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Technical Manual - Farr KT5500 with

1. 2 16 ILLUSTRATION 2 F 1 LEVELING SipE To SIDE 2 17 ILLUSTRATION 2 F 2 TONG LEVELING assa 2 18 ILLUSTRATION 2 F 3 LOAD CELL CONFIGURATION Make Up 2 18 ILLUSTRATION 2 F 4 CELL CONFIGURATION BREAK OUT 2 19 ILLUSTRATION 2 2 5 TENSION LOAD GELL CONFIGURATION HARI FR 048164 1610198 60480141056 2 19 ILLUSTRATION 2H 1 TONG MOTOR CONTROL VALVE 212445858 sao naa rite pesa a aba Ya ra TR ATE eu E Ya NEEN RR Ta 2 21 ILLUSTRATION 2 H 2 Der CYLINDER CONTROL VALVE 2 27 ILUUSTRATION 2 FH 3 BACKUP CONTROL TEE 2 22 ILLUSTRATION 2 H 4 SHIFTING GEARS EE 2 22 ILLUSTRATION 3 D 1 Cam FOLLOWER LUBRICATION e 3 2 ILLUSTRATION 3 0 2 SUPPORT ROLLER BEARING enne nennen th nasus eras asas 3 2 ILLUSTRATION 3 0 3 ROTARY IDLER BEARING sese ada 3 3 ILLUSTRATION 3 D 4 PiNION IDLER BEARING LUBRICATION we 3 3 ILLUSTRATION 3 0 5 PINION BEARING 3 4 IL USTRATION 3 D 6 CLUTCH BEARING LUBRICATION ia doe ER STR XY ROMA RE Eed 3 4 I
2. 1 dem frm el af the wore socian Lightly mp ihe end ol the Screw iriver andir wb mumamer t borak Rene H ivo iinet pales rris 1 dem A Gw reng Dag mem 7 and die sexi uma 1 em Bt age orar with rhe onproppate werk iSenkificahum nimbe See Step 5poot sci Fu 1 back up wuar Ep 1 7 dell Step amp Transition Check trimsstion check Located in tic bongen center of ilie work section botsing Caref lly bam lie wok seii dp a vibe w bali peris Das eom veer em adhue sec hened surtsce Hemove the ehecksvalve cap Fig I L ars it fe em Iii Dian seu Remove dur check spei 1 pap La and the Jack vk poppettPie 1 teen 134 OTE Only eviind r werk sections iports blocked in hara check lamir secre have anb a cap COY TECHNICAL MANUAL 7 23 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER BACKUP VALVE INFORMATION 6 Valve Disassembly Instructions spool Disassembly Spring Centered Spool The spring should nas he removed from tha spari unless these paris need 10 replaced nee the apo is froe of the warki sectiien hacen i enum be carefully bo aed damage Plage the spen verrscadly vn a vesc ciampsng e Hie apod
3. A TONG WILL NOT DEVELOP SUFFICIENT TORQUE POSSIBLE PROBLEM SOLUTION S 1 A M EE EES See Section 4 B Relief Valve Troubleshooting 22 24 Check directional valve Neutral position should return fluid directly to the reser 2 Directional valve is leaking voir Replace or repair valve to ensure correct operation 3 Power unit is not producing adequate pressure Troubleshoot power unit see user s manual for your particular unit Poor hydraulic pressure at the tong despite ad Restrictions exist in line between power unit and tong Inspect integrity of self 4 equate pressure at the power unit or excessive sealing couplings to ensure they are allowing full fluid flow Check to ensure no back pressure in the return line other restrictions exist contaminated catch screens or filters for example Ensure hydraulic fluid being used is the viscosity recommended by McCoy Drill ing amp Completions Power unit pump may not prime if fluid is too heavy and the 5 Fluid viscosity is not appropriate too high or too hydraulic system will overheat if fluid is too light Replace with proper viscosity fluid low Hydraulic fluid viscosity is affected by environmental conditions Ensure the fluid being used is suitable for high or low temperatures Replace with proper viscosity fluid for the operating conditions if necessary 6 Worn or damaged tong motor causing slippage Replace or repair worn or damaged motor 7 2 bearings EE
4. p rrrj 1 xx 4 LOAD mi RE HEX DIMENSION Be ACROSS FLATS 1 1 8 28 6 2 PILOT VALVE in mm Technical Features e Provides hose break protection e Standard unsealed pilot allows air prevents loads from drifting and trapped in the pilot line to be purged positively locks pressurized loads from the circuit e Extremely low leakage The seat and e Optional external porting out of the hex poppet are heat treated for long life If end of the cartridge is available for the load drifts due to the valve the seat external piloting In this configuration has probably been damaged by port 3 is blocked See Control options contamination and the valve should be E and P replaced e Pilot to open check cartridges are e This 3 port pilot to open check valve locking valves not motion control and 3 port counterbalance valves are valves For motion control applications physically interchangeable i e same DRILLING amp AACCCOY TecHNicAL MANUAL 7 35 MOVING GLOBAL ENERGY FORWARD 5500 5 amp B VALVE INFORMATION use counterbalance valves cavities same flow path for a given frame size However cartridge extension dimensions from the mounting surface may vary e Stainless steel cartridge options P or W e Incorporates the Sun floating style are intended for use within corrosive construction to eliminate the effects o
5. DRILLING amp AACCCOY TecHNICAL MANUAL 5 13 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER SHIFTER ASSEMBLY DRILLING amp 5 14 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SHIFTER ASSEMBLY 5500 5 14 amp CLINCHER Backup Item Type Description Qty Part Number A Weldment Shifter Handle 1 1037 D 20B B Part 5 16 x 1 1 2 ANSI ASME 18 8 1 Clevis Pin 2 09 0256 C Part BS 1574 5 64 x 5 8 Cotter Pin 2 D Part Shifting Shaft 1 1400 71 E Part Shifter Detent Tube 1 101 0019 F Part Shifter Detent Ball 1 02 0018 G Part Shifter Detent Spring 1 997 0 64 H Part 7 16 UNF Hex Nut 1 09 5908 J Part 7 16 UNF x 1 1 4 Hex Bolt 1 09 1608 K Part Shifting Yoke 1 997 D13 72 L Part 5 8 NF Hex Jam Nut 1 09 5915 M Part 5 8 NF Hex Nut 1 09 5914 N Part Bottom Shifter Bushing Typically welded to bottom plate 1 1064 B1 95 P Part 3 8 x 1 Hex Bolt 4 09 1170 Q Part 3 8 Carbon Steel Lock Washer 4 09 5106 Weldment Shifter Lug Weldment 1 101 0016 S Part Top Shifter Bushing Threaded 1 101 0020 DRILLING amp AACCCOY TecHNicAL MANUAL 5 15 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER BACK ASSEMBLY DRILLING amp 5 16 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS
6. TECHNICAL MANUAL KT5500 5 1 2 13 97cm 18 7K Lbs Ft Hydraulic Power Tong amp CLINCHER Backup e Specifications Operation Maintenance Assembly Model 80 0422 Copyr obici SC SE Wi rporation All rights Published by McCoy Con echnical Publicatio mccoyglobal com 14755 121A Tm Ta TSL 2T2 MOVING GLOBAL ENERGY FORWARD 300 5 1 amp CLINCHER Backup This manual covers the following models OVERALL BACKUP DESCRIPTION MODEL MODEL 5 1 2 configured power tong amp low profile compression load cell style 80 0420 16 80 0420 3 85 0408 CLINCHERQ backup Tong equipped with hydraulic motor control lift control backup control rigid sling amp and safety door system 5 1 2 configured power tong amp tension load cell style 80 0421 3 80 0420 3 85 0506 backup Tong equipped with hydraulic motor control lift control backup control rigid sling amp and safety door system 5 1 2 configured power tong amp compression load cell style CLINCH 80 0422 80 0420 3 85 0404 ERG backup Tong equipped with hydraulic motor control lift control backup control rigid sling amp and safety door system NOTE Some illustrations used in this manual may not exactly match your model of tong PATENTED amp PATENTS PENDING ORIGINAL INSTRUCTIONS EE Feet Manuat i MOVING GLOBAL EN
7. 2 99 5 5 38 Low Profile Backup Body Compression LC 5 40 CLINCHER Cylinders 5 42 Rigid SHINGASSOMDIY 5 44 SECTION SIX TORQUE MEASUREMENT A BASIC TORQUE MEASUREMENT A dei saps ret Ka oda ott ed a eu EE a RF HER MER RR 6 1 B 5 c 6 5 C PERIODIC INSPECTION AND MAINTENANCE 7 7 redo D 6 6 2 Fluid Recharge 6 6 3 Reference Checking The Torque Measurement 1 nnns nnns 6 6 4 RepairAnd Calibtatlon rerit petala ra id au Ne ka EL d eds enne a ea 6 7 SECTION SEVEN HYDRAULIC COMPONENT INFORMATION MCCOY 207 X 3801 TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD List oF ILLUSTRATIONS ILLusTRATION 1 4 1 KT5500 amp CLINCHERQO Backup 80 0421 3 5 2002000000000000 1 1 ILLUSTRATION 1 A 2 KT5500 amp CLINCHER BACKUP DIMENSIONS 1 2 amp 2A TEE 2 1 ILLUSTRATION 2 B 1 KT5500 CBU ID 01 e 2
8. arul remove the srripper Fig gem deme Lighth mp e stripes holt wiih a hanaier amd panch reih the adhesive application af ipa y he sequence do Dez e sa ripper unce an fpa wlbarg Aes Surg ips CAUTION Too much heal may distoni the spool ds the stripper eh Vitals dime the apang Fig 2 iem 153 spring oides Fig 2 em pn will from ihe spinal Detent Spool deci s sbeuslid oa be reese rena Ihe pro unless these parts need in be replaced Wrap the deleng derye rig 2 171 sient A clean kb the elach covered sieeve and pull tht sleeve moves backwards the degent halls Fig 2 er PR and Ehe deren apog Pg 2 geen 201 wall release baal The campane thee pars um prevent lee ces clamp ihe sp l sese rere the papper ramer Fig 1 Spem 20 Place m bur thraugli ther dereen ball bore te saree im weeds Lightly tat he delen poppet relganer with krnpwer and help ihe adhesive autism app af ance ep anasscbsc ve wa alix wad im ihe degen CAUTION Too much heat may distort the spool CLEANING INSPECTION AND REPAIR b
9. amp CLINCHER BACK Setup amp OPERATION 2 Die Removal continued ILLUSTRATION 2 E 2 KT5500 CBU Jaw Die REMOVAL 3 Backup Jaw Availability The following table lists all inserts that are available as standard sizes for the 5 1 2 CLINCHER backup If your desired size is not listed Farr can engineer custom jaw sizes contact sales for further information 2 375 CLINCHER Backup Insert 12 6118 2 375 CLINCHER Backup Aluminum Insert 12 6043 2 875 CLINCHER Backup Insert 12 6130 2 875 CLINCHER Backup Aluminum Insert 12 6046 3 50 CLINCHER Backup Insert Grit 3 50 CLINCHER Backup Aluminum Insert 5 50 CLINCHER Backup Insert 3 6875 CLINCHER Backup Insert 5 50 CLINCHER Backup Aluminum Insert DRILLING amp 2 14 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Setup amp OPERATION 5 amp CLINCHER Backup 4 CLINCHERO Backup Jaw Removal Installation i Extend CLINCHERO cylinders enough so that the hex flat head cap screws securing the die retainer tabs well exposed Turn off hydraulic power ILLUSTRATION 2 E 3 KT5500 CBU CLINCHER CYLINDER EXTENSION ji Remove the two hex flat head cap screws securing the die retainer tab on the top of the CLINCHER die iii Remove the top die retainer tabs iv Slide the die straight up and remove ILLUSTRATION 2 E 4 KT5500 CBU WnaPAROUND
10. 27 Compression Load Cell DRILLING amp e ee MANUAL 2 7 MOVING GLOBAL ENERGY FORWARD 5500 5 amp CLINCHERG B C HYDRAULIC SCHEMATIC COMPONENT IDENTIFICATION Your tong may be equipped with one or two control valves as well as safety door switch and hydraulics depending upon the Setup amp OPERATION specific model Disregard the control valves indicated on the following schematics that do not apply to your model MOTOR ar alr Q 3 OPTIONAL CLINCHER BU _ 99 00 Cine d rm 8 i jO OPTIONAL EN OPTIONAL LIFT KO P 5 6 ILLUSTRATION 2 1 KT5500 CBU HYDRAULIC SCHEMATIC Item Description Part Number 1 Inlet Valve DVA35 A880 w 2500 3500 DVG35 HMRV CARTRIDGE 10 9016 2 Relief Valve DVA35 MRV 1 10 0010R 3 Motor Section DVA35 MA8 4WAY SAE PORTS 10 9014 4 Backup Section DVA35 DA8 4WAY SAE PORTS 10 9019 5 Lift Section DVA SA8 1 ORB PORT 10 9015 6 Outlet Section DVA35 TR99 SAE PORT 10 0086 7 Flow Control Valve N800S not shown 08 9062 8 Pilot To Operate Cartridge Valve LKHC XDN 08 1625 9 Safe
11. at bath ends of the bolt Step 3 Section Seals Che med inici ag parallel work section bag am seals Fi 1 paren 1 A janbe d ine muting Lies feries work sectors and the fle mid hare seciion seals ar the downutream mating Pig eerie ba 3 These section scalis fad be dod diaaa REMINDER ALL WORK MUST BE PERFORMED IN CLEAN AREA DRILLING amp 7 22 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION 55005 1 amp CLINCHER Backup Valve Disassembly Instructions 3 Step 4 Valve Back Using a Lirge penewdriver remire e rk cay Saxones Era 1 demm 4 thick fasion De been cap s she wrek ssela Lightly tmp ine end pf the wih a 5ammjer r hrak adecme Remote the back cap Fic T tem 5 Step 5 Control Spool and Seals moe he end ef the Spec oth A clean Hort fni and pall ife insi cif the baam using d vu kin Cere gall iue remmer Ee temp d bc Lol ai Em H wall anme enit wilh Mhe spond CAUTION For delonted pool models be careful nol to remove the detent pappet sleeve Fig 2 ltem 17 unl ss 4 js t be servicad Lising a Lee Phillipsshend rege the vea
12. MANUAL 5 29 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER LEG ASSEMBLIES DRILLING amp 5 30 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD LEG ASSEMBLIES 500 5 1 amp CLINCHERG Backup li G Zb Dco Item Type Description Qty Part Number A Part 1 1 4 NC x 8 Hex Bolt 2 09 0222 B Part 1 NC x 7 Hex Bolt 2 09 9165 C Weldment Rear Leg Weldment Tension Load Cell Configuration 1 1010 1987 Weldment Rear Leg Weldment Compression Load Cell Configuration 1 1010 1547 D Part 1 1 4 NC Hex Nylock Nut 2 09 1484 E Part 1 NC Hex Nylock Nut 2 09 5725 F Part 3 8 Carbon Steel Lockwasher Leg Body 10 09 5106 G Part 3 8 NC x 2 1 4 Hex Bolt Leg Body 10 09 1055 H Part 3 8 NC x 1 1 2 Hex SHCS Rear Leg Body 2 09 2051 J Part Front Leg Tube 2 101 2155 K Part Top Spring Cap Front Leg Tension Load Cell Configuration 2 1302 905 03B Part Top Spring Cap Front Leg Compression Load Cell Configuration 2 101 4489 L Part 1 2 NC x 3 Hex Bolt 4 09 1178 M Part Front Leg Spring Tension Load Cell Configuration 2 1391 905 02B Front Leg Spring Compression Load Cell Configuration 2 1302 905 08 N Part Bottom Spring Cap Front Leg 2 1302 905 03C P Part 1 2 NC Nylock Nut 4 09 5610 Q Part Rear Backup Suspension Spring Tension Load Cell Configuration 2 139
13. 7 Tong pops out of gear Ensure that detent ball amp spring assembly has been correctly set AACCCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL CONTENTS 4 7 KT5500 5 1 amp CLINCHER Back TROUBLESHOOTING G GENERAL COMMENTS The following factors generally contribute to poor hydraulic operation and premature wear of equipment 1 Contaminated hydraulic fluid due to overuse overheating or inadequate fluid filtration 2 Unsuitable hydraulic fluid especially in extreme climatic conditions 3 Defective packing or seals in components of the hydraulic system 4 Poor or incomplete hydraulic system training Users must be fully qualified to operate the equipment and have complete understand ing of the hydraulic system If your hydraulic troubleshooting procedures involve flow and pressure tests at the power unit McCoy Completions amp Drilling recommends construction of a test rig that can easily be connected to the main suction and discharge ports of the power unit DRILLING amp 4 8 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD PARTS AND ASSEMBLIES Model 80 0422 Shown Pe 8 DRILLING amp AACCCOY COMPLETIONS Section Contents TECHNICAL MANUAL SECTION CONTENTS 5 1 KT5500 5 1 amp CLINCHER BACKUP GEAR TRAIN LAYouT DRILLING amp 5 2 SECTION CONTENTS TECHNICAL MANUAL
14. DRILLING amp 3 22 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 200 5 15 amp CLINCHER Backup J DAILY INSPECTION amp MAINTENANCE CHECKLIST BACKUPS Farr Canada recommends that the following inspection and maintenance procedures be performed before each use and at least once per day when the backup is in steady use in the order in which they are listed Do not perform any maintenance while the tong and backup assembly is connected to any hydraulic power supply Farr Canada recommends that all hydraulic lines are fully disconnected and residual hydraulic pressure is bled off Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid ALL UNITS 1 a Perform an initial wash of the backup in order to remove the majority of dirt and grease build up 2 Perform an external inspection Check to ensure there are no loose or missing fasteners replace if necessary 3 C Check to see if backup is parallel to the tong if the backup is resting at an angle one of the front leg springs is likely broken 5 fatigued to point it must be replaced Backup ONLY Remove access cover from top plate Perform a visual inspection ot the interior of the backup use a flashlight if necessary 4 Premature wear where there are moving parts bare metal where there used to be paint and metal shavings in
15. Item Type Description This is the standard tension load cell supplied by McCoy Assembly Tension Load Cell 4 08 ir Drilling amp Completions Farr Contact our sales depart A Part 1 4 NC x 1 2 Binding Head Machine Screw ment for information about optional application B rm specific tension load cells C Part O Ring D Part O Ring E Part Load Cell Piston F Part Flange Gasket G Part Load Cell End H Part Load Cell Rod J Part Wiper K Part O Ring L Part Load Cell Body N M Part 3 8 NC x 3 8 Cup Point Hex Set Screw H Seal Kit Replacement Seal Kit 4 08 ir Tension Load Cell ILLUSTRATION 6 4 TENSION Loan CELL ExPLODED DRILLING amp AACCCOY TECHNICAL MANUAL 6 3 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER Torque MEASUREMENT Compression Load Cell 8 Item Type Description Item Type Description A Part 5 16 UNC x 1 Hex Socket Head Cap Screw E Part Diaphragm B Part Load Plate F Part Diaphragm Casing C Part 5 16 x 3 4 Hex Socket Head Cap Screw G Part Street Elbow D Part Retainer Ring H Part 1 4 NPT Brass Plug This is the standard hydraulic compression load cell supplied by McCoy Drilling amp Completions Farr Contact our sales department for information about optional application specific compression load cells b ILLUSTRATION 6 5 Compression Loan CELL EXPLODED D
16. REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER WISE SPECIFIED DRILLING amp e ee TECHNICAL MANUAL 3 11 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER MAINTENANCE 1 Position the tong body gear case on a suitable stationary support such that the bottom body plate is accessible 2 Assemble ten support roller dumbbell assemblies Insert an inner support roller spacer PN 1064 183 into each dumbbell support roller PN 1064 181 Press a support roller bearing PN 02 0099 into each end of the dumbbell rollers Slide a support roller bearing spacer PN 1064 182 over each support roller shaft 5 x PN 101 3942 4 x PN 101 3944 1 x PN 101 3943 Insert a support roller shaft through completely through each dumbbell assembly 3 Place four support roller assemblies along one side of the cage plate opening ILLUSTRATION 3 H 1 ASSEMBLY INITIAL SUPPORT ROLLER INSTALLATION 4 Install rotary gear PN 1064 D1 making sure the backing pin slots on the side facing up Ensure one side is supported by the support rollers installed in Step 3 and the opening in the rotary gear is oriented toward an open support roller space as shown in the following illustration ILLUSTRATION 3 H 2 ASSEMBLY RorARY GEAR INSTALLATION 3 12 SECTION CONTENTS TECHNICAL MANUAL
17. amp CLINCHER Backup 11 Compression Load Cell Compression Load Cell Style Backups Only Apply grease to the flat surfaces of the compression load cell where contact is made with the rear leg and the paddle of the backup E Ke d APPLY A THIN LAYER OF GREASE TO THESE SURFACES As i ILLUSTRATION 3 0 11 BAckuP LUBRICATION Farr recommends that a liberal coating of grease be applied to the cam surface of the rotary drive gear prior to jaw installation Also the clutch inspection plate should periodically be removed and a coating of grease applied to the clutch drive gears and shifting shaft E ADJUSTMENTS 1 Brake Band Tension Adjustment The top and bottom brake bands must be periodically adjusted to continue to provide smooth and efficient jaw cam action If the cage plate turns with the rotary gear the jaws will not cam properly and therefore will not bite on the tubing or casing Tightening the brake band against the cage plates will increase frictional resistance allowing jaws to cam properly and grip the casing Adjust the brake band using the adjustment nut and bolt set as shown in the illustration below Use caution as over tightening will cause excessive wear to the brake bands Adjustment Mechanism ILLUSTRATION 3 E 1 BRAKE BAND ADJUSTMENT TOP AND BOTTOM BRAKE BANDS MUST BE ADJUSTED SIMULTANEOUSLY AND EQUALLY 52222 TECHNICAL MANUAL CONTENTS 3 7 KT5
18. g Confirm all hydraulic hoses with the exception of the supply amp return to the backup are securely fastened to the tong and are not in contact with the cage plate or creating a snagging hazard h Ensure the tong door is securely closed before rotating tong DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE TONG ROTATION IN ORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL Shift the tong to low gear see Section 2 H 4 and rotate the tong slowly forward for approximately a minute Stop the tong and then reverse the rotation direction for approximately another minute Stop the tong shift to high gear and operate in high gear for approximately another minute Stop the tong and rotate in the opposite direction in high gear for approximately another minute If at any time abnormal operation is suspected surging grinding squealing or other noises deemed to be unusual or failure to operate discontinue operation of the tong and contact McCoy Drilling amp Completions immediately 1 Re inspect all hydraulic lines and connections the tong and correct all leaks safety door system is the prime protective measure separating the operator from the rotary gear and must be in working condition when operating tong Carefully inspect the safety door components and test the operation of the safety door using the following procedure Keep non essential personnel clear of the unit under test This test procedure will only i
19. 1 Install load cell If using tension load cell perform a visual inspection and replace any cracked broken or distorted components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression Inspect load cell for damage or signs of stress Check oil level in load cell and fill if necessary refer to technical manual Section 7 or Section 8 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression load cell only If the integrity of the weld has been compromised the tong must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so the weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved Refer to the maintenance section of the manual for instructions on properly adjusting brake bands Perform a full functional test of the tong including if applicable backup components lift cylinder and floa
20. As needed ihe sectional stack type construction provides flexibility for the addition of subtraction of work sections to an existing valve bank This design also permits the combination of parallel tandem amd series Circuitry in a single bank The intermal of each valve section delermines its circuitry and the number of gasket seals required Al seenons with optional features such as relief valves crossover relief valves and anti eavitatian checks are dimensionally larger when measured from the top of the port to the bottom of the housing These are referred to W boy sections Those withoul work por options can use the low profile castings Which are called lo boy sections NALCO Y MOVING GLOBAL ENERGY FORWARD REPLACEMENT PARTS The illusiratiens and instructions im this manual apply only to the series assemblies subassemblies and components All valve except for spaols and housings nre available as replacement parts subasstmblies Spools are hione fitted to their individual housings damage to eher of these components means the entire section must be replaced We recommend that you usc only genuine YANG series replacement parts in your service program Manufaetured the same xacting l lersnees and quality controls as the original equipment genuine replacement parts may help prevent premature component failure and costly d
21. IR 2 23 5 General Comments 2 24 EXTREME COLD WEATHER OPERATION DROCEDURES 2 24 SECTION THREE MAINTENANCE A GENERAL MAINTENANCE SAFETY PRACTICES 3 1 CLEANING REETS 3 1 C PREVENTIVE MAINTENANCE 8 2 0 000000001 0044004 iiai s tns insane thes aset hein sth nns nas 3 1 De LUBRICATION 3 2 E ADJUSTMENTS 1 Brake Tension Adjusimoent nce rit reri aab eina a 3 7 2 Door Latch Adjustment 3 8 3 Shifter Detent Force Adjustment ene t e ena 3 8 F RECOMMENDED PERIODIC CHECKS T e M 3 9 2 BACKING PIN ME 3 9 3 SAIMN e E 3 9 4 Torque Gauge Assembly 3 9 OVERHAUL PROCEDURES EE 3 9 H ASSEMBLY le 3 11 l DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER TONG 3 21 J MONTHLY MAINTENANCE CHECKLIST POWER TONG 3 23 DAILY INSPECTION amp MAINTENANCE CHECKLIST IGACKUDS 3 27 L TUBULAR CONNECTION EQUIPMENT DE COMMISSIONING PROCEDURE 3 28 M TUBULAR CONNECTION EQUIPMENT RE COMMISSIONING PROCEDURE 3 31 SECTION FOUR TROUBLESHOOTING A TONG WILL NOT DEVELOP SUFFICIENT TOROUE 4 1 B RELIEF
22. SHIPPING INSTRUCTIONS CONTINUED 5 Securely strap the equipment in place using metal strapping Place strapping as close to the cross members under the equipment legs as possible and use caution not to entrap any flexible hydraulic hoses beneath the strapping guide strapping through beneath the hydraulic hoses Use the following guidelines to determine the strapping requirements Assemblies weighing 1000 Ibs 454 kg or less 3 4 x 0 029 metal strapping 3320 Ibs 1509 kg tensile strength Minimum two straps Assemblies weighing more than 1000 Ibs 454 kg or less 1 1 4 x 0 031 metal strapping 5500 Ibs 2500 kg tensile strength Minimum two straps for assemblies weighing less than 5000 Ibs 2273 kg Minimum three straps for assemblies weighing more than 5000 Ibs 2273 kg Before tightening strapping place strapping protectors wherever the metal strapping comes into contact with the equipment Place the wooden crate containing the tong accessories on the crate next to the equipment Strap the crate to the pallet using 3 4 0 029 metal strapping see Illustration 3 M 4 E NW NI ILLUSTRATION 3 L 4 SHIPPING INSTRUCTIONS STRAPPING EquiPMENT PALLET If it is not practical to place larger loose items a wooden crate ensure they are also securely strapped to the pallet using 3 4 x 0 029 metal strapping 6 Use a large polyethylene shipping bag sometimes called a pallet cover to complete
23. Slide the short backing pin spacer PN 101 4096 over the top of the stud and thread the backing pin knob PN 02 0017 on to the top of the threaded stud Lift the backing pin and insert into one of the two receptacles in the rear of the top cage plate Install the top and bottom lined brake band lug weldments 1064 D4 29 Secure the brake bands to the top and bottom plates using one brake band retainer PN 101 0140 and two 3 8 UNC x 3 4 hex bolts and 3 8 lock washers at the rear of each brake band and a 3 8 UNF x 2 hex bolt and 3 8 UNF hex nylock nut at each brake band lug weldment Install the tong legs Secure the front leg mount mount weldments to the bottom of the tong over the exposed support roller shafts using 7 8 UNF thin nylock nuts See the drawings and BOM on Pp 5 32 5 33 to determine the correct leg mount weldments for your application ILLUSTRATION 3 H 6 TONG ASSEMBLY FRont LEG Mount WELDMENT INSTALLATION DRILLING amp 3 16 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE KT5500 5 1 amp CLINCHERG Backup Mechanical Assembly Procedure Continued 55 Attach the door latch weldment PN 1064 C7 15 to the door weldment PN 1400 10 using the door latch cam PN 1400 14 ensure that the door latch springs PN 997 16 are installed between the door latch and the door weldment Thread the door latch cam into the door weldment until in bottoms out and
24. amp 69 NOTE Slight design variations may exist in motors manufactured either before or after the printing of this manual WHEEL MOTOR SHAFT AND BEARING ASSEMBLY PROCEDURE Clean ALL assembly parts w lacquer thinner Dip clampnut and clamping bolt separately in lacquer thinner Steps 3 thru 10 must be conducted to completion ONE assembly at a time Press bearing cups into bearing housing Make sure they are pressed completely against bearing shoulders Coat inner race of large cone with 609 green Loctite and press cone onto the shaft Make sure the cone is completely against the shoulder of the shaft Insert shaft and large cone into bearing housing Coat inner race of small cone with 609 green Loctite and press small cone onto shaft Apply 272 red Loctite to the clampnut threads of the shaft Apply 242 blue Loctite to the threads of the clamping bolt and install in the clampnut Spin clampnut onto shaft with the B face towards bearings After the nut threads are fully engaged but prior to the nut contacting the bearings 1 tighten the clamping bolt until there is drag on the clamping nut see note Fig 1 Tighten the nut until a 20 to 30 inch pound rolling torque is achieved Tighten clamping bolt on clampnutto 70 inch pounds and recheck rolling torque Apply inspectors lacquer to head of the bolt 0 Allow a minimum of 24 hrs to dry CUTAWAY Note The slit in the clampnut allows for loose assembly on the shaf
25. from a crane capable of supporting the known weight in Step 3a d Connect the rod side of the load cell to the known weight and use the crane to hoist the weight from the surface to be sus pended freely e Perform a simple calculation to determine the expected indication on the torque gauge based on the known hoisted weight This is a calculation that must be performed using the arm length expressed in imperial units feet The calculation is KNOWN WEIGHT x ARM LENGTH AS DISPLAYED ON THE TONG PLACARD in feet For example if the arm length is 32 inches and the hoisted weight is 1000 Ibs the calculation is 1000 x 32 12 2667 Therefore the expected indication on the torque gauge should be 2667 165 DRILLING amp AACCCOY TecHNicAL MANUAL 6 7 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER Torque MEASUREMENT Reference Checking Your Torque Measurement System continued Tension Load Cell continued 4 6 8 e Perform a simple calculation continued Calculations for a metric torque measurement system using tension load cell are as follows KNOWN WEIGHT kg x 2 2 x ARM LENGTH INDICATED ON TONG PLACARD in feet x 1 356 For example if the arm length is 32 inches and the hoisted weight is 500 kg the calculation is 500 x 2 2 x 32 12 x 1 356 3977 6 Therefore the expected indication on the torque gauge should be approximately 3980 Ibs ft C
26. inspect te bore em Ap check zent sna fram X Web all parts ma damlag alen for deep erly pouge ur excessive wer blew deu reassendhiv of rese coulis exist replace rhe Mgr ariete bi ff and on the parts surface damage on the comtral and check p ppej cam m Step marks are removed during cleanme re palisherl rath a very fine clot mark 2 Eemume the machsnod subes wf the vaie housing foe Pone Crea at SM rato mi ems tht vould couse setius heure acces hen wu Tasse TH Chose Lrahibt aver surfaces be rerioye amy rough spala Dese Kemmer CAUTION A shallow millad reet area extonde across the O ring face of the valve howaing This ahold nni be sloned or ground offi TECHNICAL MANUAL AACCCN MOVING GLOBAL ENERGY FORWARD 7 24 Section CONTENTS VALVE INFORMATION 5500 5 1 amp CLINCHER Backup Valve Assembly instructions f Preparation of Parts CAUTION Fallure to fallow tha inre IUE la recommended assembly instructions iu d Dont t MV ya e VID D can result in poor performance or Feb of the housing wiih LOSS Primer Grade product malfunction Product should and Jet dry be
27. prior to storage Farr recommends that the motor and valve assembly be periodically removed along with the top tong plate so that guides rollers and gears can be properly cleaned Ensure that cleaning solvents and chemicals are captured to prevent environmental contamination and dispose of all materials according to your company s proscribed environmental protection regulations C PREVENTIVE MAINTENANCE PRACTICES Regular maintenance programs are necessary and must be established to assure safe dependable operation of your Hydraulic Tubular Connection System and to avoid costly breakdown maintenance The following maintenance procedures provides information required to properly maintain your equipment Your equipment may require more or less maintenance depending upon the frequency of use and the field conditions under which your equipment operates These maintenance procedures are designed for equipment operating at 10 to 35 ambient temperature for 10 hours per day McCoy Drilling amp Completions recommends that the inspection and maintenance procedures in this section be performed as recommended in the maintenance checklists see Appendices or in conjunction with your maintenance foreman s experience and best estimate of when your equipment is due for this maintenance Purchased components included with your hydraulic tubular connection equipment for example motors valves etc may specify main tenance tasks and intervals over an
28. 1302 905 03C Secure each leg spring and bottom spring cap to the leg tube using a 7 16 UNC x 3 hex bolt 7 16 narrow flat washer and a 7 16 UNC nylock nut 85 0604 and 85 0606 backup assemblies only a Thread a 3 8 NC shoulder pattern 2 A eye bolt in to the tong body from the bottom of the top plate of the rear leg weldment near the front of the rear leg see Pp 5 42 5 43 b end of a rear backup support spring PN 1391 905 03 to one of the eye bolts installed in the previous step and the other end of the spring to the v bracket installed in step 71d Secure the end of the spring to the v bracket using a spring retainer PN 1480 500 00 04B and a cotter pin Repeat for the second spring Use a crane to hoist tong and backup assembly off the backup supports and lower assembly so that it sits on its legs Install grease fittings a Install one 1 4 straight thread grease fitting PN 02 0097 into the top side of each support roller shaft including the door pivot rollers 10 locations total b Install one 1 4 straight thread grease fitting PN 02 0097 into the top side of the latch adjustment cam c Install one 1 8 NPT grease fitting PN 02 0005 into the top of each idler shaft or half shaft three locations total d Install one 1 8 NPT grease fitting PN 02 0005 into the end of the clutch shaft in the centre of the clutch bearing cap e Install two 1 8 NPT 90 grease fittings PN 02 0093 in e
29. 18 ILLUSTRATION 3 L 1 SHIPPING INSTRUCTIONS Pater 3 29 ILLUSTRATION 3 L 2 SHIPPING INSTRUCTIONS WRAPPING CHAIN 3 30 ILLUSTRATION 3 L 3 SHIPPING INSTRUCTIONS BACKUP SUPPORT 3 30 ILLUSTRATION 3 L 4 SHIPPING INSTRUCTIONS STRAPPING EQUIPMENT 1 2 000000000000000000000002200000000000 nsns nna nnn 3 31 ILLUSTRATION 4 1 RELIEF VALVE TROUBLESHOOTING TEMPORARY GAUGE INSTALLATION 00000000000000000000000000005000028 4 2 ILLUSTRATION 6 1 TORQUE GAUGE ILLUSTRATION PURPOSES ONLY 6 1 ILLUSTRATION 6 A 2 TENSION LOAD GEUL inier ette a tn td ego dA a duh FT ae E Va epe nae ERE ER 6 1 UFEI I o P geo Hc Mo MOTO YI RE eJ P 6 1 ILLUSTRATION 6 A 4 TENSION LoAD CELL EXPLODED we 6 3 ILLUSTRATION 6 5 COMPRESSION LOAD CELL seen anna 6 4 ILLUSTRATION 6 A 6 TURN COUNTER ENCODER MOUNT 2 2 002 0 000000000000000000000000000000000000000 6 5 DRILLING amp AACCCOY TecHNicAL MANUAL xi MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHERG The information presented in this document will provide setup operating and maintenance instruc tions for your KT5500 tong amp CLINCHER backup Due to the wide variety of operatin
30. 2 hex bolts and lock washers and two 3 8 NC x 1 1 2 flat head countersunk cap screws iv Attach safety door latch block PN 101 1104 to the safety door latch block installed in step 42 iii using four 3 8 NC x 7 8 hex cap screws and lock washers v Insert load plunger PN AE12 306 into LH safety door latch block vi Attach three 1 4 NPT JIC elbows to the Deltrol safety door valve PN 08 0337M Position a 15 16 valve lock nut as shown below and secure the safety door valve to the safety door latch block using the valve lock nut see illustration below ILLUSTRATION 3 H 7 ASSEMBLY SAFETY Door SWITCH INSTALLATION vii Attach the safety door switch guard plate PN 101 1480 to the safety door switch guard weldment using three 3 8 NC x 3 4 hex bolts and lock washers 59 Thread door cylinder mounting post PN 1050 12 001 into top plate just adjacent to the top LH brake band lug weldment 60 Install door cylinder PN 101 0069 secure onto posts with 1 2 NC x 1 2 hex socket head shoulder bolts UNC DRILLING amp e ee TEcHNICAL MANUAL 317 MOVING GLOBAL ENERGY FORWARD 5500 5 amp CLINCHER BACKUP MAINTENANCE Mechanical Assembly Procedure Continued 61 62 63 64 65 66 67 68 69 70 Attach the rigid sling hanger LH weldment 101 0150 RH weldment PN 101 0151 to the top plate using two 3 8 NC x 1 3 4 bolts outs
31. 301 3384 311 391 3782 208 TECHNICAL MANUAL SECTION CONTENTS 7 21 KT5500 5 1 amp CLINCHER Backup VALVE INFORMATION Valve Disassembly Instructions Reference exploded view and parts list page 2 and 3 for work section Detail Step 1 Valve Bank is rhe pros eriucak ie the disnssermbiv paseis ke El lok ich ei Ae valve bank amp property reassembled alter repairs hara beer made Waho vwarerproat quick airveinjt m rker mark aich wih amp eaquesitis nimmer m rking Ehe inler cening with the finish by maskeng Ge emer willy hee deed the p ni chest Du lack ap on esch Wek with a H be hack cap end Tim iil de quond barsa a ilur each Work section wills C7 dor clevuc endi af remet vule cx ered adve bank They marked wll the corresgesndirg uge oF the sl pert or C from which they renict d Inlet ariel relief vales are with a muamber viride Slop 2 Tie Bolis Eumene tte four lie beds ihal beid ihre rk Topeller thee seis iwi NOTE VA valve cle belis threw inte dhe watai rastinp Nie valve fie pass through the cndire bank rearing washers ap bes murs va be
32. 7 8 narrow flat washer and 7 8 UNF thin nylock nut Do not place fasteners on the four long shafts at this time Install thirteen cam followers PN 02 0016 into the bottom cage plate PN 1400 22 Secure each with a 5 8 UNF nylock jam nut Install thirteen cam followers PN 02 0016 into the top cage plate PN 1400 21 Secure each with a 5 8 UNF nylock jam nut Support the bottom cage plate in position beneath the rotary gear ensuring the cam followers are nested within the groove in the rotary gear Place the top cage plate in position over the rotary gear ensuring the cam followers are nested within the groove in the rotary gear Place cage plate spacers PN 1064 38 between the two cage plates at their connection points one in the rear centre and one each side just inside the rotary gear Slide a 1 2 narrow flat washer followed by the backing pin spacer PN 101 4093 over a 1 2 UNC x 8 hex bolt Slide the larger diameter hole in the backing pin retainer PN 101 4095 over the backing pin spacer Attach the bottom cage plate to the top cage plate Use two 1 2 NC x 6 hex bolts at the front and the 1 2 x 8 bolt and spacer assembly in the rear ensuring the backing pin spacer remains between the head of the bolt and the top of the top cage plate Thread the 3 8 UNC x 1 1 2 threaded stud PN 101 4097 into the backing pin PN 101 4042 Insert the backing pin and stud through the bottom of the backing pin retainer installed in Step 49
33. AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD GEAR TRAIN Layout KT5500 5 7 amp CLINCHER Backup 4 Description Qty Part Number A Part Hydraulic Motor 1 87 0110 Part Motor Gear 1 997 A10 149 C Assembly Clutch Assembly Pp 5 14 5 15 1 D Assembly Rotary Idler Assembly Pp 5 8 5 9 2 E Assembly Support Roller Extended Shaft For Front Leg Mount Pp 5 4 5 5 4 F Assembly Support Roller Extended Shaft For Front Leg Mount Pp 5 4 5 5 5 G Assembly Shifter Shaft Assembly Pp 5 16 5 17 1 H Assembly Pinion Assembly Pp 5 12 5 13 1 J Assembly Pinion Idler Assembly Pp 5 10 5 11 1 K Assembly Door Pivot Support Roller Pp 5 6 5 7 1 L Part Rotary Gear 1 1064 D1 DRILLING amp AACCCOY MANUAL 5 3 MOVING GLOBAL ENERGY FORWARD KT5500 5 17 amp CLINCHER Support ROLLER 5 4 4 j i emm A DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Support ROLLER 5500 5 7 amp CLINCHER Backup Item Type Description Qty Part Number A Part 1 4 UNF Straight Grease Fitting 1 02 0097 B Part Support Roller Shaft 1 1 101 3942 Part Support Roller Shaft Backup Ready Tong
34. ARE PERMITTED TO PERFORM MAINTENANCE ON THE TORQUE MEASUREMENT SYSTEM 1 Inspection The torque measurement system supplied with your equipment is designed and built to provide years of trouble free service with minimum maintenance Periodic inspections of the load cell hydraulic lines and fittings are recommended in order to keep the system in top operating condition A thorough inspection should be made at each rig up 2 Fluid Recharge Recharge hydraulic system with W15 16 fluid through the check valve on the torque indicating gauge Recharging must only be performed when there is no load on the load cell Refer to the illustrations on pages 6 3 amp 6 4 for guidance if required a Place the torque indicating gauge higher than the load cell Remove the brass 1 4 cap from the fitting on the check valve on the top of the gauge Connect the hand pump to the check valve fitting C Elevate the load cell so it is higher than the torque gauge and hand pump UN CONTAINED SPILLAGE OF THE HYDRAULIC FLUID IN THIS SYSTEM MAY CONTRAVENE GOVERNMENTAL ENVIRONMENTAL REGULATIONS OR THE ENVIRONMENTAL REGULA TIONS AND POLICIES OF YOUR COMPANY FARR CANADA CORP HIGHLY RECOMMENDS PLACING YOUR LOAD CELL IN A CONTAINMENT BASIN BEFORE PROCEEDING WITH THE BLEEDING amp REFILLING PROCESS Fill hand pump bowl with W15 16 hydraulic fluid MAINTAIN GREATER THAN HALF FULL FLUID LEVEL IN THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO T
35. CONTENTS TEcHNICAL MANUAL 878 68 8 8 7 97 22 30 432 222 1 5 0 40 No Rust No Rust 0 04 1A Pass Pass P69 Approved Pass Pass Pass 10 2500 325 12 DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 300 5 1 amp CLINCHER Backup Adequate setup and proper hydraulic connections are essential in ensuring reliable operation of your tong For best results and long term reli ability read and obey the start up instructions in this section DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR A SLING LOAD BEARING DEVICE SAFETY THE SUPPLIED LOAD BEARING DEVICE CHAIN SLING RIGID SLING SPREADER BAR ASSEM BLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT DESCRIBED IN THIS MANUAL HAS BEEN SPECIFIED OR DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS DOCUMENT FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEMBLY OR COMBINA TION OF PARTS AND ASSEMBLIES OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SUPPLIED BY MCCOY DRILLING amp COMPLETIONS MCCOY DRILLING amp COMPLETIONS DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD BEARING
36. CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 200 5 1 amp CLINCHER Backup Mechanical Assembly Procedure Continued 71 72 73 74 75 76 7T 78 79 80 81 82 Use a crane and temporary sling to hoist the backup assembly onto a support structure next to the assembly location of the tong Minimum height for the backup supports must be 36 in order to allow clearance for installing the front legs 80 0420 16 assembly uses 85 0408 backup only install the rear backup support spring assembly in the rear leg see Pp 5 40 5 41 a Place two springs PN 991 13 over the nubs on one of the two spring plate weldments PN 101 4495 Place the second spring plate weldment over the springs and use four 1 2 UNC x 6 hex bolts 1 2 narrow flat washers and 1 2 UNC hex nylock nuts to fasten the assembly together b Install the spring support weldment in the rear leg using two 3 8 UNC x 9 1 2 hex bolts 3 8 narrow flat washers and 3 8 UNC hex nylock nuts The location of the support can be changed as required when leveling the backup 85 0404 and 85 0506 backup assemblies only if using either of these backups ensure they are properly prepared for mating with the tong and rear leg assembly Refer to Pp 5 40 5 41 a Thread a 1 1 4 UNC heavy hex nut on to the 1 1 4 UNC x 8 threaded rod PN 101 1993 b Coat at least 2 of thread on the
37. Part 3 8 NC x 3 4 Hex Bolt 16 09 1044 S Part Side Cover Plate 2 1421 500 11 T Assembly Cylinder Assembly 2 1403 00 00B U Part 1 NC Nylock Nut 4 09 5725 V Weldment Backup Body Weldment 1 1421 500 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL 5 37 5500 5 1 amp CLINCHER BACKUP Low PnoriLE Backup ASSEMBLY Compression LC CowriG DRILLING amp 5 38 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD _ 15500 5 amp CLINCHER Backup Backup ASSEMBLY Compression LC Conric ltem Type Description Qty Part Number A Weldment Backup Body 1 1421 500 LP B Weldment 2 Load Cell Holder 1 01 9116D C Part Relief Valve Body 1 08 1839 D Part BCJ Body 1 08 1327 E Part Rear Cover Plate 1 101 4482 F Part 3 8 NC x 3 4 Hex Bolt 16 09 1044 G Part 3 8 Lock Washer 16 09 5106 H Part Front Cover Plate 2 1421 500 11 l Part 3 8 NC x 1 1 4 Hex Bolt 1 09 1048 J Part 1 NC x 9 Hex Bolt 4 09 0288 K Weldment Gauge Protector Weldment 1 1483 500 18 L Part CLINCHER Rear Jaw 1 1403 08 M Assembly CLINCHER Cylinder Assembly 2 1403 00 00B N Part Rear Cover Plate 1 101 4481 Part 3000 PSI Pressure Gauge Not Shown 1 02 0245 MOVING GLOBAL ENERG
38. a load during lifting 3 Storage Of Load Bearing Devices Proper storage of out of service load bearing devices is important to ensure full integrity of the device once it is returned to service Farr recommends observing the following practices Wipe off all excess grease Use a solvent based cleaner on rags to wipe all external surfaces to remove residual grease or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove residual solvent Farr recommends that an anti corrosive agent such as 506 be applied to all external surfaces Refer to manufacturer data sheets for proper application and safety information Allow the anti corrosive coating ample time to dry refer to manufac turer data sheets for drying times at room temperature Store in a clean dry location When returning to service note that a full inspection of the device must be performed DRILLING amp AACCCOY TecHNicAL MANUAL 2 3 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER BACKUP Setup amp OPERATION B MAJOR COMPONENT IDENTIFICATION ILLUSTRATION 2 B 1 KT5500 CBU Component ID 01 Item Description 1 Master Lifting Link 2 Rigid Sling 3 Front Leg Assembly 4 CLINCHER Backup Tension Load Cell Configuration 5 Power Tong 6 Rear Leg Assembly Tension Load Cell Configuration 7 Rear Backup Spring Support Assembly
39. b schen Typical Work Section Schematics I aqui m B el ERIS METTE T i DA Cylinder Cylinder DA Mater EA Cylinder Parallel Tandem Vater DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD TEcHNICAL MANUAL 718 SECTION CONTENTS HvoRAULIC VALVE INFORMATION 5500 5 7 8 CLINCHER Backup VA VG Valve Service Instructions INTRODUCTION This has been prepared t assis you in the proper maintenance of the VA2IO VAIS and VG2UTM VG351M VORO directional control valves Before any work is done we supasi tuat you read the assembly and disassembly msliructions completely The first rule of good maintenance is cleanliness which includes clean environment MARE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT CLEAN AREA Dirt is the natural enemy of any hydraulic sysicm GENERAL INFORMATION The VA and V Cr model valves are updated versions of eur proven and ASST unit The VG models are cast from compacted graphite high strength won alloy which allows the valve to be mied to 3504 psa models cast from ion and rated at 2500 psi These open center directronal control valves are available in parallel tandem and series circuitry
40. bearing retainer spacer PN 1400 59A over the bottom of the top clutch bearing retainer PN 997 D11 59 and mount top clutch bearing retainer and spacer to the top plate with two 10 24 x 3 4 hex socket head cap screws 29 Press top clutch bearing PN 02 0002 into top clutch bearing retainer Insert clutch bearing bushing PN 997 60 shoulder side up between bearing and clutch shaft 30 Secure clutch drive gear PN 997 A3 61 to the top of the clutch shaft with retaining snap ring PN 02 0001 31 Install rotary idler pads PN 997 D20 125 over the top of the rotary idler shafts and secure with 1 1 2 UNF hex nylock nuts 32 Press remaining pinion bearing into the top pinion bearing cap PN 997 D15 89 and secure over the top of the pinion gear shaft with four 1 2 UNC x 1 1 4 hex bolts and 1 2 lock washers 33 Slide the top shifter bushing PN 101 0020 over the shifting shaft and thread in to the top plate until snug 34 Thread the detent tube PN 101 0019 into the top shifter bushing as shown Thread three 5 8 NC x 5 8 hex socket set screws into the remaining three ports in the top shifter bushing do not bottom out the set screws on the shifting shaft or the shaft will not move ILLUSTRATION 3 H 4 ASSEMBLY SHIFTER BUSHING INSTALLATION 3 14 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD MAINTENANCE 115500 5 amp CLINCHERG Backup Mechanical Assembly Proc
41. been crushed or otherwise distorted through compression If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression load cell only If the integrity of the weld has been compromised the tong must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so the weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam Re energize power unit DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 3500 5 7 A CLINCHER Backup 2 0 C Perform a full functional test of the equipment including if applicable backup components and float frame components Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used If using a frame mounted tong and backup system raise the tong off the beams that it is resting upon Remove the beams 2 1 and protective cloths inspect the paint on top of the backup and the bottom of the tong to ensure it has not been damaged by the beam Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low gear 2 2 3 in both di
42. detent spring Ensure the locknut is tightened once the desired detent pressure has been set To shift to the high speed gear move the shifting handle upward from neutral position To shift to the low speed gear move the shifting handle down through the neutral detent to its lowest position Note that the high clutch gear or the low clutch gear may not be exactly aligned when shifting so the operator may need to bump the motor control handle slightly to turn the main clutch gear shaft and shifting collar into alignment This is most effective when applying a small amount of pressure on the gear shift lever in the direction you want to shift the tong ensuring the shifting collar will catch when the main clutch gear aligns with either the high or low clutch gear ILLUSTRATION 2 H 4 SHIFTING GEARS SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE DRILLING amp 2 22 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 00 5 1 amp CLINCHER Backup 5 Pre Operational Checks McCoy recommends that the following pre operating tests be performed prior to releasing the tong assembly to a operational envi ronment a Connect the tong to a hydraulic power source in a controlled environment Ensure the power unit s operating parameters are within the specifications as identified on Pg 1 3 E
43. es This can be acenmplishesl by acing cri food socios be Tom of rise and ihe spe inverting s reum heel ried on amp aewisniver the hole ini the ball retainer Step 3 Detent Balls and Spring iien balls Eig 2 derent apring 2 gem 19 and entire iride diameter o1 be ileten sleeve Fig 2 gem VT wath gres Jusen the deiten men le OG Hr lee dis Cle detent hall dee balks on the ends of ihe apne Compress the halls ind eprom then sim aom ibe desent Lure The detent sleeve ia miii semaines one eod of the sleeve has a lead in Tha fice ihe when Max 3 ihe deser eleva meatal middle ho prevent sidb ssemhly Mom separmrime dusimy sulseiquemi 7 26 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION 15500 5 1 A CLINCHER Backup Valve Assembly Instructions Step 1 Spool Subassambly Apoly Z 3 drops o Loctit 26279 or equivalent to tc fills ier sies indes vut bol ende ud henry Apply lighi costag al clean brau mil le the valve Carefully die sp vd assembly mus the exuri n Do mot
44. interval are 2 2 Normal Service yearly Severe Service monthly to quarterly Special Service as recommended by a qualified person DRILLING amp SEcTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION Units designed and manufactured in accordance with EN 12079 and DNV 2 7 1 should be tested and examined in accordance with the following schedule of examination and test The user of the load bearing device shall place a permanent placard or plate upon which the type and date of the last test shall be recorded To avoid confusion the plate shall not carry the date of the next test or examination only the most recent Non DESTRUCTIVE THOROUGH Surrix To BE MARKED Examination NDE VISUAL ON PLATE ATTACHED TiME INTERVAL LIFTING TESTS LIFTING POINTS EXAMINATION Initial Certification By YES YES YES Farr Superior Interval Not Exceeding At the discretion of At the discretion of YES 12 Months inspection body inspection body Interval Not Exceeding At the discretion of 60 Months inspection body Following Substantial YES YES YES T Repair or Alteration 1 Lifting test as per S 7 3 BS EN 12079 or DNV 2 7 1 May 1995 2 T Proof Test non destructive examination VN non destructive examination and visual examination V visual examination 3 Dependant upon whether non destructive examination has been carried out 4 For the purposes of this standard a substantial
45. missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp outlet line supports tong legs shifter handle pivot lugs Tighten or replace loose or missing fasteners Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is a good indication of wear Inspect all paint locations in which the paint has been damaged must be repaired prior to the tong being returned to service Prepare areas to be painted to ensure they are free of grease dirt or solvent Touch up using a solvent based acrylic paint McCoy Grey is paint color number RAL7015 McCoy Yellow hazard areas is RAL1007 and McCoy Green is RAL6029 contact Farr sales for paint number for custom paint applications Allow sufficient time for paint to dry before proceeding Visually inspect all load bearing welds Any weld that is cracked or separating must be repaired and repainted before returning the tong to service Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong in service Also inspect all chains master links and turnbuckles again if any damage is noted replace the damaged
46. necessary Ensure that the jaw rollers rotate freely 15 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brake band linings replace if lining is found to be flaking or is missing pieces of material Unequal 16 wear of the brake bands indicates that the brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands 1 7 Inspect door springs Ensure the springs retain sufficient strength to be able to assist the opening of the door and to keep S the door open The springs should also help to snap the door shut Inspect backup springs if applicable The rear extension springs where used should be equally extended and the front leg springs should be equally compressed Ensure that neither of the rear backup springs have been over extended and 18 2 lack sufficient tension to adequately support the backup Ensure that neither of the front leg springs or when installed the single rear backup leg spring have been over compressed and still retain enough spring strength to support the front of the backup 19 Extend all hydraulic cylinders and inspect cylinder rods for signs of mechanical damage flaking or rust Farr recommends that damaged cylinders be replaced prior to storage Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigu
47. new seccuan Aral Place sels id A ar atoms Tp Fhe pre pene Maie cen sis say im Beer ppo donne Step Install Tie Bolts aide the hug ther niet eap place a Weller on the cep screw prium bo isre ike valve sextiana po the pie bits proper sequence isse Hep page wi by hand engnge several p ihe outlet ITI YG senem auem mec ble end lo ciber end ua iz aud follow obave Togor be e bb m 4 reas conmer paler Bolt Torque Values VAZO 29 iba 34 1 Ib VG20 42 ft Ibs 504 in Ibs 34 fi Iba 404 in bs VG35 1 ibd 200 8 150 ft iba 10490 Iba 7 28 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION KT5500 5 7 amp CLINCHER Backup Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Punched or misie Replace section seal section seal Chil leaks between sections Stud f steners not correctly Replace section seals and retorque Los qued Mounting plate sot level Liosen mounting bolts and shim as required Contamination burrs on seal Clean seal groove replace section Chl leaks At end wer pressurized tank core Correct high back pressure of spool condition Wom damaged spoal
48. seals Replies seals ind seal retainers Broken centenng sprime Replace centering spring spring centered spooks ligriement af Cheek linkage for do nint retin t neutral linkage mechanical binding Foreign particles in system Clean valve and system Cylinder leaking or wur Check eviinder repair Load will not haki Port relief valve not holding Remove amd clean or replace Spool or housing scoredor Replace section Wom exeessively Lrad drops when spoo Diri or particles Disassemble clean mowed from neutral lodged berween check valve amp reassemble poppet and sgag Scored or sticking check Replace pappel ITE Defective cylinder or motor Repar or replace No moto sow o Clea oe cai system Chek ine Relief valve not properly sei Check pressure sting Relief valve poppetor Replace relief E seat scoped amp sticking open valve Valve spool mot shrfled Check spool linkage to full stroke travel DRILLING amp AACCCOY TecHNICAL MANUAL 7 29 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHERG Hyprautic VALVE INFORMATION H d H H Capacity Pilot to open spring biased closed unbalanced 60 gpm 240 L min poppet logic element Functional Group Products Cartridges Corrosion Resistant Logic Element Unbalanced Poppet Pilot to open Switching Element Spring biased closed External Pilot Port 3 LKHC pilot source Model Product Descriptio
49. seen from the top of the tong This is the desired direction of rotation for making up a joint Pulling the valve handle in the opposite direc tion results in counter clockwise rotation which is the desired direction of rotation for breaking out a joint ILLUSTRATION 2 1 Motor CoNTROL VALVE LIFT CYLINDER This is a direct acting valve Pulling out on the valve handle will cause the lift cylinder to lift the tong vertically Pushing in on the valve handle will cause the lift cylinder to lower the tong Releasing the valve handle will immediately stop the lifting or lowering action ILLUSTRATION 2 H 2 Der CYLINDER CONTROL VALVE DRILLING amp AACCCOY TEcHNICAL MANUAL 2 21 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER Back Setup amp OPERATION BACKUP Depending on the type of backup with which your system is equipped Wedge Clincher or Hydraulic pushing forward on this valve will extend the backup cylinder s or actuate a sequence valve Pulling backward towards the operator reverses the action D LN ILLusrRATION 2 H 3 BAckuP CoNTROL VALVE Coen VALVE 4 Shifting Gears The shifting shaft has three detent positions identifying the low speed high torque position the neutral or free spinning position and the high speed low torque position The detent strength may be adjusted by releasing the locknut on the detent tube and increas ing or relaxing pressure on the
50. the grease are good indicators may show where a component needs to be adjusted or if necessary replaced 5 Inspect latch mechanism to ensure the door latch plate completely engages the door Adjust or replace if necessary 6 Grease UC 300 slider pads guides door cylinder pivots and door pivots CLiNCHER Backup ONLY Use a flashlight to perform a visual inspection of the interior of the backup remove one side panel if necessary Premature 4 wear where there are moving parts bare metal where there used to be paint and metal shavings in the grease are good gt indicators may show where a component needs be adjusted or if necessary replaced Replace any removed panels when inspection is complete 5 Grease clincher cylinder guides using the grease fittings on the top body plate 6 Ensure the splines on the clincher cylinder faces and on the rear of the die are clean and free of debris before inserting s clincher die If die are already installed ensure fasteners in the die retainers are tightly secured 7 Inspect rear spring hanger assembly Ensure all eye bolts shackles and cotter pins are in place and in good condition 8 Inspect clincher cylinders for hydraulic fluid leaks once the system pressure has been restored FanR SrvLE Backup ONLY 4 Inspect cam ring gear for broken teeth 5 Lubricate the follower array Inspect the jaws and dies Inspect the jaw roller pi
51. then back it off until the first adjustment hole in the latch cam aligns with the threaded hole on the top of the door weldment Secure the latch cam to the door weldment with a 3 8 UNC x 1 hex bolt and 3 8 lock washer 56 Insert the the door pivot shoulder bushings top bushing PN 101 5110 bottom bushing PN 101 5111 in the door weldment note that the bushings are installed from the insides of the door plates 57 Align the door pivot holes with the pivot holes in the top and bottom plates and insert the door pivot roller shaft PN 101 3943 it may have to be tapped lightly with a soft metal or rubber hammer Use caution when sliding the shaft through the support roller components Once the shaft has been tapped all the way through secure the bottom of the shaft with a 7 8 UNF thin nylock nut and 7 8 narrow flat washer 58 If your tong is equipped with the safety door option it may now be installed See Pp 7 32 7 33 using the following procedure L Attach safety door latch block PN 101 1103 to safety door latch plate PN 101 1105 using three 3 8 NC x 7 8 flat head countersunk cap screws i Place safety door latch plate PN 101 1105 onto the bottom plate of the safety door guard weldment 101 1481 and align the bolt holes Secure to the top plate using three 3 8 NC x 2 1 4 hex bolts and lock washers Attach the safety door latch block 101 0914 to the top of the door plate using two 3 8 NC x 1 1
52. 09 5906 F Weldment LH Brake Band Lug Weldment 1 101 0134 Weldment RH Brake Band Lug Weldment 1 101 0132 G Part 3 8 NF x 1 1 2 Brake Band Adjustment Bolt 2 09 1553 TECHNICAL MANUAL SECTION CONTENTS 5 21 KT5500 5 17 amp CLINCHER Motor Mount ASSEMBLY DRILLING amp 5 22 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor Mount ASSEMBLY KT5500 5 1 amp CLINCHER Backup Item Type Description Qty Part Number A Weldment Torque Gauge Mount Weldment 1 1500 09 03A B Part 1 2 NC x 1 1 4 Hex Socket Head Cap Screw 2 09 2168 C Part 1 2 NC x 1 Hex Socket Head Cap Screw 2 09 2166 D Part 1 2 Lock Washer 4 09 5110 E Part Rineer GA15 13 Hydraulic Motor 1 87 0110 Part Rineer GA15 13 6 5 Two Speed Hyaraulic Motor Optional 1 87 0007 F Part Motor Gear 1 997 A10 149 G Part 3 8 NC x 3 8 Hex Socket Set Screw 2 09 0106 H Part 1 2 NC x 1 1 2 Hex Socket Head Cap Screw 4 09 2170 J Part 1 8 NPT 90 DEG Grease Fitting 1 02 0093 K Weldment Torque Gauge Holder Weldment 1 1500 09 04A L Part 20 1 1 4 Split Flange Kit 2 02 9217 Part O Ring 1 Part 20 1 1 4 Split Flange 2 Part 7 16 Lock Washer 4 Part 7 16 NC x 1 1 2 Hex Bolt 4 M Part Square 5 16 x 5 16 x 1 1 2 Key 1 01 0317 N Part Motor Mount 1 1400 150 P Part 20 1 1 4 JIC 1 Flange Elbow 2 02 9216 Q Part 0 14
53. 1 1 1 2 Eet 1 6 SECTION TWO SETUP amp OPERATION A SLING LOAD BEARING DEVICE SAFETY iiie imer iiai ear PELA RE 2 1 1 Inspection Of Slings au 1022 2 Proper Use Of Load Bearing Devices 2 3 3 Storage Of Load Bearing Devices 2 3 B MAJOR COMPONENT IDENTIFICATION 2 4 C HYDRAULIC SCHEMATIC COMPONENT IDENTIEICATION esses nnne nne 2 8 D JJHYDRAULIC CONNEGTIONS iari ae trt t tid ne epp ER ra edF sited 2 11 E TONG JAW AVAILABILITY amp INSTALLATION SE UE EE 2 12 2 Jaw Jaw Die Removal 2 13 3 Backup Jaw Availability 2 14 4 CLINCHERQ Backup Jaw Removal Installation 2 15 F TONG RIG UP amp LEVELING 7 Restraint 2 16 2 TONG MOV ONIN 2 17 3 Compression Load Cell Configuration 2 18 4 Tension Load Cell Conttouration sessi 2 19 G TONG OPERATION 1 Operator Training Pm 2 21 2 Initial Start up and Break in Procedure 2 21 3 Desai gle Les ead optics essei ee diu dive sa ek Pos voc Cue epa ad ud gu un deua bu ode Uude 2 22 4 Shifting
54. 1 905 03 Part Rear Backup Suspension Spring Compression Load Cell Configuration 2 1302 905 03A Weldment LH Front Leg Mount Weldment Tension Load Cell Configuration 1 101 2152 Weldment RH Front Leg Mount Weldment Tension Load Cell Configuration 1 101 2153 Weldment LH Front Leg Mount Weldment Comp Load Cell Configuration 1 101 0786 Weldment RH Front Leg Mount Weldment Comp Load Cell Configuration 1 101 0787 S Part 7 8 Narrow Washer 2 09 5123 T Part 7 8 NF Hex Thin Nylock Nut 2 09 5722 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL Section CONTENTS 5 31 5500 5 17 8 CLINCHER Lee ASSEMBLIES 1 Y LS 4 Hti 7 i DRILLING amp LEG ASSEMBLIES 00 5 1 amp CLINCHER Backup Item Type Description Qty Part Number A Weldment LH Front Leg Mount 1 101 0787 B Part 7 16 NC x 3 1 2 Hex Bolt 4 C Part 7 8 NF Thin Nylock Nut 4 09 5722 D Part Support Leg 2 1364 909 E Part Front Leg Spring Top Cap 2 101 4489 F Part Front Leg Spring 2 1302 905 08 G Part Bottom Leg Cap 2 1302 905 03A H Assembly Support Roller Shaft 4 101 3944 Weldment 2 Load Cell Holder 1 01 9116D J Part 1 2 NC x 6 Hex Bolt 4 09 1190 K Weldment RH Front Leg Mount 1 101 0786 L Weldment Rear Backup Leg Spring Plate Top 1 101 4495 M Part 1 2 Hex Nu
55. 1483 500 00 01 P Assembly CLINCHER Cylinder Assembly 2 1403 00 00B Q Part 1 UNC Nylock Nut 4 09 5725 R Weldment Gauge Protector Weldment 1 1483 500 18 Part Relief Valve Body 1 08 1180 Part Relief Valve Cartridge 1 08 0481 DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 5 35 5500 5 amp CLINCHER Backup Compression LC Conric a Beef weg DRILLING amp 5 36 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Backup Bop AssEMBLY Compression LC 5500 5 1 amp CLINCHER Backup Item Type Description Qty Part Number A Weldment Load Cell Holder Weldment 1 01 9116D B Part 3 8 Regular Flat Washer 1 09 5006 C Part 3 8 NC x 1 1 4 Hex Bolt 1 09 1048 D Part 1 1 4 NC Hex Nut 3 09 5832 E Part Suspension Spring V Bracket 1 1483 500 00 04 F Part Suspension Spring Retainer 2 1483 500 00 4B G Part 1 1 4 NC x 8 Threaded Rod 1 101 1993 H Part 1 4 NC x 3 4 Hex Bolt 2 09 1005 J Part 2 1 2 Face 0 3000 PSI 1 4 NPT Gauge 1 02 0246 K Weldment Gauge Protector Weldment 1 1483 500 18 L Part 3 8 NC x 1 1 2 Hex Bolt 1 09 1050 M Part 3 8 Carbon Steel Lockwasher 17 09 5106 N Part 1 NC x 8 1 2 Hex Bolt P Part Rear Jaw 1403 08 Q Part Rear Side Cover Plate 2 1421 500 11B R
56. 4 ILLUSTRATION 2 2 KT5500 CBU ID 02 2 5 ILLUSTRATION 2 3 KT5500 CBU ID 03 22222 2 2 2000 0 0 00000000000000000000 2 6 ILLUSTRATION 2 B 4 KT5500 CBU ID 04 26 ILLUSTRATION 2 B 5 KT5500 CBU ID 05 ann 2 7 ILLUSTRATION 2 C 1 KT5500 CBU HYDRAULIC SCHEMATIC 2 8 ILLUSTRATION 2 C 2 KT5500 CBU Hyprautic ID 01 we 29 ILLUSTRATION 2 C 3 KT5500 CBU HybDRAULIC COMPONENT ID Oe 2 9 ILLUSTRATION 2 C 4 KT5500 CBU HybDRAULIC COMPONENT DO 2 10 ILLUSTRATION 2 C 5 KT5500 CBU Component ID 04 2 10 ILLUSTRATION 2 C 6 KT5500 CBU COMPONENT ID Op 2 11 ILLUSTRATION 2 0 1 KT5500 CBU HYDRAULIC CONNECTIONS OT 2 11 ILLUSTRATION 2 D 2 KT5500 CBU CONNECTIONS 02 2 12 ILLUSTRATION 2 E 1 KT5500 CBU JAW ue 2 13 ILLUSTRATION 2 E 2 KT5500 CBU Jaw DIE Rewovat 0 2 14 ILLUSTRATION 2 E 3 KT5500 CBU CLINCHER CYLINDER EXTENSION su 12215 ILLUSTRATION 2 E 4 KT5500 CBU WhAPAROUND DIE REMOVAL 2 15 ILLUSTRATION 2 E 4 KT5500 CBU REAR BACKUP JAW EXTENSION
57. 4 14 98 DRAWN BY DWG NO JERRY W 0150041 7 9 s o z o TECHNICAL MANUAL DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHERG Back Hyprautic Motor INFORMATION WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION REMOVAL OF SHAFT SEAL k 1 Two of the 3 8 bolt holes are provided with jack screw threads 2 Insert a piece of 1 4 round stock by 2 1 2 long into each jack screw hole 3 Screw two 7 16 14 bolts into the jack screw threads until the bearing box is free ofthe motor 1 Remove snap ring WARNING Use caution when removing snap ring If released accidentally it can become an airborne hazard Lift up on the bearing box 1 Pry out shaft seal plate to remove from motor with two screw drivers 2 Remove seal plate o ring from groove in bearing bore 1 Loosen and remove 8 each 10 32 bolts 2 Pry off seal plate with screw driver 1 Loosen clamp screw in lock nut 2 Unscrew lock nut and remove 1 Press shaft out of bearing box 2 Proceed to step 9 disregarding steps 11 amp 12 Loosen and remove 8 each 3 8 bolts with 5 16 socket head wrench DRILLING amp 7 10 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic Motor INFOR
58. 500 5 amp CLINCHER MAINTENANCE 2 Door Latch Adjustment Normal operation of the tong may cause wear of the door latch which will cause the door to develop a loose fit at the latch A latch cam plate is located at the top face of the door The cam plate has eight positioning holes located on a 360 degree bolt circle The latch cam shaft extends down through the door and is secured at the top by a 3 8 hex head bolt To make adjustments in door align ment remove the 3 8 bolt and turn the cam with a wrench When the door has been adequately aligned replace the 3 8 bolt see illustration 3 E 2 THE DOOR IS AN IMPORTANT PART OF THE STRUCTURAL INTEGRITY OF THE TONG IT IS IMPERATIVE TO KEEP A SECURE FIT AT THE DOOR IN ORDER TO MAINTAIN PROPER GEAR ALIGNMENT AND TO MINIMIZE THE POSSIBILITY OF DAMAGE TO THE GEAR TRAIN WHEN OPERATING THE TONG AT SPECIFIED TORQUE A CLOSED DOOR ALSO ENSURES SAFETY OF OPERATING PERSONNEL eg P A H ILLUSTRATION 3 E 2 Door CAM ADJUSTMENT 3 Shifter Detent Force Adjustment Over time wear to the shifting shaft wear to the detent ball and loss of spring tension in the detent spring may result in a loose or sloppy fit within the top shifter bushing The detent pressure may be increased or otherwise adjusted by loosening the 7 16 UNF locking jam nut and turning the 7 16 UNF detent bolt Should adequate detent action not be achieve
59. 500 5 1 amp CLINCHERG Backup POSSIBLE PROBLEM SOLUTION S Obstruction in tong hydraulic circuit preventing adequate flow Inspect self sealing couplings to ensure they are properly engaged The main hydraulic lines supply and discharge to the tong are obstructed Re move and clean if required Power unit is not producing adequate flow or pressure Troubleshoot power unit see user s manual for your particular unit Tong motor is excessively worn and is leaking hy draulic fluid past the vanes Replace motor or rebuild as per Section 7 of this manual Bearings in gear train and rotary section are ex cessively worn Overhaul tong See Section 3 of this manual for tong overhaul procedures Shifter has malfunctioned and the tong is not shifting to high gear Inspect and repair shift mechanism as necessary Hydraulic fluid viscosity too high Ensure hydraulic fluid meets McCoy Drilling amp Completions specifications Ensure hydraulic fluid is appropriate for climatic conditions especially during cold weather operation By pass valve not functioning Check and repair MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL Section CONTENTS 45 KT5500 5 1 amp CLINCHERG Bac E FAILURE OF JAWS TO GRIP PIPE TROUBLESHOOTING POSSIBLE PROBLEM SOLUTION S 1 Dies have become too dull to p
60. 8 X 2 938 HITCH PIN 1 09 0090 DRILLING amp AACCCOY TEcHNICAL MANUAL 5 23 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 6 CLINCHER BackUp ASSEMBLY X DRILLING amp 5 24 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC ASSEMBLY 3500 5 1 amp CLINCHERG Backup Item Type Description Qty Part Number A Part M NPT F NPT 90d 1 Fitting 1 02 9221 B Part 1 Long Nipple 1 101 0079 C Assembly M ORB F NPT 90 1 Fitting Includes seals 1 02 9206 D Part Hyaraulic Inlet DVA35 A880 1 10 9016 E Part Male 1 Quick Coupler Fitting 1 02 9214 F Part 1 Dust Cap 1 02 9213 G Assembly 1 Hydraulic Connection Hose Assembly 2 08 1724 H Assembly M ORB JIC LONG 90d 1 Includes seals 1 02 9210 J Assembly Motor Drain Hose Assembly 1 101 0072 K Part ORB HEX BUSHING 1 10 9001 L Assembly 90 DEG 3 8 Fitting Includes seals 2 02 9200 M Part 1 1 4 Dust Cap 1 02 9212 N Part Male 1 1 4 Quick Coupler Fitting 1 02 9215 P Part 1 1 4 Long Nipple 1 101 0070 Q Assembly M ORB F NPT 90d 1 1 4 Fitting Includes seals 1 02 9202 R Part M NPT F NPT 90d 1 1 4 Fitting 1 02 9220 S Part Hydraulic Outlet DVA35 TR99 1 10 0086 T Part DVA35 DA8 4WAY SAE Ports 1 10 9019 U Assembly Handle Assembly 3 01 0409 Part Hydraulic Valve Ha
61. 90 Rigtalrier Prabes 39121832001 2183 1205 91 215 157 d Back up Rings d 41 268 1 376 21 2681 Saale d 181 1885 043 381 2887 212 221 2283 006 8 Plaie Screws 2 381 1432 015 381 1433 002 41 24 402 015 10 Cneck Varie 1 334 U5B81 044 797 058 EUR Or Valve CaF ANM 1 39 1 228140417 181 2281 015 11 Ring Seal 1 331 28B 1 204 3801 288 1 204 321 2881 248 12 Chock 1 364 3581 713 304 354 713 381 3581 778 14 Check Vole Poppet 1 383 2383 051 Parallel Face indii and iol Elsa Sections 7 20 SECTION CONTENTS TEcHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS HvoRAULIC VALVE INFORMATION Spool 5500 5 7 8 CLINCHER Backup Nm Spring Centered and Detent Spool Operators 14 Stripper Bolt 15 Centenng Spring MOVING GLOBAL ENERGY FORWARD 1 18 Spnng Guides 2 17 Detent 1 16 Detent Balte 2 19 Daten Spring 20 Deipnt Poppet Retainer 21 Detent Spacer 1 381 1432 D272 381 3581 D08 391 1642 045 381 3283 015 391 0282 010 381 3581 130 381 2583 008 See Figure 2 391 1432 021 381 3581 833 301 1642 013 391 3283 008 391 0282 009 391 3581 015 381 2583 006 381 1402 457 391 3581 330 391 1542 161 391 3384 310 391 0282 011 391 3581 316
62. CCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 5500 5 1 8 CLINCHER Backup Suspension amp Restraint continued McCoy Drilling amp Completions recommends using dual backup snub lines of sufficient strength to withstand the force imparted by the maximum rated torque of the tong and backup assembly in use The snub lines will arrest uncontrolled movement of the tong and backup in the event slipping of the backup jaws Calculate the force on the snub lines by dividing the maximum torque of the tong by the tong s torque arm expressed in feet For example a 25 000 Ibs ft tong with a 32 inch 2 667 ft torque arm will generate 9375 Ibs of force against the snub line Select your snub lines based upon the total force and the margins of safety dictated by the policies of your company and by established engineering practices Ultimately calculating the force on the snub line and selection of the snub line is the complete responsibility of the customer Snub lines must be securely connected to the rear of the tong and backup assembly and tied off to a suitable anchor MCCOY DRILLING amp COMPLETIONS ACCEPTS NO RESPONSIBILITY FOR DESIGNING AND SELECTING AN ADEQUATE SUSPENSION AND RESTRAINT SYSTEM FOR YOUR DRILLING EQUIPMENT ALL SELECTED FASTENERS SHACKLES CLAMPS ETC USED FOR CONSTRUCTING THE SUSPENSION AND SNUB LINES MUST BE RATED FOR THE CALCULATED FORCES 2 Tong Leveling The tong must b
63. COY MOVING GLOBAL ENERGY FORWARD MAINTENANCE 200 5 1 amp CLINCHER Backup Mechanical Assembly Procedure Continued 5 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Install support roller assemblies in the locations exposed by the opening in the rotary gear Continue to rotate the rotary gear install ing support roller assemblies in the rotary gear opening as it is rotated Finish with the rotary gear aligned with the opening in the bottom plate Press pinion bearing PN 02 0007 into bottom pinion bearing cap PN 997 D15 89 and install bearing cap into bottom plate of tong using four 1 2 UNC x 1 1 4 hex cap screws and four 1 2 lock washers ASSEMBLY NOTE Do not neglect to install the clutch bearing cap spacer PN 1400 89 between the bearing cap and the bottom plate of the tong Press bottom clutch bearing PN 02 0004 into clutch bearing PN 997 D1 1 54 and install bearing cap into bottom plate of tong using four 3 8 UNC x 1 1 4 hex cap screwsand four lock washers ASSEMBLY NOTE Do not neglect to install the clutch bearing cap spacer 1400 54A between the bearing cap and the bottom plate of the tong Install a retainer clip PN 02 0009 into all three idler gears PN 997 A2 119 Press an idler bearing PN 02 0011 into each gear and secure with a second retainer clip Lightly grease the larger circumference of the two rotar
64. DEVICES UNLESS THOSE MODIFICATIONS ARE PERFORMED BY MCCOY DRILLING amp COMPLETIONS McCoy Drilling amp Completions recommends following an industry accepted standard such as OSHA ASME B30 9 2006 or manufacturer s guidelines when performing any rigging and overhead lifting Use by untrained persons is hazardous Improper use will result in serious injury or death Do not exceed rated capacity Slings will fail if damaged abused misused overused or improperly maintained Only grade 80 or grade 100 alloy chain should be used for overhead lifting applications Working Load Limit WLL is the maximum allowable load in pounds which may be applied to the load bearing device when the device is new or in as new condition and when the load is uniformly and directly applied The WLL must never be exceeded Working Load Limit WLL is the maximum working load for a specific minimum sling angle measured from the horizontal plane The Working Load Limit is identified on the sling The Working Load Limit or Design factor may be affected by wear misuse overloading corrosion deformation intentional alterations sharp corner cutting action and other use conditions Shock loading and extraordinary conditions must be taken into account when selecting alloy chain slings See OSHA Regulation for Slings 1910 184 ANSI ASME B30 9 SLINGS ANSI ASME B30 10 HOOKS ANSI AMSE B30 26 RIGGING HARDWARE for additional information T
65. DRILLING amp 2 4 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 5500 5 7 amp CLINCHER Backup 13 14 15 16 17 ILLUSTRATION 2 B 2 KT5500 CBU Component ID 02 Item Description 8 Rigid Sling Leveling Device 9 Cage Plate Assembly 10 Safety Door Switch Guard 11 Safety Door Switch 12 Tong Door Latch 13 Backing Pin Assembly 14 Tong Jaws with Die Inserts 15 Brake Band Adjustment 16 Tong Door Cylinder 17 Tong Door Weldment DRILLING amp e ee TecHNicAL MANUAL 2 5 MOVING GLOBAL ENERGY FORWARD 5500 5 amp CLINCHER BACKUP Setup amp OPERATION ILLUSTRATION 2 B 4 KT5500 CBU Component ID 04 Item Description 18 Hydraulic Valve Bank Assembly 19 Manual Shift Assembly 20 Access Panel 21 Cylinder With Wraparound Insert 22 Torque Gauge Mount 23 Hydraulic Motor 24 Motor Mount 25 Tension Load Cell DRILLING amp 2 6 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT5500 5 7 amp CLINCHER Backup ILLUSTRATION 2 B 5 KT5500 CBU Component ID 05 Item Description 25 CLINCHER Backup Compression Load Cell Configuration 26 Rear Leg Assembly Compression Load Cell Configuration
66. Die REMOVAL INSTALLATION DRILLING amp AACCCOY TEcHNICAL MANUAL 2 15 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER Setup amp OPERATION To remove the die from the rear jaw ensure both cylinders are retracted Remove the hex bolt securing the rear jaw assembly then slide rear jaw forward enough so that the flat head cap screws securing the die retainer tab is well exposed Remove the die following the same procedures as for the CLINCHER cylinders ILLUSTRATION 2 E 4 KT5500 CBU Rear Backup Jaw EXTENSION Reverse this procedure to install or replace jaws F TONG RIG UP amp LEVELING 1 Suspension amp Restraint Suspend the tong and backup from a location as near to the centre of the drill rotary as possible and from a location high enough on the mast to ensure easy handling The lower the point from which the tong is suspended the more effort will be required to move the tong and backup assembly on to and off the connection The suspension line may be extended over a pulley and balanced by a counterweight equal to the weight of the tong and backup or simply tied off in the derrick to form a dead line When using a dead line arrangement it is necessary to use a FARR spring hanger assembly see specification page for recommended spring hanger This spring hanger compensates for the downward movement of the casing as the thread is made up and imparts additional force to the su
67. ERGY FORWARD This page intentionally left blank 00 5 amp CLINCHER Backup WARNINGS A LOAD BEARING DEVICE IS A CHAIN SLING RIGID SLING SPREADER BAR ASSEMBLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH THIS MANUAL HAS BEEN PRODUCED THE LOAD BEARING DEVICE SUPPLIED BY MCCOY DRILLING amp COMPLETIONS IS DESIGNED TO SUP PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL MCCOY DRILLING amp COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEM BLY OR COMBINATION OF PARTS AND ASSEMBLIES MCCOY DRILLING amp COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD BEARING DEVICE OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SUPPLIED BY MCCOY DRILLING amp COMPLETIONS WHEN RE ASSEMBLING LOAD BEARING DEVICES CHAIN SLINGS RIGID SLINGS BACKUP LEGS ETC NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE OF FASTENER SEE SECTION 3 OVERHAUL ANY THREADED FASTENER A LOAD BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE ANY REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED DRILLIN
68. G amp AACCCOY TecHNicAL MANUAL MOVING GLOBAL ENERGY FORWARD This page intentionally left blank 0 5 17 amp CLINCHERG Backup Copyright 2007 2012 McCoy Corporation including its wholly owned subsidiaries McCoy all rights reserved This document is the property of McCoy and is supplied as reference information for users of our products This document and the contents within are considered confidential information not to be disclosed copied transmitted transcribed in any form or stored on any type of data storage media without the express written consent of McCoy McCoy has made every effort to ensure the information contained in this document is accurate and current This manual is intended to provide equipment operation and safety instructions for your equipment However McCoy does not warrant or guarantee that the information is either complete or accurate in every respect and the user of the manual should consult with its McCoy sales representative for any clarifications and updates The user of the manual shall protect indemnify and hold harmless McCoy and its directors officers employees and agents from and against all liability for personal injury death or property damage resulting directly or indirectly from the use of the information contained in this manual Observance of all descriptions information and instructions set out in this manual is the full responsibility of the user Th
69. GHT in kg x 2 2 x ARM LENGTH in feet x 1 356 For example if the arm length is 32 inches and the known weight is 250 kg the calculation is 250 x 2 2 x 32 12 x 1 356 1988 8 Therefore the expected indication on the torque gauge should be approximately 1990 Nm Repair And Calibration Return the load cell and indicator gauge to the authorized repair facility for repairs and calibration DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 Tone amp CLINCHER Backup MOVING GLOBAL ENERGY FORWARD FARR Section 7 Hydraulic Component Information The manufacturer information contained in this section has been obtained from publicly available web sites and has been provided for information purposes only Farr Canada Corp does not guarantee the accuracy of the in formation contained in this section All original copyrights claimed by the manufacturer s apply DRILLING amp AACCCOY MANUAL 71 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank 15500 5 amp CLINCHERG Backup Features of the 15 Series Standard Motor Standard Motor 3000 PSI Code 61 Fight fixed displacement motors ranging from 6 in to 15 103 Starting and stall torques equal to 90 9496 of theoretical torque Speed to 2 000 RPM co
70. Group Model Cartridges Relief 2 Port Pilot Operated Balanced Piston RPGC Product Description Pilot operated balanced piston relief cartridges are normally closed pressure regulating valves When the pressure at the inlet port 1 reaches the valve setting the valve starts to open to tank port 2 throttling flow to regulate the pressure These valves are accurate have low pressure rise vs flow they are smooth and quiet and are moderately fast L 2 12 oR Locating Shoulder K 2 38 61 1 88 47 8 L Gontrol shown Installed Cavity Inlet Hex Dimension 2 across flats 1 1 8 28 6 Outlet in mm Technical Features e Will accept maximum pressure at port 2 suitable e Main stage orifice is protected by a 150 micron for use in cross port relief circuits If used in cross stainless steel screen port relief circuits consider spool leakage e Not suitable for use in load holding applications e Back pressure on the tank port port 2 is directly due to spool leakage additive to the valve setting at a 1 1 ratio e All 2 port relief cartridges except pilot reliefs are e Stainless steel cartridge options P or W are physically and functionally interchangeable same intended for use within corrosive environments flow path same cavity for a given frame size with all external components manufactured in stainless steel or titanium Internal working components remain the same as the standard valves e Incorpor
71. HE MINIMUM SLING ANGLE THE ANGLE OF THE LEG OF THE SLING MEASURED FROM THE HORIZONTAL MUST NEVER FALL LOWER THAN THE ANGLE SPECIFIED FOR THE SLING IN USE Sling Angle ILLUSTRATION 2 1 SLING ANGLE DRILLING amp AACCCOY TECHNICAL MANUAL 21 MOVING GLOBAL ENERGY FORWARD 5500 5 1 amp Setup amp OPERATION 1 Inspection Of Slings McCoy Drilling amp Completions strongly recommends the following practices A complete inspection of new load bearing devices and attachments shall be performed by a qualified designated person prior to initial use Each link and component shall be examined individually taking care to expose and examine all surfaces including the inner link surface The sling shall be examined for conditions such as those listed in the removal criteria below In addition daily inspection of slings fastenings and attachments shall be performed by a designated person If damage or defects are found at either inspection the damaged or defective component shall be quarantined from service until it can be properly repaired or replaced Removal Criteria A load bearing device shall be removed from service if conditions such as the following are present Missing or illegible sling identification Cracks or breaks Evidence of tampering is seen sling tag has been modified or obscured or tamper proof nuts are missing Signs of impact on load bearing components including
72. HE SYSTEM DO NOT ALLOW THE LEVEL TO FALL BELOW ONE HALF FULL e Remove the vent plug screw Stat O Seal Items and D on Illustration 6 A 4 or item on Illustration 6 A 5 to allow trapped air to escape Pump fluid into the system until no more air is seen escaping from the vent port g Replace the vent plug screw and Stat O Seal and tighten securely h Remove load cell from containment vessel and wipe clean Reclaim the hydraulic fluid if it is clean or dispose of all waste materials according to governmental or your company s proscribed environmental protection regulations Disconnect the hand pump from the torque gauge 1 Replace the brass the torque gauge check valve fitting 3 Reference Checking Your Torque Measurement System The following steps define a process for determining if your torque measurement system is correctly measuring and indicating within an expected range This procedure is best suited for performing in a shop or location removed from the floor within range of a crane This is a reference check and not a calibration Calibrations must be performed at an authorized calibration facility Tension Load Cell a Locate a known weight in the range of approximately 500 to 1000 16 227 to 455 kg and move the weight next to the tong and backup assembly b Remove the tension load cell from the tong but do not disconnect from the torque gauge Suspend the load cell piston side up
73. ILLING amp AACCCOY TEcHNICAL MANUAL 3 15 MOVING GLOBAL ENERGY FORWARD 5500 5 amp MAINTENANCE Mechanical Assembly Procedure Continued 44 45 46 47 48 49 50 51 52 53 54 Install the remaining support roller shafts excluding the door pivot roller shaft Stand Alone Tongs Models 80 0420 5 80 0420 12 Slide 7 8 narrow flat washer over the remaining five support roller shafts PN 101 3942 and insert into the remaining port roller assemblies excluding the door pivot support roller ii Secure the bottoms of the support roller shafts with 7 8 narrow flat washers and 7 8 UNF thin nylock nuts with the exception of the two shafts directly behind the brake band lug weldments These two shafts will serve as leg mounts in a future step Backup Ready Tongs Models 80 0420 3 80 0420 9 80 0420 14 80 0420 15 i Slide a 7 8 narrow flat washer over the remaining short support roller shaft PN 101 3942 and four long support roller shafts PN 101 3944 Insert the short shaft into the support roller assembly directly in front of the RH brake band lug weldment and insert the four long shafts into the four remaining support roller assemblies two per side directly behind each brake band lug weldment i Secure the bottoms of the short support roller shaft directly in front of the RH brake band lug weldment with a
74. Idler Bearing 1 02 0011 J Part Idler Gear 1 997 A2 119 DRILLING amp e ee TECHNICAL MANUAL 5 7 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER BACKUP Pinion IDLER ASSEMBLY DRILLING amp 5 8 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Pinion IDLER ASSEMBLY 5500 5 7 amp CLINCHER Backup Item Type Description Qty Part Number A Part Idler Bearing Retainer 1 02 0008 B Part Bearing Seal 1 02 0010 C Part Retainer Ring 2 02 0009 D Part Idler Gear 1 997 A2 119 E Part Idler Bearing 1 02 0011 F Part Idler Half Shaft 1 997 017 105 Pinion Idler Pad 1 1400 109 H Part 5 8 Carbon Steel Lock Washer 3 09 5114 J Part 5 8 UNC x 2 1 4 Hex Bolt 3 09 1235 K Part 1 1 2 UNF Nylock Nut 1 09 5740 L Part Grease Fitting 1 8 NPT 1 02 0005 DRILLING amp e ee TecHNicAL MANUAL 5 9 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER BACKUP ASSEMBLY DRILLING amp 5 10 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Pinion ASSEMBLY 5500 5 1 Tonc amp CLINCHERG Backup Item Type Description Qty Part Number A Part Grease Fitting 1 8 NPT x 90 Degree 4 02 0093 B Part 1 2 UNC x 1 1 4 Hex Bolt 8 09 1168 C Part 1 2 Lock Washer 8 09 5110 D Part Pini
75. LLUSTRATION 3 0 7 MOTOR GEAR CLUTCH DRIVE GEAR LUBRICATION we 3 5 5 3 082 SHIFTING SHAFT LUBRICATION EE 3 5 ILLUSTRATION 3 D 9 DOOR LATCH CAM SHAFT LUBRICATION 3 6 ILLUSTRATION 3 0 10 CLINCHER CYLINDER LUBRICATION 3 6 ILUUSTRATION 3 D 1 EE 3 7 ILLUSTRATION BRAKE BAND ADJUSTMENT e 3 7 ILLUSTRATION 3 E 2 DooR LATCH CAM ADJUSTMENT 3 8 ILLUSTRATION 3 E 3 SHIFTER DETENT FORCE ADJUSTMENT 3 8 ILLUSTRATION 3 H 1 TONG ASSEMBLY INITIAL SUPPORT ROLLER INSTALLATION 2 2 222 22 22 01000000000000050000000000222000 3 12 ILLUSTRATION 3 H 2 TONG ASSEMBLY ROTARY GEAR INSTALLATION we 3 12 ILLUSTRATION 3 H 3 TONG ASSEMBLY TOP PLATE FASTENER JNsratiamoN 3 14 ILLUSTRATION 3 H 4 TONG ASSEMBLY TOP SHIFTER BUSHING INSTALLATION nna nenas 3 14 ILLUSTRATION 3 H 5 ASSEMBLY BRAKE BAND WELDMENT INSTALLATION su 9219 ILLUSTRATION 3 H 6 TONG ASSEMBLY FRONT LEG MOUNT WELDMENT INSTALLATION 2 2 2220 000000000000000000000000 3 16 ILLUSTRATION 3 H 7 TONG ASSEMBLY SAFETY DOOR SWITCH INSTALLATION 2 20000 0 00 000000000000000 3 17 ILLUSTRATION 3 H 8 ASSEMBLY LEVELING BOLT INSTALLATION 3
76. LOBAL ENERGY FORWARD 41 TECHNICAL MANUAL CONTENTS KT5500 5 amp CLINCHER BACK TROUBLESHOOTING B RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING POSSIBLE PROBLEM SOLUTION S Relief pressure set too low resulting in in sufficient tong torque 1 Relief pressure set too high resulting in Adjust setting See following rocedure crushed pipe or gear train failure a If your tong is equipped with a system pressure indicator proceed to step f If your tong does not have a system pressure indicator a temporary 0 3000 PSI indicator must be installed on the hydraulic inlet b Isolate your tong from hydraulic power and depressurize following the procedure in section 3 0 c Tee in temporary indicator at the safety door supply pressure port Ensure all hydraulic connections are performed by a qualified hyaraulic technician Connect a temporary 0 3000 PSI pressure indicator at this location ILLUSTRATION 4 1 RELIEF VALVE TROUBLESHOOTING TEMPORARY GAUGE INSTALLATION Re establish hydraulic power to your tong Ensure that no equipment functions are active Loosen the locking nut on the pressure relief valve Open the tong door to activate the safety door system and inhibit tong rotation Activate motor control valve Observe the pressure displayed on the pressure indicator Adjust the relief valve until the pressure indicated is at the ma
77. M 400 RPM 10 1500 2000 PRESSURE psid ACTUAL FLOW 6 CID 100 RPM 3000 TORQUE ft lbf pan of Sa I 1500 2000 PRESSURE psid ACTUAL TORQUE AND POWER 11 5 CID 1600 RPM 00 RPM 1600 RPM 1200 RPM 800 RPM 400 RPM 200 RPM 1500 2000 PRESSURE psid ACTUAL FLOW 11 5 CID 100 RPM 2500 5 2 o a o FLOW gpm E 5 1500 2000 PRESSURE psid FLOW m e a OW opm B 80 2 8 o ACTUAL TORQUE AND POWER 9 5 CID Hyprautic MOTOR INFORMATION 1700 100 RPM 1700 RPM 1300 RPM 900 RPM 500 RPM 300 RPM 1500 2000 PRESSURE psid ACTUAL FLOW 9 5 CID 100 RPM 500 PRESSURE psid 2000 ACTUAL TORQUE AND POWER 15 CID 1500 RPM 100 RPM a 5 1500 a 1100 RPM 2 a 700 RPM 500 RPM 8 POWER HP 300 RPM a 1500 2000 PRESSURE psid ACTUAL FLOW 15 CID 100 RPM o 2000 PRESSURE psid The above performance data wa
78. MATION 5500 5 1 amp CLINCHER Backup WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION DISASSEMBLY OF ROTOR STATOR CARTRIDGE DISASSEMBLY OF FRONT HOUSING AND SHAFT MOVING GLOBAL ENERGY FORWARD 1 Mark one side of the motor for proper assembly paying careful attention that the cartridge will not be installed upside down 2 Secure the motor prior to loosening the 5 8 11 bolts 1 Remove front housing With the seal plate removed press shaft and ball bearing out of front housing 1 Remove snap ring from shaft 2 Press shaft out of 16 Lift up rotor stator cartridge and remove from the rear housing 1 Place E any 2 Note Two 5 16 ball object which will hold it off checks and one main body the table o ring may be dislodged 2 Remove two each 10 32 and fall free place screws 3 Remove timing plate 1 Remove o ring and springs with a small screwdriver 2 Remove dowels pins 1 Replace plate on rotor stator cartridge 2 Turn rotor stator bearing cartridge over 3 Repeat steps 14 amp 15 MCCOY 5 TecuicuL Manuat 7 11 5500 5 1 Tone amp CLINCHER 1 Remove the rotor 2 Remove both the rotor and stator vanes 3 Note On motors manufactured prior to 1987 rotor vane slots and rotor vanes should be numbered so that vanes can be reassem
79. MOVING GLOBAL ENERGY FORWARD ASSEMBLY 15500 5 7 amp CLINCHERG Backup Item Type Description Qty Part Number A Part 1 2 UNC x 8 Hex Bolt 1 09 1198 B Part 1 2 Narrow Flat Washer 1 09 5119 C Part Backing Pin Spacer 1 101 4093 D Part Jaw Pivot Bolt 2 1064 28 E Part 1 2 NC x 6 Hex Bolt 2 09 1190 F Part Top Cage Plate 1 1400 21 G Part Cage Plate Spacer 3 1064 38 H Assembly Jaw Assembly 5 1 2 shown see 2 12 2 J Part Rotary Gear 1 1064 D1 K Part Bottom Cage Plate 1 1400 22 L Part 1 2 UNC Thin Nylock Nut 3 09 5610S M Part Backing Pin Knob 1 02 0017 N Part 3 8 UNC x 1 1 2 Threaded Dowel Pin 1 101 4097 P Part Backing Pin Spacer 1 101 4096 Q Part Backing Pin Retainer 1 101 4095 Part Backing Pin 1 101 4094 S Part 1 8 NPT Grease Fitting 26 02 0005 T Part 5 8 UNF Thin Nylock Nut 26 09 5915 U Part Cam Follower 26 02 0016 DRILLING amp AACCCOY TEcHNICAL MANUAL 5 17 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER Back JP AssEMBLY A D J DRILLING amp 5 18 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD ASSEMBLY 15500 5 1 amp CLINCHER Backup Item Type Description Qty Part Number A Ass
80. NC hex nut on to each of two rigid sling leveling adjustment weldments PN 1053 C 1L Thread the leveling adjustment weldments into the front of the rigid sling weldment mounting brackets roughly adjusting them so the rigid sling is approximately perpendicular to the top plate of the tong see illustration 3 H 10 Thread 1 2 UNC hex nuts on to two 1 2 UNC x 1 3 4 hex bolts Thread the bolts into the rear of the rigid sling weldment mounting brackets see following illustration ILLUSTRATION 3 H 8 ASSEMBLY LEVELING BOLT INSTALLATION Use a crane and temporary sling to hoist the backup assembly onto a support structure next to the assembly location of the tong Minimum height for the backup supports must be 36 in order to allow clearance for installing the front legs Attach the rear leg assembly to the tong a Position rear leg weldment on a flat surface near the tong assembly location Model 80 0420 16 uses rear leg weldment 101 4487 Model 80 0422 uses rear leg weldment PN 101 1547 Model 80 0421 3 uses rear leg weldment PN 101 1987 b Use a crane to hoist the tong assembly off the assembly surface Bring the tong into contact with the rear leg ensuring the crane continues to support the entire weight of the tong Attach the rear leg weldment to the tong using two 1 1 4 UNC x 8 hex bolts and 1 1 4 UNC hex nylock nuts and two 1 UNC x 7 hex bolts and 1 UNC hex nylock nuts DRILLING amp 3 18 SECTION
81. NC x 1 1 2 hex socket head cap screws and 1 2 lock washers Attach the two 20 1 1 4 x 1 flange elbows PN 02 9216 to the motor ports using two 20 split flange kits PN 02 9217 Attach the shifter lug weldment PN 101 0016 to the top plate of the tong next to the top shifter bushing weldment using four 3 UNC x 1 1 4 hex bolts and 3 8 lock washers Connect the shifter handle weldment s PN 1037 D 20B pivot point to the pivot point of the shifter lug weldment using a 5 16 x 1 1 2 clevis pin Connect the end of the shifter handle weldment to the top of the shifter shaft using a 5 16 x 1 clevis pin Secure the clevis pins with 093 X 1 125 hitch pins Position the two top brake band lug weldments RH Lug Weldment PN 101 0132 LH Lug Weldment PN 101 0134 on the top plate over the holes for the support roller shafts as shown in the following illustration Insert four short support roller shafts PN 101 3942 through the weldments and support roller components until the shoulders of the shafts are tight to the lug weldments Slide the two bottom brake band lug weldments LH Lug Weldment PN 101 0132 RH Lug Weldment PN 101 0134 over the bottom of the support roller shafts and secure with 7 8 UNF thin nylock nuts ASSEMBLY NOTE The support roller assemblies coincidental with the brake band lug weldments DO NOT use flat washers ILLUSTRATION 3 H 5 ASSEMBLY BRAKE BAND WELDMENT INSTALLATION DR
82. OT CONTINUE AFTER RELOADING 1 Symptom Possible Problem Solutions Possible Problem Solution Possible Problem Solution 2 Symptom Possible Problem Solutions procedure in Section 6 C Possible Problem Solution Possible Problem Solution 3 Symptom Possible Problem Solution Possible Problem Solutions Possible Problem Solution Possible Problem Solution Possible Problem Solution 4 Symptom Possible Problem Solution Possible Problem Solution Possible Problem Solution Possible Problem Solution 6 6 CONTENTS No indication on gauge Obstruction in hydraulic hose Check hyaraulic hose for kinks Replace hydraulic hose Loss of hydraulic fluid Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Internal mechanism of torque gauge is damaged Replace gauge Gauge indication unexpectedly high Excessive hydraulic fluid Completely drain hydraulic fluid from torque gauge load cell system Recharge following the Internal mechanism of gauge is damaged Replace gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication unexpectedly low Insufficient hydraulic fluid Recharge hydraulic fl
83. RILLING amp 6 4 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Torque MEASUREMENT 5500 5 7 amp CLINCHER Backup i B N Y Description Qty Part Number Assembly Standard Turn Counter Encoder Mount 1 60 0001 A Part 6 32 x 3 8 Hex Socket Head Set Screw 4 B Part Helical Flexible Encoder Shaft Coupling 1 60 0130N C Part Internal Retainer Ring 2 1376 13 D Part Bearing 2 1376 05 Encoder Housing 1 1392 104A F Part Internal Retainer Ring 1 02 0436 G Part Encoder Shaft 1 1392 103A 01 H Part Encoder Gear 1 01 0320A M J Part 10 24 x 1 1 4 Hex Socket Head Set Screw 1 G H ILLUSTRATION 6 6 Turn Counter Mount ExPLODED DRILLING amp AACCCOY MANUAL 6 5 MOVING GLOBAL ENERGY FORWARD TORQUE MEASUREMENT 5500 5 amp CLINCHERG B B TROUBLESHOOTING Under normal operating conditions and with proper maintenance the torque gauge and load cell system are designed to give lasting trouble free performance Faulty indication on the gauge will very often define a fault within the gauge IF TROUBLESHOOTING REVEALS THAT THERE IS INSUFFICIENT FLUID IN THE SYSTEM BEFORE RECHARGING CHECK THAT ALL SYSTEM COMPONENTS ARE FREE FROM DAMAGE THIS WILL ENSURE THAT FLUID LOSS WILL N
84. VALVE IS INCORRECTLY SET OR NOT EUNCTIONING nennen nnne 4 2 C SAFETY DOOR DOES NOT OPERATE OR IS MAL EOUNCTIONING sisse 4 4 D TONG RUNNING TOO SLOWLY ee 4 5 E FAILURE OF JAWS TO GRIP PIPE co o iate ote st e prede 4 6 FAILURE OR DIFFICULTY OF TONG TO SHIFT ise st e e Ro Rte oa Eed 4 7 GENERAL COMMENTS note Ra 4 8 SECTION FIVE PARTS AND ASSEMBLIES Train T M 5 2 Support Roller 5 4 eet ET 5 6 SET CIO ee Ee Ce Ee 5 8 Pinion Assembly 5 10 CIULCH denges eeneg EES 5 12 usa 5 14 Continued on next page DRILLING amp AACCCOY TecHNicAL MANUAL ix MOVING GLOBAL ENERGY FORWARD 5500 5 8 CLINCHER Bac TABLE OF CONTENTS SECTION FIVE PARTS AND ASSEMBLIES Continued EE 5 16 TONG 5 18 Tong Body Assembly 5 20 Brake Band SEENEN ENEE 5 22 e ee 5 24 Hydraulic Assembly 5 26 Tong Door Assembly 5 28 Safety Door Assembly 5 30 Leg 5 5 32 Backup Body Tension LC Configuration 5 36 Backup Body Compression LC
85. Y FORWARD Technical 5 39 5500 5 17 amp CLINCHERG CLINCHER CYLINDERS DRILLING amp 5 40 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD CLINCHER CYLINDERS 5500 5 1 amp CLINCHERG Backup Item Type Description Qty Part Number A Part 3 8 UNF x 1 Hex Socket Flat Head Cap Screw 4 09 4046 B Part Die Retainer Top 2 101 2981 Part Die Retainer Bottom 2 101 2290 C Part Wraparound Insert See Pp 2 14 1 D Part Cylinder Housing 1 1403 01 E Part Cylinder Rod 1 1401 04B G Part Cylinder Piston 1 1401 05B J Part 3 8 UNC x 1 Hex Bolt 4 09 1170 K Part 3 8 Carbon Steel Lock Washer 4 09 5106 L Part 3 8 Plain Narrow Washer 4 09 5124 M Part Backing Plate 1 1403 03 N Part 5 8 UNC x 1 1 4 Hex Socket Head Cap Screw 4 09 0240 P Part Cylinder Gland 1 1401 06B Kit CLINCHER Cylinder Seal Kit 1401 00 00 SK F Seal 2 231 O Ring 1 H Seal 37504750 POLYPAK 1 Q Seal SH940 41 Wiper 1 R Seal STD 25004500 Polypak 1 S Seal W2 4750 625 Wear Ring 1 T Seal SEAL PARKER POLYPAK 25005000 1 DRILLING amp AACCCOY TEcHNICAL MANUAL 5 41 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER Ricip ASSEMBLY DRILLING amp 5 42 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Ri
86. ach pinion bearing cap four locations total f Install two 1 8 NPT 90 grease fittings PN 02 0093 in clutch bearing cap two locations total g Install one 1 8 NPT 90 grease fitting PN 02 0093 or one 1 8 NPT 45 grease fitting PN 02 0006 in the top of the motor mount h Install two 1 8 NPT 90 grease fittings PN 02 0093 into the top plate of the backup directly above each clamping cylinder and two into the bottom backup plate directly beneath each of the clamping cylinders eight locations total i Install drive in grease fittings PN 02 0012 into the ends of each cage plate cam follower 26 locations total Install hydraulic inlet support base PN 101 1138 to the top plate directly adjacent to the RH rotary idler using two 3 8 NC x 1 hex bolts and 3 8 lock washers Attach the adjustment plate PN 101 0022 to the support base using two 3 8 NC x 1 hex bolts 3 8 narrow flat washers and 3 8 UNC hex nylock nuts Attach the outlet coupling support mounting base PN 101 0021 to the top plate to the RH side of the motor mount using four 3 8 UNC x 2 hex socket head cap screws DRILLING amp AACCCOY TecHNicAL MANUAL 3 19 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER Back MAINTENANCE Mechanical Assembly Procedure Continued 83 Attach the outlet coupling support weldment PN 101 0023 to the weldment mount using two 3 8 NC x 1 hex bolts and 3 8 lock washers Attach t
87. al manual The images on this page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supplied with your equipment THE IMAGES DISPLAYED ARE SUPPLIED FOR ILLUSTRATION PURPOSES ONLY ILLUSTRATION 6 A 2 TENSION LoAD CELL ILLUSTRATION 6 A 1 ToRQUE GAUGE FoR ILLUSTRATION Purposes ONLY ILLUSTRATION 6 3 Compression LoAD CELL Torque gauges and load cells are supplied as a matched calibrated pair Substituting one or the other will render the calibration inaccurate even if the actual model numbers appear to be identical The serial numbers of matching load cell and torque gauges are clearly identified on the calibration certificate Should you suspect the accuracy of your torque measurements or wish to replace either component the pair should be returned to the factory for re calibration before placing into service TORQUE GAUGES AND LOAD CELLS ARE FACTORY SUPPLIED SUPPLIED AS MATCHED CALI BRATED PAIRS IF REPLACING EITHER COMPONENT THE LOAD CELL AND TORQUE GAUGE MUST BE RETURNED TO THE FACTORY FOR RE CALIBRATION BEFORE PLACED INTO SERVICE DRILLING amp AACCCOY TecHNicAL MANUAL 61 MOVING GLOBAL ENERGY FORWARD 5500 5 amp BASIC TORQUE MEASUREMENT Continued The images on the preceding page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supp
88. alled support roller assemblies or to damage the threads on the end of the shafts Locate the three un threaded holes in the side body of the tong one in the rear centre and one just to either side of the front open ing If old dowel pins are in place remove them before installation of the top plate If the dowel pins are in any way damaged or deformed McCoy recommends replacing them with new 3 8 x 1 1 4 hardened dowel pins If necessary clean the dowel pin holes and do not insert dowel pins until after the top plate has been installed Use a temporary lifting sling and crane to maneuver the top plate PN 1400 7T into position and place on to the side body Insert the three positioning dowel pins PN 09 0021 through the top plate into their respective holes in the side body Use a hammer to tap the dowel pins until they are flush with the top plate DRILLING amp AACCCOY TecHNicAL MANUAL 3 13 MOVING GLOBAL ENERGY FORWARD KT5500 5 Tone amp CLINCHER Backui MAINTENANCE Mechanical Assembly Procedure Continued 27 Secure the top plate with fourteen 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers and five 3 8 UNC x 1 low head height hex socket head cap screws Do not install fasteners coincidental with the rigid sling brackets shown circled in green or the door cylinder post shown circled in red ILLUSTRATION 3 H 3 ASSEMBLY PLATE FASTENER INSTALLATION 28 Slide the clutch
89. amp 7 8 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SERIES 15 STD MOTOR EXP VIEW ITEM PART NO DESCRIPTION 1 0150111 SEAL PLATE SNAP RING 0150135 SEAL PLATE 0150161 SEAL SHAFT TCN NOT USED 0150114 SEAL PLATE O RING 0150730 SNAP RING BEARING 0150710 BALL BEARING 0150701 SHAFT KEYED 0150702 SHAFT SPLINED 0150901 BOLT 0150102 FRONT HOUSING INTERNAL 0150428 DOWEL PINS FRONT 0150610 O RING 0150902 BALL CHECKS 0150620 PLATE SCREW 0150608 PLATE 0150400 STATOR GA 11 5 5 lt o e m o o 5 HF NS 0150401 STATOR GA 15 0150402 STATOR GA 13 0150403 STATOR 9 5 0150404 STATOR 8 0 0150406 STATOR GA 7 0 0150407 STATOR GA 6 0150409 STATOR GA 3 0 0150300 ROTOR 0150313 ROTOR 0150320 ROTOR VANE SPRING OUTER 0150321 ROTOR VANE SPRING INNER 0150410 STATOR VANE 0150420 STATOR VANE SPRING 0150429 DOWEL PINS REAR 0150720 NEEDLE BEARING 0150800 REAR HOUSING CORPUS CHRISTI TEXAS Hyprautic Motor INFORMATION SERIES MODEL CODE 015 61 15 015 30 1 15 Jan epep STANDARD MOTOR RECORD DATE RINEER HYDRAULICS REFERENCE
90. ar 200 3 Non Adjustable Fixed psi 14 Setting Standard Setting C Tamper Resistant Factory D 25 800 psi 1 7 Set 55 bar 400 psi 30 bar Standard Setting B 50 1500 psi 3 5 105 bar 1000 psi 70 bar Standard Setting Q 60 400 psi 4 25 bar 200 psi 14 bar Standard Setting N 60 800 psi 4 55 bar 400 psi 30 bar Standard Setting Special Setting required specify at time of order DRILLING amp 7 34 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION 900 5 12 8 CLINCHER Backup Capacity 30 Pilot to open check valve with standard pilot gpm 120 L min Functional Group Model Products Cartridges Pilot to Open Check Valve 3 Port Non Vented Standard CKEB Pilot Steel Seat Product Description M This valve is a pilot to open check valve It has a non sealed pilot a steel seat and is non vented It allows free flow from the valve port 2 to the load port 1 and blocks flow in the i opposite direction Pressure at the pilot port 3 will open the valve from port 1 to port 2 Pilot pressure needed at port to open the valve is directly proportional to the load pressure at port L 1 Pressure at port 2 directly opposes pilot pressure LOCATING SHOULDER L 2 81 71 4 1 38 35 1 X 1 38 35 1 INSTALLED 1 38 35 1 E 1 38 35 1 1 38 35 1 T 2A CAVITY
91. ar train cavity if shavings or metal pieces are seen the tong must be overhauled before it is returned to service Clean the exterior of the tool thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and cleaning agents Inspect all fasteners and fastener safety wires Replace any missing fasteners use Grade 8 bolts only Re torque all external fasteners to SAE specifications Inspect backing pin s If cracked broken or bent it they must be replaced Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Inspect all paint locations in which the paint has been damaged must be repaired prior to storage Prepare areas to be painted to ensure they are free of grease dirt or solvent Touch up using a solvent based acrylic paint McCoy Grey is paint number RAL7015 Allow sufficient time for paint to dry before proceeding Perform a liberal lubrication of the equipment refer to Maintenance section of manual to determine lubrication points Gener ously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear Connect the equipment to a hydraulic power unit Ensure all lines are fully made up
92. at 100 SSU or higher Fluid temperature should not exceed 180 F Elevated fluid temperature will adversely affect Seal life while accelerating oxidation and fluid breakdown Fire resistant fluids may be used with certain limitations Contact Rineer for additional information CASE DRAIN The 15 Series Motor is designed for either internal or external case drain Two case drain ports are supplied When using internal case drain simply plug the two ports When using external case drain use the port at the highest elevation We recommend case drain pressure of 35 PSI or less when using the standard seals CASE DRAIN CIRCULATION Fluid should be circulated through the case when a temperature differential exists between the motor and the system in excess of 50 F Should this occur contact a Rineer Application Engineer MOUNTING The mounting position is unrestricted The shafts pilots and mounting faces should be within 002 TIR INTERMITTENT CONDITIONS Intermittent conditions are to be less than 10 of every minute OTHER AVAILABLE MOTORS For information on additional Rineer Motors request one of the following publications Publication 05371003 22222222 Publication 05571003 q25 Senesc ee Publication 0 1251003 75 ACTUAL TORQUE AND POWER 6 CID 2000 RPM 100 RPM 2000 RPM 1600 RPM 5 1200 POWER HP 800 RP
93. ates the Sun floating style construction to minimize the possibility of internal parts binding due to excessive installation torque and or cavity cartridge machining variations DRILLING amp 7 32 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION 00 5 15 amp CLINCHER Backup Technical Data 50 200 L min Increase Setting Series from Cavity 2 J Seal Kits Viton 990 203 006 Seal Kits L 990 203 007 Typical Pressure Rise Minimum Setting 8 200 8 o D 100 100 200 100 Q Unin JE Pressure Rise Minimum Setting e I DRILLING amp AACCCOY TecHNicAL MANUAL 7 33 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 Tone amp CLINCHER Bac VALVE INFORMATION Option Selection RPGC L A N SI Preferred Options External Control Adjustment Range _ Material Seal Material L Standard Screw Adjustment 100 3000 psi N Buna N 7 210 bar 1000 psi 70 bar Standard Setting W 150 4500 psi 10 5 315 bar 1000 psi 70 bar Standard Setting Standard Options J Capped Screw Adjustment C 150 6000 psi P Stainless K Handknob 10 5 420 bar N 1000 psi 70 i with Panel Mount bar D w Head Screw with Setting M Viton Locknut E 25 400 psi 1 7 W Max Setting Limiter 28 b
94. bled in the same vane slot Inspect all springs and seals We recommend replacement of all seals and springs whenever the motor has been disassembled Inspect all parts and replace any parts which obviously show excessive wear or damage VANES Normal wear results dad in slight flattening of vane tips which does not motor performance Replace vane if radius is reduced 50 Clearance between the rotor vane and rotor vane slot varies with the vane selection The design allows the vane to lean slightly in the slot providing the required mechanical seal SEcTION CONTENTS TECHNICAL MANUAL Hyprautic Motor INFORMATION WARNING RINEER RECOMMENDS FOLLOWING STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION PLATES Normal wear results in marking of timing plates which does not impair motor performance Replacement of the timing plate is required D smearing galling or heat cracks are present ROTOR Normal wear results in polishing of rotor faces which does not impair motor performance Examine the rotor vane Slots closely Polishing down in the slots is normal but if there is any indication of a pocket forming in the wall of the slot the rotor should be replaced STATOR Normal wear results in polishing of cam form which does not impair motor performances Noticeable wear may be apparent along the corner of one side of the staor vane Slot This
95. causing excessive Replace or repair worn or damaged gears or bearings s Ensure jaw dies are not worn to the point that they cannot grip Ensure the correct 8 Jaws slipping on pipe 2 sized jaws in use Incorrect gauge is being used Ensure gauge is the proper range and has been properly calibrated for the arm length of the equipment in use 9 Torque gauge is indicating incorrectly Gauge has been damaged Check gauge operation and calibration on indepen dent system Gauge has mistakenly been married to an incorrect load cell Incorrect load cell is being used Air is trapped in torque measuring circuit load cell hydraulic line or gauge Refer 10 Load cell is measuring incorrectly to torque measurement troubleshooting in Section 6 of this manual Load cell has been damaged Replace load cell or return to McCoy for repair and re calibration MCCOY DRILLING amp COMPLETIONS GUARANTEES CALIBRATION OF A LOAD CELL TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR MCCOY SUGGESTS THAT THE LOAD CELL TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE CALIBRATION ON A YEARLY BASIS POSSIBLE PROBLEM SOLUTION S 11 Incorrect motor speed selected applies to Maximum torque can only be developed when LOW motor speed maximum hy 2 speed motors only draulic displacement is selected 12 Incorrect tong gear selected Maximum torque can only be developed when LOW motor gear is selected AACCOY DRILLING amp COMPLETIONS MOVING G
96. cip ASSEMBLY 5500 5 amp CLINCHERG Backup Item Type Description Qty Part Number Assembly Chain Sling Assembly 1 101 2211 A Part 3 4 NC Hex Nut 3 09 5818 B Part Lift Link 1 02 0516 C Part Adjusting Helix 1 1053 1 H D Part 3 4 NC x 9 Hex Bolt 1 09 1322 E Weldment Rigid Sling Weldment 1 101 0656 F Weldment Leveling Bolt 2 1053 C 1L G Part Rigid Sling Pin 2 1053 C 1C H Part 3 8 NC x 1 Hex Bolt 4 09 1170 J Part 3 8 Carbon Steel Lockwasher 8 09 5106 K Weldment LH Rigid Sling Bracket 1 101 0150 Weldment RH Rigid Sling Bracket 1 101 0151 L Part Hitch Pin 1 4 x 5 4 09 9075 M Part 1 2 NC x 1 1 4 Hex Bolt 2 09 1168 N Part 1 2 NC Hex Jam Nut 2 09 5810 P Part 3 8 NC x 1 3 4 Hex Bolt 4 09 1557 DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 543 This page intentionally left blank A ToRQUE MEASUREMENT 5500 5 7 amp CLINCHERG Backup BASIC TORQUE MEASUREMENT Basic torque measurements are performed using a simple hydraulic measurement system A hydraulic load cell connects to a calibrated torque gauge through a reinforced flexible hydraulic hose The torque gauge is factory calibrated to display accurate torque measurements for a tong or tong and backup assembly with a particular arm length The arm length is a measurement from the centre of the pi
97. colo bom ga Eri Echt hae quic Fus mers cord uar lice ipiis zy bnn ed reser napi canas senor can be Spang Gans pr Lampe and an pring yalh iha Ste biens coena Thwewkvis Te mum a ge A Dus cries cnn net D circuli or main dot paia adii Parallel Circuits Paradisi ziii pim rei cman mi re rien De ang Mech dn be molar manus acci menos IT wem Anoa dp huy Cent ac Fa mas ena Pma Ce en Leben bas eg Geen Fc Ve Duel eg tuas De od au rue pe Sedi cam Gnade How Pet Mesemeni cl thy tege g ew of c ite ta pass ani Poppen F age P IT ra i a work uae serate i Pa i ris ice VALVE INFORMATION Tandem Circulls hel program Teden crags gne gormerrcee culled Deng nr ceded pray By Tier seins ipm ihe open passage Daul mium iye na ern Doan aet a net avad Liu rl B Ure on ole by mi aerars ence macie aoe ang Uus Gergen Ape En Fem Enn Ue el misser rann LER TEE FERT io gr B Fe
98. d the shifting shaft detent ball or detent spring or possibly all three may need to be replaced see Pp 5 16 5 17 ILLUSTRATION 3 E 3 SHIFTER DETENT FORCE ADJUSTMENT DRILLING amp 3 8 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 0 5 1 amp CLINCHER Backup RECOMMENDED PERIODIC CHECKS 1 Door Stop Spring The spring inside the actuator cylinder must be of sufficient strength to enable the door latch mechanism to snap closed properly and to hold the door in the open position when opened Door stop spring fatigue will result in sluggish latch operation Replace the latch spring inside the cylinder when this occurs 2 Backing Pin Perform a visual inspection of the backing pin after each job Replace the pin if stress cracks or excessive wear is found or if either pin is bent 3 Shifting Shaft The shifting yoke is secured to the shifting shaft by a locknut on the bottom of the yoke Check locking nuts after each job Do this by removing the clutch inspection plate and ensuring a snug fit prior to lubrication 4 Torque Gauge Assembly Periodic calibration of the torque gauge is recommended to assure accurate torque readings When having the torque gauge ser viced and calibrated it is critical to note the arm length of the tong as indicated in the Specifications section Farr recommends that the torque gauge assembly be calibrated yearly Perio
99. d above what McCoy Drilling amp Completions recommends as part of their recommended procedures Users of this equipment may choose to perform or ignore these additional tasks at their discretion Premature fouling of particulate filters within your prime mover or ancillary hydraulic power unit requires immediate hydraulic fluid labora tory analysis to prevent premature wear of hydraulic system due to high levels of wear metals in the fluid McCoy Drilling amp Completions recommends tracking all maintenance activity including the lubrication schedule This may be a simple as keeping a paper log or using a software based maintenance tracking utility A maintenance log is a valuable tool that can be used for easily retrieving maintenance history or identifying trends that require correction DRILLING amp AACCCOY TecHNicAL MANUAL 31 MOVING GLOBAL ENERGY FORWARD 5500 5 1 amp CLINCHERG Baci D LUBRICATION INSTRUCTIONS MAINTENANCE Use a quality multipurpose bearing lubricant that will remain within its viscosity range at expected operating temperatures In addition Farr recommends the following lubrication procedure at the completion of each job prior to storage 1 Plate Cam Followers Apply grease to the grease fittings recessed in both the top and bottom cage plates 26 locations total 13 top 13 bottom ILLUSTRATION 3 0 1 FoLLowER LUBRICATON 2 Support Roller Bearings Apply g
100. dically check to ensure the load cell is filled with oil see Section 6 G OVERHAUL PROCEDURES The tong may be overhauled following the disassembly instructions in the following procedure Access to the gear train is possible by removing the top plate of the tong ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED REPLACEMENT FASTENERS BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT FASTENERS USED FOR MAINTENANCE OVERHAUL OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS LEGS MUST BE TIGHTENED TO THE PROPER TORQUE SEPARATION OF TONG FROM BACKUP 1 Suspend tong assembly with crane Construct a support structure that will support the weight of the backup Lower the tong backup assembly onto the constructed support until all weight is removed from front leg suspension springs Disconnect all hydraulic lines from the backup Remove the nylock nut and bolt sets from the bottom of the front legs and slide the lower spring caps front leg springs off each leg Note that the top spring caps will remain within the backup body assembly 4 Disconnect the two rear backup support springs connecting the backup to the rear leg not applicable for low profile compression style backup Remove the load cell assembly Lift tong and legs up and a
101. dly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INDUCED INJURIES Perform an initial wash of the tool in order to remove the majority of dirt and grease build up Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the ge
102. does not necessarily require replacement of the Stator but may slightly affect volumetric efficiency Note Measure the rotor and stator length to the fourth decimal point and supply measurement when ordering rotor stator or vanes AACCCOY TA Gu MOVING GLOBAL ENERGY FORWARD Hyprautic Motor INFORMATION 5500 5 1 amp CLINCHERG Backup WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION ASSEMBLY OF ROTOR STATOR ASSEMBLY OF WHEEL MOTOR CARTRIDGE FRONT HOUSING MOVING GLOBAL ENERGY FORWARD 1 Reverse the procedures in steps 17 16 15 and 14 2 NOTE Make sure that the radiused edge of each stator vane points to the rotor and the radiused edge of each rotor vane points to the stator 3 NOTE Make sure Springs are seated in the bottom of the spring pocket in both the rotor and stator ASSEMBLY OF FRONT HOUSING 2 Install snap ring Press shaft and bearing assembly into front housing by pressing on the outer race of bearing 1 Place seal in seal plate 2 Place seal plate o ring into groove in the front housing 3 Press seal plate into front housing 4 Install snap ring 5 Proceed to step 30 DRILLING amp COMPLETIONS 1 Press bearing onto shaft 1 Reverse the procedures in Steps 8 thru 3 2 Screw lock nut onto shaft until all threads are engaged Tighten clamp screw unti
103. e leveled side to side and front to rear before placing into service The following guidelines wil assist you when leveling your tong Place a level axially side to side across the tong ensuring that it is parallel with the surface of the tong Use a thin wrench on the flat of the adjusting helix to rotate the helix forcing the lift link to move towards the outer supports of the sling The 1 jam nut on the pin may have to be slightly loosened to allow the helix to rotate Adjust the helix until the level shows that the tong is level side to side retighten the nut if necessary ILLUSTRATION 2 F 1 LEVELING SIDE To SIDE DRILLING amp e ee TecHNicAL MANUAL 217 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER BACK Setup amp OPERATION Tong Leveling Continued ii Place a level lengthwise front to back along the tong ensuring that it is parallel with the surface of the tong Loosen the 3 4 jam nuts on the adjusting bolts on rigid sling brackets Completely loosen the adjusting bolts Turn each adjusting bolt equally until tong hangs level front to back Lock adjusting bolts in place with the jam nuts Loosen 3 4 hex jam nut be fore rotating adjustment bolt ILLUSTRATION 2 F 2 LEVELING 3 Compression Load Cell Configuration The backup is directly coupled to the compression load cell via the backup body paddle The load cell
104. e piach mil damage tur saals Make vire bat piod d osa dine ira The proper see Ate 1 pape 9 deaseerhivi Step 2 Spool Seal and Back up Apply Parier Lube o he spoal seul Fi 1 uem 3 and slide top de Aide op ile back un ring gem 7 bah inii Ihe comes bore al ey bone uw Asssenhle dee aa Don maner planes Fig Dem 61 unag the Pao short Hiler screwed Fue 1 go Check plates for proper alipsinena Tuben tera final goug of 34 In Bre 2 in The Step 3 Back cap the back cap dig Ele eer Jazz fien acne Ey 1 d do a final a 35 am Fed im Vers Caution Excessive or will damage the hack rap COY TECHNICAL MANUAL 7 27 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHERG Backu VALVE INFORMATION 19 Valve Assembly Instructions Step 4 Install Transition Check Then Given check enciponienis Tor check popper Fog iiem 12 Be transition chock cai Am he Cheech Fig 2 square the poppet then place the check Fig 111 aver rhe poppe and spemz Tammy by hand enge several theese Tighten to a final tongug Bf 78 Ra i bs Step 5 Relief Valves Rem all valves Io tnesr purcser pasisans Itocu e 5 H nasal
105. ed or have visible 20 signs of wear from contact with a rigid object If your tong is equipped with rigid hydraulic lines replace any line that is dented or appears to be stressed or cracked 21 C Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear Perform a full lubrication refer to Maintenance section of manual to determine lubrication points 2 2 Ensure main supply and return connections to the tong are fully made up Re connect the remainder of the hydraulic lines FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE If using a stand alone power unit start it now refer to the power unit technical manual for startup procedures Listen to power unit for a moment to see if there are any unusual mechanical sounds rubbing grinding excessive pump noise If using a diesel unit allow sufficient time for the engine to reach operating temperature before increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 2 3 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi 2 4 C Perform a visual inspection of pressurized hydraulic lines If any hydraulic fittings or hoses are leaking they must be repaired or replaced before proceeding Rotate tong fo
106. ed hydraulic schematic for assembly not equipped with safety door 2 8 Corrected hydraulic schematic B O M 2 2 16 Revised Section 2 F 1 Tong Rig Up amp Leveling Suspension amp Restraint 2 18 Added Section 2 F 3 Tong Rig Up amp Leveling Load Cell Configuration 2 19 Inserted Section 2 G 1 Operator Training 3 1 Revised Section 3 A General Maintenance Safety Practices 3 1 Revised Section 3 B Cleaning 3 1 Inserted Section 3 C Preventive Maintenance Practices Nov 2011 3 3 6 Added lubrication instruction CLINCHER cylinders S Hargreaves 3 7 Added lubrication instruction compression load cell 3 11 3 20 Revised Section H Mechanical Assembly Procedures 3 21 3 32 Moved all maintenance procedures from appendices to maintenance section 4 4 1 4 6 Revised troubleshooting section New support roller assembly and B O M Removed door pivot roller pages and incorporated with support roller assembly 5 5 7 Corrected rotary idler B O M 5 16 5 17 New cage plate assembly and B O M 5 4 5 5 5 24 5 25 Replaced motor amp motor mount assembly amp B O M Continued on next page DRILLING amp AACCCOY TecHNicAL MANUAL vii MOVING GLOBAL ENERGY FORWARD Summary Of Revisions Continued Date Section Page Description Of Revision Approved 5 5 28 5 29 Replaced tong door assembly amp B O M Nov 2011 6 Complete revision of torque measurement section S Har
107. edure Continued 35 36 37 38 39 40 41 42 43 Insert the detent ball PN 02 0018 through the end of the detent tube attached to the top shifter bushing followed by the detent spring PN 997 0 64 Thread a 7 16 UNF jam nut on to a 7 16 UNF x 1 1 4 hex bolt and then thread the end of the bolt into the detent tube on the top shifter bushing Insert two 5 16 x 3 4 production ground dowel pins into the top plate one on either side of the motor shaft and gear cut out directly behind the clutch assembly Position the motor mount PN 1400 150 over the dowel pins and secure to the top plate using four 1 2 UNC x 2 hex socket head cap screws Insert 5 16 x 5 16 x 1 1 2 square key into the key slot on the motor shaft Secure the motor gear PN 997 A10 149 to the lic motor shaft using two 3 8 UNC x 3 8 flat point hex socket set screws Ensure that the motor gear is oriented so that the machined end of the motor gear the end in which the set screws are threaded is flush with the end of the motor shaft Mount hydraulic motor PN 87 0110 to motor mount Secure the RH side of the motor as seen from the back of the tong with two 1 2 UNC x 1 1 4 hex socket head cap screws and 1 2 lock washers The torque gauge holder weldment PN 1500 09 04A is secured by the two LH motor screws position the torque gauge holder weldment in place and secure it and the LH side of the motor with two 1 2 U
108. een the right hand side of the rear leg and the backup a ILLUSTRATION 2 F 5 TENSION LoAD CELL CONFIGURATION DRILLING amp e ee TecHNICAL MANUAL 2 19 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER Bz Setup amp OPERATION H TONG OPERATION 1 Operator Training Many companies set qualification standards that must be met before equipment may be operated without supervision McCoy Drilling amp Completions recommends operator training which typically consists of operation of the equipment under the supervision of a trained equipment operator until a satisfactory level of competence is achieved Typical operator training should include Introduction to and general description of equipment Technical specifications and performance data Operating instructions Control systems and interlocks Operating hazards Checks and inspections Operator Safety McCoy recommends that a hazard assessment of the work area be performed by a designated safety representative before com mencing operations A designated safety representative is responsible for verifying that all operators have adequate equipment and safety training The safety door system is the primary device protecting the tong operator and nearby personnel from the rotary gear Confirm the correct operation of the safety door before every job Never disable the safety door device The area surrounding the tong operating area must be clu
109. embly Door Assembly See Pp 7 30 7 31 B Part 3 8 NC x 1 3 4 Hex Socket Cap Flat Head Height 5 09 2052 C Assembly Door Cylinder Assembly 101 0069 D Part 3 8 NC x 1 1 4 Hex Bolt 2 09 1048 E Part 3 8 Carbon Steel Lockwasher 39 09 5106 F Part 3 8 Narrow Flat Washer 2 09 5124 G Part 3 8 NC x 1 1 2 Hex Bolt 29 09 1050 H Part Rigid Sling Pin 2 1053 C 1C J Weldment Rigid Sling Bracket 2 101 0151 K Assembly Rigid Sling See Pp 7 32 7 33 1 L Part Hitch Pin 1 4 x 5 4 09 9075 M Weldment Shifter Lug Weldment 1 101 0016 N Assembly Motor amp Motor Mount See Pp 7 26 7 27 1 P Part Top Plate 1 1400 7T Q Weldment Side Body Weldment 1 101 0236 R Part Bottom Plate 1 1400 7B S Part Brakeband Assembly See Pp 7 24 7 25 2 AACCCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 5 19 KT5500 5 1 amp CLINCHER BACKUP BRAKEBAND ASSEMBLY DRILLING amp 5 20 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD BRAKEBAND ASSEMBLY 1 55 500 5 1 amp CLINCHER Backup MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Item Type Description Qty Part Number A Part 3 8 NC x 3 4 Hex Bolt 2 09 1044 B Part 3 8 Carbon Steel Lock Washer 2 09 5106 C Part Brake Band Retainer 1 101 0140 D Assembly Brake Band Lined 1 1064 D4 29 E Part 3 8 NF Hex Nut 2
110. ent bolt on the top shifter lug weldment Once the force from the detent ball has been removed from the shifter shaft the top shifter bushing can be un threaded from the top plate Take care not to lose the detent ball when the bushing comes free of the shaft Remove the hex head bolts and hex flat head cap screws around the perimeter of the tong that secure the top plate With all the above steps taken the top tong plate can be lifted off providing access to the inside of the gear case LIFT THE TOP PLATE STRAIGHT UP TO AVOID SNAPPING THE DOWEL PINS A SNAPPED BENT OR OTHERWISE DAMAGED DOWEL PIN CAN BE EXTREMELY DIFFICULT TO REMOVE DRILLING amp 3 10 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 0 5 1 amp CLINCHER Backup H ASSEMBLY PROCEDURES Assembly of Farr Hydraulic Power Tongs is simple and can be accomplished without the use of special tools The instructions on this page are presented as a guide only and are similar to the assembly sequence our technician would use while assembling the tong in our plant NOTE ON INSTALLATION PRACTICES Ensure all bearings are liberally greased before installing over a shaft or into gears or bearing caps When inserting a shaft through a support roller assembly ensure shaft is greased Also ensure all metal to metal contact in the gear train is adequately greased When graphics are not used in the assembly process plea
111. ent may require more or less maintenance depending upon the frequency of use the percentage of maximum torque that your equipment is routinely subjected to and the field conditions under which your equipment operates Farr recommends that the following inspection and mainte nance procedures be performed monthly or in conjunction with your maintenance foreman s experience and best estimate of when your equipment is due for this maintenance 1 Rotate cage plate rotary gear until the opening the rotary gear faces towards the rear of the tong DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CONNECT ED TO ANY HYDRAULIC POWER SUPPLY FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINATION FROM RESIDUAL HYDRAULIC FLUID DePRESSURIZE HYDRAULIC System IN PREPARATION FoR MAINTENANCE 1 De energize the power unit 2 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor 2 3 Remove the hydraulic SUPPLY line from the equipment 4 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 5 Disconnect the hydraulic RETURN line from the equipment 6 Disconnect remaining hoses such as case drains or lines c
112. ervice with the intent of short to long term storage These procedures are essential for ensuring proper protection of the equipment from environmental attack and to aid in the quick turnaround when returning the equipment to service Store all o rings seals packings gaskets etc in strong moisture proof airtight containers Ensure that these items are not crushed nicked or otherwise damaged Do not perform any further actions or maintenance while the tong is connected to any hydraulic power supply Farr recommends that all hydraulic lines are fully disconnected and residual hydraulic pressure is bled off Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid IN ORDER TO MAINTAIN THE INTEGRITY OF INSTALLED SEALS MCCOY RECOMMENDS THAT THE MAXIMUM STORAGE INTERVAL NOT EXCEED ONE YEAR AT LEAST ONCE PER YEAR ALL TUBULAR CONNECTION EQUIPMENT IN LONG TERM STORAGE SHOULD BE RECOMMISSIONED AS PER SECTION 3 M IF FURTHER STORAGE IS REQUIRED THE EQUIPMENT SHOULD THEN BE PUT THROUGH ANOTHER DE COMMISSIONING PROCEDURE DEPRESSURIZATION PROCEDURE IN PREPARATION FoR STORAGE 1 Rotate the tong so that the opening in the rotary gear faces the gear train towards the rear of the tong Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder if equipped If mounted in a frame retract the float cylinders if equipped 2 De energize the power unit 3 Repeate
113. f environments with all external internal parts binding due to excessive components manufactured in stainless installation torque and or steel or titanium Internal working cavity cartridge machining variations components remain the same as the standard valves Technical Data Series from Cavity 2 j 2 Seal Kits Buna 990 202 007 2 Seal Kits Viton 990 202 006 2 Typical Pressure Drop Typical Pressure Drop DRILLING amp 7 36 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD HvoRAULIC VALVE INFORMATION 5500 5 1 8 CLINCHER Backup Option Selection Preferred Options External Control Cracking Pressure Material Seal Material X Standard Pilot C 30 psi 2 bar N Buna N Standard Options L Manual Load Release A 4 psi 0 3 bar P Stainless Buna B 15 psi 1 bar D 50 psi 3 5 bar M Viton E 75 psi 5 bar W Stainless Viton F 100 psi 7 bar Customer specified setting stamped on hex 1 10 MOVING GLOBAL ENERGY FORWARD TECHNICAL 7 37
114. g must be replaced before the equipment is returned to service Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines If a seal line or fitting begins to leak while tong is rotating it must be replaced before the equipment is returned to service Finish this step with the rotary gear opening facing the gear train De energize the power unit Inspect all flexible hydraulic lines for signs of wear blistering or any other signs of potential failure replace if signs of potential failure are identified Inspect the gear train housing If the amount of grease is inadequate liberally grease the gear train through the access panel and through the opening in the rotary gear Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands Ensure that all grease is wiped from brake band linings and the parts of the cage plates that come into contact with the brake band linings Re install access panel Install a set of pre inspected jaws that are the correct size for the pipe or casing being run Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted compo nents including links and chains If using a compression load cell replace any component that has
115. g conditions these instructions must be considered guidelines rather than absolute operating procedures It is the responsibility of the user to use these guidelines together with an experienced manager to develop operating procedures that conform to all policies set forth by the operating authority ies IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS INSTALLATION GUIDE McCoy Drilling amp Completions uses three indicators to describe items of three degrees of importance A HAZARD to operators or equipment is represented by an exclamation point within a red triangle and identifies items of the highest importance Failure to heed information identified by a HAZARD symbol may result in bodily injury death catastrophic equipment damage or any combination of these A HAZARD may also indicate the potential for dangerous environmental contamination This identifies a HAZARD to operators or equipment A WARNING is represented by an exclamation point within an orange triangle and contains information that will alert per sonnel to a potential safety hazard that is not life threatening A WARNING may also serve to alert the user to information critical to the correct assembly or operation of the equipment in use This identifies a WARNING to users A CAUTION is represented by an exclamation point within a yellow triangle and highlights information that may aid the user during assembly or operation of your equipmen
116. greaves Feb 2012 2 2 12 Corrected list of available tong jaw dies Intro Inserted list of illustrations Removed old subsection 2 H 2 Initial Start up amp Break in 2 2 20 Inserted new subsection 2 H 2 Operator Safety 2 23 Inserted new subsection 2 H 5 Pre operational Checks 3 21 3 22 Revised section 3 1 Daily Inspection amp Maintenance Checklist 3 24 3 26 Revised section 3 1 Monthly Inspection amp Maintenance Checklist SEP 2012 3 Removed old Section 2 K Power Unit Daily Inspection amp Maintenance D Bowles Revised Section 2 L Tubular Connection Equipment Decommissioning amp re SEH named Tubular Connection Equipment Decommissioning and Shipping 4 1 Revised Section 4 A Troubleshooting Tong Will Not Develop Sufficient Torque 4 4 2 Inserted new Section 4 B Troubleshooting Relief Valve Incorrectly Set 4 4 Inserted new section 4 C Troubleshooting Safety Door 6 6 7 Inserted new subsection 6 C 3 Reference Checking Torque Measurement System DRILLING amp SEcTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TABLE OF CONTENTS 00 5 1 amp CLINCHER Backup SECTION ONE INTRODUCTION Introduction amp Contact INMOMMALION sicsiiecisecsvercieenssscascacsttcivenseesttnstacsaensunedsnsesazetotaecidnnsssesssisnataessacdunavedsiaastaedaesivacodtsaesiineeee
117. hanger is simply hung on the paddle and secured through the top of the U by a bolt and washer set and in normal operation does not need to be adjusted or removed The assembly in the first of the following two illustrations has been configured in the make up configuration to convert the assembly to the break out configuration remove the bolt and washer set securing the load cell holder to the paddle and move the entire assembly to the other side of the paddle EA oa en ILLUSTRATION 2 F 3 Loan CELL CONFIGURATION Make Up TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 2 18 Section CONTENTS SETUP amp OPERATION 5500 5 1 amp CLINCHER Backup Compression Load Cell Configuration continued ILLUSTRATION 2 4 Loan CELL CONFIGURATION BREAK OuT 4 Tension Load Cell Configuration The backup is coupled to the rear leg of the assembly with a tension load cell on one side and a restraint chain on the other To change the torque measurement configuration make up to break out or visa versa simply remove the heavy duty bolts securing the load cell and restraint chains and switch to the opposite sides Reinstall the heavy duty bolts to secure the load cell and restraint chains in place For your reference the assembly in the following illustration has been configured to measure make up torque If mea surement of break out torque is desired the load cell would be connected betw
118. he adjustment plate PN 101 0277 to the outlet support weldment using four 3 8 NC x 1 hex bolts 3 8 narrow flatwashers and 3 8 UNC hex nylock nuts 84 Coat the threads of the hydraulic valve mounting posts PN 101 0116 with Loctite and thread into the top plate just behind the brakeband on either side of the brakeband retainer 85 Mount the DVA35 hydraulic valve assembly on the mounting posts using two 1 2 UNC x 4 1 2 hex bolts and 1 2 narrow flatwash ers DRILLING amp 3 20 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 00 5 1 Tone amp CLINCHER Backup I DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER TONG Farr recommends that the following inspection and maintenance procedures be performed before each use and at least once per day when the tong is in steady use in the order in which they are listed 1 Rotate cage plate rotary gear until the opening in the rotary gear faces towards the rear of the tong DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CONNECT ED TO ANY HYDRAULIC POWER SUPPLY FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINATION FROM RESIDUAL HYDRAULIC FLUID DePRESSURIZE HYDRAULIC SYSTEM IN PREPARATION FoR MAINTENANCE 1 Rotate the tong to the open throat position Ensu
119. here is an effect and when the valve is pulled back there is an opposite effect These valves feature proportional control which means that further extension of the valve handle thereby further opening the valve orifice results in proportionally higher hydraulic output to the controlled device The illustrations on the following pages demonstrate the type and effect of the hydraulic valves with which this tong is may be equipped DRILLING amp 2 20 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 5500 5 7 amp CLINCHERG Backup 3 Valve Operation 4 way proportional valves control operation of hydraulic devices on the tong assembly such as hydraulic motors and cylinders When any one valve is centered or in the detent position there is no hydraulic output from the valve When the valve is pushed forward there is an effect and when the valve is pulled back there is an opposite effect These valves feature proportional control which means that further extension of the valve handle thereby further opening the valve orifice results in proportionally higher hydraulic output to the controlled device The following illustration demonstrates the type and effect of the hydraulic valves with which this tong is may be equipped TONG MOTOR This is a proportional valve Pushing the valve handle forward will cause the tong motor to rotate in a clockwise direction as
120. id has reached operating temperature as specified by hydraulic fluid data sheet 5 Allow for adequate drying of moisture prior to lubricating when cleaning tong parts in cold weather AACCCOY MOVING GLOBAL ENERGY FORWARD 2 24 CONTENTS TEcHNICAL MANUAL MAINTENANCE 300 5 1 amp CLINCHER Backup McCoy Drilling amp Completions recognizes that minor on site repairs and modifications are required to maintain peak operating condition of your equipment or to match your equipment with the operating environment Examples of minor repairs are replacement of damaged hydraulic hoses and fittings replacement of malfunctioning pressure gauges and valves replacement of door cylinders replacement of fasteners Any replaced component must be an identical component supplied by McCoy Drilling amp Completions Replaced fasteners must be Grade 8 or equivalent or whatever fastener is specified by McCoy Drilling amp Completions A GENERAL MAINTENANCE SAFETY PRACTICES The practices identified here are intended as a guideline All personnel are responsible for performing their tasks in a manner that ensures worker equipment and environmental safety and may require taking additional steps that are not identified in this section Equipment maintenance shall be performed only by designated qualified maintenance personnel Wear approved eye wear and footwear and follow all of your company s safety gu
121. ide two 3 8 NC x 1 bolts inside and four 3 8 lock washers per hanger Install inlet coupling support assembly PN 1050 C 175 to the top plate between the RH pinion idler and RH rotary idler using two 3 8 NC x 1 hex bolts and 3 8 lock washers Attach the outlet coupling support base PN 101 0023 to the top plate right of the pinion bearing cap using two 3 8 NC x 1 hex bolts and 3 8 lock washers and attach the adjusting plate PN 101 0022 to the support base using two 3 8 NC x 1 hex bolts two 3 8 flat washers and two 3 8 UNC nylock nuts Install two hydraulic valve mount weldments PN 101 1442 to the top plate on either side of the brake band retainer using one 3 8 NC x 1 hex bolt and 3 8 lock washer per weldment Install the hydraulic valve assembly to the valve mount weldments using one 1 2 NC x 4 1 2 hex bolt and 1 2 narrow flat washer per valve mount Install main inlet and outlet lines and the remainder of the hydraulic connections See the hydraulic schematic for hydraulic connections Slide the master lifting link PN 02 0516 over the adjustment helix PN 1053 1 H and install the adjustment helix in the rigid sling weldment PN 101 0112 using a 3 4 UNC x 8 hex bolt and 3 4 UNC nylock nut Use a crane fto hoist the rigid sling weldment Connect the rigid sling weldment to the rigid sling mounting lugs with rigid sling pins PN 1053 C 1C Secure each pin with two 0 148 x 2 938 hitch pins Thread a 3 4 U
122. idelines Do not begin a maintenance task without the proper tools or materials on hand or the proper drawings and documentation necessary Schedule planned maintenance with operators to avoid conflicts unnecessary downtime and the danger of accidental equipment activa tion Notify operations when maintenance procedures are complete and equipment functionality is restored Isolate the location of the maintenance under way to prevent unaware personnel from inadvertently exposing themselves to a hazard Use tape rope or signage to clearly indicate off limits area Replacement of large heavy individual parts and or heavy structural components must be performed using an approved lifting device of sufficient lifting capacity Use care when attaching the lifting device and safeguard area to avoid endangering personnel or equipment All spare parts must meet or exceed OEM specifications in order to maintain equipment integrity especially protective equipment McCoy Drilling amp Completions recommends that disconnection of hydraulic connectors be performed with the power unit off and the hydraulic circuit depressurized Your equipment uses materials that may be harmful to the environment if improperly disposed of hydraulic fluid grease etc Dispose of all materials according to your company s proscribed environmental protection regulations B CLEANING Clean tong thoroughly cleaned with a good petroleum based cleaning agent after each job
123. is manual is intended for guidance and informational purposes and must be used in association with adequate training and on the job supervision to provide safe and effective equipment use It is the responsibility of the user to conform to all regulations and requirements issued by an authority or agency which may affect the opera tion safety or equipment integrity that may overrule the content of this documentation The user will acknowledge and obey any general legal or other mandatory regulation in force relating to accident prevention safety and equipment integrity Summary Of Revisions Date Section Page Description Of Revision Approved Sep 2007 N A N A Initial Release K Isaacson inh iii Corrected table of assemblies covered by this manual added compression LC style backup 1 1 3 Added arm length specs for compression LC style backup APR 2008 3 3 4 Added imagery for parts identification for compression LC style backup D Yakimchuk 7 7 38 Created parts lists for compression style LC backup 8 8 1 Added compression load cell information 8 8 4 Added detailed compression load cell parts list APR 2009 7 7 21 Corrected reference to page number showing the jaw availability D Bowles AUG 2009 Intro iii Added model 80 0420 16 tong with low profile CLINCHER backup D Bowles Sep 2010 scsemhiies added drawings for 86 0408 backup and mounting kt KDuhon 2 8 Remov
124. l lock nut turns with a slight drag 4 Tighten lock nut until desired rolling drag of bearing is obtained see procedure Page 9 5 Tighten clamp screw 6 Tighten all seal plate bolts 1 Install dowel pins into rear housin 2 Install into rear housings 3 Install main body o ring 1 Place rotor stator cartridge onto rear housing 2 NOTE Make sure assembly marks from step 3 are lined up 1 Install main body o ring into front housing 2 Install ball checks into front housing 3 Place a small amount of grease over ball checks and o ring 4 Wipe off excess grease TECHNICAL MANUAL Section CONTENTS 7 13 5500 5 amp CLINCHER Bact Hyprautic Motor INFORMATION WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 1 Rotate shaft in both directions to assure that the shaft turns smoothly 2 Torque motor to 190 ft Ibs 3 Rotate shaft again in both directions to assure that the shaft turns smoothly 1 Install dowel pins into rotor stator cartridge 2 Pour a small amount of Clean oil into the cartridge 3 Install front housing onto rotor stator cartridge 4 Make sure alignment marks are lined up SPOOL ASSEMBLY FOR THE 1 Install 5 8 11 bolts TWO 2 Torque bolts to 50 ft Ibs SPEED MOTOR NOTE Spool should be oriented as shown for two speed motors with model codes 62 63 68
125. l for instructions on properly adjusting brake bands Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have visible signs of wear from contact with a rigid object LI m LI L L 12 DRILLING amp AACCCOY TecHNicAL MANUAL 321 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER MAINTENANCE 13 Perform a complete greasing of the tong refer to Maintenance section of the technical manual 1 4 Ensure main supply and return connections to the tong are fully made up Re connect the remainder of the hydraulic lines and if applicable the electrical line to the turns counter FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE Perform a visual inspection of the load cell If using a tension load cell replace any cracked broken or distorted components 15 including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression Inspect hydraulic line fittings and diaphragm seals for fluid leaks 1 6 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen If using a stand alone power unit start it now refer to the power unit technical manual for star
126. lable to allow use of die inserts intended for specialized applications Call our sales office for information on jaw and die systems designed for higher or lower grip or non marking applications The table lists standard contoured flat and wraparound die inserts that are available as spare parts However a wide variety of diamond tooth GRITFACE aluminium and wrap around fine tooth dies are available for specialized applications Please refer to our website for complete information http www mccoyglobal com dies inserts STANDARD JAW DIE KITS Inserts Not Included Description Part Number 2 3 8 Jaw Die 1064 JDK 65 2 7 8 Jaw Die Kit 2 1064 JDK 70 3 Jaw Die Kit 1064 JDK 71 3 1 2 Jaw Die Kit 1064 JDK 75 4 Jaw Die Kit 1064 JDK 80 4 1 2 Jaw Die Kit 1064 JDK 85 5 Jaw Die Kit 1064 JDK 90 5 1 2 Jaw Die Kit 9 1064 JDK 95 1 Uses 2 375 Contour Die 12 0004 2 Uses 2 875 Contour Die 12 0007 3 Uses 1 x 3 875 Flat Die 12 0006 314 0 All other Standard Die Kits use 1 1 4 x 3 875 Flat Die 13 0008 314 0 Continued On Next Page 2 12 SECTION CONTENTS TEcHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS SETUP amp OPERATION 5500 5 7 amp CLINCHER Backup WRAPAROUND JAW DIE KITS Inserts Not Included Description Part Number 2 3 8 3 1 2 Wrapa
127. lied with your equipment Please note that the parts listed in the following table are correct for accurate torque measurement while using the equipment for which this manual is supplied TORQUE MEASUREMENT THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE THE PART NUMBERS LISTED IN THE FOLLOWING TABLES ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED Item Type Description Qty Part Assembly 30 Arm 20K Tension Load Cell Gauge 1 10 0028T A Part 4 08 Tension Load Cell 1 10 0008T B Part Torque Gauge 20 000 Ft Lbs 36 Arm 1 10 0028G C Part Hydraulic Hose 1 02 0069 Item Type Description Qty Part Assembly 32 Arm 20K Compression Load Cell and Gauge 1 10 0029C A Part 8 in Compression Load Cell c w hoses amp fittings 1 10 0008C B Part Torque Gauge 20 000 Ft Lbs 32 Arm 1 10 0029G C Part Hydraulic Hose 1 02 0069 6 2 LOAD CELLS ARE NOT USER SERVICEABLE ILLUSTRATION 6 A 4 AND 6 A 5 ARE PROVIDED FOR INFORMATION PURPOSES ONLY DAMAGED LOAD CELLS MUST BE RETURNED TO THE FACTORY FOR REPAIR AND RE CALIBRATION CONTENTS TEcHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS MEASUREMENT 5500 5 7 amp CLINCHER Backup
128. ly enclose the equipment Seal polyethylene bag to the pallet using 1 mil polyethylene wrap Use the wrap to conform the plastic cover to the general shape of the equipment but do not wrap so tight that sharp edges on the equipment perforate the cover 7 McCoy recommends enclosing the equipment in a sturdy shipping crate which is securely fastened to the pallet DRILLING amp AACCCOY TEcHNICAL MANUAL 3 31 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER MAINTENANCE TUBULAR CONNECTION EQUIPMENT RE COMMISSIONING PROCEDURE Perform the following recommissioning procedures when removing tubular connection equipment from short or long term storage back into regular service These procedures are essential for ensuring proper equipment preparation and operation The following procedures also assume that the decommissioning and storage procedures recommended by Farr have been strictly observed 1 2 A 00 0 OU O U 14 15 16 a N 18 19 3 32 Remove all protective plastic wrapping If there are desiccant packs with the assembly they may be disposed of with the regular garbage Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Wipe excess grease or heavy oil from exposed cylinder rods If applicable re connect chain sling to lifting lugs Perform a visual inspec
129. n These unbalanced poppet logic valves are 2 way switching elements that are spring biased closed Pressure at either work port 1 or 2 will further bias the valve to the closed position while pressure at port 3 will tend to open it The force generated at port 3 must be greater than the sum of the forces acting at port 1 and port 2 plus the spring force for the valve to open NOTE The pilot area port 3 is 1 8 times the area at port 1 and 2 25 times the area at port 2 LOCATING SHOULDER X 1 81 46 0 1 81 45 0 X CONTROL SHOWN INSTALLED T 17A CAVITY d I 7 HEX DIMENSION d 1 Se ACROSS FLATS 1 1 4 31 8 PILOT PORT in mm Technical Features e Because these valves are unbalanced e These valves are pressure responsive operation is pressure dependent at all three ports therefore it is Opening and closing of the poppet are essential to consider all aspects of functions of the force balances on three System operation through a complete areas 1 Port 1 100 Port 2 80 cycle Pressure changes at any one and Port 3 180 port may cause a valve to switch from a closed to an open position or vice versa All possible pressure changes in the complete circuit must be considered to assure a safe functional system design DRILLING amp 7 30 TECHNICAL MANUAL AACCCOY MOVING GLOBAL ENERGY FORWARD AACCOY MOVING GLOBAL ENERGY FORWARD HvoRAULIC VALVE INFORMATION e These valves have positive
130. n and catastrophic movement when pressure is removed from the float cylinders Cover the top of the backup with protective cloth to protect the paint on the backup Place two wooden beams across the top of the tong ensuring that the beams have a minimum size of 4 x 4 x the width of the tong Cover the tops of the wooden beams with more protective cloth to prevent paint damage to the tong When lowering the tong onto the beams ensure that the beams come into flat contact with the bottom of the tong away from bearing caps brake bands or other protrusions on the bottom of the tong Ensure that the tong hanger chains are loose but not dangling into contact with the hangers or top plate of the tong DEPRESSURIZATION PROCEDURE STORAGE 1 2 3 4 5 6 7 8 9 18 19 20 21 22 23 24 Rotate the tong to the open throat position Exercise each hydraulic cylinder several times open the tong and backup doors if equipped retract and extend the remote backing pin ramp if equipped retract and extend the float cylinders Leave all cylinders except for the door cylin ders in their fully retracted position The general idea is to have as little of the chrome cylinder rods exposed as possible De energize the power unit Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor Remove the hydraulic SUPPLY line from
131. nclude two people to run the control valve and one to operate the door i Ensure the tong door is securely closed Shift to LOW gear iv Begin rotating the tong direction of rotation is not important v Open the tong door while the rotating the tong The tong must immediately and completely stop rotating as soon as the door is opened vi Continue to apply rotation control and open amp close the door throughout its complete range Slowly close the door until it latches Rotation must not begin until the door is completely closed and securely latched If the safety door does not operate as designed the safety door switch may require adjustment or further troubleshooting of the safety door system may be required See Section 3 F 4 for safety door switch adjustment procedures and Section 4 D for safety door troubleshooting instructions The safety door switch is protected from impact by a sturdy metal guard painted yellow This guard must be inspected before each use of the tong All components of the guard must be in place and all fasteners securing the guard must be intact and tight DO NOT OPERATE TONG WITH A MALFUNCTIONING OR NON OPERATING SAFETY DOOR SYSTEM DRILLING amp e ee TecHNicAL MANUAL 2 23 MOVING GLOBAL ENERGY FORWARD 5500 5 1 amp CLINCHER Setup amp OPERATION 6 General Operational Comments a Position rotary gear in contact with both idler gears when breaking out j
132. nd prepare parts properly may result in axem Caller et Lil raai ie ceni sarin whi kah Hues Io Suet fe md Lat vu eure goa maimam ef ber Aner iret ther hol 4 make ceran d 125 in ba ol breakaway longae DRILLING amp e ee TECHNICAL MANUAL 7 25 MOVING GLOBAL ENERGY FORWARD 5500 5 17 amp CLINCHERG BACKUI UF VALVE INFORMATION s Valve Assembly Instructions Detent Spool Assembly Step 1 Spool Assembly Detant Apply Parker Super Lilbe p Ure spool seal Fu em 8 and aftde it onya the wool Slide the back up ring Fig 1 Heim 7 tinal ome plaie Erg tem bi go the these Seres ona The span 33 h i There do rir interfere dh the spool operator mocha duu Do nor allow ihe O rng in Gem ic raue eri le he exl ese of Uie pache Apply 2 3 Lane 287P9 ar an equivalent anaerobic ner the moddle of the female ibreads im ha apen CAUTION Follow the adherive aianufs rurer i instructions for preper cleaning and Failure to chan and prepare park property max Perili Step 2 Spool Assembly Detent Thread the detent ball Fig 2 irem 20 Ehe sol sau Tute illie fell tee 175 pi Ibis P A m
133. ndle 1 01 0409 HANDLE Part Valve Handle Link 2 01 0409 LINK Part Hydraulic Handle Pin 2 01 0409 PIN1 Part Hydraulic Handle Auxilliary Pin 1 01 0409 PIN2 Part Valve Handle C Clip 2 01 0409 CIRCLIP Part Cotter Pin 2 01 0409 COTTER DVA35 SA8 Valve 1 ORB PORT 1 10 9015 Part DVA35 MA8 4 Way Directional Valve SAE Port 1 10 9014 x Assembly Hydraulic Relief Valve includes seals 1 10 0010R Y Part 1 Orb Plug Fitting includes o ring 1 02 9222 NALCO Y MOVING GLOBAL ENERGY FORWARD 5 25 TECHNICAL MANUAL KT5500 5 amp CLINCHER BACK JP Door ASSEMBLY _ Q cr E r XL DRILLING amp 5 26 TECHNICAL MANUAL e ee MOVING GLOBAL ENERGY FORWARD Door ASSEMBLY 175500 5 amp CLINCHER Backup Item Type Description Qty Part Number A Part 5 16 x 3 4 UNC Shoulder Bolt 2 09 0227 B Assembly Door Cylinder 1 101 0069 C Part 3 8 NC x 1 Hex Bolt 1 09 1046 D Part 3 8 Carbon Steel Lock Washer 3 09 5106 E Part Adjustment Cam 1 1400 14 F Weldment Door Weldment 1 1400 10 G Part 3 8 UNC Hex Nut 2 09 5806 H Part 3 8 NC x 1 1 2 Hex Bolt 1 09 1553 J Part Latch Spring 2 997 16 K Weldment Door Latch Weldment 1 1064 C7 15 L Part Shoulder Bushing 1 101 5110 M Part Door Bushing Bottom 1 101 5111 N Part Door Pivot R
134. ng accessories Ar E ILLUSTRATION 3 L 1 SHIPPING INSTRUCTIONS PALLET COY TECHNICAL MANUAL 3 29 MOVING GLOBAL ENERGY FORWARD 5500 5 1 amp CLINCHER Backur MAINTENANCE SHIPPING INSTRUCTIONS CONTINUED 3 Useacrane to support the chain sling if equipped Wrap the chain sling with bubble wrap or another similar protective wrapping and secure the wrapping with tape Lower the wrapped chain sling so it sits inside the opening of the tong ILLUSTRATION 3 L 2 SHIPPING INSTRUCTIONS WRAPPING CHAIN SLING 4 Do not allow the backup if equipped to float on its support springs during shipping Build a sturdy wooden support structure under the front and back of the backup to support the weight of the backup and release the compression on the springs Strap the backup to the support blocks and pallet independent of the tong using minimum 3 4 x 0 029 metal strapping in at least two locations Place strapping as close to the backup supports as possible and use caution not to entrap any flexible hydraulic hoses beneath the strapping Before tightening strapping place strapping protectors wherever the metal strapping comes into contact with the equipment ILLUSTRATION 3 L 3 SHIPPING INSTRUCTIONS BACKUP SUPPORT DRILLING amp 3 30 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 5500 5 1 amp CLINCHER Backup
135. ns for signs of damage replace pins if necessary If the pins are welded 6 in place replace the entire jaw assembly Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely Check to ensure the size of the loaded jaws match the size of casing or pipe you are running f Inspect front and rear cam cylinder supports Repair or replace any parts that are broken cracked or bent 8 Inspect rear spring hanger assembly Ensure all eye bolts shackles and cotter pins are in place and in good condition 9 Open the backup door and inspect the condition of the latch Repair or replace damaged latch components If latch ap pears to be in good condition close the door then tug firmly on it to ensure the door remains latched ALL Units AFTER STARTING Power 10 Perform a visual inspection of pressurized hydraulic lines document and correct any hydraulic fluid leaks 11 L Perform a full functional test of the backup Document and correct hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that in use the backup DRILLING amp AACCCOY TecHNicAL MANUAL 3 23 MOVING GLOBAL ENERGY FORWARD 5500 5 1 amp CLINCHER MAINTENANCE K MONTHLY MAINTENANCE CHECKLIST POWER TONG The following maintenance checklist is intended as a guideline rather than a definitive maintenance schedule Your equipm
136. nsure the hydraulic connections from the power unit are properly and securely made up see Section 2 E Do not neglect to connect the motor drain line b Start the power unit as specified by the power unit operator s manual Open the Bypass Valve on the hydraulic system and inspect all pressure and return line hose connections to ensure correct and secure installation A restriction in the pressure supply hose will result in high pressure within the power unit hydraulic system which will activate the hydraulic governor and increase the engine speed to as high as maximum RPM A restriction in the return line will result in high pressure within the power unit and the tong hydraulic system causing engine speeds as high as maximum RPM and possible failure of the motor seal A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR c Allow hydraulic system to warm by circulating fluid for about 10 minutes then slowly close the bypass valve to allow hydraulic fluid to circulate through the hoses and tong Ensure circulating pressure does not exceed 200 psi d Inspect all hydraulic hoses and connections on the tong Immediately correct any hydraulic fluid leaks e Inspect all gauges Replace leaking or cracked gauges or any gauge not registering a reading f Confirm that all load bearing pins and R clip retainers are installed and in good condition rigid sling pins lift cylinder pins
137. ntinuous Up to 75 HP continuous Conforms to SAE C mounting specification Weighs 43 lbs CROSS SECTION _ 7 Nes A Made in USA 63 PUBLICATION 0 151005 8 03 DRILLING amp AACCCOY MANUAL 73 MOVING GLOBAL ENERGY FORWARD 5500 5 1 amp CLINCHER Hyprautic Motor INFORMATION 15 Series Standard Motor Envelope CENTER 3 8 O RING BOSS CASE DRAIN SAE STD 1 25 2 PLACES 1 38 4 BOLT FLANGE NEAR AND FAR SAE 14 12 24 PITCH OPTIONAL SHAFT FLAT ROOT SIDE FIT INVOLUTE SPLINE DRILLING amp 7 4 Section CONTENTS MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic Motor INFORMATION Technical Information All Styles VANE CROSSING VANE The Rineer patented vane crossing vane design produces much higher volumetric and mechanical efficiencies than is possible with a standard vane type design This design provides a sealing vane between cavities to improve mechanical and volumetric efficiencies STARTING AND STALL TORQUE The Rineer motor produces torque curves which are virtually flat with starting and stall torque equal to approximately 90 94 of theoretical torque MORE POWER STROKES PER REVOLUTION The 15 Series has four stator cavities and 10 rotor vanes Each rotor vane works in each
138. nufacturer data sheets for proper application and safety information DO NOT ALLOW ANTI CORROSIVE AGENTS TO CONTACT CYLINDER RODS CYLINDER ROD DAMAGE WILL OCCUR Allow the anti corrosive coating ample time to dry refer to manufacturer data sheets for drying times at room temperature Wrap entire assembly in 100 gauge 1 mil corrosion inhibiting wrap at least 3 layers thick Attempt to ensure that the tool is well sealed within the wrapping including the bottom If possible store in a sealed climate controlled environment If isolated storage is not available Farr recommends storing your wrapped equipment in a secure out of the way location using silica gel desiccant to reduce the humidity within the wrapping As a guideline use 125 g of desiccant for each cubic metre of space or 3 5 g per cubic foot see calculations next page 3 28 NALCO Y TA Gu MOVING GLOBAL ENERGY FORWARD Section CONTENTS TECHNICAL MANUAL MAINTENANCE 115500 5 1 amp CLINCHERG Backup CALCULATION Or REQUIRED DESICCANT 1 2 Calculate the trapped air volume by measuring the outside dimensions of the tool to be stored and treat that as the volume to be stored For example the external dimensions of a KT20000 20 power tong are 80 25 x 50 5 x 28 which calculates to an approximate volume of 113500 or 66 ft 1 87 m Multiply the calculated air volume in cubic feet by the recommended amount of desiccant per cubic foo
139. oints or collars where high torques are required b When making up integral shouldered joints it is essential to make up the last turn of the threads in low gear This reduces the tendency of an instant stop or a sudden increase in torque which induces extremely high stresses on the gear train c DO NOT employ the snap break method of breaking out joints when pulling a string By definition the snap break method is a procedure used by some operators to break out connections accomplished by leaving slack in the jaw pipe engage ment and then quickly pulling the throttle valve control lever allowing the tong to snap into its loaded or high torque condition Although this method is very effective in breaking out joints the extremely high stress placed on the gear train frequently causes gear breakage THE SNAP BREAK METHOD IS HAZARDOUS TO PERSONNEL AND EQUIPMENT L EXTREME COLD WEATHER OPERATION PROCEDURES 1 Consult the power unit engine operator s manual for all cold weather operating procedures and precautions 2 Select gear and bearing lubricants that are compatible with expected climatic conditions 3 Select hyaraulic fluid that is compatible with expected climatic conditions 4 Allow hyaraulic fluid to circulate for approximately 20 minutes after starting the power unit prior to activating the bypass valve to allow fluid to circulate to tong If the power unit is equipped with an oil temperature gauge ensure that the flu
140. oller 1 101 3943 P Part 7 8 Narrow Flat Washer 2 09 5123 Q Part Door Cylinder Mounting Lug 1 1050 12 001 R Part 7 8 UNF Thin Nylock Nut 1 09 5722 Part 1 4 Straight Grease Fitting Adjustment Cam not shown 1 02 0097 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL 527 KT5500 5 1 amp CLINCHER Door ASSEMBLY DRILLING amp 5 28 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Door ASSEMBLY Item Type Description Qty Part Number A Part 3 8 NC x 3 4 Hex Bolt 4 09 1044 B Part Switch Guard Top Plate 1 101 1480 C Part 3 8 NC x 2 1 4 Hex Bolt 3 09 1055 D Part 3 8 Carbon Steel Lock Washer 9 09 5106 E Part Safety Door Latch Block 1 101 1104 F Part 15 16 Valve Lock Nut 1 09 0278 G Part Safety Door Latch Block 1 101 1103 H Part Safety Door Latch Plate 1 101 1105 J Part 3 8 NC x 1 1 2 Hex Bolt 2 09 1553 K Part 3 8 NC x 1 1 2 Flat Head Countersunk Cap Screw 2 09 4050 L Part Safety Door Latch Block 1 101 0914 M Part Load Plunger 1 AE12 306 N Part 1 4 inch NPT JIC 90 degree elbow 3 08 0284 P Part Deltrol Gauge Isolator Valve 61215 1 08 0337M Q Weldment Safety Door Switch Guard Weldment 1 101 1481 H Part 3 8 NC x 7 8 Flat Head Countersunk Cap Screw 3 MCCOY 55 COMPLETIONS
141. omplete Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp outlet line supports tong legs shifter handle pivot lugs Tighten or replace loose or missing fasteners Farr recommends that damaged or missing body parts be repaired or replaced Inspect the jaws and dies Inspect the jaw roller pins for signs of damage replace pins if necessary If the pins are welded in place replace the entire jaw assembly Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely Check to ensure the size of the loaded jaws match the size of casing or pipe you are running Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong in service Also inspect all chains master links and turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is a good indication of wear 9 10 11 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the brake band tension is not evenly adjusted Refer to the maintenance section of the manua
142. ompression Load Cell a Locate a known weight and move the weight next to the tong and backup assembly b Remove the compression load cell from the tong but do not disconnect from the torque gauge c Place the compression load cell piston side down on a sturdy surface such as a concrete shop floor d Use a crane to hoist the known weight on to the rod end of the compression load cell This is a small area so an ideal known weight should be relatively small and dense A block of solid metal or concrete is preferred The weight must be centered exactly on the rod end of the load cell to ensure even and accurate compression Do not use a tall unrestrained known weight that could topple Do not disconnect the known weight from the crane but ensure the crane exerts no upward force on the weight The attached crane prevents an un centered weight from toppling e Perform a simple calculation to determine the expected indication on the torque gauge based on the known weight on the load cell This is a calculation that must be performed using the arm length expressed in imperial units feet The calculation is KNOWN WEIGHT x ARM LENGTH in feet For example if the arm length is 32 inches and the known weight is 500 Ibs the calculation is 500 x 32 12 1333 3 Therefore the expected indication on the torque gauge should be approximately 1333 Ibs ft If you are using a metric torque measure system calculations are as follows KNOWN WEI
143. on Bearing Cap 2 997 D15 89 E Part Pinion Bearing Spacer 2 1400 89A F Part Pinion Idler Bearing 2 02 0007 G Part Low Pinion Gear 1 997 A5 88 H Part Pinion Gear 1 997 A7 86 J Part High Pinion Gear 1 997 A4 87 DRILLING amp AACCCOY TEcHNICAL MANUAL 5 11 MOVING GLOBAL ENERGY FORWARD 5500 5 amp CLINCHER Backui CLUTCH ASSEMBLY DRILLING amp 5 12 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD CLUTCH ASSEMBLY 5500 5 1 amp CLINCHERG Backup Item Type Description Qty Part Number A Part Outside Snap Ring 1 02 0001 B Part Drive Shaft Clutch Gear 1 997 A3 61 C Part 3110 24 x 3 4 Hex Socket Head Cap Screw 2 09 0001 D Part Top Clutch Bearing Retainer 1 997 D11 59 E Part Top Clutch Bearing Retainer Spacer 1 1400 59A F Part Clutch Bearing Bushing 1 997 60 G Part Top Clutch Bearing 1 02 0002 H Part Low Clutch Gear 1 997 A1 52 J Part Needle Bearing 4 02 0003 K Part Clutch Shaft 1 997 A8 50 L Part Shifting Collar 1 997 A9 62 M Part High Clutch Gear 1 997 A1 51 N Part Bottom Clutch Bearing 1 02 0004 P Part Clutch Bearing Cap Spacer 1 1400 54A Q Part Clutch Bearing Cap 1 997 D11 54 R Part 3 8 Carbon Steel Lock Washer 4 09 5106 S Part 3 8 UNC x 1 1 4 Hex Bolt 4 09 1048 T Part Grease Fitting 1 8 NPT 1 02 0005 U Part Grease Fitting 1 8 NPT x 90 Degree 2 02 0093
144. onnected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INJURIES Clean the exterior of the tool thoroughly using either water if using a pressure washer ensure a low pressure wash wand is used or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and cleaning agents Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the gear train cavity if shavings or metal pieces are seen the tong must be overhauled before it is returned to service Inspect all fasteners and fastener safety wires if equipped Replace any missing fasteners use Grade 8 bolts only unless otherwise specified Re torque all external fasteners to SAE specifications Repair or replace any damaged or
145. onnection when the power unit is not running or when the hydraulic pump is disengaged The possibility of error in inter changing the high pressure supply hose and the low pressure return hose has been eliminated because the supply side coupling is smaller than the return side NN Hydraulic Supply 1 em E e Hydraulic Return 1 1 4 ILLUSTRATION 2 D 1 KT5500 CBU v CONNECTIONS 01 DRILLING amp AACCCOY TECHNICAL MANUAL 2 11 MOVING GLOBAL ENERGY FORWARD 5500 5 amp CLINCHERG Back Setup amp OPERATION These hose couplings are self sealing and care should be taken to ensure complete engagement to prevent partial closure of the check valve in the coupling Ensure that the nut female side is completely made up onto the male connector there is a line on the male fitting that indicates complete make up Snug the female fitting right up to the line Make up female fitting to Marked point on male fitting ILLUSTRATION 2 D 2 KT5500 CBU 02 E TONG JAW AVAILABILITY amp INSTALLATION 1 Availability The following table lists all jaw die kits that are available as standard stocked sizes for this model of tong McCoy Drilling amp Completions Farr offers a good selection of standard jaw sizes However please note that we can custom engineer and manufacture any size of jaw within the range of the tong Jaw systems are avai
146. overed in this manual please contact McCoy Drilling amp Completions FARR 14755 121A Avenue Edmonton Alberta Canada T5L 2T2 Phone 780 453 3277 Fax 780 455 2432 Sales Fax 780 481 9246 Email Engineering engFarr mccoyglobal com Email Sales salesFarr mccoyglobal com Website http www mccoyglobal com drilling completions ILLUSTRATION 1 A 1 KT5500 CLINCHERO Backup 80 0421 3 SHOWN DRILLING amp e ee MANUAL 1 1 MOVING GLOBAL ENERGY FORWARD 5500 5 gt 8 CLINCHER Backup SPECIFICATIONS Model 80 0421 3 Shown 37 ILLUSTRATION 1 A 2 KT5500 amp CLINCHER Backup DIMENSIONS DRILLING amp 1 2 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SPECIFICATIONS 300 5 1 amp CLINCHERG Backup Torque Table Pressure High Gear Low Gear PSI MPa Lbs ft Nm Lbs ft Nm 1000 6 89 1530 2074 7650 10372 1400 9 66 2250 3050 11250 15253 1800 12 41 2970 4027 14845 20127 2250 15 513 3780 5125 18894 25617 MAXIMUM RATED TORQUE 18700 LBS FT 25354 Nm Speed Table Single Speed Motor Flow US GPM LPM Low Gear RPM High Gear RPM 10 37 9 2 7 13 4 20 75 71 5 4 26 8 40 151 4 10 7 53 6 60 227 1 16 1 80 5 These are ideal values Actual achieved torque is highly dependant upon tong efficienc
147. owntime Service parts and assemblies available through your onginal eguipanent dealer or amy authorized distributor MAINTENANCE Valves are often used in hazardous environments Inspect them frequently for damage due te improper use corrosion or normal wear If needed repairs should be made immediately Always refer to the machine manual for the proper procedure to remove the valve from the machine Remove the valve bank from the equipmeni disconnecting all hoses contral handles and linkage connectors that might be attached to the valve Plug all ports and thoroughly clean ihe exterior of the valve bunk dien poit pluga cun be removed TECHNICAL MANUAL SEcTION CONTENTS 719 5500 5 17 amp CLINCHER BACKUP HvoRAULIC VALVE INFORMATION Exploded View of Work Section Ma cr en Parts List For Work Section Hem Oty VAWG20 Part vaga ban Parallel Section See Figure 1 4 Square Seals 3 381 2951 206 321 2654 361 0884 433 2 Square 1 381 2881 20 451 2667 40a 351 2881 070 Series Becton Seala 1 Sure Sonis d 29 1 288 1 0 391 2524 200 Sal 249 280 1 627 391 268 628 Parallel and Series Section Component Parts See Figura 1 BACK Screws ed 381 1431020 3n 14343 0049 381 1402 068 bank H PT a 3891 3783 D38 5 Back Cap 1 254 L 100 3482 BO000 TOO 341 0 45 0
148. part s before placing the tong in service Refer to Section 2A of the technical manual Sling Load Bearing Device Safety for information on recommended testing and recertification Please note that turnbuckles with part number 101 3086 short turnbuckles use a high strength pin which must be supplied by Farr DRILLING amp 3 24 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD 12 MAINTENANCE 00 5 1 amp CLINCHERG Backup SHORT TURNBUCKLES HAVING PART NUMBER 101 3086 EMPLOY HIGH STRENGTH PINS WHICH MUST BE SUPPLIED BY FARR Remove hyaraulic motor and rotate the gear train by hand and use a flashlight to perform a visual inspection of the gear 1 3 train through the access panel and the opening of the rotary gear while the gear train is being rotated If gear damage or chips of metal are seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is complete Inspect all jaws and dies in use for the maintenance interval Remove pin amp roller and inspect for signs of damage replace 1 4 pins if necessary If the pins are welded place amp the welds are found to be damaged remove and quarantine the jaw until 5 the weld is repaired Clean the pins and rollers and reassemble using a liberal coating of anti seize compound Ensure dies are secure in the jaw amp die retainers are present Replace worn dies if
149. pe or cas ing to the centre of the force being applied to the load cell Two load cell options are available A tension load cell is typically used with a suspended stand alone tong This application requires that the load cell be attached to the rear of the tong as part of the restraint line that opposes the force generated when the tong makes up or breaks out a joint A compression load cell is used in a tong and backup assembly and is typically located on the rear of the backup between the backup and a stationary frame The load cell must be located in the centre of the compression force vector generated between the backup and the frame Hydraulic force generated by a load cell is transmitted to the torque gauge via a reinforced flexible hydraulic line The hydraulic force is displayed as torque in units of Ft Lbs The torque gauge has a red peak torque indicator that tracks with the torque gauge needle to the point of highest torque and remains at the point of highest torque until manually reset Note that every model of tong and tong and backup assembly has a unique arm length and the torque gauge must be calibrated for that arm length Torque gauges that are not calibrated for the arm length of the tool in service will not display correct torque To ensure correct torque measurement ensure the arm length or handle as displayed on your torque gauge matches the arm length of the tool in service as listed on the specifications page of the technic
150. r ASTM D 2266 Fretting wear mg ASTM D 4170 Four ball EP kgf ASTM D 2596 Weld point Load wear index Timken OK load test 16 D 2509 Low temperature torque N m ASTM D 4693 LT 37 pumpability g min Copper corrosion ASTM D 4048 Oil viscosity 40 C 104 F cSt 100 C 212 F cSt Flash point F C ASTM 92 Lithium Complex 2 GC LB 265 295 minimum 0 1 mm worked 60 strokes 550 288 minimum 160 minimum 100 hr 300 hr 0 3 1 8 max pass 1 1 max 24 hours 25 C 77 F 1 0 max 0 40 max 3 4 max 400 minimum 50 minimum 50 1 3 max 40 C 40 F 360 7 60 F 0 F 16 C 18 C 1B 151 19 2 450 232 Use a premium quality hydraulic fluid that meets or exceeds the following specifications Typical Density kg m3 Viscosity cSt 40 C cSt 100 C Viscosity Index Pour Point F C Flash Point F C Colour ASTM Neutralization Number Rust Protection Distilled Water Sea Water Hydrolytic Stability Cu Mass Loss mg cm2 Copper Corrosion Test Filterability Denison Wet amp Dry Afnor Wet amp Dry Cincinatti Milacron Spec Approved Denison HF 0 Denison P 46 Piston Pump Denison T6C Vane Pump Vickers 35VQ25 Vane Pump Test Vane pump test total ring and vane wear mg Oxidation Stability Turbine Oil Stability Test Life hours Rotary Bomb Oxidation Test minutes FZG Spur Gear Test Failure Load Stage FLS 14
151. r one minute in both high and low gear Stop the tong and reverse the direction of rotation for another minute 25 in both high and low gear ending with the opening of the rotary gear facing the gear train De energize the power unit and perform another generous lubrication of the gear train including the gear housing 2 6 Energize power unit Rotate tong for one minute in both high and low gear Stop the tong and reverse the direction of rotation for another minute in both high and low gear ending with the opening of the rotary gear facing the gear train 2 f De energize the power unit and perform a third generous lubrication of the gear train including the gear housing 2 8 Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines If a seal line or fitting begins to leak while tong is rotating it must be replaced before the equipment is returned to service Rotate tong in high gear for 5 minutes while monitoring temperature of top and bottom bearing caps If the bearing caps are 29 hot to the touch higher than approximately 50 replace the applicable bearings Likewise if the tong is making unusual noises check for damaged bearings see Maintenance Manual for all bearing locations DRILLING amp AACCCOY TecHNicAL MANUAL 3 25 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 8 CLINCHERG MAINTENANCE 30 ets 32 33 1 34 35 36
152. re tong and backup doors if equipped are closed Fully extend the lift cylinder 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the 2 valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INJURIES Perform an initial wash of the tong in order to remove the majority of dirt and grease build up Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Use a flashlight to perform a visual inspection of the gear train through the access panel and the opening of the rotary gear If gear damage or chips of metal are seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is c
153. rease to the support roller bearings through the grease fittings recessed into the top of each support roller shaft ten loca tions total ILLUSTRATION 3 0 2 SuPPORT RoLLER BEARING LUBRICATION 3 2 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD MAINTENANCE 2 15500 5 8 CLINCHER Backup 3 Rotary Idler Bearings Apply grease to the rotary idler bearings through the grease fittings recessed into the top of each shaft on the top face of the tong two locations total ILLUSTRATION 3 0 3 RoTARY IDLER BEARING LUBRICATION 4 Pinion Idler Bearing Lubrication Apply grease to the pinion idler bearing through the grease fitting recessed into the top of the half shaft located on the bottom face of the tong one location only ILLUSTRATION 3 D 4 Pinion IDLER BEARING LUBRICATION DRILLING amp Ile e e TecHNicAL MANUAL 3 3 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER BACKUP MAINTENANCE 5 Pinion Apply grease to the pinion bearings through the grease fittings located on the bearing caps on the top and bottom faces of the tong two locations top two locations bottom ILLUSTRATION 3 0 5 Pinion BEARING LUBRICATION 6 Clutch Bearings Apply grease to the clutch bearings through the two grease fittings located on the clutch bearing cap on the bottom face of the tong and the single grease fitting recessed into the end of the clutch shaft
154. rections makeup and breakout If cage plate begins rotating the safety door mechanism is not functional and the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR 2 3 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved 24 When all of the previous steps are completed you may return your re commissioned equipment to service DRILLING amp AACCCOY TecHNicAL MANUAL 3 33 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank TROUBLESHOOTING 0 5 amp CLINCHERG Backup Adequate maintenance and proper fluid selection is essential for minimizing hydraulic related failures All troubleshooting must be performed by a technician trained in hydraulic systems and familiar with the equipment design assembly and operation The following troubleshooting instructions are intended to be guidelines only Any faults not solved through the use of this guide should be referred to our engineering department for their evaluation and recommendations
155. repair or modification is defined as any repair and or modification that has been carried out which may in the opinion of the inspection body affect the load bearing elements of the container or lifting device or elements that contribute directly to its structural integrity IF MECHANICAL DAMAGE IS SEEN OR SUSPECTED ON A LOAD BEARING DEVICE OR IF THE LOAD BEARING DEVICE HAS BEEN OVERLOADED IT MUST BE REMOVED FROM SERVICE AND QUARANTINED UNTIL RECERTIFIED Written records of the most recent periodic inspection shall be maintained and shall include the condition of the sling 2 Proper Use Of Load Bearing Devices Whenever any load bearing device is used the following practices shall be observed Load bearing devices that are damaged or defective shall not be used Slings shall not be shortened with knots or bolts or other makeshift devices Sling legs shall not be kinked Load bearing devices shall not be loaded in excess of their rated capacities Slings shall be securely attached to their load Load bearing devices shall be protected from snagging and shall not be further obstructed by any object Suspended loads shall be kept clear of all obstruction All employees shall be kept clear of loads about to be lifted and of suspended loads Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load Shock loading is prohibited Do not stand directly under
156. round Jaw Die Kit 1064 WJK 350 4 5 1 2 Wraparound Jaw Die Kit 1064 WJK 550 2 3 8 Wraparound Insert for use in 1064 WJK 350 12 2001 2 7 8 Wraparound Insert for use in 1064 WJK 350 12 2003 3 1 2 Wraparound Insert for use in 1064 WJK 350 12 2006 4 Wraparound Insert for use in 1064 WJK 550 12 2007 4 1 2 Wraparound Insert for use in 1064 WJK 550 12 2009 5 Wraparound Insert for use in 1064 WJK 550 12 2011 5 1 2 Wraparound Insert for use in 1064 WJK 550 12 2012 2 Jaw Jaw Die Removal The tong jaws will often require removal to change jaw size or replace worn jaw die inserts Support the jaw being removed from the bottom and use a wrench to loosen and remove the jaw pivot bolt Slide the jaw away from the rotary gear towards the centre of the cage plate assembly and lift clear of the tong Repeat for the other jaw Note that removal process for jaws with wraparound dies is identical ILLUSTRATION 2 E 1 KT5500 CBU Jaw Removal and replacement of die inserts Removing the centre keeper screws Insert a narrow punch through the slot at the bottom of the jaw groove and lightly tap the die from the bottom until it loosens enough to remove Reverse the process to install new jaw dies Do not neglect to reinstall the keeper screws See illustration 2 E 2 next page DRILLING amp AACCCOY TecHNicAL MANUAL 2 13 MOVING GLOBAL ENERGY FORWARD KT5500 5
157. rovide adequate grip Replace dies 2 Incorrect jaws are being used casing being run Double check jaw size to ensure they are rated for the diameter of pipe or 3 Incorrect dies are being used Ensure dies loaded in the jaws are appropriate for the type being run of pipe or casing ing jaws to cam properly Brake band s is are insufficiently adjusted not allow Adjust brake bands to give proper resistance to cage plates 5 Jaw roller broken or worn Remove jaw assembly and inspect Replace rollers that are ted or otherwise damaged visibly flat spot 4 6 SECTION CONTENTS TECHNICAL MANUAL AACCCY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TROUBLESHOOTING F FAILURE OR DIFFICULTY OF TONG TO SHIFT 3500 5 7 amp CLINCHERG Backup POSSIBLE PROBLEM SOLUTION S Bent or broken shifter handle Replace shifter handle Frozen or hard to move shifter handle Grease shifter shaft Bent or broken shifter yoke Inspect components through inspection door Replace shifter yoke if neces sary 4 Bent or broken shifter shaft Replace Locking nuts on shifting shaft have loosened and position of yoke has changed Reposition yoke and re tighten locking nuts 6 Shifting yoke has come loose from shifting shaft Inspect yoke and inspect for damage If free of damage replace on shaft and tighten locking nuts
158. s Only 1 101 3943 Part Door Pivot Roller Shaft 1 101 3944 C Part 7 8 Narrow Flat Washer 2 2 09 5123 D Part Support Roller Sleeve 2 1064 182 E Part Tapered Roller Bearing 2 02 0099 F Part Support Roller Shaft Spacer 1 1064 183 G Part Support Roller 1 1064 181 H Part 7 8 UNF Hex Thin Nylock Nut 1 09 5722 1 Backup ready tongs use 5x support roller shaft PN 101 3942 Use four long support roller shafts PN 101 3944 where coincidental with the front leg mount weldments The door pivot shaft remains PN 101 3943 2 Top and bottom flat washers are not used where the support roller shaft is coincidental with the brake band lug weldments Bottom flat washers are not used where the support roller shaft is coincidental with the front leg mount weldments MOVING GLOBAL ENERGY FORWARD DRILLING amp AACCCOY TecHNicAL MANUAL 5 5 KT5500 5 17 amp CLINCHER Rotary IpLER ASSEMBLY TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5 6 Section CONTENTS Rotary IDLER ASSEMBLY _ 05500 5 1 amp CLINCHER Backup Item Type Description Qty Part Number A Part Grease Fitting 1 8 NPT 1 02 0005 B Part 1 1 2 UNF Nylock Nut 2 09 5740 C Part Rotary Idler Pad 2 997 D20 125 D Part Idler Bearing Spacer 2 997 D20 121 E Part Bearing Seal 2 02 0010 F Part Bearing Retainer Ring 2 02 0009 G Part Idler Shaft 1 997 D19 117 H Part
159. s obtained at 140 F with ISO 46 DTE 25 These values must be maintained to obtain the performance indicated Contact Rineer Hydraulics Inc for additional displacements 7 6 SECTION CONTENTS TEcHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Hyprautic Motor INFORMATION KT5500 5 1 amp CLINCHER Backup Model Code M015 61 62 1S 015 31 B1 TV 000 Special Code Designator Seal Package Selection M015 61 015 Single Speed M015 62 015 Two Speed Options 62 Two Speed Single Pilot Bearing Package Selection Open During Crossover 63 Two Speed Single Pilot Closed During Crossover 65 Two Speed Double Pilot Open During Crossover 67 Two Speed Double Pilot Closed During Crossover 30 Keyed Shaft 31 Splined Shaft 32 Wheel Motor 006 6 in 98cc rev 010 10 5 in3 172cc rev 34 Double Key 007 7 in3 115cc rev 011 11 5 in 189cc rev 50 Retractable 008 8 in3 131cc rev 013 13 in3 213 53 API Thread 009 9 5 in 156 015 15 in 246cc rev 1S Std 1H High Speed MOVING GLOBAL ENERGY FORWARD TECHNICAL 71 Motor INFORMATION _ Repair Manual 15 Series HYDRAULICS ING Standard Motor Two Speed Motor 331 BREESPORT SAN ANTONIO TX 78216 210 341 6333 FAX 210 341 1231 DRILLING
160. se refer to the relevant exploded diagrams in Section 5 ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FASTENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOC TITE TIGHTENING TORQUE GUIDE SAE GRADE 8 FINE THREAD SIZE CLAMP LOAD PLAIN PLATED 1 4 28 250 3 263 14 ft Ibs 10 ft Ibs 5 16 24 3125 5 113 27 ft Ibs 20 ft Ibs 3 8 24 375 7 875 49 ft Ibs 37 ft Ibs 7 16 20 4375 10 650 78 ft Ibs 58 ft Ibs 1 2 20 500 14 400 120 ft Ibs 90 ft Ibs 9 16 18 5625 18 300 172 ft Ibs 129 ft Ibs 5 8 18 625 23 025 240 ft Ibs 180 ft Ibs 3 4 16 750 33 600 420 ft Ibs 315 ft Ibs 7 8 14 875 45 825 668 ft Ibs 501 ft Ibs 1 12 1 000 59 700 995 ft Ibs 746 ft Ibs 1 14 1 000 61 125 1019 ft Ibs 764 ft Ibs 1 1 8 12 1 125 77 025 1444 ft Ibs 1083 ft Ibs 1 1 4 12 1 125 96 600 2012 ft Ibs 1509 ft Ibs 1 3 8 12 1 375 118 350 2712 ft Ibs 2034 ft Ibs 1 1 2 12 1 500 142 275 3557 ft Ibs 2668 ft Ibs SAE GRADE 8 COARSE THREAD SIZE CLAMP LOAD PLAIN PLATED 1 4 20 250 2 850 12 ft Ibs 9 ft Ibs 5 16 18 3125 4 725 25 ft 16 18 ft Ibs 3 8 16 375 6 975 44 ft Ibs 33 ft Ibs 7 16 14 4375 9 600 70 ft Ibs 52 ft 16 1 2 13 500 12 750 106 ft Ibs 80 ft Ibs 9 16 12 5625 16 350 153 ft Ibs 115 ft Ibs
161. seals between port 3 and port 2 e Incorporates the Sun floating style construction to eliminate the effects of internal parts binding due to excessive installation torque and or cavity cartridge machining variations Technical Data 300 5 1 amp CLINCHER Backup e Stainless steel cartridge options P or W are intended for use within corrosive environments with all external components manufactured in stainless steel or titanium Internal working components remain the same as the standard valves Cavit Capacit Area Ratio A3 to A1 Area Ratio A3 to A2 Maximum Operating Pressure Maximum Valve Leakage at 110 SUS 24 cSt Pilot Volume Displacement Series from Cavit U S Patent Valve Hex Size Valve Installation Torque Seal Kits Seal Kits Full Open Pressure Din U S Units Metric Units LLL 0 _ 2401 ____ 2257 __ _________ EE SEN __ _ ___ 4795120 O Buna 990 017 007 Viton 990 017 006 Full Cusen Doo qi D e up i min Option Selection Preferred Options Control Standard Options X Not Adjustable DRILLING amp COMPLETIONS Cracking Pressure External Material Seal Material N Buna N V Viton TECHNICAL MANUAL CONTENTS 7 31 KT5500 5 1 amp CLINCHER Bac Hyprautic VALVE INFORMATION Capacity Pilot operated balanced piston relief valve 50 gpm 200 L min Functional
162. spension cable a single spring hanger typically applies 420 Ibs 191 kg to the suspension line for every inch of thread made up a double spring hanger typically applies 840 Ibs 382 kg to the suspension line for every inch of thread made up If you do not know which specific spring hanger is in use check the specification page in this manual for information on the recom mended spring hanger for this application McCoy Drilling amp Completions will not guarantee or specify spring hangers other than what has been supplied by McCoy Many applications use a lift cylinder for adjusting the height of the tong Ensure the weight of the lift cylinder is known if it has not been included in the total weight of the tong All forces upon the suspension line must be considered when calculating necessary strength of the suspension line The weight of the tong the weight of the lift cylinder the weight of the spring hanger and the force imparted on the suspension line by the spring hanger must all be added together in order to arrive at the total force supported by the suspension line Select your suspension line based upon the total force and the margins of safety dictated by the policies of your company and by established engineering practices Ultimately calculating the force on the suspension line and selection of the suspension line is the complete responsibility of the customer DRILLING amp 2 16 SECTION CONTENTS TECHNICAL MANUAL AA
163. spreader bars lifting lugs rigid slings amp rigid sling weldments and legs amp leg mounts Broken or damaged welds Excessive wear nicks or gouges Refer to the chart below to ensure minimum thickness on chain links supplied is not be below the values listed Inches Refer ASME B30 9 7 3 8 10 1 2 13 5 8 16 3 4 20 7 8 22 1 26 32 Stretched bent twisted or deformed chain links or components Evidence of heat damage Excessive pitting or corrosion Lack of ability of chain or components to hinge articulate freely Weld splatter For hooks removal criteria as stated in ASME B30 10 Other conditions including visible damage that cause doubt as to the continued use of the sling Inspect all lugs and fixing points for signs of elongation and or bending or for material build up around the hole Repair or replace components that appear distorted Ensure all hardware is tight and in good condition Replace missing hardware if necessary All hardware must be free of rust and corrosion Additional inspections shall be performed during sling use where service conditions warrant Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on Frequency of use of the load bearing device Severity of service conditions Nature of lifts being made Experience gained on the service life of load bearing devices used in similar circumstances Guidelines for the
164. stator cavity once per revolution which results in 40 power strokes per revolution This helps produce higher mechanical efficiency and flatter torque curves BEARING LOADING The bearings in the 15 Series can accept radial load per the radial capacity chart Thrust load is not recommended under most conditions Consult with a Rineer Application Engineer for optional bearing configurations to match your application SEALS Buna N seals are supplied as standard on the Rineer 15 series motors Viton seals may be ordered as an option ROTATING GROUP 1S or 1H Under most operating conditions 1S standard rotating group parts should be used Under some high speed conditons 1H can be specified ROTATION The 15 Series Motor rotates equally well in either direction and smoothly throughout its entire pressure and speed range Looking into the end of the shaft rotation is clockwise when oil is supplied to port A HORSEPOWER LIMITATION Maximum horsepower limitations may vary with different applications When using the 15 Series Motor above 75 HP consult a Rineer Application Engineer AACCCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 0 5 17 amp CLINCHERG Backup FILTRATION 25 micron minimum FLUID We suggest premium grade fluids containing high quality rust oxidation and foam inhibitors along with anti wear additives For best performance minimum viscosity should be maintained
165. t Once in position the clampnut clamping bolt MUST be tightened to CLAMPING BOLT a slight drag in order to correctly engage the threads the shaft to achieve the clamp force required Figure 1 DRILLING amp 7 14 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor INFORMATION 200 5 1 amp CLINCHER Backup Information Bolt Torque Seal Kits Main Bolts 5 8 11 190 ft Ibs Standard 15 series seal kit S eal Plate 3 8 16 30150940 Wheel Motor only 45 ft 165 Standard 15 two speed seal kit Grease used for bolt threads 30150940 and o ring retention Standard 15 wheel motor seal kit Pennzoil 707L RED 0150936 Shaft seal assembly lube Mobilgrease special with Moly U 1 DRILLING amp AACCCOY comprenons TecHNicAL MANUAL 715 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 amp CLINCHER BACKUP VALVE INFORMATION Inlets 2500 psi End inlet fie Io 3 main Roy or RV amc are wath cinis inis 7 Seann Page 12 Gren ie zg D Outlets Tank Return Type B arg Position Fina Meatai SA8 1 Sacion Se Tay Piso Mold in Cybndar Sooo DAB Deu
166. t CAUTIONS are also used to ensure common errors are not made during assembly or operation of your equipment This identifies a CAUTION to users Observance of the following is the full responsibility of the user all descriptions information and instructions set out in this manual any regulation or requirement issued by an authority or agency which may influence operation safely or integrity of the equipment that overrules the content of this document any legal or other mandatory regulation in force governing accident prevention or environmental protection DRILLING amp xii SEcTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD INTRODUCTION KT5500 5 7 amp CLINCHER Backup Congratulations on the purchase of your FARR KT5500 5 1 2 tong and CLINCHER backup This unit will provide you with years of outstanding performance Simple maintenance and care will extend its life and ensure years of excellent performance and reliability The setup operating and maintenance instructions in this manual will assist you in giving your equipment the care it requires Please carefully read the manual before installing and using your equipment Replacement parts are readily available from McCoy Drilling amp Completions FARR in Edmonton Alberta Note that many parts are transferable between FARR tongs and backups Should you need replacement parts or should you experience any difficulty not c
167. t Carrying forth the example used in the previous step the required desiccant charge would be 3 5 g x 66 18 equaling 231 g Several manufacturers offer silica gel desiccant in packaged quantities of 125 grams per bag so two packages of desiccant would be required Please keep in mind that this is a guideline only more or less desiccant may be required in extreme environmental conditions For best corrosion resistance the equipment should be removed from storage and exercised on a regular basis depending on the storage environment Farr recommends that for equipment stored in a salt water maritime or exposed dusty environment repeat steps 9 through 24 monthly For equipment stored in isolated storage in a non maritime environment repeat steps 9 through 24 quarterly Replace desiccant packs at this time depleted desiccant packs may be treated as regular dunnage SHIPPING INSTRUCTIONS The following procedure lists the steps to be followed to prepare your tong for shipping 1 If not already done remove accessories tong jaws load cell torque gauge etc McCoy recommends wrapping these items protective wrap and placing in a separate wooden crate Place the equipment on a sturdy pallet constructed of 4 x 4 cross members and 2 x 4 flooring McCoy recommends placing a 2 x 6 board across the width of the tong under the legs see Illustration 3 M 1 Ensure the pallet is large enough to accommodate the wooden crate containing the to
168. t and use a soft alloy material e g brass rod etc to lightly tap the shaft down through the support roller assembly until it comes free at the bottom Use caution that the threads on the ends of the support roller shafts are not damaged Do not lose the door shoulder bushings Remove the hitch pin securing the torque gauge holder to the torque gauge mount weldment and remove the mount Remove the four hex socket head cap screws securing the motor and the torque gauge mount weldment Remove the torque gauge mount weldment then lift the motor up and away from the motor mount Inspect the motor gear located at the bottom of the motor shaft for gear clashing or tooth damage Also ensure that the motor gear is securely attached to the motor shaft Remove the cotter pin and clevis pin connecting the shifter handle to the shifter shaft it is not necessary to disconnect the handle from the pivot lug weldment Unbolt the pivot lug weldment from the top plate and remove the pivot lug and handle assembly Remove the four hex socket head cap screws securing the motor mount to the top plate Use care not to dislodge and lose the two positioning dowels Remove the snap ring securing the drive gear to the top of the clutch shaft Carefully remove the drive gear from the clutch shaft Remove the two 10 24 x 3 4 hex socket head cap screws securing the top clutch bearing retainer to the top plate Remove the top clutch bearing retainer and bearing re
169. t 4 09 9124 N Weldment Rear Backup Leg Spring Plate Bottom 1 101 4496 Part Heavy Hex Bolt 1 101 0040 P Part 7 8 NC x 7 Hex Bolt 1 Q Part 0 148 x 2 938 Hitch Pin 2 R Part 1 1 4 Hex Nut 2 09 5832 S Part 7 8 Narrow Plain Washer 2 09 5123 T Part 7 8 Hex Nut 2 09 5822 U Part 3 8 NC x 9 Hex Bolt 2 V Weldment Rear Backup Leg 1 101 4487 WwW Part Door Stop Spring 2 997 13 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL Section CONTENTS 5 33 KT5500 5 1 amp CLINCHER BACKUP Backup AssEMBLY TENSION LC Conric DRILLING amp 5 34 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Backup TENSION LC 5500 5 1 amp CLINCHERG Backup Item Type Description Qty Part Number A Part Rear Body Plate 1 1391 7 3 B Part 1 1 4 UNC Hex Nut 3 09 5832 C Part 1 1 4 UNC x 8 Threaded Rod 1 101 1993 D Part Suspension Spring V Bracket 1 1483 500 00 04 E Part Suspension Spring Retainer 2 1483 500 00 4B F Part 3 8 UNC x 1 1 2 Hex Bolt 1 09 1050 G Part 3 8 Carbon Steel Lock Washer 21 09 5106 H Part 1 UNC x 8 1 2 Hex Bolt 09 0287 J Weldment Backup Body Weldment 1483 500 00 K Part Rear Jaw 1 1403 08 L Part Rear Side Cover Plate 2 1483 500 00 02 M Part 3 8 UNC x 3 4 Hex Bolt 20 09 1044 N Part Side Cover Plate 2
170. t ag Gestion D rage E Hid on a DRILLING amp 7 16 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION Adjustable Relief Valve Cartridges For Inlets and Mid sectlon Inlets Description DVAMA pressure mun 800 2000 psi Faction er 62 1500 Gei 50 gom DAISAR VE pressure range 2001 2500 ps Faclory set 602500 pi 50 gam DVAXSAMRVP relie valve plug Lo Boy Work Sections Parallel Circuits dac Ka peso eent nl a mew Ime 1 ee puso __ 1 pam jew 0 E MCCOY 515 MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL 717 5500 5 17 amp CLINCHER Backup Brief Circuit Descriptions Series Cinculll us DWAR only eor where De ns Supp ls erte Win ud weg lincsona pem Papin Fna AS ef Ee ewe iur Poss Pug Ee Cer Gente wien adi apo Ei Em Thun P ende Dames cer Mi nik cel gariak Dicas gn leui recht Jeep ihe ees ceria pa oe Cc apio iE nri ru Pimp Tia Pd
171. t frame compo nents refer to Section 2 1 4 Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used Test safety door feature if equipped Begin rotating the tong at low speed and open the tong door s If rotation does not immediately stop this is an indication that the safety door mechanism is not operating correctly and the tong must be re moved from service until the mechanism is repaired Repeat the test while operating the tong in the opposite direction If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR Farr recommends that an anti corrosive agent such as Tectyl amp 506 be applied to all external unpainted surfaces and chain slings EXCEPT cylinder rods jaw rollers and rotary gear camming surfaces Refer to manufacturer data sheets for proper application and safety information Once all of the above maintenance checklist items have been satisfactorily completed the tool may be returned to service 3 26 DRILLING amp SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 0 5 17 amp CLINCHERG Backup L TUBULAR CONNECTION EQUIPMENT DE COMMISSIONING amp SHIPPING Perform the following decommissioning procedures when removing tubular connection equipment from s
172. tainer spacer The top clutch bearing and clutch bearing bushing may come off with the bearing retainer Pull the top bearing cap and spacer for the pinion drive gear by removing the four 1 2 bolts which secure the bearing cap Thread two of the removed bolts into the extra holes on top of the bearing cap and use them as lifting lugs to lift the bearing cap out of place IF THE BEARING REMAINS ATTACHED TO THE GEAR SHAFT AFTER THE BEARING CAP IS PULLED MCCOY DRILLING amp COMPLETIONS SERVICE PERSONNEL RECOMMENDS LEAVING IT IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED Remove the jaw pivot bolts and the jaw assemblies Ensure the bottom cage plate is supported before beginning this step Remove the two front cage plate bolt and nut sets Remove the backing pin assembly and the rear cage plate bolt and the cage plate spacers The top and bottom cageplates may now be removed Note that the cam followers are fastened to the top and bottom cage plates so use caution not to damage them THE CAGE PLATE BOLTS ARE THE ONLY ITEMS FASTENING THE BOTTOM CAGE PLATE TO THE TONG SUPPORT THE BOTTOM CAGE PLATE FROM BELOW PRIOR TO REMOVING CAGE PLATE BOLTS IN ORDER TO PREVENT DAMAGE TO THE BOTTOM CAGE PLATE PERSONAL INJURY TO THE MECHANIC Remove the top nuts and pads for the rotary idler gears Remove the remaining top roller shaft nuts Note that the top brake band adjustment lug weldments are removed at this point Loosen but do not remove the det
173. the equipment Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system Connect a low pressure air supply line 10 PSI or less to the hydraulic supply line and force a small amount of the remaining hydraulic fluid from the valve assembly this will allow for thermal expansion of the hydraulic fluid if the equip ment is stored or transported in high ambient temperatures Failure to do this may result in damaged or destroyed seals in the equipment Disconnect the hydraulic RETURN line from the equipment Disconnect remaining hoses such as case drains or lines connected to the turns counter If any hyaraulic fittings or hoses are leaking they must be repaired or replaced before proceeding Wipe all excess grease from outside of equipment Replace the access door panel Use a solvent based cleaner on rags to wipe all external surfaces to remove residual grease or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove residual solvent Farr recommends that chain slings be removed and stored separately Rigid slings and other rigid suspension devices may remain in place Apply grease or heavy oil to all exposed cylinder rods Farr recommends that an anti corrosive agent such as Tectyl 506 be applied to all external surfaces EXCEPT cylinder rods including chain slings Refer to ma
174. thoroughly tested to ensure proper operation before the valve is placed back into service Spring Center Spool Assembly Stap 1 Spool Assembly Spring Centered Olimp ihe chami ed of e spool m soft jawed Apply Parker Suter abe in the gra Fig amd i feto Tbe end af thee fromi the clive Slod on Che tak ep rime Fig en 7 and Fig nen hj bg pore omo de ot ap tbar hey dia nar wilh the pas operalur during Dawa Allem the Chreag rontsz aul alee Of he spool Step 2 Attach Spring Guides and Spring Appl 3 1 doors apial npactr ate ah jit pa iee inicie ai ihe Temale in ie spul Assemble he mig puides Fip 2 ilemi Lip zentenuag gene hy 7 mem 14 ded steet bral Ep 2 item 14 bande the amp puvl Reverse of Step Tongue he 123 i m Bu CAUTION Care be rakem to mawra that the spring retainer b pinched under he holt daring This can result in burrs that ma cane Check for binding by Fem the spring and gabisa or ry rotating the sprinz guide nearest the housing CAUTION Follow the adbesive manufactarer s instructions fer proper cleaning aml curing Failure clean u
175. threaded rod with red Loctite Screw the threaded rod into the heavy hex bolt welded to the top plate of the backup until the rod bottoms out Lock the threaded rod in place using the heavy hex nut threaded on to the rod in the previous step c Coat at least 4 of thread at the top of the threaded rod with red Loctite Thread on a 1 1 4 UNC heavy hex nut ensuring enough thread is exposed to allow installation of the suspension spring v bracket and another 1 1 4 UNC heavy hex nut d Install the suspension spring v bracket PN 1483 500 00 04 on to the threaded rod and secure with another 1 1 4 UNC heavy hex nut Remove the side panels from the backup Use a crane to hoist the tong and rear leg assembly and place in position over the backup If using the 85 0604 or 85 0607 1 compression load cell style backups the rear leg must be guided so that the paddle on the backup sits between the vertical plates of the rear leg when the tong and rear leg assembly is in position over the backup Hold a top spring cap PN 1302 905 03B under the top plate of the backup and insert a front leg tube PN 1302 904 905 from the bottom of the backup through the spring cap and in to the leg mount weldment on the tong Secure the leg tube with a 7 16 UNC x 4 hex bolt 7 16 narrow flat washer and a 7 16 UNC nylock nut Repeat for the other leg tube Slide a leg spring PN 1391 905 02B over the bottom of each leg tube followed by a bottom spring cap PN
176. three locations total ILLUSTRATION 3 D 6 CLUTCH BEARING LUBRICATION DRILLING amp 3 4 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 5500 5 7 amp CLINCHER Backup 7 Motor Mount Apply grease to the motor gear clutch drive gear through the grease fitting located on the top of the motor mount one location only ILLUSTRATION 3 0 7 Motor Gear CLurCH Drive GEAR LUBRICATION 8 Shifting Shaft Apply grease to the shifting shaft and top shifting shaft bushing The shaft and shifting yoke can be accessed through the cover plate on the side of the tong LG es I T through this panel ILLUSTRATION 3 0 8 SHIFTING SHAFT LUBRICATION DRILLING amp e ee MANUAL 3 5 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER MAINTENANCE 9 Door Latch Apply grease to the door latch through the grease fitting located in the top of the adjustment cam ILLUSTRATION 3 D 9 Door Cam SHAFT LUBRICATION 10 CLINCHER Cylinders Apply grease to the external surfaces of the clincher cylinders through the grease fittings in the top and bottom body plates eight locations total ILLUSTRATION 3 0 10 CLINCHER CYLINDER LUBRICATON DRILLING amp 3 6 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE 900 5 12
177. tion of all lifting points if visible damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong in service Also inspect all chains master links and turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service If your company requires yearly certification of lifting equipment ensure that the most recent test date falls within the past year Perform recertification if necessary Perform a liberal lubrication of the equipment refer to Maintenance section of manual to determine lubrication points Gener ously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear Connect the equipment to a hydraulic power unit Ensure all lines are fully made up to prevent equipment damage from exces sive back pressure Do not neglect to connect the motor drain FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE Energize power unit Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi Perform a thorough inspection of pressurized hydraulic lines and fittings Any leaking hydraulic fluid lines or fittings must be replaced before the equipment is returned to service Perform a thorough inspection of all seals Any seal that is leaking or weepin
178. to prevent equipment damage from exces sive back pressure Do not neglect to connect the motor drain NOG A N HALTO AHG TEE EIE el Energize power unit DRILLING amp AACCCOY TecHNicAL MANUAL 3 27 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER MAINTENANCE 121 13 L 14 15 16 17 _ Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of the rotary gear facing the gear train De energize the power unit and perform another generous lubrication of the gear train including the gear housing Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of the rotary gear facing the gear train De energize the power unit and perform a third generous lubrication of the gear train including the gear housing Energize power unit and rotate the tong for a final time one minute in one direction stop and reverse the direction of rota tion for another minute this time ending with the rotary gear in the open throat position Extend all hydraulic cylinders and inspect cylinder rods for signs of mechanical damage flaking or rust Farr recommends that damaged cylinders be replaced prior to storage If you are using a frame mounted tool the tong must be lowered onto the backup in order to remove the risk of sudde
179. tter free and free from tripping hazards or protruding objects that may snag hydraulic hoses on the tong backup lift cylinder or torque measurement system Operating surface or drill floor must be kept free of slipping hazards like grease oil water etc Adequate lighting of the work area is required All warnings labels gauges and signs must be clearly visible The components of the tong commonly manipulated or requiring control input are painted green and are safe for continuous han dling Areas painted yellow are designated as hazardous areas and contact with those areas must be avoided during operation Always wear all personal protective equipment PPE specified by your company s HSE policy and follow all of your company s safety guidelines ALWAYS WEAR APPROVED PERSONAL PROTECTIVE EQUIPMENT PPE WHEN OPERATING HYDRAULICALL Y POWERED EQUIPMENT Ensure hydraulic power is deactivated and tong hydraulics are de pressurized before disconnecting the main hydraulic lines McCoy recommends depressurizing the tong hydraulic system before connecting or disconnecting quick connect fittings DEPRESSURIZE EQUIPMENT BEFORE DISCONNECTING MAIN HYDRAULIC LINES Valve Operation 4 way proportional valves control operation of hydraulic devices on the tong assembly such as hydraulic motors and cylinders When any one valve is centered or in the detent position there is no hydraulic output from the valve When the valve is pushed forward t
180. tup procedures Listen to power unit for a moment to see if there are any unusual mechanical sounds rubbing grinding excessive pump noise If using a diesel unit allow sufficient time for the engine to reach operating temperature before increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 1 7 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than S 350 psi 18 Perform a visual inspection of pressurized hydraulic lines Document and correct any hydraulic fluid leaks 19 Perform a full functional test of the tong refer to section 2 1 4 Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low gear 2 0 in both directions makeup and breakout If cage plate begins rotating the safety door mechanism is not functional and the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR 21 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved
181. ty Door Valve Block 101 0727 10 Safety Door Switch 08 0337 11 Check Valve SH4600 02 9022 12 Rineer GA15 13 Hydraulic Motor 87 0110 13 Relief Valve RPGC KAN 08 1180 14 Relief Valve Block Sun CAJ 08 1844 15 Check Valve CKEB XCN 08 0481 16 Check Valve Block Sun BCJ 08 1327 17 3000 psi Pressure Gauge 02 0245 18 CLINCHER Backup Cylinder 1403 00 00B AACCOY 2 8 CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Setup amp OPERATION 5500 5 1 amp CLINCHER Backup ILLUSTRATION 2 C 3 KT5500 CBU Component ID 02 DRILLING amp e ee MANUAL 2 9 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER BACK JP Setup amp OPERATION ILLUSTRATION 2 C 4 KT5500 CBU Component ID 03 ILLUSTRATION 2 C 5 KT5500 CBU Component ID 04 DRILLING amp 2 10 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 5500 5 7 amp CLINCHER Backup 15 eee ILLUSTRATION 2 C 6 KT5500 CBU Hyprautic Component ID 05 D HYDRAULIC CONNECTIONS A pair of hydraulic lines a 1 supply line and a 1 1 4 return line connect the tong to the power unit see illustration below Ancillary devices hydraulic motors hydraulic cylinders etc are connected through the valve block Perform any hydraulic c
182. uid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Obstruction in hydraulic hose Check hyaraulic hose for kinks Replace hydraulic hose Snub line not at right angle to tong handle Check angle of snub line and correct if necessary Internal mechanism of gauge is damaged Replace gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication is erratic or sluggish Insufficient hydraulic fluid in torque measurement section Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Loss of damping fluid in torque gauge Top up or refill damping fluid NOTE Ensure leakage points in gauge are identified and repaired to prevent further loss of damping fluid Air bubbles in hydraulic fluid in the torque measurement system Bleed air from load cell and torque gauge and top up fluid if necessary as per Section 6 C Internal mechanism of gauge is damaged Replace gauge DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD TEcHNICAL MANUAL ToRQuE MEASUREMENT 00 5 1 Tone 8 CLINCHER Backup C PERIODIC INSPECTION AND MAINTENANCE ONLY QUALIFIED DESIGNATED PERSONNEL
183. way from the backup and set tong onto a flat work surface that will support the weight of the tong and allow access to the bottom plate ensure that the legs do not have any weight on them REMOVAL OF LEG ASSEMBLIES 7 Remove the rear leg assembly by removing two 1 1 4 x 8 hex bolt and nut sets and two 7 8 x 9 hex bolt and nut sets 8 Remove the front leg assemblies by removing the 1 2 x 3 3 4 bolts and nut set on each leg and slide leg tubes out of leg mount weldments REMOVAL OF TOP PLATE 9 Remove the rigid sling assembly by disconnecting the leveling devices from the hanger brackets 10 Remove the two rigid sling hanger brackets 11 Disconnect the three hydraulic connections from the motor Undo the restraints securing the inlet and outlet lines from their supports and lift the hydraulic valve section away from the tong Remove the inlet and outlet support pieces 12 Remove top brake band assembly leave adjustment lug weldments in place for now 13 Remove the tong door stop cylinder DRILLING amp AACCCOY TecHNicAL MANUAL 3 9 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 TONG amp CLINCHER B MAINTENANCE Removal of Top Plate Continued 14 15 16 17 18 19 20 21 22 23 16 17 18 19 20 21 22 Remove door assembly by removing the door roller shaft Support door assembly as the roller shaft is removed Remove the nut from the top of the roller shaf
184. wdriver to completely un thread the poppet and spring from the relief assembly Inspect the relief valve spring poppet and valve seat If no debris is found in relief valve and if seat and poppet are undamaged replace relief valve spring Reassemble relief valve Relief valve must be re set to allow maximum system pressure Follow the procedure in Step 1 of this section to properly adjust relief valve h If maximum system pressure still cannot be reached replace the entire relief valve assembly DRILLING amp AACCCOY TecHNicAL MANUAL 4 3 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER Bac TROUBLESHOOTING C SAFETY DOOR DOES NOT OPERATE IS MALFUNCTIONING POSSIBLE PROBLEM SOLUTION S 1 Safety door switch requires adjustment Adjust switch as per section 3 F 5 2 Safety door switch has failed Test safety door switch for proper function and replace if necessary 3 Contamination in hydraulic lines Ensure all three flexible hydraulic lines to safety door switch are free flowing 4 Pilot to open valve in safety door valve block is Remove each valve Inspect seats and springs Replace valve s if damage is seen malfunctioning on valve seats or if spring appears to be damaged or broken DRILLING amp 4 4 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING D TONG RUNNING TOO SLOWLY 3
185. with the high pinion gear Install shifting collar PN 997 A9 62 over the top of the clutch shaft and mesh with the center clutch gear Slide the shifting fork PN 997 D13 72 over the end of the shifting shaft PN 1400 71 and secure the fork in place with a 5 8 UNF hex jam nut followed by a 5 8 UNF regular hex nut Place the end of the shifting shaft in the lower shifter bushing typically welded to the bottom plate and mesh the shifting fork with the shifting collar Slip the low clutch gear PN 997 A1 52 over the top of the clutch shaft and seat on remaining two needle bearings ensuring the smaller diameter on the high clutch gear is oriented toward the center gear on the clutch shaft Slide the pinion idler half shaft PN 997 D17 105 through the remaining idler gear assembly Place a bearing seal over the end of the half shaft and secure the gear assembly to the half shaft with a retainer ring PN 02 0006 Place the end of the pinion idler half shaft through the bottom plate and mesh the pinion idler gear with the two rotary idler gears Secure the half shaft to the bottom plate with the half moon idler pad PN 1400 109 three 5 8 UNC x 2 1 4 hex bolts and 5 8 lock washers and a 1 1 2 UNF hex nylock nut Install the low pinion gear PN 997 A5 88 shoulder side up over the top of the pinion gear shaft meshing with the low clutch gear Carefully remove all support roller shafts using caution not to shift the position of the inst
186. ximum system pressure specified on the specifications page maximum system pressure is the pressure at which your tong achieves its specified torque DO NOT ADJUST PRESSURE RELIEF TO A SETTING THAT ALLOWS HIGHER THAN MAXIMUM SYSTEM PRESSURE DOING SO CREATES A POTENTIAL FOR SERIOUS INJURY OR DEATH AND MAY CAUSE CATASTROPHIC EQUIPMENT FAILURE h Release the motor control valve and tighten the locking nut on the pressure relief valve Isolate your tong from hydraulic power and depressurize following the procedure in section 3 D j Close the tong door and remove the temporary pressure indicator Restore the safety door pressure supply line to factory specifi cations Verify that safety door is operating correctly see section 2 1 5 k Continued on next page AACCCOY 4 2 SEcTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING 3500 5 7 A CLINCHER Backup RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING Cont d POSSIBLE PROBLEM SOLUTION S Debris on valve seat Relief cannot be adjusted to maximum system pres sure high fluid bypass results in low system pressure Valve spring I broken Valve spring has lost spring force due to continuous tension PROCEDURE Isolate your tong from hydraulic power and depressurize following the procedure in section 3 D Loosen the locking nut on the pressure relief valve Use a large flat head scre
187. y and final position of rotary gear when full torque load is reached Maximum Hydraulic Requirements 60 US GPM 227 1 LPM 2500 psi 17 2 MPa Length Doors Closed 52 inches 132 1 cm Height 60 152 4 Wiath 37 94 cm Model 80 0421 3 Tension LC 34 89 cm Models 80 0422 amp 80 0406 Comp LC Torque Arm Length 30 inches 76 2 cm Tension Load Cell Configuration 32 inches 81 3 cm Compression Load Cell Configuration Centre line of pipe to centre line of anchor Weight Approximate without jaws 2050 Ib 932 kg Recommended Spring Hanger 85 0106XXH Capacity 3500 Ibs 1591 kg Casing Jaws Available inches See Pp 2 12 2 14 ALL REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER WISE SPECIFIED DRILLING amp e ee TECHNICAL MANUAL 13 MOVING GLOBAL ENERGY FORWARD KT5500 5 amp CLINCHER Ba SPECIFICATIONS Use an EP synthetic grease that meets or exceeds the following specifications Thickener NLGI consistency grade NLGI performance grade Penetration ASTM D 217 25 C 77 Dropping point F C ASTM 02265 High temperature life hours ASTM D 3527 Oxidation stability psi ASTM D 942 Water washout percent ASTM D 1264 Rust and corrosion ASTM D 1743 Oil separation percent loss ASTM D 1742 Leakage g lost ASTM D 4290 Four ball wear test mm sca
188. y idler shafts PN 997 D19 117 and slide them through two bearing and gear assemblies centering the gear on the shaft Slide two bearing seals PN 02 0010 over each end of the idler shafts and press against the retainer clips See the exploded view of the rotary idler assembly on pp 5 8 5 9 for correct orientation of the bearing seals Slide a bearing spacer PN 997 D20 121 over each end of the rotary idler shafts Place each rotary idler assembly through the bottom plate ensuring the ends of the shafts with the threaded holes for the grease fittings are pointed upward Place an idler pad PN 1400 125 over the bottom side of each rotary idler shaft and secure each with a 1 1 2 UNF nylock nut Place high pinion gear PN 997 A4 87 shoulder side down over the lower bearing and bearing cap centering as best as able Install pinion gear shaft PN 997 A7 86 into the spline of the bottom pinion gear and the lower pinion bearing Slide 4 needle bearings PN 02 0003 onto clutch shaft PN 997 A8 50 two on either side of the center gear Press bearings firmly against centre gear Slide high clutch gear PN 997 A1 51 over the bottom end of the clutch shaft and seat gear on the needle bearings ensuring the smaller diameter on the high clutch gear is oriented toward the center gear on the clutch shaft Place lower end of clutch shaft into the lower clutch bearing that has been pre mounted in the lower body plate and mesh the high clutch gear

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