LTO LUBRICATION, SERVICE, AND MAINTENANCE DATAnor. Ay 0 w v w vr CoorER Lo RIGS MAINTENANCE AND OPERATING MANUAL TABLE OF cownENts unereatton 1, Draving ~ Rig Lube - 401 2. Drawing ~ Derrtek tube D545 3. Lube Specs. 1-618 4. Rig Lubrication Data (lube Intervals) 5. Rig Lubefeation Data ~ (Continued) 6. Filter Element Data COOPER LTO RIG SERVICE AND INSPECTION DATA Belly Inopettion | incpereor Tacks a. Mntnly tection | Br Sete espestion RIG OPERATION 1. Pre-Check 2. Ingine Start-Up Procedures 3. Engine Shut-Down 4 Roading 5. Driving Suggestions 5. Location Preparation 7. Rig-lp on Location, 8. Derrick Set-Up 9. operator Platform 10. control Preparation, (a) Ate System (b) Tubing Drum Clutch Operation (c) Tubing Drum Brake control (@) Sendline Drum Clutch (e) Sandline Drum Brake Control (2) Mater Brake Cooling () Hydraulie syster 5 OPTIONAL, AUXILIARY pQUTEMENT 1. Hydrotarder Operation and Contxols 2. notary Drives (a). Chain Driven Rotary Drive () > Propettes Share Rotary Drive 3. Aueitiary Catline Winch = (fiydraulte) 4i Mydrasub’ (Power Swivel) Deive (iydraulte) x 6 Catworke ‘Tong Drive [FRONT HN ALIGNMENT AND TOW-IN_ ADJUSTMENT BUDD WIEEL, MATNTENANCE. DATA ASSEMBLY TORQUE VALUES PAGE NO. saa a 10 rr 2 13 a a ua u is 15 5 1s 16 Fa 16 16 i uv v ” 18 1 18 a8 a Fa vb 20 thru! 27 20“ * pa 5 |INTERNATIONAL, SALES CHECK LIST Dare wir custoxen (Before starting this check 11st - famitiarize yourself with Sales Order) Cheek oach iten and £111 in blank, Sf overything is OK, just initial, If Ghaitional space is required for remarks, use reverse side of paper. 1. ENGINE: Engine O11 j Is idle sot? ‘transmission O11 {Ie transmission and shisTer Tights synchronized? Engine cooling fluid un engine, check instruments, noise, ete. LUBRICATION: (Drawworks and Carrier) Chain cases lubricator } Grease Drawiorks boaring® 5 Revel Gear Tox Rear Axles (ALL) PAIL hydraulic: tank 4. Povor Steering tank 5, Check air to brake water tank 6. COMPRESSOR: Hoses & Leaks j Check alr at clutches (120 Pst) 7. HYDRAULIC PUMP (2000) PST: Hoses & Leaks Level Legs 8. Adjust brakes, if required, all drums. Check Linkage, clevis, pins, seers tumnbuckles, levers, noise and other itens that are involved wth brakes. 9, Run drums through all gears, check for noise fre drums correct size por sales order 10, ELECTRICAL (Lights): Front 5 Roar j Clearance 5 ‘Turn signals Sinstrimenes Cov 11, TIRES (Front and Rear): Are. they per sales order 5 Wheel lub nuts tight “7 Axle torque Pressure 3 rod bolts (30 Fr, ibs) walking Weis Bolts (300 ft. tbs.) Schock Tine up with straight edge and visually (tain Fearing wheel to Limit in both directions, then recheck Line wp.) 12, Check drive Hnos, tighten bolts 18, Check bolts around unit for tightnoss 14, Check nane plates and serial plates MA, Lige eyes or equipment? >a, 2 23. 24, 25. 26, Raise and extend derrick or pole (4 tities minimum) Check for leaks, valves 5 cylinders! hoses Check wireline clearances at racking board, crown, rod board, drum guards, derrick and derrick Lights GUYLIMES: 4 Crovm 5 2 Cron to rig j 2 Rack board Rod Board Rod Air Lite 3 cable support Hines: Rack Board Anchor Lines CROWN: Are sheaves lubricated? 5 Ts crow’ sheaves ‘and wireline spool grooving CoFFece Np. 5 5.D, re thoy per Sales Order" APPEARANCE: Paint per Sales Order 5 Derrick paint Drawvorks and rig paint Fy Witals, bends or sexatcher on guards or rig 7 Ties and wheels cab SWAT unit and visually “Cheek OrrioNs: Hydrotarder 5 lydrotarder Taink fs Rotary Drive “~“———>Tatline Wineh ; Cathead TS Overall appearance of rig and aast Overall condition of unit Standard tools to go with unit: Spanner wrench ase plates for Jacks liydraulic jack 3 Cone~A-Longs P TAIT chains 7 wok ——; Spider "| uinks SF Hvators : Tongs Change hydraulic of1 fitter after completing aboveM-6IS, A a cooreR LUBE SPEC. [BP=2_BUARING GREAS! LrTuNUM SOAP nase Viscosity SUS ‘Ae 10081" 990-1200 ] Be 2I'P 75-85 250'F { Maximum Operatering Temperature | WIGt Grade 2 } eeaco wal eda t Shell Alvania 1 Phillips Phtlube , coorER Lupe spec. ES { [RUAR AXLES, SPIRAL BEVELS & HYPOTD GEAR GREASE EP. APL 2h} ~ 26.5 6.0.0. 400" = 42 Viscootty SUS At 100" F 700-991 Viscosity SUS At 210° P 60-86 ‘Texaco oltigear Lube EP-85-1-90 Shell Spirax iD. 80-W-90 Bevels & Rear Axles Spirax WD, 5-140 Steering Coax Phitltps Philube SMP Gear O11 80-H-90 85-4140 coormn wns sesc. [Wuse OTL, = CHAIN CASES AND OTLERS = SAE~20 . Viscosity SUS At 100° 203-350 Dao F 52.456 . Viscosity Index 100-108, Pour rosne 10°F ‘Texico ‘sat-20 Shell Rotella 011 20 Phillips Condor 20-20-H Lubricant spectfleatione shown on this page are for fhominal operating temperatures of 32 F to 110 FM-6I8 corm uae spre, BEARING GREASE ~ CALCIUM BASH —_GIATER RESTSTANT Texaxo Tovatex BP-Z shell Alvanta Ep? Philip Phitube EP-2 coopen LUBE spec. E> (HvDRAMLTC OTL) Viscosity Index 90 Min, Viscosity sus ‘At 100°F 125 to 250 Viscosity sus Ac 210°F 43 to 50 Pour 20° Aniline Point Lists. Rust & Oxidation Inhibitors RECOMMENDED AMBIENT TEMPERATURE OPERATING RaNcr TTexaxo Rando O11 H.D. Az32- HOF to 100°F) shell Donax T6 O11 (23°F to 100°) Tellus 012 32 C Or to 100°F) Exxon Univis 3-13 (40°F to 70°F) PhLLips Magnus 1-150 CAP to 100°F) A215 CAG to 100°)00 RIG_LUBRICATION 1 NOTE #1~ Lubiteation capacities are approxinate. Correct Levels should be J checked vith dipstick, gauge, of2 level plug, of other means provided Wore #°2~ due to widely varying conditions under which Cooper rigs aay operate Le 49 Amposstble to set extct tise Antervals for lubrication. These recomendations represent minimin intervals for average condition Operator experience and Mis first hand knowledge ot local operating conditions should better determine correct service and lubrication 7 Intervals. (See 4-618 lube Specs. (Page 3 & 4) for datatied lubricant spectfteattons). ecomeNDED HECK conc coven x WwBRICANT. QTY. Penton CHANGE PERIOD hevels ~ Right Angle Goar HP-85N-90 O11 Lovel Plug Mookly 6 Months Rear axle Gear joussng ¥9-654-90 O41 Level Plug 1000 Hitles 1 Year Drua Drive Chain Case 20 We. SAE Keep 042 Level ; at Pltch Line Of Drsye Spr. Weokly 1 Year AU neartoge m2 Zetk 2 Shot Bach Tour 7. | + Pivot Pine ara Zork ~ 2 Shots Rach Tour Déredok Rasal Bach Rig Up | GyLinder Pine cay Zork - 2 shote & Rig Down crown Bearings m2 erie ~ 2 Shots Dally Traveling Bock hearings m2 Zork ~ 2 Shots Datly nee Beartiige m2 ek ~ 2 Shots Yonthly : Front Axles and Suspension 2 Jerk ~ 2 Shote Monthy Near Suspension EP-2 ek - 2 shots Monthly warking Bean concer Show of Kew bushing Grease Monthly Tog Ate FP-854-50 —FLLL-PIog In ‘axle 6 Months Steoring Gear P5410 Weekly 1 Year Power Steering sAt-20 Wéckay 6 onthe Tower Dividers san50 Weckly 6 Month ydsauite caebine ‘inch P-054-90 2 Month 6 MonthsRECOMMENDED ream SCANT. Front Steering Derrick Seope Rams Jackserey Note red hydraulic Systen See Chart hydraulic Filters Return Line ydraulic Tank ‘breather Ase Filters Diesel tngine Filters Allison Transmission cueex. cueex, ucoreuNDED PERIOD uANCHE PERIOD, ‘Show of New Grease Weekly Clean Bxposed Ram & Coat W/ Hyd. 011 Monthly zerk ~ 3 snots wonthty ach Clean When Indicator Shows By-Paseing — Datly Wash Ost Keep Clean very 1000 tie clean'ae Required Refer to Mfg. ‘Manual Refer to Mtg. Manuva3 coor PNOINE om Para ‘wooet, carererpce orn ac Praga wen Ae Praise ove ac Prei32 wen ae Re “ALLISON "TRANSHISSION cur & cust~750 cour & oxBr-5860 POWER STEERING (GARRISON) ‘Ate Line Filter Air Compressor Strainer (8/4) Can-Plo Suction Line Filter PO RIG FILTER - REPLACEMENT RLIMiaTS POEL FILtER PRIMARY scownany 915 w-916 rans e916 91s TH916 ris 1-916 ELEMENT 3576200 3576200 # 612 (iNstDe RESERVOIR) P8-201 (Parker) 239292 Washable Element lydeauliec Félter (Parker) Model 41-RF 9287 Element. (@eturn Line) Washable and Reusable)COOPER RIG SERVICE AND INSPECTION DATA (cuneraL. succeszz0Ns) fa It 4a reconmended that a maintenance schedule be established for each Cooper rig, and that this service schedule be rigidly followed. Such a program will aid in the prevention of pre-nature parte failure, and failure in rig assenbiies. Tt will afd dn reduction of wear, and maintenance of rig condition; thus assuring Jouger se WLU Lew cust for Lepalts and dowi-tine, Rig maintenance will also provide leas hazardous conditions and therefore a more safe operation of the cquipsent. Cooper rige axe designed and manufactured with @ generous safety factor for strength in excess of that required for normal conditions. lovever, every rig. | begins to wear on the day At begine €o vork, This vearing process continues throughout the rig uéage until some day At will no longer perform its original work tack, Proper rig meintenanee, proper service and replacement of worn parts fas needed will extend useful rig Life. Due to widely varying conditions under which Cooper rige nay operate, those reconnendations are intended to be nominal operating service intervals for aver~ ‘age conditions, Experience of rig operator and his full knowledge of local conditions should better determine a correct echedule for apecifie use and area “conditions. Periodic viaual {napections are recommended to determine possible need for repairs bolts should be for replacenent of worn parta, During the inspection, loo: tightened, hydraulle or afr ayaten Leaks repatredyand any unusual vibration or noise corrected to prevent @ condition frow becoming dangerous and hazardous to operating personnel and equipnont.(COOPER RIG SKRVICE AND INSPRCTIOW ‘DATA 1 tn addition to the maintenance of inspection uted in thie schedule the rig operator wld follow the recomnonded maintenance and operating procedures 4n ‘ API Specification 4E for Portable Masta, APT RPOB Recomonded Practice om Application, Care and use of Wire Rope for OL1field Service and APIRPEN Recommended Practice for Hoisting Tool Tnapeetion and Maintenance Procedures, DALY INSPHCTION to Yo certain that rig ts safe for fmedtate use and ready to perform all required operations safety, 1 Iabricate the rig properly, 2 Fill Evel, lube of1, coolant, hydraulic of1, battery, and brake cooling water reservoiis to proper level, 3. Visually check for of1 leaks. 4 Visually check for loose bolts and nuts. 5 Check rig air system for leaks ~ adequate ale pressure. (Min. 100 PST ~ Max 130) DRAIN WATER PROM ATR TANKS AND GHECKATR LINE FILET, [ 6 chick derrick position on front headache frame, Lf rig ts An roading condition. 7 Gheck operation of hydraulte systen - no teaks, adequate Pressure capability (2000 P51 Max.) and adequate hydraulic ofl dn reservoir. (See edght gauge om tankt 8 See that alt brake Linkages are intact, brakes are properly adjusted and operate freely. 9 Gheck 11 control functions, see that all pine and keys are in place, 10 If rig 4s tn operation check giylines for proper tenston and ; ‘anchors for proper placement. ‘ 11 Gheck traveling block alignment with weil boro. 32 Drain water from atr tanks, 13 Check engines for noreal of1 pressure, coolant temperature, and alternator eharge rate.« (COOPER RIG SERVICE AND INSPECTION DATA DAILY INSPECTION ~ CHECK LIST ~ (CONTINUED) 14 hock tranomtsston for normal operating temperature and pressure. 15 Sheck load latches between top and mid section of derrick for proper position. 16 Check rig jacks and foundation for proper placement to correct any signs of settling or misalignment, MEEELY_msreRCrrON In additiosi to the items shown below, the weeldy inspection schedule should Anclude alt {tens Listed in the daily inspection, Operator experience and Knowledge of Local conditions, age and condition of the rig, the severity of operations to be encountered and consequences of failure of rig functions will, govern the degree of additional inspection required to assure operator and personnel, safety. {INSPECT THE FOLLOWING: 1 All drive Hines and Flange bolts. Replace any missing bolts with SAE Grade 8 capscrevs of proper dia. and length to conform to original drive flange bolts, All bolte are to be tightened to the proper torque. 1710 Series Drive Line: Mlange bolt eize 3/8" - Torque tbs./fe. 36 1000 Series rive Line: Flange bolt size 7/16" ~ Torque ibs./fe. 58 2 Chock alr quick release’ valves and relay vaives for proper actién. 3 Re-lube rig. See Spec. M-618 ABCDGE. See Lube Data Sheet, 4 Check brake vine and blocks ~ for even block wear, proper adjust= tment and smooth unscored rin eurface condition.C ; COOPER RIG SERVICE AND INSHECTION DATA vowrmy >) Th addftion to the tens shoun below, the: monthly achedule should include 411 Atoms shown for datly and weekly inspection, 1 Check all "V" belts for proper tension and condition. 2 heck chain drives for any signs of sprocket weaty cll Iooseness or misalignment. Check bolted sprocket hub bolts to assure all are in place and tight, (Bee Torque Chart Page 28). 3 Chock rig tires for any cuts, brutses or signs of uneven wear ~ recheck for. proper inflation pressures 20:00 x 20 wry 75 Pst ib ply 90 PSE azely 75 PST Mery 90 Pst Duplex 14 Ply 5 PSE Duplex «6 Ply 100 FST 5 Duplex 16 Ply 90 PST Duplex «16 Ply 85. PSL Duplex «18 Ply 100 PST 4 Re-tighten ali axie torque rod bolts, 200 1bs./£t, 5 Check axle walking beam bushings and tighten eaddle cap nuta to 300 Ibe./fe, 6 check front end axle alignment and tov-in. (See Page 20). Recheck all vheot lug bolts - review Budd wheel recommended sounting torque. (See Page 21 to 27). 8 Vipually inspect rig and derrick for paint cracking or Making. Check alt nonbers of derrick and rig for dents, deformation, ete. that may require inmediate correction. 9 thoroughly examine the entire hydravlle ayaten for leaks, hose derormation, hose abrasive vear or severe seuft damage, Replace any danaged’hoses or Citeings 10 Check a11 mechanteal control Linkages for secure keys and pins or retaining nuts and set screws. Check freedom of movement of Linkages t6 be sure all are in safe working condition, 11 check ats suspe 85 PSI pressure. sion pressure on 3rd rear axle, Maintain 75 ¢o #061479( gute sx (6) own 5 COOPER RIG SEEVICE AND INSPECTION DATA 2 2 3 Review all previous Anspection items. Inapect chain drives for worn chains or sprockets. Inspect al1 contol Linkages particularly brake control Linkages. Replace any pin that shows .060-.070 looseness in retaining lug holes, Recheck brake blocks, bands, and'rins for any needed replaco- ment due to vear or abuse damage. Examine for rust or paint chip areas that may lead to a rust condition. Correct a5 needed to prolong rig life ani good appearance, Examine all derrick components, hydraulic rans, vire Lines, sheaves, traveling block, pine and latches, guylines aad matting material to. assure safe operation of rig, te prevent oF at Least minimize the potential for personal injuries of rig oquipnent damage.I un coven Lro ids OPERATING AND MATNTENANCE, MANUAL. IG_ OPERATION 1 Pre-check before starting @) ” © @ © @) @ ro) @ © © Tubrseatl Refer to Pages 1, 2, 3, 4, 5) & 6 Engine - Dip stick Torque converter/trananteston 11 devel plug and dip stick lydravlie steering ~ Dip stick ydraulic system ~ Sieht eauze Bevel box = O11 Level plug Chain case (O11 bath type) OL1 level sight window (Keep o11 at lover piteh Line of drive sprocket) Control Positioning 1 Put Transmission Gontrol in Neutal in eab 2 Tura aly supply to "ON" tn cab "orp" at drae-worke control 3 Move Hoad-Winch Mechanical shift in road drive position. 4 Mave Parking Brake in "Pull to Yark" position. 5 Wydraulic System ~ Pup and all Contrel Valves in "OPE" or "NEUTRAL" position. 6 fapine Shut-Down valves or switches in OFF" position, Tuo ~ Check vieual fuel. gauges. ‘Atr System ~ Check alr gauge. If no aiy pressure shown - ‘Air Safety Brakes will be acitated until air pressure builds ‘up to n{nimua 60 PSI (100 PSI for rig operation) Radiator Coolant ~ Visual check water Level shout 1" above tube [BNGINE START-UP_PRODEDURES ‘Turn Key to right,- Push starter button ~ Release when ‘engine starts. Chock O11 Pressure, Alr Prasaure and Water Tenperature, Mngine {e equipped vith Safety Gauges. lov ofl pressure and high water temperature shut-down, Warning Buzzer in cab and Red Light at rig operator position ‘Always let engine idle For approximately 30 seconds before Anereasing throttie to assure Lube of1 circulation before acceleration. Drain uator condonoate from rig #1 ads tank, Alow check-fur water in other air tanks: After a short period of operation, check engine and transmission of1 pressure and tenperature for normal operating level.3” Nor @ o coor 10 RIGS (OPERATION AND MAINTENANCE MANUAL, si mm Norma Engine shut-Down L Shift transm{selon to neutral, pondtion. 2 Parking brake = "Pull to Park" position. 3 Turn key off. This cuts off fuel to diesel engine. NOTE: If engine has been under heavy load and 42 hot wllow to dle a fev minutes to cool, then shut-off with: normal engine shut-down, Beergeney Shut-Down This 4a a push button that operates electric solenoid to shut off ait ‘supply to Supine. (CAUTION DO HOT USE AS NUMMAL SHUT-DOWN, as continued je may damage engine seals). 1 Air supply fo cab controls 18 "ON", Air supply to drav-works control 4s "OFF". 2 Check alr pressure ~ aust be 100 PSI before driving. 3 Gheck a2 cab gauges and instrusents for nornal indications. 4 Be sure that road-vinch mechanical control in in road drive position. 5 Ie certain inter~axte differential lock fa disengaged. This 1s to be engaged only wheh rig te in mud or slick road condition {in order to give all rear wheels traction. 6 Release road brakes. loreal driving position - Valve pushed in. To relesse parking brake push valve in. Make hard brake application on atx foot pedal and release. If buzzer sounds = indicated low aly pressure ~ run compressor until gauge shows 100 PST. 5 DRIVING succesrrons (@) Gear Section: Ist gear to be uscd for moving rig out slowly, * 4m rough terrain and dn lose placess (@) een ALtison cLI-750 = cab shifeing 4¢ through dual mode valve to give seui-autonatie operation. Jet gear ~ Remains wnti1 manually shifted up. ‘2nd gear = Renains until manually shifted up: 3rd gear ~ Autonwete ahifta 2nd to 3rd 4th gear ~ Automatic shifts 2nd, 3rd, to 4th. Sth gear ~ Automatic shifts 2nd, 3xd, 4th, to Sth. (©) If converter indicates heating, shift to lover gear’ to prevent. slippage in converter. This will usually inerease speed and cool down tenperature of ofl. (@) When output RPM is at upper range in 3rd-sth & Sth gears converter goes Anto coupling stage ~ this keeps engine at maximum ef ficiency. (©) Avoid dovn shifting during high throttle operations Alvays allow ‘engine to come to {dle RPM for dow shifts. No restztctions on ap shife onder loads excopt keep in correct gear range to naintain road speed With Allison cLT-5860 the tranomisefon will maintain the gear selection shown fon the indfeator panel,CooreR 100 x16 OPERATING AND MAINTENANCE MANDAL 6 IEPARATION (SUE APT POREARLE MAST STANDARD 42) (a) etermine gof1 conditions at location (Refer to working load distetiveion to ground, (8) Mat av roqutred to obtain proper load distribution into ground. (©) hocate guyline anchors per’ instructions on wast base nane plate. 7 RIG UP ov Locarton (@) spotting rig. 1 Back rig in unetl rig center ine intersects well center Line. Gheck wathes and derrick instruction plate for proper leat aed @stance from derrick marker to well center. Tn order for block and Lines over derrick crown to eenter on well center Line. Put transnteeton 4a noutrel. Engage atx safety brakes on rear axle brakes (For use at well) Nove voad~winch shifter to wineh control position, Shut-off atr supply valve tn cab, Open air supply valve at draw-vorks operator control position, If rig has threo rear axle vith control valve in cab, remove air from air spring on rear tag axle suspension: 8 mgage hydraulic punp eyeten with eperator control valve st rig control position. 9 asily engage hydraulic valve controle to rear Jackacrews to level rig. Check level bubble on rig rear beans Pick up lead off Fear tives only ~ Do not lift rear tives, axles and rig off aroud with rear jacks. This to renove derrick and rig loads from tives gad suspension only, Tighten Jackserew safety tock nat after rig evel. 30 Do sane for front Jackscrevs to remove vig weights from front aprings. Also do not Lift rig front end off ground, only enough to unloed front tires and springs. Tighten safgty dock uta after tis levels 8 peaRIcK xarsiNe (a) Refer only to operating instruction plates tn derrick vertical base section, DeRRroK exrexDING (©) Refor only to operating instruction platoe in derrick vertical base section, curing (©) Conform serfetly to guying diagram plate in derrick vertical base section, (@ Make cottatn that alt derrick latch pine are properly extended before pulling any Joads on derrick.10 coor Lt0 RIGS (OPPRATING AND MAINEENANCH MANUAL [RIG OPERATOR PLATFORM AND WORKING PLATFORM Your 7" X 2" iulde open-netp steel folding platforms on operator side. Extended ftom derrick vertical base section and control position to near rig. engine and tranenission area. fone off operator side platform {e 1" X 12" long platform to allow convenient access from the front to rear deck areas when making 14g ready to travel or set-up procedures at location, (Optional) Work platform fixed to derrick vertteal base section with renovable center section to straddle well head. (optional) Safeey hand rails as required, (CONTROL, PREPARATION (a) Rig Ate syatem Cooper 170 rigs axe equipped with 26 Gu, Ft. (Tu-Flo 1000 B/W) air compressor mounted on the engine. the alr preacure governor ie € for 130 PSI alr pressure. An alcohol scrubber will reduce air Line frecze up by adding aleohol to the air. the first air tank (wet tank) w1il contain most mofature condensation and miat be drained regularly to prevent motsture accumblation in rig atx aystem, An alr Line filter 19 located near the inlet to the draw-worke control console. The rig air systom has check valves to keep air in the adr brake tanks separate fron rig aix controls to provide an air safety brake tank for parking and/or emergency brake application for highway usage. ALL tanke are charged from che main aysten and compressor. (®) Tubing Deua Clutch Operation The first 10° cravel of the drum clutch control valve handle dedivers full alr pressure to drum clutch and further handle travel dnereases engine throttle to provide proper pover and apecd level. ‘The 0-65 PST marking on the valve plate 1a for throttle actuation only. Drum clutch delivery te full Line pressure ~ (130 P51) for maximum elutch capacity ‘and maxinun Line pull required. Control valve handle is friction hold in desired position and locked in extrene travel for maximus RPM. Roturn handle to neutral lets engine return to ddie and disengages drus clutch, Handle travel 12 opposite Atrection (tovard operator) is for engine speed control only ae required for operation of rotary drive speeds, ete, (©) Tubing Drum Brake controls 1 “Wechanical brake control Linkage actustes a self-enerpizing brake band for positive controled brake application with the operator in conplete control of braking effort needed to handle loads. (Optional) Foot pedal control 4e avatlable for operator to spray cooling water into brake rise to reduce heat busld-up. 2 (Optional) Hydrotarder drive 4¢ available as an assist to the mechanical brake to provide longer brake Lining 11fe tnd allo nore flexible brake control. (See brake section of parts and operating manual for additional information) « (A) SandLine Deus Clutch Operation Sane aa: tubing drum clutch and throttle control except valve docs not include separate throttle in opposite lever movenent. 718 core 10 RIGS * OPERATING AND MATITENANGK MANUAL 10 conteon Pitepniarion = (covetuED) @ © @ Sandline Druw Brake Gontrot Mechanical brake control Linkage to actuate self-energizing brake bband for positive controled brake application with operator in complete control of braking effort needed to handle Lond. ator Brake Cooling System AE preanurized water ayatem with (ate valves to direct vater to I either tubing drun or sandline drum a9 desired for brake cooling. The amount of water is controled by foot or hand valve at operator position to alloy flow regulation as needed. An atr regulator and guage Se located on the water reservoir to provide and control the pressurization, Limit pressure to 25 PSI maximum. Experience will determine asount of vater required to maintain brake cooling and prevent Fim over-heating, Nore: Use as Little water as required to cool the rims. Excessive water under the unit indicates too mich water 48 being used. 4A slight dripping on the ground is gufficient. eat is re~ ‘moved by forsution of otean in the brake ring. over-heating of drus brakes severly reduces load carrying capactty, hortens block 1ining 1ife and causes destruction of Tins due to scoring. Excessive heat will tabed pisces of steel in the brake 2 blocks.” This will severly score the brake rins. If metal chips are noted in blocks replace imediately with ney block set to prevent ‘costly rim replacenent. ydraulte Syeten A hydraulic pump de mounted on a P.T.0, driven by the Allison trane~ rniseion enclosed gear drive, with an ofl clutch to engage or disengage the hydraulic pump. The punp drive clutch is operated by an air valve at rig control position. iydraulfe fluid and pressure te directed through valves For selection of rig-up circuit (Derrick and hydraulic leveling jackscrevs) or operational ireuit, tongs or drilling sub, ete: iiydraulte system ofl reservoir has sight gauge and temperature gauge 89 operator can deteraine adequate asount and quality of oil in eystem. Relief valves and filters are provided to pravent over-pressure damage to components and reduce of1 contamination. A large capacity of reservoir allous tine for the of1 to cool and deserate. Additional o11 cooler radiator 1s avaliable, 1f required. 0-000 PSI proseure gauge at operator's position gives visuble indication of loads imposed on hydraulic fayaten for each rig operation. If abnorsal pressures are indseated operator should be avare of potential problens before dasage occurs. Refer to Lubriation Data ~ Section 1 for ofl and {iter data for hydraulic aysten."9 cooreR ura RIGS OPERATING AND MABNTENANCE MANUAL ‘ihe afr clutched, chain driven Parmae hydeotarder 13 a water~ cheat brake assist to give wafe and governed rate of fall of tublag being lovered into well, The rig mechanical band brakes fare used for final stepping load descent. This gives the operator full control of the load being Lowered. The hydrotarder gives proper control for safe operation and greatly improves brake block Lining 1ife, ‘An ate operated clutch. with control at the operator's position, engages the tubing drum to the hydrotarder and drive. The clutch muse be engaged at the start of the descent of each stand of pipe if it ia to be used on that stand. The clutch mist not be engaged after the pipe ds falling. Severe rig danage will occur if thie rule is, ‘not folloved. Rig controle regulate the inlet Flow of water to the Drake and this regulate the amount of braking effect. ‘in adequate supply of cool water 18 necessary to naintain braking effieteney, The water supply on the rig should be supplinented with lan external source of cool water to prevent steaming condition in the Dreke and subsequent loss of braking. Rotary Driven A. Chain Drive Rotary ~ Primary chain drives from eubing drum asseably to coustershaft with air clutch to select final chain Grive to rotery table eprocket, Final drive 4s on outside of derrick basé section da side opposite operator. The primary chain drive is enclosed in a safety guard with ofl lubrication, B’ Propeller Shaft Rotary Drive ~ Chain drive from drun to counter shaft coupled to spiral bevel gear/pinion drive to rear of rig. Uses 1710 series propeller shaft to an oi} bath vertical chain drive chain case mounted in derrick base for final drive to rotary table. ‘The final drive 1s optional depending on substructure and todel. rotary table used. Auxillary Hydraulic Catline Winch ‘Thin 1s a uetlity winch primarily used for handling pick-up of auxiliary surface equipment at ell location. Hydraulic valve at operator poal- tion supplies fluid to hydraulic motor to drive holst or winch drum for Lifting {tens av well site, » Winch has worm gear brake to add aafety to control of loads being handled, ilydraulie valve also adda hydraulic fluid braking accfon for additional control. Operator caution must be exercised at ali tines to see that personal safety of crew 19 maintained. ‘AE no tine should any person be under the load or {tex being Lifted.22, ‘coven Lto Rros OPERATING AND MATNTENANCE MANUAL AV coOPER HYDRASUES 4 Goneral Description cooper offers a complete Line of hydrasubs for well servicing and wwork-over operations. Three uodels: il5-25, HS~60 and 15-90 The hydrasub 49 a hydraulic motor driven asseubly that 1e suspended under the conventional swivel and rotates the drill string suspended From ts quill shaft. The onooth application of torque by hydraulte motor drive gives easy, shock free Fotation of d#il1 string. Tt 1s ‘2 weans of rotating the tubing this elisinating need of rotary drive, Fotary table, kelly and kelly bushing. Excellent torque control and ‘nooth application minimize twlst-off hazards to the drill string waking the unit particularly useful with tubing strings. Applications (@) Light end medium duty dri1ting operation. () DrilLing out plugs and packer: (@) Drilling out bridges. (@) Internal cutting off casing and pipe. (e) ittiling Jobs. (2) Sexaping Jobs. (G)_Coring operations. (i) Ald dn Elahing operations. 5 Mydraulte Gatworks Hydraulic cylinders for make-up and break-out sounted in derrick with cables and sheaves to rig substructure floor to tongs for make-up and break-out pipe with controls at driller's console, 6 Tong Drive hydraulic eysten with flow director valve applies pressure to roar of rig for hydraulic cong power outlet with ample of1 supply in rig hhydvaulte tank after rip-up operation to run tongs. Various volumes of flow can be provided to ft nest tong requirements,2 cooren 10 Ribs OPERATING AND MATITENANCE MANUAL = FRONT AXLE: MIEEL, ALIGRMENE Place a straight edge across the mid-point (center of axle) of the two right front tires. Turn the steering wheel to get as near contact at front and rear of each tire (4 points) as possible. Adjust drag link between axles to obtain the 4 point contuet, SSS N Turn the steering wheel until there 4s 1/16 to 1/32 inch gap between the front contact point on the two right front tires and the etraight edge, Note the gap fon each axle, Place tho straight edge acroes the mid-point (center of axle) of the two left front tires. Adjust the tie rod on each axle to obtain the sane gap at the front of each tive as was noted on the right sido. os 1/16 t0 J J ays 1/16 to 1/32 Yor 3 axle units adjust as sbove on the two front axles then place the straight ledge across the left side second and third axle. Adjust the drag Link from the second to third axle to provide the 1/16 to 1/32.inch rap aa noted dn step 2 above. Adjust the axle tle rod, to provide the proper nap on the right side tire. Check the power steering cylinder on each axle to be eure that 4t is in the center of its stroke. toosen the clamp of the cylinder rod to the tio Tod and adjust ‘a5 necessary to center the eylinder rod.atroke, ‘Turn the steering wheel to the extrone right turn position. Check the tires for contact with steering suspension aysten. Check the steering eylinder for addi- tional available stroke. Set the ateering stop on the steering box under the cab aa necessary to prevent tire contacts, Turn the stecring wheel to the extreme Left turn position and follow the gane procedure.“aupp RECOMENDED MAINTENANCE PROCEDURES. | PRESERVICE OR NEW VEHICLE INSPECTION A.Dismount the wheels and check the ball seats for evidence of paint or ther forcign substance, Check the “fats” or wheels 10 see that tints such as clotted paint, burrs, dirt, ete. that ould prevent good whecl-to-hub or wheel- to-wheel contaet. sof the 3. Cheek the threads of the studs at the bub face for evidence of damaye, crus thread- ing, dir. : 4. Remount the inner dual wheel making sure that the‘ bail mounting faves of the cap rnuts seat securely in the matching ball seats of the wheel stud holes Tighten ball faces of cap nuts into. ball seats. in wheel, ‘Then tighten the nuts to 4450-500 /t. Ibs. this i done by tightening “opposites”, that is first Nu. 1 then No. 6, then then 9=—and soon). = 6. Remount the cuter dual whee, takin ilar precautions in placement af wheel and in tightening the eap nus in cecommended sexquence al to proper torque NRUNAN CHECK Remember that all precision parts “seat during normal aperation. ‘The wheels rust “run in’ tod. In the case of she Budd Incels, the first tip may affect the ori- nal seating, therefore, it is recommended all mountings be re-checked after the first 5040 100 miles. ‘Then the mechanic should proceed to restighten to the original levels recommended in the Torque ‘on Page 1-4, On duals, the following. pro- cedure must be applied: * luosen outer nuts f@ check thé torque or inner nuts to 450- S00. bs tighten outer nuts to the same specitica- is done as recommended, cap nuts will NO'T loosen in operation. MAT TIRE: INFLATION CHECKS ‘This is an ideal time to look at the wheels, rims and cap nuts. A VISUAL. check this time should be made 19 took for evie lence of cap nut looseness. Streaks of rust emanating from the cap nut ball seats are a efinive indication of loose mounting. At this time, also cheek for broken studs, vim damage or improperly seated lock rings. i23 1. The mounting face of the hub (or drum, inthe case of the out-board mounted drums) should be free of foreign material sucl as grease, diet, burrs, We sure that the drum retaining screws (in utchaard drums) are securely seated 2. Clean the threads of the studs and inspect for evidence of wear ur damage. Replace damaged or broken studs, When a broken suid te replaced, the stud on each side of it Gna 10-stud mounting). should be re= placed. In the case of smaller bolt circles, all studs should be replaced. 3. Clean the ball seats and flat mounting faces of the wheels and inspect for wear. Replace any damaged wheels or rings. IV AT Tike CHANGE 4.Check the mounting face of the hub for ‘This is the MOST IMPORTANT STEP eat, I the wear is veadily visible, the face in your wheel inspection pram, shouldbe machined fla, ar i worn too badly, replace the hub. VISUAL SAFETY ust by overs Road failures are generally onding og erg In enantio. program. Many times an operational fale lurecan be avoided by catching potential in the shop before the ve- begins its run. Simple VISUAL. in- spection can save hours of downtime, WORN WHEEL STUD HOLES ‘This condition will usually be accompanied bby evidence of ‘a. bright ‘worn surface on the wheel face, indicating that the loose wheels were working against each other. You will note that the stud holes are out of shape and that a build-up of metal oc- curs around them, ‘These wheels must be replaced,BUDD MOUNTING PROCEDURES ly recommends the wee of heat weated (io file haedness) cap nuts, to alin and nut compression resulting in loose wheel mountings, stud DOUBLE CAP NUTS DUALS [STANDARD BUDD MOUNTING | HEAVY DUTY BUDD MOUNTING Basic Practice unser ste ond ny gh fleon ond fre of for {Son mere or exces, pom 2. theods of sds and tat should ‘be eon ‘nd undomoned a Tere. Ape the outer op nut ths IMPORTANT POINTS 1, Wheels on new equipment should be checked before first trip. Actual removal for inspection and remunting as above insures long troubectree operation. 2. Alter first trip, oF as soon as practical, eap nut torque shoul be rechecked — first lootening outer nuts belore checking inner nuts — then retightening all nuts to recommended torque. ae ut should back off with quter nur — (ase Ken ‘Tool #TX-9) to hold outer for re- seating inner.) 3.Ac tice changes all mounting surfaces and bolt holes should he checked for wear or damage. Rings should be checked for damage, excessive carrosian or sprung condition and properly sated with remounting, 4. Care shouldbe taken to assure coreect ring to rim combination as related to manulacturer. 5. Condition of ai wrench shoul be periadically checked and where practical, she torque de- livered should be ascertained, 6 uid breaks and a vehicle djacent studs whieh maybe fa 1s for any length of tim ted or evacked dsr tori I new stud and replace both 7. Permit no oil oF lubricant of kind tu get iy Ball seats of wheels oF on ball faces of expBUDD RECOMENDED MOUNTING TORQUE ‘The Budd Company strongly recomm cap nuia to eliminate thread binding, Tose wheel mountings, stud 28 the use of heat treated (10 file hardness) galling and nut compression resulting In Drenkage und wheel damage. Dry Threads No Lubrication ® “APPLUCATION WHEEL STUD ToRQUE (Headed TYPE [Shoulder | —THUEAD SE Fras eon 7/1620 70:90 «| Possenger Cor Soe 172 20 70.90 zt 9ft6.18 70-90 Tight Wrla --- 172 20 7090 Possenger Type Mig. ficeaes fit afore No-140 eoded «=| — — — 5/818 125-140 Headed =| — — — 618 175.225 Wwowrcainat ie | emia | = >| eH 17828 Highway Vohidler Trecktralor Bus Heoded | — — 16-16 300-400 Headed 25 3/416 450-500 Budd Sid. DEN Heoded | Use Boctnvt Ys 16 450.500 Ott theRood Vehicles Headed | Use Docknur | 1-1/8 -16 450500 Budd Sid. DCN Mi. Heoded | Use Bocknut aA 16 450-500 Hooded | Use Becki | 1/8 16 650-750 Budd Heovy Duly DCN Mig. | Headed | Use Bocknut 15/1612 750-900 === | usopeenu | .'siie3 750.900 Tocknas {inner End of Whee! Stud) aya 16 175-200 718 “14 175-250 ea 175-300 *Under conditions of abnormal corrosion, a MODEST AMOUN'T THREE THREADS of the wheel studs should CAUTION: No lubricant should be permitted to of cap nuts, “Standard Wrench, Handle and Extension By using this simple two), a mechanic can easily arrive at the proper torque. Sinee “foot pounds of torque” is. nothing more than weight applied, times distance in Tee, the mechanic weighing 150 Ibs. steadily applying his full weight 3 feet out un the extension until the cap nut will aa longer ighten, will have 450 Ms. of wrque. A200) {b. man applying his weight 2-172 (tam fon the extension, would get SO My. ol torque. MOUNT of lubricant on the FIRST alleviate difficulties. (De not use pentrating ol) enter the all seats of wheels or to get on ball faces Prrgmangemoe2b cHACKS ing trim tnd bole to stud hole or Tule had tle, oF hand hole to dliret sel of overloading u of failure occurs, the position cf the failed lice! on the vehicle should hue mated and the actual working, loads of that ale sal be checked cracks unning from stud hole to stud hole on the halt circle indicate-a ,loase mounting, eon= dition. Where this ype of erack appears, the assembly should be checked. ‘The hub may hive a worn mounting face as a result ‘of moving of the inner wheel on the hub. "The stuls may have turned in the hub and worn the stud groove or the studs may hhave actual eracks or breaks resulting from this condition. ‘The wheel may have worn baal seats in the stud holes. Al these pos- sibilities must be checked and corrected if a sound and safe assembly is to be assured, DAMAGED OR BROKEN STUDS Stripped threads on the studs may be the result of excessive torquing of the studs, oF it may be-a result of daniage daring. wheel installation, when placing the wheel over the stud. Where a damaged thread is discovered, the stud shout be replace Broken studs are’ direct result of oper- ating with loose cap nuts or improperly seated wheels. When a broken stud is replaced, the stud on cach side of it (in 10-hole mount- ings) should be replaced. In the case, of smaller bolt’ circles-all studs should be rep wed. ‘This is because he other studs the assembly have been subjected to undue strain in carrying all the load and ay have levee excessively fatigued,DAMAGED INNER OR OUTER CAP NUIS When is condition ix found-=it is a defi- nite indication of a loose mounting condi tion. Cap nuts and sturs, if necessary, must be replaced. If wheel bull seats are damaged, the wheel aiso should be replaced. FREEZING OF NUT ‘This condition. results from one of wo basic causes: sion or galling of the stud and nut assembly en reach a point where removal ‘of cap nts is difficult, I this is persistent problem, the first three threads of the sud and the first three threads. of inner cap nut can be lubricated. Care should be taken to keep all lubricant from ball seat of stud hole or ball faces of eap nuts ‘To further aid in this problem, Budd admin plated cap. nuts: with a dichro- mate dip are available from Budd Distrib- ‘The second basic eause of cap nut freer- ing is improper tightening of the INNER ap nuts. Ifthe ianer nut, during assembly, ig. UNDER-TIGHTENED to only 200: 250 {ulls. and then the outer correctly to 480-500 f.tIbs., the very act fof backing off the outer nut will some= times tuea the inner BROKEN, CRACKED OR WORN HU FACE Inthe este of a broken or eracked hub barrel of flange, it sould obviously need replacement {A badly wore ub face is always caused by running wheel assemblies in a loose cone dition, One of two actions eam be taken. Th the wear is not tou excessive, the entire hhub face can be machined to a flat surface with the studs removed. Otherwise, with a hilly out-offiat or worw condition, the hub should be replaced. atww DAMAGED OR CRACKED RIMS “Thin rim has cracked trom fatigue or avers load, While this «ype of failure is not com mon, it is dangerous, and for this rea fareful checks should. be made for this condition before the tire i installed ‘Corrosion sometimes is also observed and where cofrosion is excessive, may fause poor seating of lock or side Where damage of excessive corrosion is observed, wheel should be replaced DAMAGED OR SPRUNG RINGS Broken or racked rings are generally caused by rough use of tire tools. or im- proper initial seating in gutter of rim, When found, the ring should be replaced Bent or sprung rings are caused by rough and. improper removal of this part and ftanaot he properly sprung back so as 10 Seat accurately in the rim gutter, “They should he replaced RUST STREAKS ON DISCS EMANATING FROM STUD HOLES ‘This isa positive indication that the cap nuts are, o¢ have been, loose, In this case, the assembly should be checked carefully inasmuch ag damage to hub, studs or wheel may have heen caused by running in this condition,ASSEMBLY TORQUE VALU ‘ALL VAUUES ARE 135. /P". UNLESS OTIIERUISE sPuCTPLED SAE GRADE 2 SAK GRADES SAE cRaDE 8 sx ASSENDLY TORQUE ASSEMBLY TORQUE ASSEMBLY TORQUE Ayte20__we 50 In./1bs. 15 In./ube. 9 1fie20 We 36 In. /Lbs. 136 tn bs 70 3/1618 Ne. 3 13 18, 3716-25 WE 9 i 20, 378-16 NC. TS, 28 35) Jee i/is-14 ve 2h 35 35 76-20 AF 2 20) 60, 3 we 35 35 80) 3/720 40, 65 30, 3g-12 ne. 35 80) T10- 3fg=18 NC. 60) 90, 30 3/e=1i Ne 75 10. Do. 5/e=18 iF 35, 0 80. 3/4=10 we T30- 200. 280 3/416 wr 0 220 320 77-9 we =5 320. 60 Ko. 560- 500 130 80 ei 710. ———— 7 an Ne. 270 00. 360 Taye E1/e NF 300- 60 080. Eyer e309 ir TsUNE AB. Poor Leverace. BAD-NO BRAKES 1 Poner’C* Meseunes Mare Tuas 14"From | Pon C" Has Passeo Bevan UNE ACB. BRAKE _AMIUSTR NOTE: CHECK CONDITIONS WITH BRAKES APPLIED HARD. “SERVICE BULLET