1]
"F"

PORTING LOCATIONS 1.63


.77 [41.4]
.50
[19.6]
[12.7] #8-32 UNC-2B
x .38 DEEP
MTG. HLS.
3.60 (2) PL.
-1 IN-LINE [91.4]
LO PRESS .88 1.06
PORT [22.4] [26.9]
CL GA. 1.75 2.13 .63
-1 IN-LINE [44.5] [54.1] CL [16.0]
HI PRESS GA.
PORT

-5 BOTTOM PORTS -4 BACK PORTS CL GA.

CL PORT SHT. 1 of 2 REV. A


MODEL 1201PGS-1 (1/4" NPT) 1 SWITCH CONFIGURATION
CL
.63 GA. #8-32 UNC-2B
[16.0] MNTG. HOLES
LOCATION OF 2ND SWITCH (2) PL.
IF APPLICABLE
CL PORT

2.00 1.63
[50.8] [41.4]

STD. FINISHED
WIRE LENGTH STD. MTG. HOLES
1.00 1/4-20 UNC-2B x .375
IS 12 in. FULL THD. DEPTH
[25.4] 1.13 (2) PLCS.
1.43 [28.7]
[36.3]
2.25
1 SWITCH SHOWN [57.2]

MODEL 1201PS (1/4" NPT) 1 SWITCH CONFIGURATION


STD. FINISHED
WIRE LENGTH
IS 12 in.

1.00
[25.4]

.50
.50 3.00
[12.7]
[12.7] [76.2]
1.00
[25.4] 3.62
[91.9]
1.43
[36.3]

SHT. 2 of 2 REV. A
Product specifications for model 1201
Product Specifications, (gauge, switch)
Sensor type Piston
Functions Gauge, Gauge/Switch, Switch
Calibration medium Units with EPDM Seals: Water Brass or PVC: Water Alum or SS: Hydraulic Oil
Dial sizes PVC: 2.5”,3.5” style “M” only All Others: 2.5”,3.5”,4.5”,6” style “B” and “F”
Dial Starting Mark Approximately 10% of full scale
Lens PVC: Plastic All Others: Glass, Plastic
Range Min: 0-5 psid Max: PVC: 0-60 psid, All other 0-150 psid
Accuracy ±2% of full scale ascending after rap at room temperature

Calibration accuracy is affected by temperature, liquid filling and follower-pointer applications.
Repeatability ±2% of full scale
Max. line\min. burst pressure PVC: 200\750 psig All Others: 3000\10500 psig
Direction of Pressure PVC: Left to Right All Others: Left to Right, Right to Left available (reverse porting)
Porting size & orientation PVC: 1/4 NPT Porting All Others: 1/8,1/2 NPT Porting and MS Ports
In-Line Only Gauge: In-Line, Back or Bottom
Gauge/Switch: In-Line, Back, or Bottom
Switch: In-Line Only
Standard max. temperature PVC: 120°F All Others: Gauge 200°F, 150°F plastic lens
Gauge/switch 176°F, 150°F plastic lens
Switch 176°F
High Temperature PVC: N/A All Others: 450°F (SST only, not available in aluminum or brass)
Minimum temperature PVC: 32°F All Others: Consult factory
Switch Type External hermetically sealed reed switch
Switch Adjustability Upper 80% of full scale ascending, 70% for B & C form switches in SS
Switch Dead Band 5-20% full scale
Switch Options PVC: N/A
All Others: -A SPST N/O (120VAC,0.7A,70VA;200VDC,1.0A,50W)
-B SPST N/C (120VAC,0.25A,5VA;175VDC,0.25A,5W)
-C SPDT (120VAC,0.25A,5VA;175VDC,0.25A,5W)
Switch Setting Top of range ascending or other set points within adjustability ascending or descending
Static & Piston Seals PVC: Viton All Others: Buna-N (Viton,Teflon,Neoprene,EPDM,Flourosilicone optional)
Primary Wetted Parts PVC: PVC All Others: aluminum, 316 SS, naval brass (in-line only)
Secondary Wetted Parts All: SS range spring, SS spacers, ceramic magnet, Teflon piston seal
Teflon coated spring, spacers & magnet available
Certification CSA (File 043810) ∗Consult factory for CE equivalent.

GN108-1, Rev. M Page 1 of 1


Oil Coolers For Temperature
Optimization In Hydraulic Systems
Catalog HY10-1700/Americas
If you have questions about
the products contained in this
catalog, or their applications,
please contact:

Accumulator & Cooler


Division - Americas
phone 815 636 4100
fax 815 636 4111
parker.com/accumulator

Extra care is taken in the


preparation of this literature, but
Parker is not responsible for any
inadvertent typographical errors
or omissions. Information in this
catalog is only accurate as of
the date of publication. For a
more current information base,
please consult the Parker
Accumulator Division web site at
parker.com/accumulator.

Offer of Sale NOTE: Failure or improper selection or


improper use of coolers or related items
The items described in this document are hereby offered for sale can cause death, personal injury and
by Parker Hannifin Corporation, its subsidiaries or its authorized property damage. Parker Hannifin shall
not be liable for any incidental,
distributors. This offer and its acceptance are governed by the consequential or special damages that
provisions in the “Offer of Sale.” result from use of the information
contained in this publication.

! WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED
HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide
product and/or system options for further investigation by users having expertise. It is important that you analyze all aspects
of your application, including consequences of any failure and review the information concerning the product or system in the
current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user,
through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring
that all performance, safety and warning requirements of the application are met.

The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are
subject to change by Parker Hannifin Corporation and its related companies at any time without notice.

© Copyright 2012, Parker Hannifin Corporation. All rights reserved.


Parker is a global player specializing in innovative, efficient system solutions for temperature optimization and
energy storage. All over the world, our products are working in the most diverse environments and applications.

Oil Coolers
Choosing the right cooler requires Cooling capacity
precise system sizing. The most
reliable way to size a cooler is
with the aid of our calculation
program. This program, together
with precise evaluations from our Lifetime
experienced, skilled engineers,
gives you the opportunity for more
cooling per $ invested. Overheating – an expensive recommended values. The correct
problem working temperature produces
An underestimated cooling a number of economic and
capacity produces a temperature environmental benefits:
that is too high. The consequences • The hydraulic system’s
are poor lubricating properties, useful life is extended.
higher internal leakage, a higher • The oil’s useful life is
risk of cavitation, damaged extended.
components, etc. Overheating • The hydraulic system’s
leads to a significant drop availability increases –
in efficiency which can be more operating time and
detrimental to our environment. fewer shutdowns.
• Service and repair costs
Temperature optimization – are reduced.
a basic prerequisite for • High efficiency level
cost-efficient operation maintained in continuous
Temperature balance in a hydraulic operation – the system’s
system occurs when the cooler can efficiency falls if the
cool down the energy input that temperature exceeds the
the system does not consume – ideal working temperature.
the system’s lost energy
(Ploss = Pcool = Pin – Pused).

Temperature optimization occurs


at the temperature at which the
oil viscosity is maintained at

4
ULAC with AC Motor
For industrial use – maximum cooling capacity 400 HP*

Optimized design with right choice of materials and components ensures reliable
and long lasting cooler with low service and maintenance costs.
Compact design resulting in lighter weight unit yet with higher cooling capacity
and lower pressure drop.
Easy to maintain and easy to retrofit into many applications.
Quiet fan design due to optimization of material and blade design.
AC motor – NEMA three phase motors are standard. Wide range of operating
voltages and frequencies available.
Cooler core with low pressure drop and high cooling capacity.

ULOC Cooling System


For industrial use – maximum cooling capacity 60 HP

Optimized design and the right choice of materials and components produce a long
useful life, high availability and low service and maintenance costs.
Integrated circulation pump produces an even flow with low pressure pulsations.
Easy to maintain and easy to retrofit in many applications.
Compact design and low weight.
Quiet fan and pump.
Cooler core with low pressure drop and high cooling capacity.

ULDC with DC Motor


For mobile use – maximum cooling capacity 40 HP

Optimized design with right choice of materials and components ensures reliable
and long lasting cooler with low service and maintenance costs.
Compact design resulting in lighter weight unit yet with higher cooling capacity
and lower pressure drop.
Easy to maintain and easy to retrofit into many applications.
DC motor 12V/24V
Quiet fan and fan motor.

ULHC with Hydraulic Motor


For mobile and industrial use – maximum cooling capacity 215 HP

Optimized design and the right choice of materials and components produce a long
useful life, high availability and low service and maintenance costs.
Compact design resulting in lighter weight unit yet with higher cooling capacity
and lower pressure drop.
Easy to maintain and easy to retrofit into many applications.
Hydraulic motor with displacement from 8.4 cc/rev to 25.2 cc/rev.
Collar bearing for fan motor on larger models provides longer operating life.
Quiet fan design due to optimization of material and blade design.
Cooler core with low pressure drop and high cooling capacity.

*At 250 gpm and 70 °F ITD

5
Calculate the cooling capacity requirement
Cooling Flow? Measure in Contact
Installed
capacity Pressure? your existing Olaer USA
horse power
requirement? Pump efficiency? unit representative

Theoretical
horse power
losses

Choose the right kind of cooler

Enter your values ....

... get suggested solution

7
Catalog HY10-1700/Americas ULAC

ULAC with AC Motor


For industrial use – cooling capacity up to 400 HP

The ULAC oil cooler with AC motor is optimized • Easy to maintain and easy to retrofit
for use in the industrial sector. Together with a wide into many applications.
range of accessories, the ULAC cooler is suitable for
installation in most applications and environments. • Quiet fan design due to optimization
of material and blade design.
• Optimized design with right choice
• AC motor – NEMA three phase motors
of materials and components ensures
are standard. Wide range of operating
a reliable and long lasting cooler with
voltages and frequencies available.
low service and maintenance costs.
• Cooler core with low pressure drop
• Compact design resulting in lighter
and high cooling capacity.
weight unit yet with higher cooling
capacity and lower pressure drop.

9
Catalog HY10-1700/Americas ULAC

Acoustic Pressure No. Of Poles/


TYPE Weight P Q
Level Capacity
Lbs. (Approx.) SAE O-Ring SAE O-Ring Boss
LpA dB(A) 3 Ft.* hP
ULAC 007B 69 4/0.5 33 ½" (#8) 1" (#16)
ULAC 011B 71 4/0.5 44 ½" (#8) 1" (#16)
ULAC 016B 74 4/0.5 53 ½" (#8) 1" (#16)
ULAC 023D 81 4/1 79 ½" (#8) 1" (#16)
ULAC 033D 82 4/1 115 ½" (#8) 1¼" (#20)
ULAC 033F 86 4/3 170 ½" (#8) 1¼" (#20)
ULAC 044D 83 4/1 143 ½" (#8) 1¼" (#20)
ULAC 044F 87 4/3 197 ½" (#8) 1¼" (#20)
ULAC 058G 90 4/5 264 ¾" (#12) 1½" (#24)
ULAC 078G 92 4/5 434 ¾" (#12) 1½" (#24)
ULAC 112H 96 4/7.5 542 ¾" (#12) 1½" (#24)
ULAC 200K 93 6/15 1,030 NA CODE 61 SAE 2" FLANGE
* Noise level tolerance ± 3 dB(A).

12
Catalog HY10-1700/Americas ULAC

TYPE
A B C D E F G H I J K L M Nø

ULAC 007B 5.2 6.3 3.2 8.0 0.24 11.7 15.6 8.0 14.4 20.1 8.4 19.8 8.8 0.35
ULAC 011B 5.4 9.0 3.2 8.0 0.12 14.3 18.5 8.0 17.3 20.1 9.8 20.8 9.8 0.35
ULAC 016B 5.2 11.7 3.2 8.0 0.28 17.0 20.7 8.0 19.5 20.1 10.9 21.6 10.7 0.35
ULAC 023D 5.2 14.9 3.2 14.0 0.20 20.2 24.0 14.0 22.8 20.1 12.6 22.2 11.3 0.35
ULAC 033D 5.2 19.1 3.2 14.0 NA 24.5 28.4 14.0 27.2 20.1 14.8 23.1 12.5 0.35
ULAC 033F 5.2 19.1 3.2 14.0 NA 24.5 28.4 14.0 27.2 24.0 14.8 25.6 12.5 0.55
ULAC 044D 4.6 26.1 3.2 14.0 NA 31.5 34.1 14.0 27.2 20.1 17.6 24.1 13.3 0.35
ULAC 044F 4.6 26.1 3.2 14.0 NA 31.5 34.1 14.0 27.2 24.0 18.3 26.6 13.5 0.55
ULAC 058G 5.2 26.1 3.2 20.0 NA 31.5 35.4 20.0 34.2 24.0 18.3 29.9 15.2 0.55
ULAC 078G 5.2 32.3 3.9 26.8 NA 38.9 41.4 20.4 40.2 35.4 21.1 30.9 16.2 0.55
ULAC 112H 5.1 38.8 3.9 31.1 0.14 45.4 47.8 23.6 46.7 35.4 24.4 31.9 17.2 0.55
ULAC 200K 7.2 50.9 5.0 49.6 1.2 61.0 64.2 55.9 59.4 35.4 32.7 41.5 18.7 0.71
All dimensions listed above are in inches.

13
Catalog HY10-1700/Americas ULAC

Order Key for ULAC Oil Coolers Technical Specifications


All positions must be filled in when ordering.

EXAMPLE: FLUID COMBINATIONS


ULAC - 007B -M - 100 - SA Mineral oil
Series Model Motor Type Thermoswitch Core Bypass Oil/water emulsion
Water glycol
1 2 3 4 5 Phosphate ester

MATERIAL
1. OIL COOLER SERIES WITH AC MOTOR; ULAC
Cooler core Aluminum
Fan blades/hub Glass fiber reinforced polypropylene/
2. COOLER SIZE/MODEL
Aluminum
007B, 011B, 016B, 023D, 033F, 033D, 044F, 044D,
Fan housing Steel
058G, 078G, 112H and 200K.
Fan guard Steel
Other parts Steel
3. MOTOR TYPE
Surface treatment Electrostatically powder-coated
No motor =W
Three-phase 190/380V 50 Hz, 208-230/460V 60 Hz = M*
COOLER CORE
Three-phase 208-230/460V 60 Hz =N
Maximum static working pressure 300 psi
Three-phase 230/460V 60 Hz =P
Dynamic working pressure 200 psi*
Three-phase 575V 60 Hz =Q
Heat transfer tolerance ±6%
Single-phase 115/230V 60 Hz =R
Maximum oil inlet temperature 250 °F
Single-phase 230 V 60 Hz =S
* Tested in accordance with ISO/DIS 10771-1
Explosion proof, Division 1, Class 1 Group D,
Class II Group F & G, T3C =X
COOLING CAPACITY CURvES
Not listed, consult Olaer USA =Z
Cooling capacity curves are based on testing in accordance with
* The M-motor is our standard motor sizes 1 hP and lower. The performance at
50 hZ will be reduced by approximately 10%
EN1048 with ISO VG 46.

4. THERMOSWITCH CONTACT PARKER FOR ADvICE ON


No thermoswitch = 000 Oil temperatures > 250 °F
100 °F = 100 Oil viscosity > 100 cSt / 500 SSU
120 °F = 120 Aggressive environments
140 °F = 140 Environments with heavy airborne particulates
160 °F = 160 High-altitude locations
175 °F = 175
195 °F = 195
Not listed, consult Accumulator and Cooler Division = ZZZ

5. CORE BYPASS*
No Bypass = SW
20 psi External Hose Bypass (standard option) = SA
65 psi External Hose Bypass (standard option) = SB
30 psi External Tube Bypass = SG
75 psi External Tube Bypass = SH
120 psi External Tube Bypass = SJ
120 °F External Thermo-Bypass = SM
140 °F External Thermo-Bypass = SN
160 °F External Thermo-Bypass = SP
195 °F External Thermo-Bypass = SQ
Full Flow External Bypass = SF
* The standard cores are single pass. Two pass cores and other options
available upon request, please consult Accumulator and Cooler Division.

The information in this brochure is subject to change without prior notice.

14
Magnaloy Flexible Drive Couplings

SECTION 1
1

MAGNALOY FLEXIBLE DRIVE COUPLINGS

NOTE: Due to Magnaloy’s policy of continuous improvement, specificaitons are subject to change without notice.
Check with the factory or our Web Site at www.magnaloy.com for the latest information.

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 1
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Magnaloy Coupling Design Features
Load-Lock Design... is simple and effective. The drive lug
configuration is tapered from top to base, as are the mating
lugs of the opposing coupling hub. Under load, the insert
conforms to the tapers, inter-locking the two hubs. This load-lock
design protects bearings and equipment by eliminating end
thrust in both directions.... and it requires only one set-screw in
each hub.

1
1 Radial Lug Design... is logical and efficient. The most common failure of an
elastomeric insert type drive coupling is hysteresis failure of the elastomeric
element - breakdown of the elastomer due to cyclical overworking and the
associated heat generation. Magnaloy Coupling’s drive lugs are in a true
radial orientation. Applied forces are evenly distributed in the compressive
direction only, eliminating the heat generating radial component. True
compressive loading reduces internal heat generation and improves elastomer
life.
Magnaloy Coupling Design...
Under loaded conditions, the resultant forces applied on the element
segments are evenly distributed in the compressive direction only. This
results in no radial forces to multiply the internal heat generation.

Conventional Design A...


Under loaded conditions this jaw design results in the applied forces
exerting components in the compressive and radial directions. These forces
change direction and magnitude along the jaw arc which greatly increase
the internal movement of the element which causes heat generation.

Conventional Design B...


This more conventional straight sided jaw design also exerts component
forces in the compressive and radial directions when under load. The
radial component is outward (acting to extrude the element) and changes
in magnitude only, as does the compressive component, along the jaw
surface. The component forces resulting from this design also causes
increased internal movement in the element.
A note about Set-Screws ...
The Premium Line of Magnaloy Couplings comes standard with a single set-screw over the keyway. Optional
Double Set-Screws are available at either 45o or 90o to the keyway. Double set-screws help improve shaft
gripping forces by increasing the hoop-stresses generated from tightening a single set-screw. Double set-screws
at 45o will produce greater forces than double set-screws at 90o. Either are available upon request by
specifying ‘DSS45’ or ‘DSS90’ following the hub part number. M30011210DSS45
Magnaloy’s Clamp feature is also availble with bored and keyed hubs, specify ‘C’ following the hub part
number. M30011210C
2 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Premium Flexible Drive Couplings

Magnaloy is the original lightweight, heavy-duty


flexible drive coupling. Light weight magnesium
construction makes Magnaloy couplings 76% lighter than
cast iron and 36% lighter than aluminum units... and
they’re stronger than either!
The benefits are many... Reduced loads on bearings,
shafts and pumps, for longer component life. Easier
handling and installation. Rust proof and corrosion 1
resistant.
Magnaloy’s close machining tolerances (TIR of .002”)
assures vibration-free operation and easy, accurate
alignment without need for special tools. Solid
magnesium alloy permanent mold castings are heat
treated and offer the highest strength-to-weight ratio
available.

Coupling Performance Specifications


Rated Torsional Horse Power Rating @
Coupling Maximum Wr2 Insert
Torque Rigidity 100 1200 1800
Model Bore lb-ft2 Number
lb-in lb-in/Deg rpm rpm rpm
170N 340.7 42 0.55 6.5 9.8
100 1 1/8 0.0046 170U 511.0 53 0.82 9.8 14.7
170H 1,022.1 182 1.65 19.8 29.7
270N 398.3 55 0.64 7.6 11.5
200 1 3/8 0.0068 270U 597.4 68 0.96 11.5 17.2
270H 1,194.9 234 1.92 23.0 34.5
370N 701.4 81 1.12 13.5 20.2
300 1 5/8 0.022 370U 1,052.1 148 1.68 20.2 30.3
370H 2,104.2 336 3.36 40.4 60.6
470N 1,056.3 138 1.69 20.3 30.4
400 1 7/8 0.031 470U 1,584.5 310 2.50 30.4 45.6
470H 3,168.9 488 5.10 60.8 91.3
570N 2,194.8 314 3.50 42.1 63.2
500 2 3/8 0.071 570U 3,292.2 695 5.30 63.2 94.8
570H 6,584.4 1,571 10.50 146.4 189.6
670N 4,946.7 676 7.90 94.9 142.5
600 2 5/8 0.16 670U 7,420.1 1,510 11.90 142.5 213.7
670H 14,840.1 2,960 23.70 284.9 427.4
770N 11,639.8 1,805 18.60 223.5 335.2
700 2 7/8 0.34 770U 17,459.7 2,104 27.90 335.2 502.8
770H 29,099.5 5,960 46.50 558.8 838.0
870N 21,889.4 3,680 35.00 420.3 630.4
800 3 7/8 0.95 870U 32,834.1 - 52.50 630.4 945.6
870H 47,062.2 11,950 75.20 903.0 1,354.5
970N 47,842.3 8,428 76.50 918.6 1,377.9
900 4 3/4 4.20
970U 71,763.5 - 114.80 1,377.9 2,066.8

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 3
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Dimensional Specifications
Magnaloy Coupling Dimensional Specifications

Models 100, 200, 300, 400


100 200 300 400
A 2.54 3.10 3.58 4.24
B 2.600 2.900 3.450 3.980
C 2.00 2.25 2.90 3.05
D 0.56 0.68 0.78 1.00
E
1
1
0.68 0.84 0.96 1.06
F 0.42 0.42 0.44 0.54
G 0.31 0.43 0.56 0.73
W 1/16 1/16 1/16 1/16
X 0.90 0.90 0.98 1.20
T
TOLERANCES: 2 Place Decimals ± .01
1/4-20 5/16-18 5/16-18 3/8-16 3 Place Decimals ± .001

Model 500
500
A 4.67
B 4.800 X*: Maximum Space between
shaft ends to allow full
C 4.00
shaft engagement in
D 1.04 Hub Bore.
E 1.23
F .064 W*: Minimum Space between
shaft ends.
G .070
W 1/16 * Given for reference only.
X 1.41
T 3/8-16 TOLERANCES: 2 Place Decimals ± .01
3 Place Decimals ± .001

Models 600, 600, 800, 900


600 700 800 900
A 5.98 6.99 7.99 10.15
B 5.975 6.900 8.600 11.400
C 4.50 5.19 7.00 8.30
D 1.60 2.08 2.25 2.75
E 1.33 1.32 1.62 2.20
F 0.62 0.89 1.00 1.32
G 1.13 1.13 1.58 1.88
W 1/16 1/16 1/16 1/16
X 1.36 1.97 2.25 2.89
T 3/8-16 1/2-13 1/2-13 3/4-10
TOLERANCES: 2 Place Decimals ± .01
3 Place Decimals ± .001

4 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Bore & Keyway Combinations
Standard Bore and Keyway Combinations
Magnaloy “Standard” Bore Key Combinations Magnaloy “Standard” Bore Key Combinations
Model Bore/Key Model Model Bore/Key Model
Code Code Bore Key Code Code Bore Key

100
200
300
400
500
600
700
800
900

100
200
300
400
500
600
700
800
900
M _ _ _ 01203 3/8 x 3/32 * * M _ _ _ 12414 1 3/4 x 7/16 * * * * *
M _ _ _ 01403 7/16 x 3/32 * * M _ _ _ 12816 1 7/8 x 1/2 * * * * * *
M _ _ _ 01404 7/16 x 1/8 * * M _ _ _ 13016 15/16 x 1/2 * *
M _ _ _ 01604 1/2 x 1/8 * * * M _ _ _ 20016 2 x 1/2 * * * * *
M _ _ _ 01804 9/16 x 1/8 * * * M _ _ _ 20416 2 1/8 x 1/2 * * * * *
M _ _ _ 02005
M _ _ _ 02006
5/8 x
5/8 x
5/32
3/16
*
*
*
*
*
* *
M _ _ _ 20816
M _ _ _ 21220
2 1/4 x 1/2
2 3/8 x 5/8
* *
* *
*
*
*
*
*
*
1
M _ _ _ 02206 11/16 x 3/16 * * * * M _ _ _ 21620 2 1/2 x 5/8 * * * *
M _ _ _ 02404 3/4 x 1/8 * * * M _ _ _ 22020 2 5/8 x 5/8 * * * *
M _ _ _ 02406 3/4 x 3/16 * * * * * * M _ _ _ 22420 2 3/4 x 5/8 * * *
M _ _ _ 02806 7/8 x 3/16 * * * * * * M _ _ _ 22824 2 7/8 x 3/4 * * *
M _ _ _ 02808 7/8 x 1/4 * * * * * * M _ _ _ 30024 3 x 3/4 * *
M _ _ _ 03008 15/16 x 1/4 * * * M _ _ _ 30824 3 1/4 x 3/4 * *
M _ _ _ 10006 1 x 3/16 * * * * * * M _ _ _ 31228 3 3/8 x 7/8 * *
M _ _ _ 10008 1 x 1/4 * * * * * * M _ _ _ 31628 3 1/2 x 7/8 * *
M _ _ _ 10408 1 1/8 x 1/4 * * * * * * M _ _ _ 32028 3 5/8 x 7/8 * *
M _ _ _ 10608 1 3/16 x 1/4 * * M _ _ _ 32428 3 3/4 x 7/8 * *
M _ _ _ 10808 1 1/4 x 1/4 * * * * * M _ _ _ 32832 3 7/8 x 1 * *
M _ _ _ 10810 1 1/4 x 5/16 * * * * * * * M _ _ _ 40032 4 x 1 *
M _ _ _ 11210 1 3/8 x 5/16 * * * * * * * M _ _ _ 40432 4 1/8 x 1 *
M _ _ _ 11212 1 3/8 x 3/8 * M _ _ _ 40832 4 1/4 x 1 *
M _ _ _ 11412 1 7/16 x 3/8 * * * M _ _ _ 41232 4 3/8 x 1 *
M _ _ _ 11610 1 1/2 x 5/16 * * * M _ _ _ 41632 4 1/2 x 1 *
M _ _ _ 11612 1 1/2 x 3/8 * * * * * * M _ _ _ 41640 4 1/2 x 1 1/4 *
M _ _ _ 12012 1 5/8 x 3/8 * * * * * * M _ _ _ 42040 4 5/8 x 1 1/4 *
M _ _ _ 12412 1 3/4 x 3/8 * * * * * M _ _ _ 42440 4 3/4 x 1 1/4 *

Shaded Area: AGMA semi-standard bore key combinations.


Part Number Usage: Magnaloy Coupling Hub part numbers may be specified Bore Tolerances
using the following format: Start with letter “M” designating Magnaloy, Over Include Tolerance
followed by 3 digit Model Code (100, 200, etc.), then the specific 5 digit -- 1 +.0008/+.0003
Bore/Key Code. 1 2 +.0013/+.0005
2 3 +.0018/+.0008
Example: Model 500 Hub with a 1 /38 bore and 5/16 keyway would be 3 4 +.0020/+.0010
4 5 +.0023/+.0010
specified as: M50011210 - No bore hubs are designated as “R” code, ie.
M500R.
Additional Coupling Specifications
Model Number 100 200 300 400 500 600 700 800 900
Maximum Bore 1 1/8 1 3/8 1 5/8 1 7/8 2 3/8 2 5/8 2 7/8 3 7/8 4 3/4
Complete Coupling Approx. Weight
3/4 1 2 3 4 7 12 18 38
(Solid Hub)
Number of Drive Lugs 3 3 3 3 4 6 6 6 6
Hub Movement for Insert Removal .74 .74 .75 .98 1.12 1.02 1.50 1.63 2.27
Basic Insert Number 170 270 370 470 570 670 770 870 970

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 5
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Insert Selection Guide
Magnaloy Coupling’s full range of flexible inserts permit
custom design performance for a wide range of applications.
All insert materials offer complete electrical insulation, as
Magnaloy’s design eliminates all metal-to-metal contact.

1
1
Neoprene (Code N) - Black material - Standard
material with Magnaloy Coupling. Good general
purpose material offering good resiliency and
load capabilities. Temp range -300F to +2500F
(-340C to -1210C). Optional 80A durometer
(painted Gold) and 90A durometer (painted
Silver) are available for slight increased load
capability and less resiliency.
Nitrile (Buna N)(Code B) - Painted Blue. Excellent
material with petroleum products. Excellent
compression set and abrasion resistance
characteristics. Temp range -600F to +2500F
(-510C to +1210C).
Urethane (Code U) - Yellow material. Excellent
mechanical and physical properties. Offers good
medium duty durability and resiliency. Urethane
tends to soften at higher temperatures and humid
conditions. Temp range -300F to +1500F (-340C
Part Number Usage: Magnaloy Coupling Insert part
to +660C).
numbers may be specified using the following format:
Viton (Fluorocarbon)(Code V) - Red material.
Start with the letter “M” for Magnaloy, followed by the 3
Excellent fluid compatibility and high temperature
digit Basic Insert Number Code (170, 270, etc.), then the
characteristics. Good compression set and
specific single letter Insert Material Code. If an optional
resiliency. Temp range -200F to +3500F (-290C to
durometer is being specified, after the Material Code
+1770C).
supply the durometer number divided by 10.
Hytrel (Code H) - Blue material. Superior physical
and mechanical properties and excellent fluid
Examples: Urethane insert for Model 300: M370U. 80
compatibility and high temperature characteristics.
Durometer Neoprene for Model 200: M270N8.
Hardness (50D) approaches that of plastic and
offers little resiliency. Excellent performance
under heavy duty conditions. Temp range -650F to
+3000F (-540C to +1490C).
Other materials are available for special applications.
Consult factory for recommendations and availability.

78 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Coupling Selection Guide
Service Factors - Load Characteristics
Type of Prime Mover
Load Standard Motor High Torque I.C. Engine I.C. Engine
Classification or Turbine Motor 6 or more cyl. less than 6 cyl.
Uniform (U) 1.0 1.5 1.5 2.0*
Moderate (M) 1.5 2.0 2.0 2.5*
Heavy (H) 2.0* 2.5* 2.5* 3.0*
Uniform Load: Steady loading, non-reversing, torque does not exceed rating.
Moderate Load: Uneven loading with moderate shock, frequent starts, infrequent reversals,
1
peak torque may exceed average rating of prime mover by up to 125%.
Heavy Load: Uneven loading with heavy shock, frequent reversals, peak torque may exceed
average rating of prime mover by up to 150%.
* Recommend use of Hytrel Insert.
Drive Unit Load Sym.
Agitators U Selection Method
Blowers U
Compressors - Centrifugal U 1. Several specifics must be considered to make the best
- Rotary M choice of couplings:
- Reciprocating H* A. Type of prime mover and load characteristics (see table
Conveyors - U
- Reciprocating M above)
- Screw M B. Shaft diameter and key size or spline configuration (No. of
- Shaker H teeth, pitch ratio, pressure angle)
Cranes & Hoists M C. Horsepower rating of loads to be transmitted.
Crushers H*
D. Maximum operating speed (rpm)
Elevators M
- Freight & Pass. H* E. Maximum operating misalignment
Fans - Centrifugal U F. Clearance limitations
- Propeller M 2. Calculate effective hp/100 rpm by use of table above and
- Cooling Tower H select the minimum size coupling recommended
Generators U
- Welding H
3. VERIFY YOUR SELECTION:
Mills H* A. Check for maximum bore size
Machine Tools M B. Check dimensions for adequate clearance
Mixers M C. Indicate any special insert specification and/or coupling
Paper Mill Machinery M coating for environmental protection, if required
Pumps - Centrifugal
U Equation: Effective HP per 100 RPM = rated HP x Service
- Rotary
- Reciprocating
M Factor x 100 / RPM
H* Example: 150 HP, 4 cyl. Diesel Engine Driving a Reciprocating
- On Injection
H*
Molding Equip. Irrigation Pump operating at 3250 RPM
Screens - Air & Water U Service Factor - 3.0 (Hytrel Insert Recommended)
Washing
Eff. HP per 100 RPM = 150 HP x 3.0 x 100 /
- Freight & Pass. H
Stokers U 3250 RPM = 13.85 HP/100 RPM. Model 600
Textile Machinery M rating with Hytrel Insert is 23.7 HP/100 RPM.
Woodworking Machinery M
Winches H*
Note: Above service factors are intended for use as a general guide only.
*Recommend use of Steel Bushing and Clamp with Splined Bores.

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 98
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Installation Instructions
Shaft spacing should be within range given by
dimensions ‘W’ and ‘X’ as shown in charts on page 4.
Position each hub on proper size shaft - Magnaloy
couplings are bored to standard “push fit” tolerances,
if a tight fit exists, check shaft for burrs.
Maximum benefits are obtained with hubs positioned
to allow complete shaft engagement within bore.
However, some equipment designs do not permit this
1
1 condition - maximum shaft engagement should be
utilized in any case.

Alignment - Place a straight edge (scale) at top and


side of coupling. Use a .005 inch feeler gauge under
scale for final inspection. This will indicate accurate
parallel and angular alignment.
Magnaloy’s precision machined outside surfaces
permit this simple, but accurate alignment method.

Secure equipment mounts and recheck alignment for


movement.
Install the insert in the coupling positioning hubs in
contact with lip around outside of insert.
Before tightening set screws, run the coupling and
check for separation of hubs or “creep”. Recheck
alignment and tighten set screws.
With the Steel Bushed/Clamp type couplings, to
facilitate installation on the shaft, it may be
necessary to slightly loosen the set-screw over the
keystock. When securing the coupling on the shaft,
first tighten the clamp bolt, then tighten the set-screw
against the keystock.

190 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Mis-Alignment Capabilities
Magnaloy Couplings offer four-way flexibility (parallel, angular, axial and
torsional) and require no lubrication. They are easily installed and
properly aligned without use of special tools or equipment - a straight
edge and hex wrench ar the only tools required. Magnaloy’s insert
reduces noise and vibration and permits needed flexibility for proper
operation within alignment capabilities.

Recommended Torques
for Fasteners 1
Model Set Screw Clamp Screw
100 60 - 70 in lbs 130 - 140 in lbs
200 75 - 85 in lbs 130 - 140 in lbs
300 75 - 85 in lbs 210 - 220 in lbs
400 190 - 200 in lbs 210 - 220 in lbs
500 190 - 200 in lbs 300 - 310 in lbs
600 190 - 200 in lbs 35 - 36 ft lbs
700 300 - 310 in lbs 35 - 36 ft lbs
800 300 - 310 in lbs 49 - 50 ft lbs
900 100 - 110 ft lbs 100 - 110 ft lbs
Intended as a general guide for fastener torques with
Magnaloy Couplings.

Perfect alignment of equipment shafts, in most cases, is impractical to obtain or maintain, and misaligned
equipment produces, excess stress on bearings and the coupling. Magnaloy’s insert design will accept
misalignment strain and, when excessive, will cause insert wear as a visual and audible indication of
misalignment problems. However, Magnaloy’s inserts are inexpensive and easily replaces; under normal
conditions the insert seldom requires replacement.

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 1110
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Technical Bulletin & Notes
Keystock Interference with Drive Lug
Since the Magnaloy Coupling keyway, in a bored and keyed hub, is broached between the drive lugs, there is a
potential for interference with the keystock of the drive hub and the drive lugs of the opposing hub. This
interference will result when ALL the following conditions exist:
A) The shaft diameter is Greater than listed below
B) This shaft extends into the hub insert core area
C) The keystock on this shaft extends with the shaft into the insert core area

1
1 The interference condition can be corrected by shortening the keystock so it does not extend into the insert core
area. The insert length should be limited to the length of the coupling hub bore.

Interference Potential exists when


shaft diameters are greater than
shown in this chart.
Model Size Shaft Diameter Key Size
100 7/8 1/4
200 1 3/16 1/4
300 1 5/16 5/16
400 1 1/2 3/8
500 1 15/16 1/2
600 2 1/2 5/8
700 2 3/4 5/8
800 3 1/2 7/8
900 4 1/2 1 1/4
Failure to correct this condition will result in assembly difficulty and could cause damage to the drive
or driven equipment. Check our web site at www.magnaloy.com for other bulletins.

Notes

1112 magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Magnaloy Pump/Motor Mounts

SECTION 2 2

MAGNALOY PUMP/MOTOR MOUNTS

NOTE: Due to Magnaloy’s policy of continuous improvement, specificaitons are subject to change without notice.
Check with the factory or our Web Site at www.magnaloy.com for the latest information.

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 17
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Pump/Motor Mounts - General Information
Magnaloy Pump/Motor Mounts
Power Unit design is greatly simplified by use of the Magnaloy Pump/Motor Mount. Direct mounting of flange
mount pumps to NEMA C’Face motors or Pilot mount engines via a Magnaloy Mount assures accurate shaft
alignment and eliminates the need for a coupling guard, foot brackets, shims, risers and mounting plate. The
result is the easiest to install, most accurate and cost effective method available to mount a pump to a drive unit.
For over 30 years Magnaloy has produced the highest quality flexible drive couplings in the industry.
Magnaloy’s long tradition of high quality and immediate delivery has become an industry goal for other
manufacturers to attain. Every mount Magnaloy manufactures is guaranteed to be within .003 inch concentric
from the motor pilot to the pump pilot. Further, the mounting faces are parallel to each other and perpendicular
to the pilot centerline within .002 inch. These exacting tolerances mean accurate shaft alignment which helps
prolong bearing, seal and coupling life in addition to reducing noise and vibration. Other mount manufacturers
talk about quality, but Magnaloy puts it in writing with measurable standards (see Illustration A).
2
Magnaloy is the most complete, single source for
Horizontal, Vertical and Engine requirements. A large
selection of SAE and Metric pump mounting flanges to
NEMA motors and I.C. Engines in a variety of lengths are
available from stock for immediated shipment. OR
special requirements can be met from our complete
offering of Welded Steel Mounts. Whatever your
mounting needs, you need look no further than Magnaloy.
Consult your Magnaloy Distributor for Magnaloy’s Product
CD ROM which includes the Magnaloy Pump/Motor Mount
Selection Program. Illustration A

Magnaloy Cast Aluminum Mounts


MAGNALOY CAST ALUMINUM MOUNTS are permanent mold cast of lightweight, high strength aluminum alloy
and incorporate many unique design features. Custom molded OSHA orange coupling access covers are
included for mounts larger than motor group size 056. These covers are quickly and securely retained via a lip-
tab on one end and a single self-tapping screw on the other. Magnaloy’s horizontal mounts are supplied with a
pre-cast drain hole for residual fluids. This unique feature assists in quick detection of leaky seals and other
trouble areas.

Using Magnaloy’s Pump/Motor Mounts ensure a lightweight, high strength, precision mount for efficient assembly,
quiet operation, accurate shaft alignment and complete coupling concealment.

Magnaloy Horizontal Pump/Motor Mounts


MAGNALOY’S HORIZONTAL PUMP/MOTOR MOUNTS are available for mounting NEMA C’Face motors in
frame sizes 56C through 449TSC to most SAE and Metric 2 and 4 bolt pump flanges.

A MOUNT KIT is included which contains all the bolts and washers required to attach the pump and motor to the
mount.

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 19
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Horizontal Pump/Motor Mounts - NEMA Frame Motors

TABLE 8A - NEMA Frames 182TC - 256TC, 213UC - 256UC


Horizontal Mounting (or Vertical Mounting - Option A)
2
MOTOR END DATA
AJ BF BD AK RADIAL CLEARANCE “Z” = 5.00
182-A Casting
2

1
25

00

XAK XAJ2 XBF2 XAJ4 XBF4 MOUNT NO. CL M MOUNT NO. CL M MOUNT NO. CL M
/3

50
7.

9.
17

8.

USA4F17 4 Bolt 1.782 2.84 5/16-18 M182474F 4.00 4.75 M182504F 4.31 5.00 M182524F 4.31 5.25
SAE AA 2 Bolt 2.001 3.25 3/8-16 M182472AA 4.00 4.75 M182502AA 4.31 5.00 M182522AA 4.31 5.25
SAE A 2(4) Bolt 3.251 4.19 3/8-16 4.12 3/8-16 M182472A 4.00 4.75 M182502A 4.31 5.00 M182522A 4.31 5.25
63 2A/B4 2(4) Bolt 63.01mm 100mm 5/16-18 85mm 5/16-18 M1824763M 4.00 4.75 M1825063M 4.31 5.00 M1825263M 4.31 5.25
63 S4 4 Bolt 63.01mm 80mm 11/32 M1824763MS 4.00 4.75 M1825063MS 4.31 5.00 M1825263MS 4.31 5.25
80 2A/B4 2(4) Bolt 80.01mm 109mm 3/8-16 103mm 5/16-18 M1824780M 4.00 4.75 M1825080M 4.31 5.00 M1825280M 4.31 5.25
80 S4 4 Bolt 80.01mm 100mm 5/16-18 M1824780MS 4.00 4.75 M1825080MS 4.31 5.00 M1825280MS 4.31 5.25
PUMP FLANGE PUMP END DATA 4.75 LENGTH 5.0 LENGTH 5.25 LENGTH
MOTOR END DATA
RADIAL CLEARANCE “Z” = 5.00
AJ BF BD AK
2

1
25

00

XAK XAJ2 XBF2 XAJ4 XBF4 MOUNT NO. CL M MOUNT NO. CL M


/3

50
7.

9.
17

8.

USA4F17 4 Bolt 1.782 2.84 5/16-18 M182584F 5.06 5.81 M182684F 6.06 6.81
SAE AA 2 Bolt 2.001 3.25 3/8-16 M182582AA 5.06 5.81 M182682AA 6.06 6.81
SAE A 2(4) Bolt 3.251 4.19 3/8-16 4.12 3/8-16 M182582A 5.06 5.81 M182682A 6.06 6.81
63 2A/B4 2(4) Bolt 63.01mm 100mm 5/16-16 85mm 5/16-18 M1825863M 5.06 5.81 M1826863M 6.06 6.81
63 S4 4 Bolt 63.01mm 80mm 11/32 M1825863MS 5.06 5.81 M1826863MS 6.06 6.81
80 2A/B4 2(4) Bolt 80.01mm 109mm 3/8-16 103mm 5/16-18 M1825880M 5.06 5.81 M1826880M 6.06 6.81
80 S4 4 Bolt 80.01mm 100mm 5/16-18 M1825880MS 5.06 5.81 M1826880MS 6.06 6.81
PUMP FLANGE PUMP END DATA 5.81 LENGTH 6.81 LENGTH

TABLE 8B - NEMA Frames 182TC - 256TC, 213UC - 256UC


Horizontal Mounting
MOTOR END DATA
AJ BF BD AK RADIAL CLEARANCE “Z” = 5.00
182-B Casting
2

1
25

00

XAK XAJ2 XBF2 XAJ4 XBF4 MOUNT NO. CL M MOUNT NO. CL M MOUNT NO. CL M
/3

50
7.

9.
17

8.

SAE B 2(4) Bolt 4.001 5.75 1/2-13 5.00 1/2-13 M182522B 4.50 5.25 M182582B 5.06 5.81 M182602B 5.25 6.00
SAE C 2(4) Bolt 5.001 7.12 5/8-11 6.38 1/2-13 M182522C 4.50 5.25 M182582C 5.06 5.81 M182602C 5.25 6.00
100 A2/B4 2(4) Bolt 100.01mm 140mm 1/2-13 125mm 3/8-16 M18252100M 4.50 5.25 M18258100M 5.06 5.81 M18260100M 5.25 6.00
125 A2/B4 2(4) Bolt 125.01mm 180mm 5/8-11 160mm 1/2-13 M18252125M 4.50 5.25 M18258125M 5.06 5.81 M18260125M 5.25 6.00
PUMP FLANGE PUMP END DATA 5.25 LENGTH 5.81 LENGTH 6.00 LENGTH

magnaloy coupling company 501 Commerce Drive Alpena, MI 49707 989 356-2186 21
A Division of Douville Johnston Corporation Fax: 989 354-4190 http://www.magnaloy.com
Bulletin E-73

Series L4 Float Switch

Specifications - Installation and Operating Instructions

Rugged and reliable the Flotect® L4 Level switch operates automatically SPECIFICATIONS
to indicate tank level. Perfect for starting or stopping pumps, opening or Service: Liquids compatible with wetted materials.
closing valves, or actuate level alarm signals. A unique magnetically Wetted Materials:
actuated switching design gives superior performance. There are no Float and Rod: 316 SS;
bellows, springs, or seals to fail. Instead, the free-swinging float attracts Body: Brass or 316 SS standard;
a magnet within the solid metal switch body, actuating a snap switch by Magnet Keeper: 430 SS standard, 316 SS or nickel optional.
means of a simple lever arm. Float arm hinge design limits the arm angle Temperature Limits: 4 to 275°F (-20 to 135°C) standard, MT high
to prevent vertical hangup. temperature option 400°F (205°C) [MT option not UL, CSA, ATEX or
IECEx]. ATEX, IECEx options: Ambient temperature -4 to 163°F (-20 to
73°C); Process temperature -4 to 163°F (-20 to 73°C).
FEATURES Pressure Limit: Brass body 1000 psig (69 bar), 316 SS body 2000 psig
• Leak proof body machined from bar stock (138 bar). Standard float rated 100 psig (6.9 bar). For other floats see
• Choice of floats dependent on maximum pressure and specific gravity model chart on next page.
• Weatherproof, designed to meet NEMA 4 Enclosure Rating: Weatherproof and Explosion-proof. Listed with UL
• Explosion-proof (listings included in specifications) and CSA for Class I, Groups C and D; Class II, Groups E, F, and G.
• Installs directly and easily into tank with a thredolet or flange ATEX 0518 II 2 G Ex d IIB T6 Gb -20°C≤Tamb≤73°C.
(see application drawings on page 4) -20°C≤Process Temp≤73°C.
• Electrical assembly can be easily replaced without removing the unit EC-Type Certificate No.: KEMA 03 ATEX 2383.
from the installation so that the process does not have to be shut down ATEX Standards: EN60079-0: 2009; EN60079-1: 2007.
• Horizontal installation or optional top mount vertical installation IECEx Certified: For Ex d IIB T6 Gb -20°C≤Tamb≤73°C. -20°C≤Process
Temp≤73°C.
APPLICATIONS IECEx Certificate of Conformity: IECEx DEK 11.0071.
• Direct pump control for maintaining level IECEx Standards: IEC 60079-0: 2007; IEC 60079-1: 2007.
• Automatic tank dump operations Switch Type: SPDT snap switch standard, DPDT snap switch optional.
• Control levels or provide alarms in sumps, scrubber systems, hydro- Electrical Rating: UL, FM, ATEX or IECEx models: 10A @ 125/250 VAC
pneumatic tanks, low pressure boilers, and various waste (V~). CSA models: 5A @ 125/250 VAC (V~); 5A res., 3A ind. @ 30 VDC
water/sewage treatment processes (V ). MV option: 1A @ 125 VAC (V~); 1A res., .5A ind. @ 30 VDC (V ).
MT option: 5A @ 125/250 VAC (V~). [MT and MV option not UL, CSA, FM,
ATEX or IECE].
Electrical Connections: UL and CSA models: 16 AWG, 6˝ (152 mm)
long. ATEX or IECEx unit: terminal block.
Process Connection: 1-1/2˝ male NPT standard, 2-1/2˝ male NPT
standard optional floats.
Mounting Orientation: Horizontal installation standard, optional vertical
top mount.
Weight: 4 lb 9 oz (2.07 kg).
Dead Band: 3/4˝ (19 mm) for standard float.
Specific Gravity: 0.7 minimum with standard float. For other floats see
model chart.

W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com


P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A. Fax: 219/872-9057 e-mail: [email protected]
Example L4 SS D C F 2 C 1 L4-SS-D-C-F2C1
Construction L4 Side Mount, Brass Body, SPDT Switch
L4-TOP Top Mount, Brass Body, SPDT Switch (Specify rod length)
Wetted Material SS 316 SS Body with 430 SS Magnet Keeper
Options 316 316 SS Body and Magnet Keeper (Order with SS option)
NI Nickel 20 Magnet Keeper
Switch Options D DPDT Switch
Float Options 50 2-1/2˝ Spherical, 304 SS rated 50 psi (3.5 bar), > 0.5 s.g.
150 2-1/2˝ Spherical, 316 SS rated 150 psi (10.3 bar), > 0.7 s.g.
300 2-1/2˝ Spherical, 304 SS rated 300 psi (20.7 bar), > 0.7 s.g.
Other Options AT ATEX
IEC IECEx
EPOXY Epoxy Coated Housing
MT High Temperature* (See specifications for rating)
MV Gold Contact Snap Switch* (See specifications for rating)
NB Neoprene Boot*
NH No Electrical Housing*
TBC Terminal Block Wire Connections*
TRD Time Delay Relay* (On flow decrease)
TRI Time Delay Relay* (On flow increase)
Flange* F Flange Process Connection
Flange Size 2 2˝
3 3˝
4 4˝
Flange Material C Carbon Steel
S 316 SS
Flange Rating 1 150 #
3 300 #
6 600 #
9 900 #
Bushing* B Bushing Process Connection
Bushing Size 1 2˝
2 2-1/2˝
4 4˝
Bushing Type H Hex
F Flush
Bushing B Brass
Material C Carbon Steel
S 316 SS
4 304 SS
* Options that do not have ATEX or IECEx
Attention: Units without the “AT” suffix are not Directive 94/9/EC (ATEX) compliant. These units are not intended for use in potentially hazardous atmospheres in the EU.
These units may be CE marked for other Directives of the EU.

FLOAT ARM & BLOCK SWITCH BODY 1-1/2 MALE NPT


FLOAT 316 STNLS. STL. BRASS OR MOUNTING CONNECTION
316 STNLS. STL OR BRASS 316 STNLS. STL. 16 GA. LEADS
(STANDARD) 6 [152.40] LONG

Ø1-5/8
Ø2-1/2 PARTS LIST
[63.50] 3-11/32
[41.28] [84.93]
MAGNET 1. Cover lock. (ATEX/IECEx unit only).
5 6 3
[127.00] [152.40] KEEPER [76.20]
430 STNLS. 5 3/4 FEMALE NPT 2. External ground. (ATEX/IECEx unit only).
STL. [127.00] CONDUIT
8-7/32
[208.76]
CONNECTION 3. Enclosure housing and cover.
19-7/32
[488.16] 4. Terminal block. (ATEX/IECEx unit only,
UL/CSA unit has 6˝ leads).
UL/CSA unit
5. Internal ground.
6 5 3 2 1
1-1/2 NPT *6. Magnet arm and switch assembly.

7. Switch body.
2-1/2
1-5/8 [63.50] 3-11/32
[41.28] [84.93] *8. Float, arm and block assembly.
5 6 *Approved replacement parts
[127.00] [152.40] 3
[76.20] 3/4 NPT
5
8-7/32 [127.00]
[208.76]
19-7/32
[488.16]
ATEX/IECEx unit
Bulletin E-73

INSTALLATION NOTE: ATEX and IECEx units only: The temperature class is
determined by the maximum ambient and/or process temperature. Units
NOTES: are intended to be used in ambient of -20°C ≤Tamb≤73°C. Units may be
• Check all ratings given in the instructions and on the product to make used in process temperatures up to 133°C providing the enclosure and
sure that the product is suitable for your application. Do not exceed switch body temperature do not exceed 73°C. The standard
electrical ratings, pressure ratings, or temperature ratings of the product. Temperature Class is T6 Process Temp ≤73°C.

• Disconnect power supply before beginning installation to prevent 5. For units supplied with both internal ground and external bonding
possible equipment damage or electrical shock. terminals, the ground screw inside the housing must be used to ground
the control. The external bonding screw is for supplementary bonding
1. Remove packing material from switch body-cap and remove tape from when allowed or required by local code. When external bonding
magnet keeper. Install standard switch in thredolet previously welded to conductor is required, conductor must be wrapped a minimum of 180°
tank. Install optional switch mountings per application drawings. Make about the external bonding screw. See below.
sure locknuts on float are tight.

2. When mounting switch in the side of a tank, the arrow on the side of
LOCKWASHER CONDUCTOR
the switch must point up.
SCREW
3. Wiring: UL and CSA units only: Thread connecting wires through
conduit and connect. Wire in accordance with local electrical codes.
Black - Common
Blue - N.O.
Red - N.C.

NOTE: Double pole, double throw switches have dual black, blue and
red leads. These are connected in the same manner as single pole,
double throw switches, as described above. CLAMP

ATEX and IECEx Installation Instructions: FRONT VIEW DETAIL SIDE VIEW DETAIL
Cable Connection
The cable entry device shall be certified in type of explosion
protection flameproof enclosure “d”, suitable for conditions of use
and correctly installed. Cable entry may exceed 70°C. Conductors
and cable gland rated ≥90°C shall be used.

Conduit Connection
An Ex d certified sealing device such as a conduit seal with setting
compound shall be provided immediately to the entrance of the
valve housing. Cable entry may exceed 70°C. Conductors and cable
gland rated ≥90°C shall be used. SPDT DPDT

TERMINAL CONNECTIONS
NOTE: The switch is deactivated and contacts are in normal condition
when the liquid is below the float.

4. Make sure conduit or cable are properly sealed. Electrical


components must be kept free of moisture, including condensation, at all MAINTENANCE
times. Inspect and clean wetted parts at regular intervals. The cover should be
in place at all times to protect the internal components from dirt, dust,
CAUTION: To prevent ignition of hazardous atmosphere, disconnect the and weather, and to maintain hazardous location ratings. Disconnect
device from the supply circuit before opening. Keep assembly tightly device from the supply circuit before opening to prevent ignition of
closed when in operation. hazardous atmosphere. Repairs to be conducted by Dwyer Instruments,
Inc. Units in need of repair should be returned to the factory prepaid.

Limited Warranty: The Seller warrants all Dwyer instruments and equipment to be free from defects in workmanship or material under normal use and service for a period
of one year from date of shipment. Liability under this warranty is limited to repair or replacement F.O.B. factory of any parts which prove to be defective within that time or
repayment of the purchase price at the Seller’s option provided the instruments have been returned, transportation prepaid, within one year from the date of purchase. All
technical advice, recommendations and services are based on technical data and information which the Seller believes to be reliable and are intended for use by persons
having skill and knowledge of the business, at their own discretion. In no case is Seller liable beyond replacement of equipment F.O.B. factory or the full purchase price. This
warranty does not apply if the maximum ratings label is removed or if the instrument or equipment is abused, altered, used at ratings above the maximum specified, or otherwise
misused in any way.

THIS EXPRESS LIMITED WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER REPRESENTATIONS MADE BY ADVERTISEMENTS OR BY AGENTS AND ALL
OTHER WARRANTIES, BOTH EXPRESS AND IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE FOR GOODS COVERED HEREUNDER.

Buyers Remedies: THE BUYER’S EXCLUSIVE AND SOLE REMEDY ON ACCOUNT OF OR IN RESPECT TO THE FURNISHING OF NON-CONFORMING OR DEFECTIVE
MATERIAL SHALL BE TO SECURE REPLACEMENT THEREOF AS AFORESAID. THE SELLER SHALL NOT IN ANY EVENT BE LIABLE FOR THE COST OF ANY LABOR
EXPENDED ON ANY SUCH MATERIAL OR FORM ANY SPECIAL, DIRECT, INDIRECT OR CONSEQUENTIAL DAMAGES TO ANYONE BY REASON OF THE FACT THAT
IT SHALL HAVE BEEN NON-CONFORMING OR DEFECTIVE.
APPLICATION DRAWINGS FOR FLOTECT®
AUTOMATIC FLOAT SWITCHES

1-1/2 THREDOLET
CUT HOLE 1-15/16 [49] DIA.

STANDARD INSTALLATION

ANSI RF
3/4 NPT
THREADED
REDUCING
ANSI RF THREADED
FLANGE
REDUCING FLANGE

11-3/4
3/4 NPT
[298.5]
*FLANGE FACE TO CENTERLINE OF FLOAT
SPECIFIED BY CUSTOMER NORMALLY HORIZONTAL, FLANGE INSTALLATION
SHOULD NOT EXCEED 20' [508 MM].
VERTICAL, FLANGE INSTALLATION

2-1/2 CUT HOLE


THREDOLET 2-7/8 [73] DIA.

2-1/2 X 1-1/2
FACE BUSHING

HORIZONTAL, 2-1/2 THREDOLET INSTALLATION


WITH OPTIONAL 2-1/2 [64] SPHERICAL FLOAT

© Copyright 2014 Dwyer Instruments, Inc. Printed in U.S.A. 9/14 FR# 82-440631-00 Rev. 5

W.E. ANDERSON DIV., DWYER INSTRUMENTS, INC. Phone: 219/879-8000 www.dwyer-inst.com


P.O. BOX 358 • MICHIGAN CITY, INDIANA 46360 U.S.A. Fax: 219/872-9057 e-mail: [email protected]
Fluid Level / Temperature Indicators Dimensions / Technical Data / Order Codes

Level Gauge § Type SNA


Design of Scale Plates Thermometer Options
Capillary Tube Thermometer
A with a dual Celsius / Fahrenheit
D scale up to +80 °C / +180 °F
C B

YOUR LOGO
80 180
70 160
60 140
50 120

L2

L3

L1
40 100
30
80
20
60
10
40
0
-10 20
C F

20
40 60
80
S N X S-T
0 100
Dial Thermometer with
Probe T1/T2 (optional)
Clearance Hole:
E F Ø13 (Ø.51) for M12 / Ø10,5 (Ø.41) for M10 /
Ø13,5 (Ø.53) for UNC, UNF and UNEF

Characteristics Dimensions Maximum admissible tolerance for the bolt center spacing (dimension L2) according to DIN ISO 2768-f: ±0,20 mm / .008 in for all nominal sizes.

Visual fluid level indication in hydraulic reservoirs with Nominal Size Dimensions (mm/in)
maximum tank pressures not exceeding 2 bar / 29 PSI A B C (Max.) D E F (with T1) F (with T2) L1 L2 L3
45 34,5 8 27 43,5 165,5 265,5 108 76 31
SNA 076
1.77 1.36 .32 1.06 1.71 6.52 10.45 4.25 2.99 1.22
Nominal Sizes and Designs 45 34,5 8 27 43,5 165,5 265,5 159 127 76
ƒƒ 6 nominal sizes from 76 mm / 2.99 in to 305 mm / 12.00 in SNA 127
1.77 1.36 .32 1.06 1.71 6.52 10.45 6.26 5.00 2.99
ƒƒ Display either undivided (SNA 076 ... 176) or subdivided 45 34,5 8 27 43,5 165,5 265,5 182 150 99
SNA 150
by strut(s) into 2 (SNA 254) or 3 sections (SNA 305) 1.77 1.36 .32 1.06 1.71 6.52 10.45 7.17 5.91 3.90
45 34,5 8 27 43,5 165,5 265,5 208 176 124
SNA 176
1.77 1.36 .32 1.06 1.71 6.52 10.45 8.19 6.93 4.88
Please see page E5 for alternative nominal sizes and designs. 45 34,5 8 27 43,5 165,5 265,5 285 254 192
SNA 254
1.77 1.36 .32 1.06 1.71 6.52 10.45 11.22 10.00 7.56
Media Compatibility 45 34,5 8 27 43,5 165,5 265,5 336 305 244
SNA 305
ƒƒ Suitable for use with Mineral and Petroleum based 1.77 1.36 .32 1.06 1.71 6.52 10.45 13.23 12.00 9.61
hydraulic fluids (HL and HLP)
Order Codes
Materials
ƒƒ Housing made of Steel St 12, black epoxy-coated
ƒƒ Sight tube and plugs made of Polyamide (PA) SNA 127 B - S - O - 12 - O - 60
ƒƒ Sealings made of NBR (Buna-N®)
ƒƒ Scale plate made of PVC

Special sight tube materials for improved UV or chemical


resistance and use with special media (such as bio-degradable a Type f Banjo Bolt Size
fluids, diesel oils, gasolines, etc.) as well as special sealing Level Gauge with visual fluid level indication SNA Metric ISO thread M12 (standard option) 12
materials, e.g. FPM (Viton®), and scale plate materials, Metric ISO thread M10 10
e.g. Aluminium, are available on request. b Nominal Size Unified coarse thread 1/2–13 UNC U1
SNA 076 (nominal size of 76 mm / 2.99 in) 076 Unified fine thread 1/2–20 UNF U2
Please see page E5 for alternative housing materials. SNA 127 (nominal size of 127 mm / 5.00 in) 127 Unified extra-fine thread 1/2–28 UNEF U3
SNA 150 (nominal size of 150 mm / 5.91 in) 150
Technical Data SNA 176 (nominal size of 176 mm / 6.93 in) 176 g Thermo Switch / Temperature Sensor Option
ƒƒ IP 65 protection rating: Dust tight and protected SNA 254 (nominal size of 254 mm / 10.00 in) 254 Supplied without Thermo Switch / Temperature Sensor -
against water jets (IP 67 on request) SNA 305 (nominal size of 305 mm / 12.00 in) 305 Thermo Switch TS-SNA/SNK; Break contact
O
ƒƒ Operating temperature range: (normally closed); Equipped with standard connector
-30 °C ... +80 °C / -22 °F ... +176 °F Please see page E5 for alternative nominal sizes. Thermo Switch TS-SNA/SNK; Break contact
OD
ƒƒ Recommended tightening torque: 8 N·m / 5.9 ft·lb (normally closed); Equipped with connector M12
c Sealing Material Thermo Switch TS-SNA/SNK; Make contact
C
Accessories / Options NBR (Buna-N®) (standard option) B (normally open); Equipped with standard connector
ƒƒ Red / blue capillary tube thermometers with a dual FPM (Viton®) V Thermo Switch TS-SNA/SNK; Make contact
CD
Celsius / Fahrenheit scale and a temperature display (normally open); Equipped with connector M12
range of up to +80 °C / +180 °F d Design of Scale Plate Temperature Sensor TS-SNA/SNK-PT100;
PT100
ƒƒ Dial thermometers with probe and a Celsius or a dual Celsius / With STAUFF logo (standard option) S Equipped with connector M12
Fahrenheit scale with a temperature display range of up to Neutral design without any logo N
+100 °C / +200 °F Custom-designed scale plate (please specify) X Thermo Switches / Temperature Sensors only available for
ƒƒ Thermo Switches banjo bolt size M12. Please see pages E8 and E9 for details.
ƒƒ Temperature Sensors e Thermometer Option
Supplied without thermometer O h Switching Temperature
Please see pages E8 and E9 for details. Red Capillary Tube thermometer on scale plate T Contact switches at +60 °C / +140 °F 60
Blue Capillary Tube thermometer on scale plate TB Contact switches at +70 °C / +158 °F 70
Dial thermometer with probe (200 mm / 7.87 in) Contact switches at +80 °C / +176 °F 80
T1C
and a Celsius scale up to 100 °C Contact switches at +90 °C / +194 °F 90
Dial thermometer with probe (300 mm / 11.81 in)
T2C
and a Celsius scale up to 100 °C Only to be indicated when using a Thermo Switch.
Dial thermometer with probe (200 mm / 7.87 in)
T1CF
and a dual scale up to 100 °C / 200 °F Options T1C/CF and T2C/CF are not available for
Dial thermometer with probe (300 mm / 11.81 in) banjo bolt size M10 and not be used in conjunction with
T2CF
and a dual scale up to 100 °C / 200 °F Thermo Switches or Temperature Sensors.
Please see page E8 for details.

Dimensional drawings: All dimensions in mm (in).


E4 www.stauff.com

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Special Options: Characteristics / Inquiry Checklist Fluid Level / Temperature Indicators

Level Gauge (Special Options) § Type SNA


Characteristics
Visual fluid level indication in hydraulic reservoirs with Materials
maximum tank pressures not exceeding 2 bar / 29 PSI; ƒƒ Housing made of Steel, Aluminium or Stainless Steel
ideal for custom applications in terms of reservoir ƒƒ Sight tube and plugs made of Polyamide (PA)
capacities and dimensions ƒƒ Sealings made of NBR (Buna-N®)
ƒƒ Scale plate made of PVC
Nominal Sizes ƒƒ Floating element made of Polyamide (PA)
ƒƒ Special sizes beyond the normal of 305 mm / 12 in
up to a maximum nominal size of 950 mm / 37.4 in – Special sight tube materials for improved UV or chemical
even for small and medium quantities resistance and use with special media (such as bio-degradable
ƒƒ High-precision manufacturing within 1 mm fluids, diesel oils, gasolines, etc.) as well as special sealing
tolerance to customer requirements materials, e.g. FPM (Viton®), and scale plate materials,
e.g. Aluminium, are available on request.
Design
ƒƒ Robust design thanks to one or more struts that Please also ask for our special low-temperature versions,
subdivide the display into 2 or more sections suitable for extreme temperatures up to -40 °C / -40 °F.
ƒƒ Positioning of the strut(s) based on engineering
considerations and/or according to particular Accessories / Options
customer requirements ƒƒ Capillary tube thermometers with a dual
ƒƒ Precise visual indication of the fluid level by use Celsius / Fahrenheit scale and a temperature display
of scale plates (only available for nominal sizes range of up to +80 °C / +180 °F
smaller than 670 mm / 26.4 in) or by use of a ƒƒ Dial thermometers with probe and a Celsius or a dual Celsius /
coloured floating element (recommended option Fahrenheit scale with a temperature display range of up to
for nominal sizes larger than 670 mm / 26.4 in) +100 °C / +200 °F
ƒƒ Plastic dampening clips to reduce vibration ƒƒ Thermo switches
of the sight tube are used for nominal sizes larger ƒƒ Temperature sensors
than 450 mm / 17.7 in
Please see pages E8 and E9 for details.

Inquiry Checklist

In case that you require a special property or custom-designed level gauge, please use this checklist to provide us
with details. If necessary, please also include further details, like the type of fluid in use, its temperature and viscosity.

Nominal Size Bolt centre distance (in mm)

Housing Material Aluminium Steel Stainless Steel

Housing Design Regular housing design with positioning of strut(s) based on engineering considerations

Please provide additional details / drawing for custom housing designs.

Accessories
Hydraulic
Banjo Bolt Size M12 M10 1/2–13 UNC

1/2–20 UNF 1/2–28 UNEF

E
Banjo Bolt Material Steel Stainless Steel

Sealing Material NBR (Buna-N®) FPM (Viton®) EPDM

Alternative sealing materials to be defined separately.

Level Indication Scale plate (only for nominal sizes smaller than 670 mm / 26.4 in)

Scale plate made of PVC With STAUFF logo


Scale plate made of Aluminium Neutral design without any logo
Custom-design (please specify)

Without thermometer on scale plate


Capillary tube thermometer with dual Celsius / Fahrenheit scale up to +80 °C / +180 °F

Floating element (recommended option for nominal sizes larger than 670 mm / 26.4 in)

Other types of level indication (magnetic floats, etc.) to be defined separately.

Options Dial thermometer with probe

Celsius scale up to +100 °C Length of probe: 200 mm / 7.87 in


Dual scale up to +100 °C / +200 °F Length of probe: 300 mm / 11.81 in

Thermo Switch TS-SNA/SNK

Break contact; Standard connector Contact switches at +60 °C / +140 °F


Break contact; Connector M12 Contact switches at +70 °C / +158 °F
Make contact; Standard connector Contact switches at +80 °C / +176 °F
Make contact; Connector M12 Contact switches at +90 °C / +194 °F

Temperature Sensor TS-SNA/SNK-PT100

www.stauff.com E5

HZB-27-03-2012-EN.indd 5 29.03.2012 10:23:16


Maintenance
Manual for

Standard
Hydraulic
Power Units
Maintenance Manual
Standard Hydraulic Power Units

Table of Contents Page

Introduction .... 1
Description .. . ... 1
Preparation for Use . . . . . . . . . . . . . . . . ...... 2
Unpacking and Checking
Storage
Removing from Shipping Skids
Installation . . . . . . . ..... 2
Locating Power Unit
Service Connections
Supply and Return Connections
Reservoir Inspection
Reservoir Filling
Coupling Alignment
Start Up Procedure ........ . . ... 5
Special Tools .. . ... 6
General Maintenance ........ . . ..... 6
Recommended Spare Parts ..... . . ... 6
Reference Data ... 6

Filter Service ... 6


Maintaining Oil Temperature ............................ . ... 7
Troubleshooting .... . .. 9
Maintenance Manual
Standard Hydraulic Power Units

Introduction
This manual provides descriptive information, operation and maintenance instruc-
tions for standard Hydraulic Power Units manufactured by the Power Unit Division
of Parker Hannifin Corporation, Orrville, Ohio 44667. Any additional information
may be obtained from the Power Unit Division by referencing to the Unit's Model
Number and Serial Number stamped on the Reservoir Nameplate, or by
contacting your authorized Parker Distributor.

Some of the information in this manual may not apply to your power unit, and
information on more custom units may require obtaining service and application
information from other sources.

Warning
It is imperative that personnel involved in the installation, service, and operation of
the power unit be familiar with how the equipment is to be used, the limitations of
the system and it's component parts, and have knowledge of good hydraulic
practices in terms of safety, installation, and maintenance.

Description
The standard Hydraulic Power Unit usually consists of a JIC reservoir (see
figure 1), or "L" shaped reservoir (see figure 2) both of which incorporate a baffle,
clean-out access, 314 NPT sump drain, oil level gage, filter/breather assembly and
spare return connections.

The pump will be coupled to the motor using a flexible shaft coupling and will be
mounted using a bell housing (requires NEMA "C" Motor) or will be foot mounted
requiring a pump foot bracket, coupling guard, and pump/motor mounting plate.
Also included on most standard units is a Pump Suction Filter (or Suction Strainer),
Relief Valve, and a Pressure Gauge with Shut-Off Valve.

More custom type power units may have heat exchangers for oil cooling; pressure
or return filters, oil immersion heaters, directional valves, and other pressure and
flow control valves, or monitoring instrumentation.

Preparation For Use


Unpacking and Checking
The Power Unit is mounted on skids and carefully packed for shipment. Do not
remove it from skid until it has been carefully checked for damage that may have
occurred in transit. Report all damage immediately to the carrier and send a copy

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Maintenance Manual
Standard Hydraulic Power Units

to the vendor. All open ports on the Power Unit were plugged at the factory to pre-
vent the entry of contamination. These plugs must not be removed until just before
piping connections are made to the unit.

Storage
If the Power Unit is not going to be installed immediately, it should be stored in-
doors, covered with plastic sheet, and all open ports plugged. If long term storage
is expected (6 months or more) we recommend filling the reservoir completely with
clean hydraulic fluid to prevent the entry of moisture.

Removing from Shipping Skids


Small JIC style Power Units should be moved with a fork-lift truck, with 2X4 boards
under the reservoir belly, to distribute and steady the load. Larger JIC style Power
Units have lifting holes in the reservoir end plates. Extra heavy 1 1/2 pipes can be
inserted into the lifting holes for allowing movement with a fork-lift truck. L-shaped
reservoirs are provided with clearance and cross braces under the base plate for
movement with a fork-lift truck.

Installation
Locating Power Unit
The unit should be installed indoors, and preferably in a clean dry environment
with an ambient temperature of 60 to 100°F. The unit can be installed outdoors if
the reservoir was provided with optional weatherproof construction, and provisions
were made for extreme temperature conditions. The reservoir can be secured to
the floor or base using the four mounting holes located on the reservoir legs.

Service Connections
Water (If water cooled heat exchanger has been provided) Connect the water sup-
ply to the inlet of the heat exchanger, with a shut-off valve and strainer (if not sup :
plied by Parker). If a Temperature Control Valve (Model WTC-* *)has been provid-
ed, it also should be installed on the inlet side. The outlet of the hear exchanger
should be connected directly to the facility drain system. On single pass heat ex-
changers the water connections should be installed as shown below. On multi-pass
heat exchanger the water flow direction is not important.
Oil In 011 Out Temperature
Control Shut-off
Water Valve Water
Strainer Inlet
Outlet .---a------.....L.....,

Heat Exchanger

Oil Sen sing Bulb

-2-
Maintenance Manual
Standard Hydraulic Power Units

Electrical Connect the pump motor to the facility power source following good
practices as outlined in the National Electric Code and any local codes which may
apply. Verify that the available voltage is the same as the voltage identified on the
motor nameplate. Most motors have dual voltage ratings, so verify that the leads
in the conduit box have been connected together as defined on the motor
nameplate to match the facility power source available.

If Solenoid valves, pressure/temperature switches, or oil immersion heaters have


been provided on the power unit, refer to the component nametag or other service
information in this manual for operating voltage and ratings.

Supply and Return Connections


Complete all necessary interconnecting piping between the power unit and
hydraulic actuators. The line sizes should be determined based on oil
flow, operating pressure and allowable pressure drop between the power unit
and actuator.

Warning
Check to insure that the proper rated hose or pipe is used on pressure lines.

One of the key ingredients for good service and long life from a hydraulic system
is cleanliness, and since it has been our experience that most dirt infiltrates
a hydraulic system during installation, we recommend the following rules be
adhered to:
a) All open ports on the power unit, cylinders, etc. must remain plugged
with tape or plastic plugs until just before the hydraulic connections are
made.
b) All interconnecting tubing, pipe, or hose should be clean, and free of rust,
scale and dirt. The ends of all connectors should be plugged until just
before they are to be installed in the system.
c) All openings in the reservoir such as the filler breather or access end
covers holes must remain closed during installation.
d) If Teflon tape, or pipe dope is used, be sure it doesn't extend beyond the
first thread of the pipe fitting.

-3-
Maintenance Manual
Standard Hydraulic Power Units

Reservoir Inspection
The reservoir has been thoroughly cleaned and sprayed with rust inhibitor at
Parker prior to shipping. It is suggested, however, to remove the reservoir access
covers and re-inspect the tank for cleanliness. JIC reservoirs are provided with a
removable baffle for greater access for cleaning.

Note
On JIC reservoirs it is important for the baffle to be centered in the tank, and for
the sealing gaskets to take a good set if the end covers are to seal properly.
Reinstall end covers as follows:
a) Locate the baffle in the center of the tank.
b) Install end covers hand tight, being careful not to move the baffle.
c) Torque one cover a small amount, and then torque the opposite end
cover a small amount more. Continue going back and forth between the
covers until both are torqued equally. (See figure 1 for proper torque
value.)

Reservoir Filling
The reservoir must be filled with clean fluid thru the filler cap on the reservoir.
The type of fluid must be compatible with the seals used on the power unit, and
must comply with the recommendations of the manufacturers of the component
parts.

Refer to the component manufacturer's catalog for fluid requirements.


The cleanliness of the fluid going into the reservoir is very important, and in some
cases, even new oil out of the drum is not adequate. We recommend that any
fluid being transferred into the reservoir be done with a transfer pump with a 10
micron filter installed. A Parker filter cart is available for this purpose.

Coupling Alignment
It is possible for pump/motor shaft alignment to be incorrect because of shock in-
curred during shipping. The alignment should be re-checked before start-up.
If the pump/motor assembly has been foot mounted, the coupling alignment should
be checked using the coupling installation instructions provided in the appendices
of this manual. If re-aligning is required, the motor mounting bolts should be
loosened, and shims inserted. Note, see figure 3 for Lovejoy or Magnaloy couplings.

If the pump/motor assembly has been mounted with a bell-housing, the only
check required is to verify that the coupling halves have adequate clearance, and
that the coupling set-screws are tight. A slot is provided in the bell housing for this
purpose.

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Maintenance Manual
Standard Hydraulic Power Units

Start-Up Procedure
1) Open any ball or gate valve (if applicable) located in the pump suction
line.
2) Back the system relief valve and/or pump pressure compensator adjust-
ment knob out, so that the pressure will be near zero during the initial
start.
Note
If the power unit has been provided with a variable displacement pump or
any piston pump, the pump case should be filled with clean oil prior to
priming. In most cases this can be accomplished by disconnecting the
pump case drain line and pouring the oil into the pump case drain port.
3) If the system has been provided with an open center directional valve,
the oil during start-up will flow directly back to tank. If the system has a
closed centered valve, it may be necessary to loosen a fitting momen-
tarily at the pump discharge, to bleed any air in the pump during the
priming operation.
4) Jog the pump motor once, and verify that the pump is rotating in the
same direction as the arrow tag on the pump case. If the direction is in-
correct, reverse two (2) of the three (3) motor leads, and recheck the
rotation.
5)Jog the pump motor (3) to (6) times to prime the pump and allow the
pump to run for several minutes at zero pressure. Check the piping for
any leaks and correct immediately. (Leaks in fittings and tubing can be
the result of vibration during shipping.)
6) Begin adjusting the relief valve and/or pump compensator to increase the
pressure gradually. Note; on systems with open center directional valves,
it will be necessary to actuate the valve to build pressure.
?)Continue increasing pressure until normal operating pressure is obtained,
and recheck system for leaks. Lock adjustment screws in place.
Note
If the system has been provided with a pressure compensated pump and
a relief valve, adjust the relief valve approximately 10% higher than the
compensator so that excessive heat is not generated by the relief valve.
8) During the start-up sequence, all filters should be monitored closely.
Replace any filters element immediately, as soon as they begin to go into
by-pass as indicated on the visual indicator.
9)After the entire system has been wetted with fluid, refill the reservoir to
the normal operating level.
10) Verify that the cooling water to the hear exchanger (if applicable) is flow-
ing. If the power unit has been provided with a water control valve (Model
WTC-* *), and the oil temperature is exceeding 135°F, adjust the valve to
increase the water flow.

-5-
Maintenance Manual
Standard Hydraulic Power Units

Special Tools
All normal service and maintenance on standard power units can be accomplished
with standard handtools. No special tools are required.

General Maintenance
Electric Motors · Lubricate as recommended by the motor manufacturer.
Filters · Change or clean as required or as indicated on filters supplied with visual
indicators.
Suction Strainers · Should be cleaned after 10 hours operation and 100 hours
thereafter. See appendicies for cleaning instructions.
Reservoirs· Maintain oil level at all times. The oil should be checked after the first
100 hours and verify that the class of oil meet the requirements of the pump being
used. Change the oil every 1000 to 2000 hours depending on the application and
operation environment.
Components · See component literature in appedicies.

Recommended Spare Parts


Spare filter elements should be purchased with the power unit, and be available
during the start-up operation. Other spare parts may be required, and are a
function of the duty cycle of the hydraulic system, operation environment, and the
acceptable down time of the equipment.

Preventive Maintenance
Filter Service
Filters must be maintained. The key to good filtration is filter maintenance.
A machine may be equipped with the best fUters available and they may be posi-
tioned in the system where they do the most good; but, if the filters are not taken ·
care of and cleaned when dirty, the money spent fot the filters and their installa-
tion has been wasted. A filter which gets dirty after one day of service and is
cleaned 29 days later gives 29 days of non-filtered fluid. A filter can be no better
than the maintenance afforded it.

NEEDS CLEANING

BY-PASSING

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Maintenance Manual
Standard Hydraulic Power Units

Maintenance Suggestions
1) Set up a filter maintenance schedule and follow it dilligently.
2) Inspect filter elements that have been removed from the system for signs
of failure which may indicate that the service interval should be
shortenend and of impending system problems.
3) Do not return to the system any fluid which has leaked out.
4) Always keep the supply of fresh fluid covered tightly.
5) Use clean containers hoses, and funnels when filling the reservoir. Use
of a filter cart when adding oil is highly recommended.
6) Use common sense precautions to prevent entry of dirt into components
that have been temporarily removed from the circuit.
7) Make sure that all clean-out holes, filler caps, and breather cap filters on
the reservoir are properly fastened.
8) Do not run the system unless all normally provided filtration devices are
in place.
9) Make certain that the fluid used in the system is of a type recommended
by the manufacturers of the system or components.
10) Before changing from one type of fluid to another (e.g., from petroleum
base oil to a fire resistant fluid), consult component and filter manufac-
turers in selection of the fluid and the filters that should be used. Also
consult the publication "Recommended Practice for the use of Fire
Resistant Fluids for Fluid Power Systems" published by the National
Fluid Power Association.
11) Parker offers an oil sampling kit which can be used to ascertain the
condition of the system fluid.

Maintaining Proper Oil Temperature


Hot oil in your equipment's hydraulic system is one of the primary causes of poor
operation, component failure and downtime. Here are some pointers on maintain-
ing proper oil temperature.

The oil in your hydraulic system was designed for operation within a specified
temperature range. You may be able to run it at hotter temperatures for short
periods of time, intermittently, without bad effects. If you run continuously with oil
that's too hot, however, your equipment will operate poorly, and eventually key
components will fail and halt your machine.

-7-
Maintenance Manual
Standard Hydraulic Power Units

How Hot is "Too Hot"?


"Hot oil" is a relative term. In most cases, 120°F. at the reservoir is considered an
ideal operating temperature. Always take an oil temperature reading at the
reservoir, not at a component or any of the piping.

Some hydraulic systems are designed to operate at 130°F. or higher. If you don't
know the maximum operating temperature for your equipment, check your component
manual for temperature and viscosity limitations.

Measuring Oil Temperature


There are several ways to check the temperature of the oil. The best, most
accurate method is by means of a thermometer. On some machines, this is
mounted on the reservoir. Make it a habit to check the thermometer periodically,
after the equipment has been running for more than an hour.

If your machine doesn't have a reservoir thermometer, use the "palm test." First
check the tank with your fingertip; if it's not too hot to touch, place your palm on
the tank. You'll be able to hold it there without discomfort if the oil temperature is
about 130°F. or below.

Isolating Trouble-Spots
To determine which components are "running hot" and overheating the oil,
feel the outlet fittings and lines at the valves, pumps and motors. If the oil is
normal going into a component but hot coming out-that could be one of the
trouble-makers.

A sticking valve can cause excessive heat. If a spool does not return promptly to
the neutral position, the pump flow will be dumped continuously. This builds up
heat rapidly.

If a relief valve is set too low, part of the oil will be dumped across the valve with
every cycle. This too, generates excessive heat. Even when all valves are set
properly, they may not be operating well because of worn orifices or seals.

Always remove and check the hot components first, before the others.

Look, Smell and Feel


Checking oil temperature periodically is good preventive maintenance. So too is
the practice of periodically siphoning an oil sample from the reservoir, and com-
paring it with a sample of clean, new oil.

Oil that has been running too hot will look darker and feel thinner than new oil. It
will also smell burned. Chances are, it will contain more contaminants, because
hot oil leads to accelerated wear of component parts.

-8-
Maintenance Manual
Standard Hydraulic Power Units

Preventive Measures
How can you keep your equipment's hydraulic system from running too hot?
1) Set up a regular schedule for checking the oil temperature,
appearance, smell and feel. Change oil as recommended by the
equipment manufacturer.
2) Be prompt about removing, checking and repairing or replacing valves,
pumps or other components that are running hot.
3) If relief or flow-control valves are running hot, check and adjust their
settings. Follow your equipment owner's manual.
4) Break in new components gradually. New, close-fittings parts expand at
different rates, and are especially prone to seize when they get too hot.
5) Start a cold pump or motor on hot oil by jogging just enough to draw the
hot oil into the component. Then wait a few minutes to allow
the temperature to equalize in all the pump's parts. Repeat until
the temperature on the outside of the pump is the same as that on
the piping.
6) Keep your equipment clean. A thick layer of dirt acts as insulation. It
will prevent the hydraulic system from getting rid of heat.
7) On hot days, and in hot climates, check and change the oil more
frequently. Be sure to use an oil recommended for hot-weather operation
by the equipment manufacturer or oil supplier.

Troubleshooting
Troubleshooting Areas
Dirty oil
1) Components not properly cleaned after servicing.
2) Inadequate screening in fill pipe.
3) Air breather left off. (No air breather provided ... inadequate unit
provided ... insufficient protection of air breather.)
4) Tank not properly gasketed.
5) Pipe lines not properly covered while servicing machine.
6) Improper tank baffles not providing settling basin for heavy materials.
7) Filter dirty or ruptured.

Fire resistant fluids


1) Incorrect seals cause binding spools.
2) Paint, varnish or enamel in contact with fluids can cause sludge deposits
on filters and around seal areas.

-9-
Maintenance Manual
Standard Hydraulic Power Units

3) Electrolytic action is possible with some metals. Usually zinc or cadmium.


4) Improper mixtures can cause heavy sludge formations.
5) High temperatures adversely affect some of the fluids, particularly the
water base fluids.
6) Adequate indentificaiton of tanks containing these fluids should be provid-
ed so that they will be refilled with the proper media.
7) As with mineral base oils, nuisance leaks should be remedied at once.
8) Make certain replacement parts are compatible with fluid media.

Foaming oil
1) Return of tank line not below fluid level. Broken pipe, line left out between
a bulkhead coupling and the bottom of the tank after cleaning tank.
2) Inadequate baffles in reservoir.
3) Fluid contaminated with imcompatible foreign matter.
4) Suction leak to pump aerating oil.
5) Lack of anti-foaming additives.

Moisture in oils
1) Cooling coils not below fluid level.
2) Cold water lines fastened directly against hot tank causing condensation
within tank.
3) Soluble oil solution splashing into poorly gasketed tanks or fill pipes left
open.
4) Moisture in cans used to replace fluid in tanks.
5) Extreme temperature differential in certain geographical locations.
6) Drain not provided at lowest point in tank to remove water collected over
possibly long operating periods.

Overheating of system
1) Water shut off or heat exchanger clogged.
2) Continuous operation at relief setting.
a. Stalling under load, etc.
b. Fluid viscosity too high or too low.
3) Excessive slippage or internal leakage.
a. Check stall leakage past pump, motors and cylinders
b. Fluid viscosity too low.
4) Reservoir sized too small.

-10-
Maintenance Manual
Standard Hyd rau Iic Power Units

5) Reservoir assembled without baffling or sufficient baffling.


6) Case drain line from pressure compensated pump returning oil too close
to suction line.
a. Repipe case drain line to opposite side of reservoir baffling.
7) Pipe, tube or hose I.D. too small causing high velocity.
8) Valving too small, causing high velocity.
9) Improper air circulation around reservoir.
10) System relief valve set too high.
11) Power unit operating in direct sunlight or ambient temperature is too
high.

Foreign matter sources in the circuit


1) Pipe scale not properly removed.
2) Sealing compound (pipe dope, teflon tape allowed to get inside fittings.
3) Improperly screened fill pipes and air breathers.
4) Burrs inside piping.
5) Tag ends of packing coming loose.
6) Seal extrusions from pressure higher than compatible with the seal or
gasket.
7) Human element... not protecting components while being repaired and
open lines left unprotected.
8) Wipers or boots not provided on cylinders or rams where necessary.
9) Repair parts and replacement components not properly protected while
stored in repair depot. (Rust and other contaminants.)

Troubleshooting Pumps
Pump makes excessive noise
1) Check for vacuum leaks in the suction line. (Such as leak in fitting or
damaged suction line.
2) Check for vacuum leaks in the pump shaft seal if the pump is internally
drained. Flooding connections with the fluid being pumped may
cause the noise to stop or abate momentarily. This will locate the point of
air entry.
3) Check alignment with drive mechanism. Misalignment will cause wear
and subsequent high noise level in operation.
4) Check manufacturers specifications relative to wear possibilities and
identification of indications of wear as high operating noise level, etc.

-11-
Maintenance Manual
Standard Hydraulic Power Units

5) Check compatibility of fluid being pumped against manufacturers


recommendations.
6) Relief or unloading valve set too high. Use reliable gauge to check
operating pressure. Relief valve may have been set too high with a
damaged pressure gauge. Check various unloading devices to see that
they are properly controlling the pump delivery.
7) Aeration of fluid in reservoir (return lines above fluid level).
8) Worn or sticking vanes (vane type pump).
9) Worn cam ring (vane type pump).
10) Worn or damaged gears and housing (gear pump).
11) Worn or faulty bearing.
12) Reversed rotation.
13) Cartridge installed backwards or improperly.
14) Plugged or restricted suction line or suction strainer.
15) Plugged reservoir filter breather.
16) Oil viscosity too high or operating temperature too low.
17) Oil pour point too high.
18) Air leak in suction line or fittings also causing irregular movement of
control circuit.
19) Loose or worn pump parts.
20) Pump being driven in excess of rated speed.
21) Air leak at pump shaft seal.
22) Oil level too low and drawing air in through inlet pipe opening.
23) Air bubbles in intake oil.
24) Suction filter too small or too dirty.
25) Suction line too small or too long.
26) Pump housing bolts loose or not properly torqued.

Pump failure to deliver fluid


1) Low fluid level in reservoir.
2) Oil intake pipe suction strainer plugged.
3) Air leak in suction line and preventing priming.
4) Pump shaft turning too slowly.
5) Oil viscosity too high.

-12-
Maintenance Manual
Standard Hydraulic Power Units

6) Oil lift too high.


7) Wrong shaft rotation.
8) Pump shaft or parts broken.
9) Dirt in pump.
10) Variable delivery pumps. (Improper stroke.)

Oil leakage around pump.


1) Shaft seal worn.
2) Head of oil on suction pipe connection-connection leaking.
3) Pump housing bolts loose or improperly torqued.
4) Case drain line too small or restricted. (Shaft seal leaking.)

Excessive pump wear


1) Abrasive dirt in the hydraulic oil being circulated through the system.
2) Oi I viscosity too low.
3) System pressure exceeds pump rating.
4) Pump misalignment or belt drive too tight.
5) Air being drawn in through inlet of pump.

Pump parts inside housing broken


1) Seizure due to lack of oil.
2) Excessive system pressure above maximum pump rating.
3) Excessive torquing of housing bolts.
4) Solid matter being drawn in from reservoir and wedged in pump.

Troubleshooting Solenoid Valves


Solenoid failures
1) Voltage too low. If voltage will not complete the stroke of alternating cur-
rent (AC) solenoid it will burn out the coil.
2) Signal to both solenoids of a double solenoid valve simultaneously. One
or both of the solenoids will be unable to complete their stroke and will
burn out. (Make certain the electrical signal is interlocked so that this
condition cannot exist.)
3) Mechanical damage to leads. (Short circuit, open connections, etc.)

-13-
Maintenance Manual
Standard Hydraulic Power Units

4) Tight spool or other mechanical parts of the valve being actuated can
prevent the solenoid from completing its stroke and subsequently burning
out.
5) Replacement springs too heavy in valve. Overloads solenoid and shortens
life.
6) Wrong voltage or frequency will either prevent operation because of in-
adequate capacity to handle the load with the lower voltage or burn out
the coil because of improper winding and excessive voltage.
7) Dirty contacts may not supply sufficient current to solenoid to satisfy
inrush demands.
8) Low voltage direct current solenoids may be affected by low battery
capacity on cold mornings directly after starting cold engine.
9) Long feed lines to low voltage solenoids may cause sufficient voltage
drop to cause erratic operation.

Solenoid valve fails to operate


1) Is there an electrical signal to the solenoid or operating device? Is the
voltage too low? (Check with voltmeter ... test light in emergency.)
2) If the supply to the pilot body is orificed, is the orifice restricted? (Remove
orifice and check for foreign matter. Flushing is sometimes necessary
because of floating impediment.)
3) Has foreign matter jammed the main spool? (Remove end caps and see
that main spool is free in its movement ... remember that there will be a
quantity of fluid escaping when the cap is removed and provide a
container to catch it.)
4) Is pilot pressure available? Is the pilot pressure adequate? (Check with
gauge on main pressure input port for internally piloted types and in the
supply line to the externally piloted type.)
5) Is pilot drain restricted? (Remove pilot drain and let the fluid pour into an
open container while the machine is again tried for normal operation.
Small lines are often crushed by machine parts banging against them
causing a subsequent restriction to fluid flow.)
6) Is pilot tank port connected to main tank port where pressures are high
enough to neutralize pilot input pressure? (Combine pilot drain and pilot
tand port and check for operation with the combined flow draining into an
open container ... block line to main tank form pilot valve ... if this corrects
the situation, reroute pilot drain and tank line.)
7) Are solenoids improperly interlocked so that a signal is provided to both
units simultaneously? (Put test light on each solenoid lead in parallel and
watch for simultaneous lighting ... check electrical interlock. This condition
probably burns out more solenoids than any other factor.)

-14-
Maintenance Manual
Standard Hydraulic Power Units

8) Has mounting pad been warped from external heating? (Loosen mounting
bolts slightly and see if valve functions. End caps can also be removed
and check for tight spool.)
9) Is fluid media excessively hot? (Check for localized heating which may
indicate an internal leak ... check reservoir temperature and see if it is
within machine specifications.)
10) Is there foreign matter in the fluid media causing gummy deposits?
(Check for contamination ... make certain seals and plumbing are compati-
ble with the type of fluid being used.)
11) Is an adequate supply of fluid being delivered to actuate the load? (Many
times there is sufficient pressure to shift the valve but not enough to
actuate the work load. Check pump supply pressure and volume if
necessary ... physical measurement of flow through relief valve with units
blocked may be necessary.)
12) Check circuit for possible interlocks on pressure sources to valve or
to pilot.

-15-
Three-Phase General Purpose Motors
Three Phase General Purpose Motors W22
W22 - Cast Iron TEFC - Cast Iron

General Purpose
General Purpose

Three-Phase
Three-Phase

Motors
Motors

Standard Features:
• 50/60 Hz rated (380V on
nameplate - 400/415 available) New Cooling System
Terminal Box
• Rated 50HZ at same horsepower Fan Cover
g Aerodynamic design
Fan
g Reinforced fan hub structure
g Better connection quality

up to 250HP 1.0 Service Factor g Noise level reduction g Noise level reduction
g Easier cable handling
Features that make a difference: g Better air flow distribution over frame g Increased air flow
during installation
for 2,4 & 6 pole motors g Increased mechanical strength g Fan with higher stiffness
g More space available for
accessory installation

• Rated 50Hz at same horsepower • All NEMA Premium ratings have a 1.25 service factor (up g Easier Maintenance

to 100 HP) resulting in cooler operation and extended life g Mounting F1/F2/F3

up to 125HP 1.0 Service Factor for of the motor


g Rotation on 90° stages

8 pole motors
• All Cast Iron Construction, including Terminal Box and
• Class F insulation (impregnation Fan Cover (*)
resin and magnet wire are class • Solid feet for reduced vibration levels and impact Bearing Caps
H) absorption External
g Finned surface for
• F1 mounted (cast iron frames are • Optimized ventilation system for cooler operation and improved bearing
heat dissipation
F2 convertible). Frames 447T and extended life Internal

up can easily be F2 converted by • High Grade FC200 cast iron provides superior mechanical
g Change of grease
path for positive
simply rotating the terminal box strength and heat dissipation lubrication
g Bearing lubrication

adapter • All WEG W22 motors are Totally Enclosed Fan Cooled quality improvement
g Reduced bearing

with a true IP55 rating against dust and moisture. (IPW56,


• Cast iron frames: regreasable ball temperature
IPW65 and IPW66 available as optional)
bearings (frames 254T and up)
• Exclusive W-Seal 364T and larger provides superior
• Gasketed conduit box bearing protection
• Taconite Labyrinth seal 586 Frame and larger Seal Subsystem
• Exclusive WEG painting system exceed 200hrs ASTM 117 g Increased dust and
moisture protection
corrosion test (Exceeds IEEE841 standard) g Increased protection

Inverter Rated • Balanced to 0.08 inches per second vibration limits to high-pressure
Frame cleaning
1000:1 for Variable Torque (Meets IEEE841 standard) g Reduced temperature on windings Enhanced Lifting Provisions
NEMA Premium • Four Bolt Conduit Cover with glued Neoprene Gasket
and bearings
Noise level reduction
g Easier handling - horizontal & vertical
g Higher mechanical strength and
g
Endshields Subsystem
20:1 Constant Torque up to 250HP g Terminal box position outlet on top handling safety
• Impregnation Resin and magnet wire are insulation class H DE (Drive Endshield)
6:1 Constant Torque 300HP and up Pad for vibration sensor Solid feet
g 
g New fin design
g Displaced 90 0 from each other More impact resistance
High Efficiency (EPAct) • Stainless Steel Nameplate - Laser etched with high g 
Ideal for high vibration level
g Bearing moved outwards for better load support
Improved bearing heat dissipation for reduced bearing
contrast background
g
applications
12:1 Constant Torque up to 250HP g 
temperature
Reinforced endshield structure
4:1 Constant Torque 300HP and up • Corrosion Proof Drains
NDE (Non-Drive Endshield)
• Inverter Duty per NEMA MG1, Part 31 g New design with smooth exterior surface
g Improved air flow

ADDITIONAL TECHNICAL DATA • Certified Class I Div 2, Groups A, B, C & D; Class II, Div 2, g Noise level reduction
g Improved structural rigidity for low vibration
Groups F & G
ELECTRICAL DATA: p. B-6
• Suitable for IEEE45 and USCG 259 – Marine Duty
MECHANICAL DATA: p. C-2
*Cast iron fan cover available as an option on 143-215T frames

A-18 www.weg.net/us Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934) A-19
Three-Phase General Purpose Motors Three-Phase General Purpose Motors

TEFC – Foot Mount continued TEFC – C-Flange – Foot Mount

General Purpose
General Purpose

Three-Phase
Three-Phase

Motors
Motors

Approx. Approx. FL
FL "C" "C"
NEMA List Mult. Shipping Service FL. Eff NEMA List Mult. Shipping Service Amps FL. Eff
HP kW RPM Catalog Number Amps Dimension Voltage (V) Notes HP kW RPM Catalog Number Dimension Voltage (V) Notes
Frame Price Symbol Weight Factor (%) Frame Price Symbol Weight Factor @ (%)
@ High (in) (in)
(lbs) (lbs) High
3600 L447/9TS 45036ET3G449TS-W22 49,610 N1 3492 1.00 475 95.8 53.431 460 1 3600 143/5TC 00136ET3E143TC-W22 566 N1 43 1.25 1.43 78.5 13.346 208-230/460
1800 586/7 45018EP3G586/7-W22 46,053 W1 5204 1.15 503 95.8 61.902 460 30 1800 143/5TC 00118ET3E143TC-S 484 RSP 43 1.15 1.47 85.5 13.583 208-230/460 9
1800 L447/9T 45018ET3G449T-W22 48,010 N1 3524 1.15 501 96.2 57.181 460 1800 143/5TC 00118ET3E143TC-W22 555 N1 49 1.25 1.41 85.5 13.346 208-230/460
1800 L447/9T 45018ET3GRB449T-W22 48,010 N1 3542 1.15 501 96.2 57.181 460 14 1800 143/5TC 00118ET3ERS143TC 484 RSP 41 1.15 1.55 85.5 14.095 208-230/460 9
1 0.75
1200 586/7 45012EP3G586/7-W22 56,592 W1 4933 1.00 536 95.4 61.902 460 1;30 1800 143/5TC 00118ET3H143TC-W22 555 N1 49 1.25 1.13 85.5 13.346 575
450 330
1200 586/7 45012EP3GRB586/7-W22 56,592 W1 5248 1.00 536 95.4 61.902 460 1;14;30 1200 143/5TC 00112ET3E145TC-S 554 RSP 43 1.15 1.58 82.5 13.583 208-230/460 9
1200 586/7 45012EP3H586/7-W22 56,592 W1 5248 1.00 429 95.4 61.902 575 1;30 1200 143/5TC 00112ET3E145TC-W22 636 N1 56 1.25 1.73 82.5 13.346 208-230/460
1200 586/7 45012ET3G586/7-W22 62,251 N1 4877 1.00 532 96.2 61.902 460 1 1200 143/5TC 00112ET3ERS145TC 554 RSP 47 1.15 1.75 82.5 14.095 208-230/460 9
1200 586/7 45012ET3GRB586/7-W22 62,251 N1 5248 1.00 532 96.2 61.902 460 1;14 3600 143/5TC 00156ET3E143TC-S 497 RSP 39 1.15 1.87 84 13.583 208-230/460 9
900 588/9 45009ET3G588/9-W22 68,715 N1 5189 1.00 554 95.8 69.381 460 1 3600 143/5TC 00156ET3E143TC-W22 571 N1 48 1.25 1.91 84.0 13.346 208-230/460
3600 586/7S 50036ET3G586/7S-W22 56,305 N1 4571 1.15 530 96.2 55.027 460 3600 143/5TC 00156ET3ERS143TC 497 RSP 40 1.15 1.95 84.0 14.095 208-230/460 9
1800 L447/9T 50018ET3G449T-W22 50,594 N1 3652 1.00 561 96.2 57.181 460 1;19 3600 143/5TC 00156ET3H143TC-W22 571 N1 45 1.25 1.53 84.0 13.346 575
500 370
1800 L447/9T 50018ET3GRB449T-W22 50,594 N1 5424 1.00 561 96.2 57.181 460 1;14 1800 143/5TC 00158ET3E145TC-S 504 RSP 43 1.15 2.02 86.5 13.583 208-230/460 9
1200 586/7 50012ET3G586/7-W22 62,962 N1 4896 1.00 603 96.2 61.902 460 1 1.5 1.1 1800 143/5TC 00158ET3E145TC-W22 579 N1 55 1.25 2.02 86.5 13.346 208-230/460
3600 588/9S 60036ET3G588/9S-W22 64,635 N1 5261 1.00 650 96.5 62.506 460 1 1800 143/5TC 00158ET3ERS145TC 504 RSP 49 1.15 2.25 86.5 14.095 208-230/460 9
600 450 1800 586/7 60018ET3G586/7-W22 60,316 N1 4900 1.00 665 96.5 61.902 460 1 1800 143/5TC 00158ET3H145TC-W22 579 N1 57 1.25 1.62 86.5 13.346 575
1200 588/9 60012ET3G588/9-W22 71,374 N1 6000 1.00 743 96.2 69.381 460 1 1200 182/4TC 00152ET3E182TC-S 690 RSP 73 1.15 2.22 87.5 16.339 208-230/460 9
3600 588/9S 65036ET3G588/9S-W22 66,835 N1 4805 1.00 685 96.6 62.506 460 1 1200 182/4TC 00152ET3E182TC-W22 792 N1 100 1.25 2.39 87.5 15.860 208-230/460
650 480
1800 588/9 65018ET3G588/9-W22 66,701 N1 3308 1.00 734 96.6 69.381 460 1 1200 182/4TC 00152ET3ERS182TC 690 RSP 90 1.15 2.39 87.5 16.404 208-230/460 9
3600 588/9S 70036ET3G588/9S-W22 71,254 N1 5754 1.00 736 96.6 62.506 460 1 3600 143/5TC 00236ET3E145TC-S 539 RSP 45 1.15 2.47 85.5 13.976 208-230/460 9
700 515
1800 588/9 70018ET3G588/9-W22 71,185 N1 5893 1.00 788 96.6 69.381 460 1 3600 143/5TC 00236ET3E145TC-W22 619 N1 58 1.25 2.53 85.5 13.346 208-230/460
750 550 1800 588/9 75018ET3G588/9-W22 74,025 N1 3308 1.00 840 96.7 69.381 460 1 3600 143/5TC 00236ET3ERS145TC 539 RSP 48 1.15 2.50 85.5 14.095 208-230/460 9
3600 143/5TC 00236ET3H145TC-W22 619 N1 56 1.25 2.02 85.5 13.346 575
1800 143/5TC 00218ET3E145TC-S 558 RSP 47 1.15 2.72 86.5 13.976 208-230/460 9
2 1.5 1800 143/5TC 00218ET3E145TC-W22 640 N1 59 1.25 2.61 86.5 13.346 208-230/460
1800 143/5TC 00218ET3ERS145TC 558 RSP 55 1.15 2.85 86.5 14.095 208-230/460 9
1800 143/5TC 00218ET3H145TC-W22 640 N1 57 1.25 2.09 86.5 13.346 575
1200 182/4TC 00212ET3E184TC-S 747 RSP 83 1.15 3.00 88.5 17.126 208-230/460 9
1200 182/4TC 00212ET3E184TC-W22 857 N1 112 1.25 3.23 88.5 15.860 208-230/460
1200 182/4TC 00212ET3ERS184TC 747 RSP 101 1.15 3.22 88.5 16.404 208-230/460 9
Continued on next page

Note: Flanged motors on Cast Iron frame sizes 143/5 to 254/6 have non-NEMA BA dimension. Refer to mechanical section of this catalog for details.

Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES” Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES”
For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com

A-32 www.weg.net/us Data subject to change without notice. Data subject to change without notice. Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934) A-33
Three-Phase General Purpose Motors Three-Phase General Purpose Motors

TEFC – C-Flange – Foot Mount continued TEFC – C-Flange – Foot Mount continued

General Purpose
General Purpose

Three-Phase
Three-Phase

Motors
Motors

Approx. FL Approx. FL
"C" "C"
NEMA List Mult. Shipping Service Amps FL. Eff NEMA List Mult. Shipping Service Amps FL. Eff
HP kW RPM Catalog Number Dimension Voltage (V) Notes HP kW RPM Catalog Number Dimension Voltage (V) Notes
Frame Price Symbol Weight Factor @ (%) Frame Price Symbol Weight Factor @ (%)
(in) (in)
(lbs) High (lbs) High
3600 182/4TC 00336ET3E182TC-S 698 RSP 71 1.15 3.67 86.5 16.339 208-230/460 9 3600 213/5TC 01036ET3E215TC-S 1,205 RSP 173 1.15 11.5 90.2 21.654 208-230/460 9
3600 182/4TC 00336ET3E182TC-W22 802 N1 103 1.25 3.63 86.5 15.860 208-230/460 3600 213/5TC 01036ET3E215TC-W22 1,383 N1 187 1.25 11.6 90.2 19.517 208-230/460
3600 182/4TC 00336ET3ERS182TC 698 RSP 91 1.15 3.68 87.5 16.404 208-230/460 9 3600 213/5TC 01036ET3ERS215TC 1,205 RSP 170 1.15 11.5 91.7 20.257 208-230/460 9
3600 182/4TC 00336ET3H182TC-W22 802 N1 103 1.25 2.90 86.5 15.860 575 3600 213/5TC 01036ET3H215TC-W22 1,383 N1 185 1.25 9.28 90.2 19.517 575
1800 182/4TC 00318ET3E182TC-S 610 RSP 87 1.15 3.81 89.5 17.894 208-230/460 9 1800 213/5TC 01018ET3E215TC-S 1,154 RSP 142 1.15 12.2 91.7 19.291 208-230/460 9
1800 182/4TC 00318ET3E182TC-W22 700 N1 100 1.25 3.88 89.5 15.860 208-230/460 10 7.5 1800 213/5TC 01018ET3E215TC-W22 1,325 N1 196 1.25 12.4 91.7 19.517 208-230/460
3 2.2
1800 182/4TC 00318ET3ERS182TC 610 RSP 72 1.15 3.91 89.5 16.404 208-230/460 9 1800 213/5TC 01018ET3ERS215TC 1,154 RSP 166 1.15 12.7 91.7 20.257 208-230/460 9
1800 182/4TC 00318ET3H182TC-W22 700 N1 100 1.25 3.10 89.5 15.860 575 1800 213/5TC 01018ET3H215TC-W22 1,325 N1 197 1.25 9.92 91.7 19.517 575
1200 213/5TC 00312ET3E213TC-S 1,028 RSP 142 1.15 4.17 89.5 19.291 208-230/460 9 1200 254/6TC 01012ET3E256TC-S 2,148 RSP 277 1.15 13.8 91 23.346 208-230/460 9
1200 213/5TC 00312ET3E213TC-W22 1,180 N1 154 1.25 4.41 89.5 19.517 208-230/460 1200 254/6TC 01012ET3E256TC-W22 2,465 N1 324 1.25 12.9 91.0 24.945 208-230/460
1200 213/5TC 00312ET3ERS213TC 1,028 RSP 142 1.15 4.41 89.5 20.257 208-230/460 9 1200 254/6TC 01012ET3ERS256TC 2,148 RSP 282 1.15 13.3 91.0 24.925 208-230/460 9
900 213/5TC 00309ET3E215TC-W22 2,166 N1 192 1.25 4.56 85.5 19.517 208-230/460 3600 213/5TC 01536ET3E215TC-W22 1,748 N1 199 1.25 17.0 91.0 19.517 208-230/460
3600 182/4TC 00536ET3E184TC-S 793 RSP 86 1.15 5.90 88.5 17.894 208-230/460 9 3600 254/6TC 01536ET3E254TC-S 1,649 RSP 220 1.15 17.4 91 22.559 208-230/460 9
3600 182/4TC 00536ET3E184TC-W22 911 N1 110 1.25 5.90 88.5 15.860 208-230/460 3600 254/6TC 01536ET3E254TC-W22 1,893 N1 283 1.25 17.2 91.0 24.945 208-230/460
3600 182/4TC 00536ET3ERS184TC 793 RSP 101 1.15 5.96 89.5 16.404 208-230/460 9 3600 254/6TC 01536ET3ERS254TC 1,649 RSP 235 1.15 16.9 91.7 24.925 208-230/460 9
3600 182/4TC 00536ET3H184TC-W22 911 N1 112 1.25 4.72 88.5 15.860 575 3600 254/6TC 01536ET3H254TC-W22 1,893 N1 282 1.25 13.8 91.0 24.945 575
1800 182/4TC 00518ET3E184TC-S 706 RSP 79 1.15 6.49 89.5 17.894 208-230/460 9 15 11 1800 254/6TC 01518ET3E254TC-S 1,670 RSP 242 1.15 18.2 92.4 22.559 208-230/460 9
5 3.7 1800 182/4TC 00518ET3E184TC-W22 810 N1 109 1.25 6.45 89.5 15.860 208-230/460 1800 254/6TC 01518ET3E254TC-W22 1,917 N1 336 1.25 18.0 92.4 24.945 208-230/460
1800 182/4TC 00518ET3ERS184TC 706 RSP 97 1.15 6.40 89.5 16.404 208-230/460 9 1800 254/6TC 01518ET3ERS254TC 1,670 RSP 259 1.15 18.0 92.4 24.925 208-230/460 9
1800 182/4TC 00518ET3H184TC-W22 810 N1 108 1.25 5.16 89.5 15.860 575 1800 254/6TC 01518ET3H254TC-W22 1,917 N1 330 1.25 14.4 92.4 24.945 575
1200 213/5TC 00512ET3E215TC-S 1,206 RSP 156 1.15 6.74 89.5 20.079 208-230/460 9 1200 284/6TC 01512ET3E284TC-W22 3,388 N1 409 1.25 17.9 91.7 27.929 208-230/460
1200 213/5TC 00512ET3E215TC-W22 1,384 N1 177 1.25 6.83 89.5 19.517 208-230/460 1200 284/6TC 01512ET3H284TC-W22 3,388 N1 408 1.25 14.3 91.7 27.929 575
1200 213/5TC 00512ET3ERS215TC 1,206 RSP 158 1.15 6.83 89.5 20.257 208-230/460 9 3600 254/6TC 02036ET3E256TC-S 2,136 RSP 256 1.15 22.7 91 22.559 208-230/460 9
3600 213/5TC 00736ET3E213TC-S 1,025 RSP 144 1.15 8.67 89.5 19.291 208-230/460 9 3600 254/6TC 02036ET3E256TC-W22 2,451 N1 318 1.25 23.2 91.0 24.945 208-230/460
3600 213/5TC 00736ET3E213TC-W22 1,177 N1 160 1.25 8.76 89.5 19.517 208-230/460 3600 254/6TC 02036ET3ERS256TC 2,136 RSP 266 1.15 22.9 92.4 24.925 208-230/460 9
3600 213/5TC 00736ET3ERS213TC 1,025 RSP 147 1.15 8.63 91.0 20.257 208-230/460 9 3600 254/6TC 02036ET3H256TC-W22 2,451 N1 319 1.25 18.6 91.0 24.945 575
3600 182/4TC 00736ET3H184TC-W22 1,112 N1 93 1.25 7.01 89.5 15.860 575 20 15 1800 254/6TC 02018ET3E256TC-S 1,978 RSP 271 1.15 24.5 92.4 23.346 208-230/460 9
3600 213/5TC 00736ET3H213TC-W22 1,177 N1 158 1.25 7.01 89.5 19.517 575 1800 254/6TC 02018ET3E256TC-W22 2,270 N1 367 1.25 24.1 93.0 24.945 208-230/460
1800 213/5TC 00718ET3E213TC-S 994 RSP 131 1.15 9.07 91.7 18.898 208-230/460 9 1800 254/6TC 02018ET3ERS256TC 1,978 RSP 286 1.15 24.4 93.0 24.925 208-230/460 9
7.5 5.5 1800 213/5TC 00718ET3E213TC-W22 1,141 N1 174 1.25 9.00 91.7 19.517 208-230/460 1800 254/6TC 02018ET3H256TC-W22 2,270 N1 366 1.25 19.3 93.0 24.945 575
1800 213/5TC 00718ET3ERS213TC 994 RSP 154 1.15 9.29 91.7 20.257 208-230/460 9 1200 284/6TC 02012ET3E286TC-W22 4,060 N1 456 1.25 24.2 91.7 27.929 208-230/460
1800 213/5TC 00718ET3H213TC-W22 1,141 N1 167 1.25 7.20 91.7 19.517 575 3600 284/6TSC 02536ET3E284TSC-W22 3,096 N1 407 1.25 28.5 91.7 26.557 208-230/460
1200 254/6TC 00712ET3E254TC-S 1,859 RSP 248 1.15 9.98 91 22.559 208-230/460 9 3600 284/6TSC 02536ET3H284TSC-W22 3,096 N1 406 1.25 22.8 91.7 26.557 575
25 18.5
1200 254/6TC 00712ET3E254TC-W22 2,134 N1 295 1.25 9.48 91.0 24.945 208-230/460 1800 284/6TC 02518ET3E284TC-W22 2,840 N1 439 1.25 29.5 93.6 27.929 208-230/460
1200 254/6TC 00712ET3ERS254TC 1,859 RSP 262 1.15 9.73 91.0 24.925 208-230/460 9 1800 284/6TC 02518ET3H284TC-W22 2,840 N1 432 1.25 23.6 93.6 27.929 575
900 254/6TC 00709ET3E256TC-W22 3,726 N1 324 1.25 11.1 87.5 24.945 208-230/460 Continued on next page

Continued on next page

Note: Flanged motors on Cast Iron frame sizes 143/5 to 254/6 have non-NEMA BA dimension. Refer to mechanical section of this catalog for details. Note: Flanged motors on Cast Iron frame sizes 143/5 to 254/6 have non-NEMA BA dimension. Refer to mechanical section of this catalog for details.

Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES” Refer to electrical and mechanical data sections for additional technical information. Please refer to back cover for description of “NOTES”
For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com For detailed specifications, data sheets, drawings and performance curves visit http://catalog.wegelectric.com

A-34 www.weg.net/us Data subject to change without notice. Data subject to change without notice. Can’t find what you are looking for? Call 1-800-ASK-4WEG (275-4934) A-35
Part Number Configuration
Ordering
WEG model numbers contains up to 20 characters, distributed as follows:

XXX XX XXX X XXXXX - W22


(HP) (rpm) (Model) (Volts) (Application + Frame) When Applicable
HP1 - .12 - .16 - .25 - .33 - .50 - .75 - 001 - 0015 - 002 - 003 - 004 - 00451 - 005 - 007 - 010 - 015 -
020 - 025 - 030 - 040 - 050 - 075 - 100 - 125 - 150 - 200 - 250 - 300 - 400 - 450 - 500 - 600 - 650 ...

RPM - 36: 3600rpm 18: 1800rpm 12: 1200rpm 09: 900rpm


30: 3000rpm 15: 1500rpm 10: 1000rpm 07: 750rpm

Model - Three Characters:

X X X
ENCLOSURE EFFICIENCY PHASE
E - Totally Enclosed S - Standard Efficiency 1 - 1 Phase
S - Severe Duty IEEE 841 P - High Efficiency 3 - 3 Phase
O - Open drip proof T - NEMA Premium
X - eXplosion proof G - Super Premium
A - Totally Enclosed Air Over
N - Totall Enclosed Non Ventilated

Application + Frame -

Volts -
For
A - 115V L - 415V Definite Purpose lines, two pre-selected
letters
B - 115 / 208 - 230V M - 220 / 380 - 415V must be used after voltage code:

C - 208 - 230V N - 220 / 380V AD - Auger Drive
D - 230V O - 380 - 415V AL - ALuminum Frame
E - 208 - 230 / 460V* P - 200V AX - ATEX Motor
F - 230 / 460V Q - 460V
BM - Brake Motor
G - 460V PWS R - 115 / 230V
CD - Compressor Duty
H - 575V V - 200 / 400V
CT - Cooling Tower
I - 220V W - 460/220-240/380-415V
J - 380V X - Other Voltage
DP - Double Pole (2 Speed)
EC - Evaporative Cooler
K - 190 / 380V Y - 460/380-415/660-690V
FD - Farm Duty
FP - Fire Pump
HP - Hydraulic Pump
HS - Hollow Shaft
IB - Inverter Duty (TEBC)
* Suitable for PWS on 254T and larger on low voltage connection.
IE - IEEE 841 (Severe Duty IEEE 841)
IP - Irrigation Pumping
1)
• For IEC Metric motors, the output will be given in kW: JP - Jet Pump
.12 - .18 - .25 - .37 - .55 - .75 - 001 - 0015 - 002 - 003 - 004 - 0045 - 005 - KD - Crusher-Duty
007 - 009 - 011 - 015 - 018 - 022 - 030 - 037 - 045 - 055 - 075 - 090 - 110 - OL - Manual OverLoad Protection
130 - 150 - 185 - 200 - 220 - 250 - 300 - 315 ... OT - Oil Well Pumping - Triple Rated
• 0015 (1.5HP) is the rating that will have four digits for output OW - Oil Well Pumping
Identification and only one for RPM. PF - Poultry Fan
• 0045 (4.5kW) is the rating that will have four digits for output PM - Pad Mount
identification and only one for RPM. R - (Before the frame size): Round Body
RB - Roller Bearings (Integrals)2
RB - Resilient Base (Fractionals)
Frame RS - Rolled Steel Frame
The frame number must be included as long as the
SA - Saw Arbor
number of remaining characters allow.
SP - Split Phase
Example: 143T, 143TC, 405T, 405TS, 184JP.
SS - Stainless Steel
-W22 Suffix VD - Vector Duty (TEBC or TENV)

-W22 Suffix will be added to the catalog number of totally
enclosed motors with the new W22 WEG design. Depending on the
number of remaining characters this suffix might appear as -W or -W2.

Roller bearings are recommended for all belt driven applications


2)

100HP and above.


8
650/850 T O N T O P D R I V E MANUAL REV 0
Section

WAGO

381
System 750
Overview

Modular Fieldbus Independent I/O System


© WAGO Corporation, Germantown WI 1

Topics of Discussion

• WAGO-I/O-SYSTEM 750 Components


• General Features
• Assembly, Mounting, and Connections
• Power Supply Groups and Isolation
• Input and Output Process Image

© WAGO Corporation, Germantown WI 2

Networks I/O Controllers IPC, HMI/PLC

IP20 PFCs Extended Temp


Digital IPCs
Analog

Specialty
Managed &
Modules
Unmanaged
Switches
Wireless IP67 PFCs
16+ Networks Bluetooth
Interface
Boards

PFC200
IP67 HMI/PLC

© WAGO Corporation, Germantown WI 3

382
WAGO-I/O-SYSTEM 750 Components

The WAGO-I/O SYSTEM 750 is a modular, fieldbus


independent, I/O system. A node is comprised of three major
components:

1) Coupler/Controller
2) I/O Modules
3) End Module

© WAGO Corporation, Germantown WI 4

Coupler vs. Controller

Coupler - Remote I/O head - the I/O is


controlled by an external scanner or
master
750-3xx

Controller – Combines the functionality of


a Coupler with a PLC. Application
programs are written WAGO-I/O-PRO
(IEC61131-3 Programming Tool)
750-8xx & 758-8xx

© WAGO Corporation, Germantown WI 5

Fieldbus Independent
• DeviceNet • ModbusTCP
• PROFIBUS • EtherNet/IP
• INTERBUS • Firewire
• MODBUS • CANopen
• LonWorks • And More…

Simply “snap in”


a Coupler or
Controller

© WAGO Corporation, Germantown WI 6

383
Programmable Fieldbus Controllers Fieldbus Couplers
CONTROLLERS (IEC61131-3 Programmable)
750-804 INTERBUS FIELDBUS COUPLERS

750-806 DeviceNet 750-301, 750-303, 750-333, PROFIBUS


750-343, 750-331
750-812, 750-814, MODBUS
750-815, 750-816 750-304, 750-344, 750-345, INTERBUS
750-334
750-819 LONWORKS
750-342,750-352 ETHERNET TCP/IP 10Mbit
750-833 PROFIBUS DP/V1
750-306, 750-346 DeviceNet
750-837, 750-838 CANopen
750-307, 750-337, 750-338, CANopen
750-873 ETHERNET w/RS232 750-347, 750-348
750-842 ETHERNET TCP/IP 10Mbit 750-305 CAL
750-860 Linux 750-312, 750-314, 750-315, MODBUS
750-871 Ethernet w/2-port switch & 750-316
758-870 Industrial Compact PC 750-310 CC-Link
750-830 BACnet/IP 750-339 Firewire

750-831 BACnet w/2 port swich & SD Card 750-319 LONWORKS


750-880 Ethernet w/2 port swich & SD Card 750-300 II/O-LIGHTBUS

750-881 Ethernet w/2-port swtich 750-354 EtherCAT


750-882 Ethernet w/Dual independent ports 750-375, 750-377 ProfiNet w/ 2-port switch
750-885 Ethernet w/Dual independent ports 750-351 SERCOS III
w/SD Card
750-880/025-001 Telecontrol

© WAGO Corporation, Germantown WI 7

ETHERNET 2.0 - Triad of Control 750-880


Efficiency Expert – SD
card for memory expansion
up to 32G, or used for
backup and restore of
750-881 application programs.

Pacesetter – High- 1MB Program Memory


performance controller 1MB Data Memory
Web Based Management, 32kB Retain Memory
Built in switch supports
MODBUS TCP and
EtherNet I/P.

1MB Program Memory


750-882
512kB Data Memory Dynamic Duo – Media
32kB Retain Memory Redundancy controller with dual
independent Ethernet ports for
network redundancy or separation
of networks

1MB Program Memory


512kB Data Memory
32kB Retain Memory

© WAGO Corporation, Germantown WI 8

750-880 Ethernet Controller

• High-speed processor(1000 instructions in 230µS)


• Program memory: 1 Mbyte
• Data memory: 1 MByte
• Retained memory: 32 kByte
• Large and fast file system (2 MB)
Web pages,data logging
• 2 Ethernet-interfaces + integrated Switch
• Supports both EtherNet I/P and MODBUS TCP
• IP-Address over DIP-switch option
• Shipped with pre-configured IP Address
– 192.168.1.xxx
• Protocols supported : HTTP, BootP, DHCP, DNS,
SNTP, SNMP, FTP
• SD Card Interface(up to 32 GB) Backup, restore,
data logging

© WAGO Corporation, Germantown WI 9

384
750-881 Ethernet Controller

• High-speed processor(1000 instructions in


230µS)
• Program memory: 1 Mbyte
• Data memory: 512 kByte
• Retained memory: 32 kByte
• Large and fast file system (2 MB)
Web pages,data logging
• 2 Ethernet-interfaces + integrated Switch
• Supports both EtherNet I/P and MODBUS TCP
• IP-Address over DIP-switch option
• Shipped with pre-configured IP Address
– 192.168.1.xxx
• Protocols supported : HTTP, BootP, DHCP,
DNS, SNTP, SNMP, FTP

© WAGO Corporation, Germantown WI 10

750-882 Ethernet Controller

• High-speed processor(1000 instructions in 230µS)


• Program memory: 1 Mbyte
• Data memory: 1 MByte
• Retained memory: 32 kByte
• Large and fast file system (2 MB)
Web pages, data logging
• 2 Independent Ethernet
• IP-Address over DIP-switch option
• Shipped with pre-configured IP Address
– 192.168.1.xxx
– 192.168.2.xxx
• Protocols supported : HTTP, BootP, DHCP, DNS,
SNTP, SNMP, FTP
• Media redundancy- Network redundancy &
network separation.

© WAGO Corporation, Germantown WI 11

750-885 Ethernet Controller

• High-speed processor(1000 instructions in 230µS)


• Program memory: 1 Mbyte
• Data memory: 1 MByte
• Retained memory: 32 kByte
• Large and fast file system (2 MB)
Web pages, data logging
• 2 Independent Ethernet
• IP-Address over DIP-switch option
• Shipped with pre-configured IP Address
– 192.168.1.xxx
– 192.168.2.xxx
• Protocols supported : HTTP, BootP, DHCP, DNS,
SNTP, SNMP, FTP
• Media redundancy- Network redundancy &
network separation.
• SD Card Interface(up to 32 GB) Backup, restore,
data logging
© WAGO Corporation, Germantown WI 12

385
WAGO ECO ETHERNET Controller 750-852

• Features
• Member of the ETHERNET 2.0 controller family
• Programmable with CoDeSys
• 2 Ethernet interfaces + integrated switch
• Maintenance free
• Advantages
• Performs like a 750-88X
• Considerations
• No Web server
• No real time Clock
• Lower memory
• Benefits
• Cost savings

© WAGO Kontakttechnik GmbH & Co. KG 04.04.2013 13


© WAGO Corporation, Germantown WI 13

The New Controller Family

Introducing PFC200

Programmable Fieldbus Controller

 Introduction of
4 different types of Controllers with
different interfaces

© WAGO Corporation, Germantown WI 14

Ethernet-Based Automation Portfolio

Starting List $1,000


762-3xxx PERSPECTO

758-8xx IPC’s
Starting List $2,100

750-82XX PFC200 Starting List $1,100

750-88X PFC’s Starting List $475.00 (750-852)

© WAGO Corporation, Germantown WI 15

386
The Controller PFC200

• Features
• Standard System 750 I/O
• Programmable in IEC and C/C++
• CoDeSys Version 2
• Maintenance-free (no battery)
• Advantages
• Small package with high performance
• Web Based Managment
• Web Server
• Benefits
• Compact Size
• Muliple Fieldbus interfaces
• Use as a Gateway
• Powerful programming software
• Easy to engineer
• Powerful controller

© WAGO Corporation, Germantown WI 16

Controller PFC200

• PFC200 Controller Ethernet & Serial


• Cortex A8, 600 MHz

• CODESYS v2.3 accessible memory


• Program Memory: 256 MB
• Data Memory: 256 MB
• Retain Memory: 128 kB

• Interfaces
• Ethernet (switch)
• RS232/485 (D-SUB 9 female)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
RESET)
• LED (System, Fieldbus, USER)
Part Number: 750-8202
© WAGO Corporation, Germantown WI 17

Controller PFC200

• PFC200 Controller Ethernet & CAN


• Cortex A8, 600 MHz

• CODESYS v2.3 accessible memory


• Program Memory: 256 MB
• Data Memory: 256 MB
• Retain Memory: 128 kB

• Interfaces
• Ethernet (switch)
• CAN; CANopen (D-SUB 9 male)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
RESET)
Part Number: 750-8203 • LED (System, Fieldbus, USER)

© WAGO Corporation, Germantown WI 18

387
Controller PFC200

• PFC200 Controller Ethernet & Serial & CAN


• Cortex A8, 600 MHz
• CODESYS v2.3 accessible memory
• Program Memory: 256 MB
• Data Memory: 256 MB
• Retain Memory: 128 kB

• Interfaces
• Ethernet (switch)
• RS232/485 (D-SUB 9 female)
• CAN; CANopen (D-SUB 9 male)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
RESET)
Part Number: 750-8204 • LED (System, Fieldbus, USER)

© WAGO Corporation, Germantown WI 19

Controller PFC200
• PFC200 Controller
Eth&Serial&CAN&PROFIB
• Cortex A8, 600 MHz

• CODESYS v2.3 accessible memory


• Program Memory: 256 MB
• Data Memory: 256 MB
• Retain Memory: 128 kB

• Interfaces
• Ethernet (switch)
• RS232/485 (D-SUB 9 female)
• CAN; CANopen (D-SUB 9 male)
• PROFIBUS Slave (D-SUB 9 female)
• SD/SDHC Card Slot up to 32 GB
• Operation Mode Switch (RUN, STOP,
Part Number: 750-8206 RESET)
• LED (System, Fieldbus, USER)
© WAGO Corporation, Germantown WI 20

Next Generation IPCs- Product Features


Universal and flexible
• Stable PLC functionality combined with classic PC
interfaces
• Control, monitor and visualization directly from the
fieldbus node
• PLC + IT functions all in one device
• Full integration of I/O-IPC in Series 750 and 753
Scalable
• Various CPU performance outputs from Geode to
Pentium® M
• Operating system Linux as WAGO Distribution
• Optional PLC functionality with CoDeSys 2.3 and
integrated visualization via Web browser or direct monitor
connection
Industrial strength
• Minimal space requirement
• Non-volatile memory
• Real-time clock

Stability
• Hot-Plug USB Sticks
– Automatic mounting and dismounting
• Application: Data logging on USB stick

© WAGO Corporation, Germantown WI 21

388
Next Generation CoDeSys IPCs

I/O-IPC-C6 I/O-IPC-C10E I/O-IPC-P14


Processor Celeron Celeron Pentium M
CPU Speed 600 MHz 1 GHz 1.4 GHz
Main Memory (RAM) 256 MB 256 MB 256 MB
Internal Memory (flash) 512 MB 512 MB 512 MB
Retain Memory 1024 kB 1024 kB 1024 kB
CF card interface Socket type I+II Socket type I+II Socket type I+II
Status LEDs 8 (tri-color) 8 (tri-color) 8 (tri-color)
USB 2.0 2.0 2.0
On-board digital I/O 2in/2out 2in/2out 2in/2out
RS-232 1 1 1
DVI (VGA via adapter) DVI-I DVI-I DVI-I
Graphics Res. (max) 1280 x 1024 1280 x 1024 1280 x 1024
Operating Temperature 0C – 55C -20C to 60C 0C to 55C
Housing Material Aluminum Aluminum Aluminum

© WAGO Corporation, Germantown WI 22

Example Architectures

Industrial PC

IP67 Programmable
Programmable Fieldbus Controllers
3rd Party Controllers & Couplers
Fieldbus Controllers

Fieldbus Couplers
Fieldbus Couplers

© WAGO Corporation, Germantown WI 23

Modular

A node can consist of a combination of analog, digital, and specialty I/O


modules, with different potentials and signals (up to 230VAC). Up to 64 I/O
modules* can be inserted in a node.
• Over 500 different I/O modules
• Digital Inputs & Outputs
5-240 VDC & 24 - 230 VAC
(1, 2, 4, 8 & 16 Channel Devices)
• Analog Inputs & Outputs
0-10 V, +/-10 V, 4-20 ma, thermocouple, RTD;
3 PH power measure. (differ. & single ended)
• Specialty Modules
Counters, encoders, serial interface (RS232 &
RS485), AS Interface, Vibration, DC Drive

* System can support up to 250 I/O modules with Bus Extension modules.

© WAGO Corporation, Germantown WI 24

389
Digital Input Modules
DI 5/12 VDC 750-1421 4 Channel DC 24V 0.2 ms, 3 conductor connection

750-434 8 Channel, DC 5/12 V, 0.2 ms , high-side switching 750-1422 4 Channel DC 24V 3.0 ms, 3 conductor connection, LSS

750-414 4 Channel, DC 5 V, 0.2 ms, high-side switching 750-436 8 Channel, DC 24 V, 3.0 ms, low-side switching

750-1425 8 Channel PTC Thermistors 750-437 8 Channel, DC 24 V, 0.2 ms, low-side switching

750-438 2 Channel, NAMUR, Proximity switch


DI 24 VDC
750-402 4 Channel, DC 24 V, 3.0 ms, high-side switching
750-435 1 Channel, NAMUR EEx i, Proximity switch
750-403 4 Channel, DC 24 V, 0.2 ms, high-side switching
750-400 2 Channel, DC 24 V, 3.0 ms, high-side switching
750-422 4 Channel, DC 24 V, 10 ms pulse extension
750-401 2 Channel, DC 24 V, 0.2 ms, high-side switching
750-408 4 Channel, DC 24 V, 3.0 ms, low-side switching
750-410 2 Channel, DC 24 V, 3.0 ms, proximity switch
750-409 4 Channel, DC 24 V, 0.2 ms, low-side switching
750-411 2 Channel, DC 24 V, 0.2 ms, proximity switch
750-430 8 Channel, DC 24 V, 3.0 ms, high-side switching
750-418 2 Channel, DC 24 V, 3.0 ms, diagnostic, ack
750-431 8 Channel, DC 24 V, 0.2 ms, high-side switching
750-424 2 Channel, DC 24 V, Intruder Detection
DI 24 VAC/VDC
750-419 2 Channel, DC 24 V, 0.2 ms, diagnostic 750-415 4 Channel, AC/DC 24 V
750-432 4 Channel, DC 24 V, 3.0 ms, low-side switching, w/(+) terminal 750-423 4 Channel, AC/DC 24 V, with power jumper contacts
750-433 4 Channel, DC 24 V, 0.2 ms, low-side switching , w/(+) terminal DI 42 VAC/VDC

750-1400 16 Channel DC 24V 3.0 ms, ribbon cable 750-428 Channel, AC/DC 42 V, 2-conductor connection

750-1402 16 Channel DC 24V 0.2 ms, ribbon cable, LSS DI 48 VDC

750-1405 16 Channel DC 24V 0.2 ms, CAGE CLAMP® S 750-412 2 Channel, DC 48 V, 3.0ms, high-side switching

750-1406 16 Channel DC 24V 0.2 ms, DI 110 VDC

750-1407 16 Channel DC 24V 0.2 ms, CAGE CLAMP® S,LSS 750-427 2 Channel, DC 110 V, Configurable high or low-side

750-1415 8 Channel DC 24V 3.0 ms, 2 conductor connection DI 120/230 VAC

750-1416 8 Channel DC 24V 0.2 ms, 2 conductor connection 750-406 2 Channel, AC 120 V, high-side switching

750-1417 8 Channel DC 24V 3.0 ms, 2 conductor connection, LSS 750-405 2 Channel, AC 230 V, high-side switching

750-1420 4 Channel DC 24V 3.0 ms, 3 conductor connection 753-440 4 Channel, AC 120/230

© WAGO Corporation, Germantown WI 25

Digital Output Modules


750-507 2 Channel, DC 24 V, 2.0 A, short-circuit-protected;
DO DC 5/12 V
high-side switching; with diagnostics
750-534 8 Channel, DC 5 V, 1A, short-circuit-protected; high-side
750-535 2 Channel, DC 24 V, EEx i, short-circuit-protected;
switching
PNP-positive switching
750-519 4 Channel, DC 5 V, 20mA, short-circuit-protected; high-side
750-504 4 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-
switching
side switching
DO DC 24 V
750-516 4 Channel, DC 24 V, 0.5 A, short-circuit-protected; low-
750-501 2 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-side side switching
switching
750-530 8 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-
750-502 2 Channel, DC 24 V, 2.0 A, short-circuit-protected; high-side side switching
switching
DO AC/DC 120/230 V
750-531 4 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-side
750-509 2 Channel Solid State Relay, AC/DC 230 V, 300 mA
switching w/4 (-) terminals
753-540 4 Channel Solid State Relay, AC 120/230 V, 250 mA
750-532 4 Channel, DC 24 V, 0.5 A, short-circuit-protected; high-side
switching, w/4 (-) terminals, w/diagnostics 750-522 2 Channel Solid State Relay, AC/DC 230 V, 500 mA, 3 A
(< 30 s)
750-506 2 Channel, DC 24 V, 0.5 A, short-circuit-protected;
high-side switching; with diagnostics DO Relay
750-1500 16 Channel DC 24V 0.5 A, ribbon cable 750-514 2 Channel, AC 125 V, AC 0.5 A, DC 30 V, DC 1 A,
isolated outputs, 2 changeover contacts
750-1501 16 Channel DC 24V 0.5 A, ribbon cable, LSS
750-517 2 Channel, AC 230 V, 1 A, isolated outputs, 2 changeover
750-1502 8DI 8DO 24V DC 0.5 A, ribbon cable
contacts
750-1504 16 Channel DC 24V 0.5 A, CAGE CLAMP® S
750-512 2 Channel, AC 230 V, DC 30 V, AC/DC 2 A, non-floating,
750-1505 16 Channel DC 24V 0.5 A, CAGE CLAMP® S , LSS 2 make contacts

750-1506 8DI 8DO 24V DC 0.5 A, CAGE CLAMP® S 750-513 2 Channel, AC 230 V, DC 30 V, AC/DC 2 A, isolated
outputs, 2 make contacts
750-1515 8 Channel DC 24V 0.5 A, 2 conductor connection
750-523 1 Channel, AC 230 V, AC 16 A, isolated output, 1 make
750-1516 8 Channel DC 24V 0.5 A, 2 conductor connection, LSS contact, bistable, manual operation

© WAGO Corporation, Germantown WI 26

Analog Input Modules


AI 0 - 20 mA AI 0 - 10 V
750-452 2 Channel, 0 - 20 mA, Differential Inputs 750-459 4 Channel, DC 0 - 10 V, single-ended (S.E.)
750-453 4 Channel, 0 - 20 mA, single-ended (S.E.) 750-467 2 Channel, DC 0 - 10 V, single-ended (S.E.)
750-465 2 Channel, 0 - 20 mA, single-ended (S.E.) 750-468 4 Channel, DC 0 - 10 V, single-ended (S.E.)
750-472 2-channel, 0 - 20 mA, 16 Bit, single-ended (S.E.) 750-477 2 Channel, AC/DC 0 - 10 V,Differential Inputs
750-480 2-channel, 0 - 20 mA, Differential Inputs 750-478 2 Channel, DC 0 - 10 V, single-ended (S.E.)
AI 4 - 20 mA AI ...
750-454 2 Channel, 4 - 20 mA,Differential Inputs 750-483 2 Channel, DC 0 -30 V, Differential Measurement Input
750-455 4 Channel, 4 - 20 mA, single ended (S.E.) 750-461 2 Channel, Resistance Sensors, PT100 / RTD
750-474 2 Channel, 4 - 20 mA, 16 Bit, single-ended (S.E.) 750-460 4 Channel, Resistance Sensors, PT100 / RTD
750-466 2 Channel, 4 - 20 mA, single ended (S.E.) 750-469 2 Channel, thermocouples (J, K, B, E, N, R, S, T, U, L)
750-485 2 Channel, 4 - 20 mA, EEx i, single ended (S.E.) 750-491 1 Channel for Resistor Bridges (Strain Gauge)
750-492 2 Channel, 4 - 20 mA, Isolated Differential Inputs 750-493 3-Phase Power Measurement
AI 0 - 1 A 750-494 3-Phase Power Measurement
750-475 2-channel, 0 - 1 A AC/DC ,Differential Inputs 750-495 3-Phase Power Measurement
AI 0 - 5 A 750-464 2/4 Analog Input RTD Configurable
750-475/020-000 2-Channel, 0 - 5 A AC/DC ,Differential Inputs 750-450 4 Analog Input RTD(2,3,4-wire) Configurable or
AI DC ± 10 V Potentiometer
750-451 8 Analog Input RTD(2-wire) Configurable or Potentiometer
750-456 2 Channel, DC ± 10 V, Differential Inputs
750-457 4 Channel, DC ± 10 V, single-ended (S.E.)
750-479 2 Channel, DC ± 10 V, Differential Input
750-476 2 Channel, DC ± 10 V, single-ended (S.E.)

© WAGO Corporation, Germantown WI 27

390
Analog Output Modules

AO 0 - 20 mA
750-552 2 Channel, 0 - 20 mA
750-553 4 Channel, 0 - 20 mA
750-585 2 Channel, 0 - 20 mA, EEx i
AO 4 - 20 mA
750-555 4-channel, 4 - 20 mA
750-554 2-channel, 4 - 20 mA
750-563 2-channel, 4 - 20 mA or 0 - 20 mA, 16 bit
AO DC 0 - 10 V
750-550 2 Channel, DC 0 - 10 V
750-559 4 Channel, DC 0 - 10 V
750-560 2 Channel, DC 0 - 10 V,10 bit
750-562 2 Channel, DC 0 - 10 V or ± 10 V , 16 bit
AO DC ± 10 V
750-556 2 Channel, DC ± 10 V
750-557 4 Channel, DC ± 10 V

© WAGO Corporation, Germantown WI 28

Specialty Modules

Serial Interfaces
750-650 Serial Interface RS 232 C
Counter Modules
750-653 Serial Interface RS 485
750-404 Up / Down Counter, DC 24 V, 100 kHz
750-652 Serial Interface RS 232/RS 485 Configurable
750-638 2 Channel, Up / Down Counter, DC 24 V/ 16Bit / 500 Hz
750-651 TTY-Serial Interface, 20 mA Current Loop
Frequency Measuring
750-654 Data Exchange Module
750-404/ Frequency Measuring 0.1Hz – 100kHz
000-003 Networking

Vibration Monitoring 750-641 DALI/DSI Master Module

750-645 2 Channel Vibration Monitoring 750-642 enocean Radio Radio Receiver

Pulse Width Module 750-643 MP-Bus Master Module

750-511 2-channel Pulse Width Module, DC 24 V, 750-655 AS-Interface


short-circuit-protected, high-side switching
750-482 2 AI 4M20mA HART Module
DC Drive Controller 750-658 CAN Gateway(CANopen/J1939)
750-636 DC-Drive Controller 24V/5A 750-644 Bluetooth® RF-Transceiver Module
Proportional Valve Module 750-657 IO Link Master
750-632 Proportional Valve Module supports Pneumatic or Hydraulic Stepper Controllers
Valves
750-670 Stepper Controller, RS422
Angle and Distance
750-671 Stepper Controller, 24V/1.5A
750-630 SSI Transmitter Interface
750-672 Stepper Controller, 50V/7.5A
750-637 Incremental Encoder Interface RS 422, cam outputs
750-673 Stepper Servo, 50V/7.5A
750-634 Incremental Encoder Interface, DC 24 V
750-635 Digital Pulse Interface

© WAGO Corporation, Germantown WI 29

Supply Modules

AC 230 V Power Supply Modules


750-612 AC/DC 230 V without diagnostics, passive
750-609 AC 230 V, max. 6.3 A without diagnostics, w/ fuse-holder
750-611 AC 230 V, max. 6.3 A with diagnostics, with fuse-holder
Filter Modules
750-624 Filter Module for field side power supply
750-626 Filter Module for system and field side power supply
Field Side Connection Module
Module Bus Extension 750-603 Field Side Connection Module, 8 (+)
750-627 Module Bus Extension, End Module 750-604 Field Side Connection Module, 8 (-)
750-628 Module Bus Extension, Coupler Module 750-614 Field Side Connection Module, AC/DC 0 ... 230 V
DC Power Supply Modules 750-1605 Field Side Connection Module 16 (+)
750-602 DC 24 V, passive 750-1606 Field Side Connection Module 16 (-)
750-601 DC 24 V, max. 6.3 A, without diagnostics, with fuse-holder 750-1607 Field Side Connection Module 8(+) / 8(-)
750-610 DC 24 V, max. 6.3 A, with diagnostics, with fuse-holder Separation Modules
750-625 DC 24 V, EEx i, diagnostics, with fuse-holder 750-616 Separation Module / DC 24 V / AC 230 V
750-623 DC Input 24V/Output 5V, 8V, 10V, 12V, 15VDC/.5A 750-621 Separation Module with Power Contacts
Internal Supply Module Binary Spacer Module
750-613 Bus power supply, 24 V DC 750-622 Binary Spacer Module
AC 120 V Power Supply Modules End Module
750-615 AC 120 V, max. 6.3 A without diagnostics, w/ fuse-holder 750-600 End Module, to loop the internal bus

© WAGO Corporation, Germantown WI 30

391
I/O Modules: Color Code and Markers

I/O Modules are color coded for easy identification

Yellow – Digital Inputs


Red – Digital Outputs
Green – Analog Inputs
Blue – Analog Outputs
Clear – Specialty or Supply

Group Marking Carriers allow clear


labeling of I/O modules. They can be
withdrawn and replaced.

© WAGO Corporation, Germantown WI 31

I/O Module Components

Status LED
(module specific) Internal Bus Contacts
(KBUS)

WSB Markers

Power Jumper Contact Power Jumper Contact


(feed blade contact) (feed spring contact)

CAGE CLAMP
Connections

© WAGO Corporation, Germantown WI 32

WAGO-I/O-SYSTEM 750 Ex i

13 Intrinsically Safe Modules


750-606 24V DC 1.0A Power Supply Ex i [ia]
*
750-625/000-001 24V DC 1.0A Power Supply Ex i [ia]
750-435 1DI NAMUR Ex i [ia] *
750-438 2DI NAMUR Ex i [ia]
750-535 2DO 24V DC Ex i [ib]
750-485 2AI 4-20mA Ex i [ib] *
750-484 2AI 4-20mA S.E. HART Ex i [ia] *
750-481/003-000 2AI RTD Ex i [ia] *
750-487/003-000 2AI TC Ex i [ia] *
750-585 2AO 0-20mA Ex i [ia]
750-586 2AO 4-20mA Ex i [ia]
750-633 Up/ Down Counter Ex i [ia] *
750-663/000-003 4F-Ex i DI 24V PROFIsafe V2 iPar

Differentiate WAGO Automation with Blue Modules!

© WAGO Corporation, Germantown WI 33

392
Series 750 For Harsh Temperature Environments

• Part Numbers: 750-xxx/025-000


• Will withstand Operating
Temperatures of –20ºC to +60ºC
Compared to standard Series 750
0ºC to +55ºC
• How did we do it?
Special components and materials
Enhanced design
Coated PCBs

© WAGO Corporation, Germantown WI 34

Series 753 Pluggable Wiring System

Tool-less assembly of
connector and module

Coding feature
For added safety

Built-in eyelet
for wire-tie
strain relief

© WAGO Corporation, Germantown WI 35

Bus Extension Modules

Bus Extension Modules make panel layout flexible.

• Max. no. of I/O


modules: 250
• Max. no. of bus
extensions: 10
• Cable length:
5m
• Cable: STP-
cable with RJ45
(straight through
cable)

© WAGO Corporation, Germantown WI 36

393
Assembly Features

Controller
Locking Disc Secure
Tongue and
Groove
Connections

DIN Rail Module


Mounting Release Lug
(without tool)
© WAGO Corporation, Germantown WI 37

Cage Clamp

All modules use WAGO CAGE


CLAMP connections. This
connection is appropriate for solid,
stranded, and fine stranded
conductors. Each clamping unit
accommodates one conductor.

1) Insert a screwdriver or operating tool in


the opening above the connection point.
2) The screwdriver blade holds the clamping
spring open. Insert the conductor into the
connection point.
The WAGO CAGE CLAMP connections
provide fast and easy wiring with high 3) Withdraw the screwdriver – the conductor is
reliability. The connections are vibration- securely clamped.
proof and maintenance-free.

© WAGO Corporation, Germantown WI 38

Isolated Power Groups

There are three electrically isolated power groups in a node. Isolation is


achieved by DC to DC converters.

INTERNAL SYSTEM SUPPLY POWER

FIELDBUS
POWER
FIELD WIRING POWER

© WAGO Corporation, Germantown WI 39

394
Internal System Supply

The Coupler/Controller requires 24VDC (-15% to +20%) for the


Internal System Supply.
+24 VDC The 24VDC for the System Supply is
converted to 5 VDC, and then is used
to power the controller electronics,
fieldbus interface, and the I/O
modules via the internal bus (K-Bus).
The I/O current draw of the 5VDC
0 VDC
bus must not exceed the specified
value for the selected controller (e.g.,
750-881 Total Current for I/O
Modules is 1700 mA).

© WAGO Corporation, Germantown WI 40

Internal Supply Module

If the I/O current consumption of the 5VDC Internal Supply


exceeds the specified value for the selected controller, an
Internal Supply Module (750-613) is required.

An Internal System Supply Module increases the


current capacity for the internal 5V bus by 2
amps. It’s placed before the module where the
current capacity is exceeded.
Very large nodes may require one or more
Internal System Supply Modules.

© WAGO Corporation, Germantown WI 41

Internal System Supply Example

A node with an Ethernet Controller (750-881) consists of 20 relay modules


(750-512) and 20 digital modules (750-405). Is an Internal System Supply
Module required?

750-881 Total Current for I/O Modules is 1700 mA (Catalog W5V3 pg 40)
750-512 Current Consumption 100mA/module (Catalog W5V3 pg 135)
750-405 Current Consumption 2mA/module (Catalog W5V3 pg 119 )

750-512 100mA /modules x 20 modules 2000mA


750-405 2mA/modules x 20 modules + 40mA
2040mA

Answer: 2040mA > 1700mA; therefore, an Internal Supply Module is


required in the middle of this node. It’s placed before the module where the
current capacity is exceeded.
© WAGO Corporation, Germantown WI 42

395
Internal System Supply Module

Internal Supply 1 Internal Supply 2

Internal
System
Supply
Module
(750-613)

© WAGO Corporation, Germantown WI 43

Field Supply

The Coupler/Controller provides a connection for the 24VDC


field wiring. The field power is extended to adjacent modules
through Power Jumper Contacts.

+24 VDC
POWER
0 VDC JUMPER
CONTACTS
GROUND

© WAGO Corporation, Germantown WI 44

Power Jumper Contacts

Power Jumper Contacts consist of blade and spring contacts built


into the sides of modules. Depending on the module type and
features, the contact configuration varies.

= Spring Contact
= Blade Contact

NOTE: Power Jumper Contacts


of adjacent I/O modules must
be compatible (i.e., blade
contacts must have a
corresponding spring contacts).

© WAGO Corporation, Germantown WI 45

396
Power Jumper Contacts

Power Jumper Contacts of adjacent I/O modules must be compatible


(i.e., blade contacts must have corresponding spring contacts).

PROBLEM
These two modules cannot be adjacent to
each other as shown. The left module does
not have a lower spring contact for the right
module’s lower blade.

SOLUTION
Rearrange the node to remove this
incompatibility (swap modules), or insert a
supply module between them. A supply
module has 0 blade contacts and 3 spring
contacts

© WAGO Corporation, Germantown WI 46

Supply Modules

Supply Modules provide field side power through the power jumper contacts.
They are use to introduce a new field potential or boost the current capacity of
the existing potential (available in 24VDC, 0-230VAC/VDC, 120VAC,
230VAC, fused, and diagnosis).

Existing Field New Field


Potential Stops Potential Starts
(e.g., 24VDC) (e.g., 230VAC)

© WAGO Corporation, Germantown WI 47

Fused Supply Module

Fused Supply Modules provide quick and easy access to fuses for
replacement. Additionally, a blown fuse indicator LED is
provided.
Fuse
Blown Replacement
Fuse LED

Fuse
Holder

© WAGO Corporation, Germantown WI 48

397
Field Supply Example

This example illustrates three different voltage sources for field


devices (i.e., 24VDC, 230VAC, and 24VDC). Two Supply
Modules are used to introduce the new voltage sources.

PFC Supply
Field Modules
Supply

24V 230V 24V

© WAGO Corporation, Germantown WI 49

I/O Module Process Image

The coupler/controller generates an internal process image from


the data width and type of I/O modules, as well as the position of
modules in the node. This image is divided into an input and
output area.
Output Process Image (words)
AO (750-550) WORD 1
0
AO (750-550) WORD 2 1
2 1 0

Input Process Image (words)


AI (750-472) WORD 1
0
AI (750-472) WORD 2 1
2 3 2 1 0

© WAGO Corporation, Germantown WI 50

I/O Module Process Image Rules

1) Input modules are mapped into the input process image


2) Output modules are mapped into the output process image
3) Analog and specialty modules are mapped first into the
process image. They are mapped in the order of their position
after the controller. The analog module closest to the
controller is mapped first, and so on.
4) If there is not a digital offset programmed in the controller, the
digital modules are mapped after the analog modules, in the
form of words (16 bits per word). When the number of digit
points exceed 16, the next word is started.
Note: Most Specialty Modules have both input and output data;
therefore, they use both the input and output process image.

© WAGO Corporation, Germantown WI 51

398
Input Process Image Example

Input Process Image


0 AI MODULE 1, WORD 1

1 AI MODULE 1, WORD 2

2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...

Each 750-472 2-Channel Analog Input module produces 2 words


of data per module in the input process image. See page 51 of the
WAGO 750-841 manual for module process data requirements.

© WAGO Corporation, Germantown WI 52

Input Process Image Example

Input Process Image


0 AI MODULE 1, WORD 1

1 AI MODULE 1, WORD 2

2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1

5 AI MODULE 3, WORD 2

6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...

Each 750-472 2-Channel Analog Input module produces 2 words


of data per module in the input process image. See page 51 of the
WAGO 750-841 manual for module process data requirements.

© WAGO Corporation, Germantown WI 53

Input Process Image Example

Input Process Image


0 AI MODULE 1, WORD 1

1 AI MODULE 1, WORD 2

2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1

5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...

Each 750-472 2-Channel Analog Input module produces 2 words


of data per module in the input process image. See page 51 of the
WAGO 750-841 manual for module process data requirements.

© WAGO Corporation, Germantown WI 54

399
Input Process Image Example

Input Process Image


0 AI MODULE 1, WORD 1

1 AI MODULE 1, WORD 2

2 AI MODULE 2, WORD 1
3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1
5 AI MODULE 3, WORD 2
6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...

Each 750-402 4-Channel Digital Input module produces 4-bits of


data per module in the input process image.

© WAGO Corporation, Germantown WI 55

Input Process Image Example

Input Process Image


0 AI MODULE 1, WORD 1

1 AI MODULE 1, WORD 2

2 AI MODULE 2, WORD 1

3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1

5 AI MODULE 3, WORD 2

6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...

Each 750-402 4-Channel Digital Input module produces 4-bits of


data per module in the input process image.

© WAGO Corporation, Germantown WI 56

Input Process Image Example

Input Process Image


0 AI MODULE 1, WORD 1

1 AI MODULE 1, WORD 2

2 AI MODULE 2, WORD 1

3 AI MODULE 2, WORD 2
4 AI MODULE 3, WORD 1

5 AI MODULE 3, WORD 2

6 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
7
...

Each 750-402 4-Channel Digital Input module produces 4-bits of


data per module in the input process image.

© WAGO Corporation, Germantown WI 57

400
Output Process Image Example

Output Process Image


0 AO MODULE 1, WORD 1

1 AO MODULE 1, WORD 2

2 AO MODULE 2, WORD 1
3 AO MODULE 2, WORD 2
4 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0
5
...

The 750-550 2-Channel Analog Output module consumes 2 words


of data per module in the output process image. The 750-501 2-
Channel Digital Output module consumes 2-bits of data per
module in the output process image.

© WAGO Corporation, Germantown WI 58

Output Process Image Example

Output Process Image


0 AO MODULE 1, WORD 1

1 AO MODULE 1, WORD 2

2 AO MODULE 2, WORD 1
3 AO MODULE 2, WORD 2
4 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0

5
...

The 750-550 2-Channel Analog Output module consumes 2 words


of data per module in the output process image. The 750-501 2-
Channel Digital Output module consumes 2-bits of data per
module in the output process image.

© WAGO Corporation, Germantown WI 59

Output Process Image Example

Output Process Image


0 AO MODULE 1, WORD 1

1 AO MODULE 1, WORD 2

2 AO MODULE 2, WORD 1

3 AO MODULE 2, WORD 2
4 1
5
1
4
1
3
1
2
1
1
1
0 9 8 7 6 5 4 3 2 1 0

5
...

The 750-550 2-Channel Analog Output module consumes 2 words


of data per module in the output process image. The 750-501 2-
Channel Digital Output module consumes 2-bits of data per
module in the output process image.

© WAGO Corporation, Germantown WI 60

401
Digital Input/Output Offset

(Programmable Fieldbus Controllers Only)

© WAGO Corporation, Germantown WI 61

Digital Input/Output Offset

Digital Inputs start at word 64 Digital Outputs start at word 64

Input Process Image Output Process Image


0 AI MODULE 1, WORD 1 0 AO MODULE 1, WORD 1

1 AI MODULE 1, WORD 2 1 AO MODULE 1, WORD 2

2 2
M M
64
1
1
1
0 9 8 7 6 5 4 3 2 1 0 64 1 0

© WAGO Corporation, Germantown WI 62

Internal Bus (K-bus)

• The internal bus is the


communication link between the
coupler/controller and the I/O
+5VDC modules, as well as a distribution
COM system for the system supply voltage
T_DIO
T_DIN • The internal bus uses 6 spring
T_CLK contacts. (see figure on the left)
T_SEL
• Data is communicated to I/O
modules in a serial fashion, similar
to a large shift register.

© WAGO Corporation, Germantown WI 63

402
Internal Bus Cycle Example

The Internal Bus can exchange one word of data per module per bus cycle.
Therefore, when multi-word modules are used, the controller requires multiple bus
cycles to exchange all module data.
EXAMPLE NODE DATA EXCHANGE PER BUS CYCLE
4 4 2 4
CYCLE 1 DIGITAL DATA 2CHAN WORD1 4CHAN WORD1
P C
H
C
H
C
H
C
H
nN

CYCLE 2 2CHAN WORD2 4CHAN WORD2


F D
I
D
I
A
N
A
N
G G A A
CYCLE 3 4CHAN WORD3
C I
T
I
T
L
O
L
O
A A G G
L L CYCLE 4 4CHAN WORD4

The 4-Channel Analog module used in this node, forces the controller to perform
four bus cycles to exchange all module data.

© WAGO Corporation, Germantown WI 64

Internal Bus Cycle Time Comparison

TEST NODE 1 TEST NODE 2

750-881 Controller 750-881 Controller


750-519 4 Chan Digital Out 750-519 4 Chan Digital Out
750-519 4 Chan Digital Out 750-519 4 Chan Digital Out
750-452 2 Chan Analog In 750-452 2 Chan Analog In
750-557 4 Chan Analog Out 750-552 2 Chan Analog Out
750-600 End Module 750-552 2 Chan Analog Out
750-600 End Module
Calculated Update Time 420us
Data Size 80 bits Calculated Update Time 260us
Number of K-Bus Cycles 4 Data Size 80 bits
Number of K-Bus Cycles 2

This comparison illustrates that using two 2 -Channel Analog module, instead of
one 4-Channel Analog module, improves the bus cycle.

© WAGO Corporation, Germantown WI 65

PERSPECTO® CP TV
Integrated HMI and PLC
Features
• PLC-HMI runtime
• Logic Programming: CoDeSys V2.3
• Graphic Development: CoDeSys
V2.3
Advantages
• Reduce engineering development
time
• Advanced logic editor
• Easy connection to WAGO I/O

© WAGO Corporation, Germantown WI 66

403
PERSPECTO® CP TV
15.0”
762-3150/000-001w/o CANopen
762-3150/000-001 w/ CANopen
Intel Atom 1.6GHz
RAM:256M
Flash: 128M

12.1”-762-3121/000-001 Control Panel Target Visualization


32-Bit XScale 520Mhz
RAM:64M •Offered in a wide variety of
Flash: 32M
screen sizes
10.4”-762-3104/000-001 •Optimize the screen size for the
32-Bit XScale 520Mhz
RAM:64M application
Flash: 32M
•Powerful processors and large
5.7”-762-3057/000-001 memory
32 Bit ARM9 240MHz
RAM:64M
Flash: 32M
3.5”-762-3035/000-001
32 Bit ARM9 200MHz
RAM:64M
Flash: 32M
© WAGO Corporation, Germantown WI 67

PERSPECTO® CP TV
10.4”, 12.1”, 15” Memory
Expansion
5.7” •Data Logging
3.5” •Trend data
•Event Data

758-879/000-000 1 GB
Industrial CF Memory Card

758-879/000-001 1 GB
Industrial SD Memory Card

758-879/000-002 1 GB
CF Card SD Card microSD Industrial microSD Memory Card

(Maximum 2 GB) (Maximum 2 GB)


Card
(Maximum 2 GB)
© WAGO Corporation, Germantown WI 68

PERSPECTO® CP TV
12.1”& 10.4” 5.7”
Multiple
Communication
Ports

Serial &
CAN bus

Ethernet USB
Port Port
Battery USB 24V Power
Serial
Ports Ports 1,2
24V Power Ethernet
Battery USB Port
Ports Serial Ports CAN bus
Ethernet 1,2 & 3
Port 3.5
CAN bus ”
Ports 1 & 2
24V Power Battery

© WAGO Corporation, Germantown WI 69

404
PERSPECTO® CP TV
RAS Server

SCADA
System
Supervisory Database
System Server

767 SPEEDWAY
Distributed I/O ETHERNET 2.0
PLCs

CF, SD,
AC Drives
MicroSD for
Serial memory
Expansion

Barcode Serial USB Mobile


Reader Memory for
application
backup and
restore

CANopen
J1939
SPEEDWAY
750/ 753 Device
Distributed
Series I/O
CANopen
Distributed
I/O
© WAGO Corporation, Germantown WI 70

TAKING IT TO THE EXTREME -


750XTR

WAGO-I/O-SYSTEM
750 XTR

© WAGO Corporation, Germantown WI 71

WAGO Automation Platforms

PERSPECTO

Industrial PC

PFC200

750 XTR Series

Automation Platforms
750 Series Standard
for your specific
SPEEDWAY – IP67
applications

© WAGO Corporation, Germantown WI 72

405
eXTReme I/O for extreme applications
TAKING IT TO THE EXTREME -
750XTR

Built on the benefits of the series


750:
• Flexible I/O system
• Network Independent
• Couplers for distributive I/O
• Powerful PLCs
• Feature rich programming
software
• Scalable solution (protect your
IP)
• Quality and reliability
• Small footprint
• Low initial costs
• Low cost of ownership

© WAGO Corporation, Germantown WI 73

eXTReme eXTReme Temperatures


Temperature

Built for eXTReme Temperatures:


• Operating Temperature: of -40 °C to
+70 °C
• Relative Humidity: 95%
• Condensation: Permitted per IEC
60721-3-3 (except wind driven
precipitation and ice formation)
Benefits:
• No air condition Required
• Reduce cabinet dimensions
• Lower energy consumption
• Reduce maintenance
• Reduce costs

© WAGO Corporation, Germantown WI 74

eXTReme Rugged Applications


vibration and shock
Built for eXTReme environments:
• Vibration: 5g per EN 60068-2-6
• Shock: 25g/6MS/1000 shocks
• EMC protection 24V modules:
0.5kVAC/775 VDC, 1Kv impulse
• EMC protection 230 V modules:
2.5kVAC/3.5 VDC, 5.0KV impulse
voltage

Benefits:
• Use in mobile applications
• Install on high vibration tools
• Use in high voltage applications

© WAGO Corporation, Germantown WI 75

406
eXTReme altitudes

Built for eXTReme environments:


• Use up to 6,500 ft without de-rating
• 6,500 ft to 9,800 ft max operating temp.
65oC
• 9,800 to 13,000 ft max. operating temp.
60oC
• 13,000 to 16,000 ft max operating temp.
55oC
• Can be used as overvoltage category II
up to 26,000 ft with max operating temp.
40oC

Benefits:
• Use in high altitude applications

© WAGO Corporation, Germantown WI 76

750 XTR series offers many control options

Programmable Fieldbus Digital Inputs and Outputs


Controllers
• 2 channels, 8 channels, 16 channels
• ETHERNET
• 24 V and 230 V
• ETHERNET Telecontrol
Analog Inputs and Outputs
• CANopen
• Current signals
Coupler
• Voltage signals
• ETHERNET
• Temperature
• PROFIBUS
Communication, Supply and Segment
• CANopen Modules
• Serial interface
• 24V and 0-230V power supply
• Filter
• Potential multiplication module
• End Module

© WAGO Corporation, Germantown WI 77

Series 750 XTR – I/O Modules


Digital Inputs and Outputs
750-1405/040-000 16 DI 24 V DC 3.0 ms /XTR
750-1415/040-000 8 DI 24 V DC 3.0 ms/2-wire /XTR
750-508/040-000 2 DO 24 V DC 2.0 A/Diagnostics /XTR
750-1515/040-000 8 DO 24 V DC 0.5 A/2-wire /XTR
750-407/040-000 2 DI 220 V DC 3.0 ms /XTR
750-517/040-000 2 DO 230 V AC 1.0 A/Relay 2CO /XTR

Analog Inputs and Outputs


750-468/040-000 4 AI 0–10 V DC S.E. /XTR
750-457/040-000 4 AI ±10 V DC S.E. /XTR
750-453/040-000 4 AI 0–20 mA S.E. /XTR
750-455/040-000 4 AI 4–20 mA S.E. /XTR
750-464/040-000 2/4 AI RTD configurable /XTR
750-469/040-000 2 AI Thermocouple configurable/XTR
750-559/040-000 4 AO 0–10 V DC /XTR
750-557/040-000 4 AO ±10 V DC /XTR
750-563/040-000 2 AO 0/4–20 mA/6–18 V DC/16 Bit /XTR
Communication, Supply and Segment Modules
750-652/040-000 Serial Interface RS232/RS485 /XTR .
750-602/040-000 24 V DC Power Supply /XTR
750-624/040-001 24 V DC Field Supply Filter/HI /XTR
750-613/040-000 24 V DC Power Supply (Bus) /XTR
750-626/040-000 24 V DC Supply Filter (Surge)/HI /XTR
750-612/040-000 0–230 V AC/DC Power Supply /XTR
750-1605/040-000 Potential Multiplication 16+ /XTR
750-1606/040-000 Potential Multiplication 16- /XTR
750-0600/040-000 End Module /XTR

© WAGO Corporation, Germantown WI 78

407
WAGO 750 Series I/O module comparison

750 Series - 750 series - Extended


Requirement 750 XTR Series
Standard Temp.
Operating
0 oC to + 55o C -20o C to +60o C -40o C to + 70o C
Temperature
Vibration 4g 4g 5g
Shock 15g / 11ms / 3 axis 15g / 11ms / 3 axis 25G/ 6ms/ 3 axis
Per Class 3K7 EN
Temporary 60721-3-3 ( except
Not Permitted Not Permitted
Condensation wind driven rain
and ice building

<60 V: 0,5 kV AC /
60 V: 0,5 kV AC / 0,5 60 V: 0,5 kV AC / 0,5 kV
1,0 kVimpulse
kV impulse voltage impulse voltage
voltage (VW1)
Electric insulation (EN
60870-2-1)
≥ 60 V: 2,5 kV AC /
≥ 60 V: 1,5 kV AC / 2,5 ≥ 60 V: 1,5 kV AC / 2,5
5,0 kVimpulse
kV impulse voltage kV impulse voltage
voltage (VW3)

© WAGO Corporation, Germantown WI 79

Taking it to the extreme –750 XTR


Characteristics
● Built on proven WAGO-I/O-SYSTEM 750
● Extreme extended temperature range -40 °C W +70 °C
● Withstands temporary condensation
● Increased vibration and shock resistance (5g acc.
EN60068-2-6)
● Increased electric strength (EN60870-2-1)
Advantages
● No air conditioning / heating required
● PLC for telecontrol applications (hardware and protocols!)
● Couplers for distributive I/O
● PLC for stand-alone applications
Benefits
● Easy configuration and maintenance
● Lower energy and maintenance costs
● Compact, flexible I/O system for eXTReme environments

© WAGO Corporation, Germantown WI 80

TAKING IT TO THE EXTREME -


750XTR

WAGO-I/O-SYSTEM
750 XTR

© WAGO Corporation, Germantown WI 81

408
Bluetooth® Ethernet Bridge (758-915)

• Wireless transmission of ETHERNET protocols


(like PROFINET, Modbus/TCP, ETHERNET IP, W)
via Bluetooth radio technology

• Bluetooth version 2.0


• Topology: Point-to-Point
• Frequency band: ISM band, 2402 – 2480 MHz
• Range: Maximum 1,000 ft
• Antenna: internal antenna, circularly
polarized
• Type of protection: IP65
• Operating temperature: -30 W +65 °C
• Dimensions: 91 x 66 x 36,2  compact
• Inputs: Power M12, A-type encoded
ETHERNET M12, D-type encode

© WAGO Corporation, Germantown WI 82

Bluetooth® Ethernet Bridge (758-915)

Applications

Ethernet Ethernet

Ethernet Ethernet

750-915 can be used in applications where point to point


communications is required.
© WAGO Corporation, Germantown WI 83

Series 852 Unmanaged Ethernet Switches

852-101 852-102 852-103


5-Port 8-Port 8TX/2FX ports

• Function monitoring via relay contact • Non-blocking, store-and-forward


switching
• DIP switches for enabling alarm functions
• Auto-negotiation on all 10/100BaseTX
• Redundant DC power supply ports
• Wide supply voltage range: 9-48VDC • Auto-MDI/MDIX (crossover) on all
• Full compliance with IEEE802.3, 802.3u 10/100BaseTX ports

© WAGO Corporation, Germantown WI 84

409
ECO 852-1111 Gigabit Switch

•Supports Ethernet Transmissions


•10, 100 or 1,000 Mbits/second
•Automatic data rate detection
•DIN rail mount
•Up to 2,000 devices can be
managed via MAC address list
•0C to +60C operating temperature

© WAGO Corporation, Germantown WI 85

Series 852-104 7TX/2FX Managed Ethernet Switch

• Web-based/SNMP • Non-blocking, store-and-


management forward switching
• Function monitoring via relay • Auto-negotiation on all
contact 10/100BaseTX ports
• DIP switches for enabling • Auto-MDI/MDIX (crossover)
alarm functions on all 10/100BaseTX ports
• Redundant DC power supply • VLAN (802.1q) VID
• Wide supply voltage range: 9- • IGMP Snooping for multicast
48VDC filtering
• Full compliance with • Port configuration, status,
IEEE802.3, 802.3u, 802.3x, statistics
802.1d, 802.1q, and 802.1p
standards • Port Trunking
• Xpress Ring (redundant ring • SNMPv1/v2 and RMON
recovery < 50ms)

© WAGO Corporation, Germantown WI 86

WAGO-I/O CHECK 3

• A Windows application for the checking of


inputs and outputs of a node during startup.
•Used to configure some specialty modules.
•The communication with WAGO-IO-CHECK
via :
•750-920 RS232 cable
•750-923 USB cable
•Ethernet
•Software to force outputs on and off directly
at the buscoupler:
•Debugging wiring
•General trouble-shooting
•Programming adjustable modules

WAGO 750-923
USB cable

© WAGO Corporation, Germantown WI 87

410
WAGO-I/O CHECK 3

Verify that the menu item “Settings…Com-Port” is correct for


your setup. Select “Node…Read Configuration”.

© WAGO Corporation, Germantown WI 88

WAGO-I/O CHECK 3

Using menu item “Node…Control Mode…Direct”, outputs can


be written to.

© WAGO Corporation, Germantown WI 89

WAGO-I/O-CHECK 3

Certain I/O modules can be configure via WAGO-I/O-CHECK.

© WAGO Corporation, Germantown WI 90

411
Applications
Gas Measurement equipment
WAGO Products:
750 I/O system

• Continuous mud sample


analysis
• Huge cost saving by using
standard gas ejection system
• Better quality sample analysis
• Automated Gas analyzer
calibration
WAGO I/O

© WAGO Corporation, Germantown WI 91

Applications
Application:
Modernize Prison Controls
WAGO Products:
Series 750 PFC & I/O
Series 758 IPC
Series 787 P.S.
Solution:
Compact Hardware
Flexible Software
Support
750-880
- Door releases, Door position,
Water, Lighting, Telephone
Intercom button, Smoke
detection
IPC’s

Sherriff’s Jail Jail Control - Visualizations


Office Control Room
Room Kiosk #2 - Input to lock out
Kiosk #1 comms to Jail Control
Room IPC’s during a
jail overrun

© WAGO Corporation, Germantown WI 92

Applications
Industry: Advanced ROV
Exploration & Ocean Research
WAGO Products:
• 750-316 MODBUS Coupler
• 788 series relays

Problem Solved:
Reduce overall weight of ROV while
increasing on-board functions for
chemical dispensing and sample
collections.

© WAGO Corporation, Germantown WI 93

412
Applications
Industry:
Transportation

WAGO
Products:ProfiBus
PFC Relays,
Distribution blks,
Fuse blks, Double
Deck

Problem Solved:
Reduced parts
and added
reliability.

© WAGO Corporation, Germantown WI 94

Applications

Industry:
Fuel Cells as
Alternative
Energy

Problem Solved:
WAGO Products: 870, Quick start up, end of loose terminations and now
280, 859, & 750-841 additional modularity with 750 series I/O
© WAGO Corporation, Germantown WI 95

Applications

This application illustrates communications between a


Allen-Bradley Controllogix system and a Yaskawa SMC-
3010 using a WAGO 750-841 as a gateway.
Because the Allen-Bradley Controllogix
uses the Ethernet/IP protocol, a gateway is
recommended to simply and quickly
establish communications via Ethernet.
Yaskawa SMC-3010, SMC-4000, and MP
series are capable of communications
using the Modbus TCP protocol. The Wago
750-841 PFC supports both the Ethernet/IP
and Modbus TCP protocol. Therefore with
minimal programming it may be used to
exchange data between an Allen-Bradley
Controllogix system with an Ethernet
module and a Yaskawa SMC motion
controller.

© WAGO Corporation, Germantown WI 96

413
Applications
Offshore Safety on drilling
and production platforms.
WAGO Products:
750-841, 750-87, I/S,
280 Series

Problem Solved: Function,


Dependability, Expansion,
Price.

© WAGO Corporation, Germantown WI 97

Applications
Industry: Pharmaceutical

WAGO Products:
WAGO 750-841 Controller along with
750 series I/O
Problem Solved:
The WAGO 750-841 provided a fast &
reliable solution to control 48x
Temperature PID zones
Drives controlled by WAGO Serial
interface/Modbus
© WAGO Corporation, Germantown WI 98

Applications
Drying Systems(Printing)
• Small and Wide Web systems
• Easily customized to customer
requirements
• Modular systems

750-881
Programmability– PID loop, RTD
module and discrete I/O.
IEC61131-3 programming tool for
selling to Europe
Ethernet IP or Modbus TCP
Built in switch

© WAGO Corporation, Germantown WI 99

414
Applications

Retrofit Diesel Engine Emissions


Monitoring System
Offshore Drilling Rigs/Ships
Offshore Service Boats
Offshore Tug Boats

NOx monitoring equipment


installed on all diesel engines

750 Series and Terminal Blocks had


all Marine and Class 1, Division 2
Approvals.
© WAGO Corporation, Germantown WI 100

Applications
Industry:
Semiconductor

Application Description:
Metallization- Sputter Problem Solved: The WAGO 750 Series I/O spec’d. as the
Deposition Systems for new preferred System Control Platform. The utilization of
WAGO products significantly reduced costly wiring and
processing wafers.
offered a much more flexible off-the-shelf I/O solution.

© WAGO Corporation, Germantown WI 101

Applications
Flight Simulators
• Wago 750-880 Ethernet
• Wago TJS Terminal Blocks
• Wago 788 Relays

Military, Commercial, Table Top FAA Cert.


Full Motion Wrap Around Screen & Enclosure

© WAGO Corporation, Germantown WI 102

415
Applications

• Industry: Chemicals
• Wago Products used:
750 Series I/0
• Problem Solved:
– Replaced expensive, obsolete
Yokogowa DCS I/O

Manufacture chemicals
used in Paper/Pulp,
Leather production,
Water Treatment, and
Performance chemicals
© WAGO Corporation, Germantown WI 103

Applications
Seam Welding Machines

• 750-881
• Thermocouple
• Encoders
• Various Other Analog & Discrete
Awnings
Inflatable life rafts
Inflatable furniture
Whitewater rafts

© WAGO Corporation, Germantown WI 104

Applications
Tug boat transfer Barges
APPLICATION:
Engine Monitoring:
Engine Data used to find the
right mix of Biofuel/Diesel

Safety Alarm system


Motion detection in the Pilot
room

Monitoring Engines
4-20 mA: Oil Pressure, Fuel Pressure
Thermocouple & RTD: Water, Oil, Exhaust,
Intake Air, Fuel
DI & DO: Fuel Tank/Water Level & Alarm
Current and Voltage Measurement: Ship Bus &
Steering Motor
Frequency Measurement: Engine Speed
© WAGO Corporation, Germantown WI 105

416
Applications

• 750-880 & Remote I/O


• WAGO Terminal Blocks

• Marine Stabilizer for Super


Yachts & Hydraulics

© WAGO Corporation, Germantown WI 106

Thank You

WAGO Corporation
P.O. Box 1015
Germantown, WI 53022

E-Mail: [email protected]
Internet: www.wago.com

© WAGO Corporation, Germantown WI 107

417

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