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KT13625 w/ McCoy Backup - Texas International Oilfield Tools LTD

1. 2 37 SECTION THREE MAINTENANCE A GENERAL MAINTENANCE SAFETY PRACTICES 3 1 B CLEANING 3 1 C PREVENTIVE MAINTENANCE PRACTICES 3 1 D HYDRAULIC SYSTEM DE PRESSURIzATION 3 2 E LUBRICATION 3 2 F ADJUSTMENTS 1 Brake Band Adjustment 3 9 2 Door Latch Adjustment 3 10 3 Door Alignment 3 11 4 Shifter Det
2. 2 24 H TONG OPERATION 1 Operator Training 2 25 2 Operator Safety 2 25 3 Valve Operation 2 25 4 Shifting Gears 2 27 5 Pre Operational Checks 2 28 6 General Operational Comments 2 29 I EXTREME COLD WEATHER OPERATION PROCEDURES 2 29 J MAKING AND BREAKING CONNECTIONS 1 Making A Connection 2 30 2 Breaking Out A Connection
3. 4 7 G GENERAL COMMENTS 4 8 SECTION FIVE PARTS AND ASSEMBLIES Critical Spare Parts List 5 2 Recommended Spare Parts List 5 3 Parts List Complete Overhaul 5 4 Gear Train Layout 5 6 Support Roller Assembly 5 8 Door Pivot Support Roller 5 10 Rotary Idler
4. 2 1 B MAJOR COMPONENT IDENTIFICATION 2 1 C SLING LOAD BEARING DEVICE SAFETY 1 Inspection Of Slings 2 5 2 Proper Use Of Load Bearing Devices 2 6 3 Storage Of Load Bearing Devices 2 6 D LIFT CYLINDER INSTALLATION 1 Installation Procedure 2 7 2 Lift Cylinder Connection 2 8 3 Lift Cylinder Safety 2 8 E HYDRAULICS 1 Hydraulic Schematics 2 10 2 Hydraulic Component
5. 5 12 Pinion Idler 5 14 Pinion Assembly 5 16 Clutch Assembly 5 18 Shifting Assembly 5 20 Supports Hydraulic Assembly 5 22 Brake Band Assembly 5 24 Motor amp Motor Mount 5 26 Hydraulic Assembly
6. 2 31 IllustratIon 2 j 4 openIng lh tong door 2 32 IllustratIon 2 j 5 openIng BacKup door 2 32 IllustratIon 2 j 6 lIFt cylInder control raIse non ce MarKed tongs 2 33 IllustratIon 2 j 7 BacKup control claMp 2 34 IllustratIon 2 j 8 Motor control MaKe up 2 34 IllustratIon 2 j 9 usIng Motor control to release jaws In MaKe up Mode 2 35 IllustratIon 2 j 11 usIng lIFt cylInder control to lower asseMBly non ce MarKed tongs only 2 36 IllustratIon 2 j 10 usIng BacKup control to release BacKup jaws 2 36 IllustratIon 2 j 12 settIng BacKIng pIn to BreaK out posItIon 2 37 IllustratIon 2 j 13 Motor control BreaK out 2 38 IllustratIon 2 j 14 usIng Motor
7. 2 23 IllustratIon 2 g 2 tong levelIng Front to BacK 2 23 IllustratIon 2 g 4 load cell conFIguratIon BreaK out 2 24 IllustratIon 2 g 3 load cell conFIguratIon MaKe up 2 24 IllustratIon 2 h 1 Motor control valve 2 26 IllustratIon 2 h 2 lIFt cylInder control valve 2 26 IllustratIon 2 h 3 Farr BacKup control valve 2 27 IllustratIon 2 h 4 shIFtIng gears 2 27 IllustratIon 2 j 1 rIgId slIng Master lInK 2 30 IllustratIon 2 j 2 settIng BacKIng pIn to MaKe up posItIon 2 31 IllustratIon 2 j 3 openIng rh tong door
8. 5 28 Cage Plate Assembly KT13625 5 30 Cage Plate Assembly LW13625 5 32 Tong Door Assembly 5 34 Safety Door Components 5 36 Rigid Sling Assemblies 5 38 Leg Assemblies 5 40 FARR Backup 5 42 FARR Backup Rotary Assembly 5 44 SECTION SIX TORQUE MEASUREMENT A BASIC TORqUE MEASUREM
9. Note Measure the rotor and stator length to the fourth decimal point and supply measurement when ordering rotor stator or vanes 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 does not necessarily require replacement of the stator but may slightly affect volumetric efficiency 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 PLATES Normal wear results in marking of timing plates which does not impair motor performance Replacement of the timing plate is required if any smearing galling or heat cracks are present INSPECTION AND REPLACEMENT OF PARTS KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 11 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 25 26 27 28 29 30 31 32 8 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
10. 12 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 1 TechnicAL MAnuAL SeTup amp opeRATion YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY HOWEVER MCCOY ADVISES INSPECTING YOUR EQUIPMENT FOR SHIPPING DAMAGE UPON RECEIPT AND TESTING YOUR TONG BEFORE RELEASING TO AN OPERATIONAL ENVIRONMENT Perform a visual inspection following removal of all packaging material Immediately identify any shipping damage to the shipping com pany and correct all damage before connecting equipment to a hydraulic power source B MAJOR COMPONENT IDENTIFICATION 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 A INITIAL RECEIPT AND INSPECTION OF EQUIPMENT Item Description 1 Rigid Sling 2 Tong 3 Front Leg Assembly 4 Rear Leg Weldment 5 FARR Backup IllustratIon 2 B 1 Kt13625 tong amp Farr BacKup Major coMponent IdentIFIcatIon 01 4 5 1 2 3 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 2 TechnicAL MAnuAL Item Description 6 Backing Pin Assembly 7 Cage Plate Assembly 8 Brake Band Adjustment 9 Tong Door Spring Stop Cylinder 10 RH Door Assembly 11 Tong Leveling Adjustment 12 Brake Band 13 Tong Jaws with Die Inserts 14 Safety Door Assembly 15 LH Door A
11. 7 13 14 15 16 17 11 12 10 9 8 MOTOR BACKUP LIFT CYLINDER KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 11 TechnicAL MAnuAL SeTup amp opeRATion If your tong hydraulics are configured as closed centre a power beyond outlet section will be used Refer to the schematic above and to the outlet section information on pg 7 25 Item Description Part Number Page 13 Flow Control Valve 08 0089 14 Relief Valve Block 08 0096 15 Relief Valve 08 0095 16 Backup Cylinder 1364 902 17 3000 psi Pressure Gauge 02 0245 18 Lift Cylinder Orifice CE Marked Tongs Only IllustratIon 2 e 2 Kt13625 tong amp Farr BacKup hydraulIc closed centre P T 1 2 3 4 5 6A 7 13 14 15 16 17 11 12 10 9 8 MOTOR BACKUP LIFT CYLINDER KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 12 TechnicAL MAnuAL SeTup amp opeRATion IllustratIon 2 e 3 Kt13625 tong amp Farr BacKup hydraulIc scheMatIc ce MarKed P T 1 2 3 4 5A 6 7 13 14 15 16 17 11 12 10 9 8 18 MOTOR BACKUP LIFT CYLINDER KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 13 TechnicAL MAnuAL SeTup amp opeRATion IllustratIon 2 e 4 Kt13625 tong amp Farr BacKup hydraulIc closed centre ce MarKed P T 1 2 3 4 5A 6A 7 13 14 15 16 17 11 12 10 9 8 18
12. 8 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 9 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 10 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 11 Energize power unit 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 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
13. D Part 1 2 Narrow Washer 1 09 5119 E Part Backing Pin Spacer Long 1 101 4093 F Part 1 2 Lock Washer 2 09 5110 G Part Top Cage Plate 1 997 D2 21 H Part Cage Plate Spacer 3 997 D3 38 J Part Rotary Gear 1 997 D1 B K Part 5 8 Lock Washer 22 09 5114 L Part 5 8 UNF Hex Jam Nut 22 09 5514 M Part 1 8 NPT Grease Fitting 22 02 0005 N Part Backing Pin Knob 1 02 0017 P Part Backing Pin Spacer Short 1 101 4096 q Part Backing Pin Retainer 1 101 4139 R Part 3 8 UNF x 2 Threaded Stud 1 101 4097 S Part Backing Pin 1 101 4142 T Part Cage Plate Cam Follower 22 02 0016 U Part Bottom Cage Plate 1 997 D2 22 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 34 TechnicAL MAnuAL Tong DooR ASSeMBLy B C R D E E F K H M P Q G J A S L T U N B A V KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 35 TechnicAL MAnuAL Item Type Description Qty Part Number A Part 1 2 NC x 2 Hex Bolt 4 09 1174 B Part 1 2 NC Hex Jam Nut 4 09 5810 C Weldment RH Door Weldment 1 101 0034 D Part 3 8 NC x 3 4 Hex Bolt 1 09 1044 E Part 3 8 Carbon Steel Lock Washer 9 09 5106 F Part Door Latch Cam 1 997 A11 14 G Part Grease Fitting 1 02 0097 H Part 3 8 NC x 1 1 4 Hex Bolt 2 09 1048 J Part 3 8 Narrow Wa
14. P K J M E F G H Q H R L KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 41 TechnicAL MAnuAL Item Type Description Qty Part Number A Part 1 1 4 UNC x 8 Heavy Hex Bolt 4 09 0222 B Part Rear Lug Spacer 2 101 1546 C Part Eye Bolt 2 101 2055 D Weldment Rear Leg Weldment 1 997 915 00 E Part 1 1 4 UNC Nylock Nut 4 09 1484 F Part Rear Leveling Spring 2 1302 905 06 G Part 1 2 UNC x 4 1 2 Hex Bolt 4 09 1184 H Part 1 2 Flat Washer 8 09 5010 J Part Support Roller Shaft Front Leg Mounts 4 101 1268 K Weldment Front Leg Mount 2 997 917 00A L Part Rubber Guard CE Marked Tongs Only 2 101 5733 M Part Top Leg Spring Cap 2 1302 905 03B N Part Front Leg Spring 2 997 906 02 P Part Bottom Leg Spring Cap 2 1302 905 03A q Weldment Front Leg Weldment 2 997 917 00B Weldment Front Leg Weldment CE Marked Tongs Only 2 101 5784 R Part 1 2 UNC Nylock Nut 4 09 5610 Leg ASSeMBLieS ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FAS TENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOCTITE KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 42 TechnicAL MAnuAL FARR BAcKup C A B D G F H K J E L M N KT LW 13
15. 09 1194 2 Hex Bolt 1 2 UNC X 9 Backing Pin Bolt 09 1202 1 5 8 Lock Washer Cam Follower Fastener LW13625 09 5114 26 5 8 UNF Jam Nut Cam Follower Fastener LW13625 09 5514 26 Shifter Detent Force Spring 997 0 64 1 Shifter Detent Force Ball 02 0018 1 HYDRAULIC COMPONENTS Description Part Number Qty Required Safety Door Switch 08 0337M 1 DVA35 Seal Kit 07 0004 1 Relief Cartridge DVA35 10 0010R 1 Relief Cartridge Safety Door 08 1625 2 Rineer GA15 Seal Kit 87 7110 1 Hydraulic Hose Lift Cylinder Supply If lift cylinder is installed 02 0934H 1 High Visibility Protective Wrap Lift Cylinder Hose If lift cylinder is installed 02 E0203 1 oVeRhAuL pARTS LiST KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 6 TechnicAL MAnuAL geAR TRAin LAyouT A B C E D G H J F K KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 7 TechnicAL MAnuAL geAR TRAin LAyouT Item Type Description Qty Part Number A Part Hydraulic Motor 1 87 0112 B Assembly Shifting Assembly See Pp 5 16 5 17 1 C Assembly Clutch Assembly Pp 5 14 5 15 1 D Assembly Pinion Idler Assembly Pp 5 10 5 11 2 E Assembly Pinion Assembly Pp 5 12 5 13 1 F Assembly Rotary Idler Assembly Pp 5 8 5 9 2 G Assembly Support Roller Assembly Front Leg Coincidental Pp 5 4 5 5 4 H Assembly Supp
16. 24 Install high pinion gear shoulder side up 25 Install high clutch gear followed by the top clutch bearing spacer PN 101 3599 Assembly Procedure Continued 12 Slide a bearing spacer PN 997 D20 121 over each end of the rotary idler shafts 13 Place each rotary idler assembly through the bottom plate ensuring the ends of the shafts with the threaded hole for the grease fitting are pointed upward 14 Place an idler pad PN 997 D20 125 over the bottom side of each rotary idler shaft and secure each with a 1 1 2 UNF nylock nut 15 Place low pinion gear shoulder side down over the lower bearing and bearing cap centering as best as able 16 Install pinion gear shaft into the spline of the bottom pinion gear and the lower pinion bearing 17 Slide 2 needle bearings 02 1404 over each end of the clutch shaft and press up against centre gear Slide low clutch gear over the bottom end of the clutch shaft onto the two needle bearings Slide bottom clutch spacer pn 997 99 over lower end of shaft and place lower end of clutch shaft into the lower clutch bearing that has been pre mounted in the lower body plate 18 Install shifting collar which will slip over clutch shaft and mesh with low or high clutch gear 19 Install the lower shifting bushing PN 101 0003 in the bottom body plate using four 3 8 UNC x 1 hex bolts and 3 8 lock washers 20 Slide the shifting fork PN 997 HT 72 over the
17. SecTion conTenTS 7 32 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion Maximum Valve Leakage at 110 SUS 24 cSt 2 in min 1000 psi 30 cc min 70 bar Response Time Typical 10 ms Series from Cavity Series 1 Valve Hex Size 7 8 in 22 2 mm Valve Installation Torque 30 35 lbf ft 45 50 Nm Adjustment Screw Hex Socket Size 5 32 in 4 mm Adjustment Nut Hex Size 9 16 in 15 mm Adjustment Nut Torque 108 lbf in 12 Nm Seal Kits Buna 990 010 007 Seal Kits Viton 990 010 006 RPEC LAN Control Adjustment Range External Material Seal Material Preferred Options L Standard Screw Adjustment A 100 3000 psi 7 210 bar 1000 psi 70 bar Standard Setting W 150 4500 psi 10 5 315 bar 1000 psi 70 bar Standard Setting N Buna N Standard Options C Tamper Resistant Factory Set F Hex Head Screw with Locknut B 50 1500 psi 3 5 105 bar 1000 psi 70 bar Standard Setting C 150 6000 psi 10 5 420 P Stainless Buna N V Viton W Stainless Viton K Handknob O Handknob with Panel Mount bar 1000 psi 70 bar Standard Setting N 60 800 psi 4 55 bar 400 psi 30 bar Standard Setting Q 60 400 psi 4 25 bar 200 psi 14 bar Standard Setting If the material seal is P the control must be L or C If the material seal is W the control must be L or C Special Setting required specify at time of order Related Models RPEC8 Expla
18. Shifter Detent Force Ball 02 0018 1 1 8 NPT Grease Fitting 02 0005 2 1 8 NPT 90o Grease Fitting 02 0093 2 1 8 NPT 45o Grease Fittings 02 0006 2 1 4 Straight Thread Grease Fitting 02 0097 5 3 8 UNC X 5 Flange Bolt Jaw Retainer 09 0229 10 5 16 UNC X 5 Countersunk Jaw Retainer 09 1338 10 Critical Spare Parts Continued HYDRAULIC COMPONENTS Description Part Number Qty Required Relief Cartridge DVA35 10 0010R 1 Relief Cartridge Safety Door 08 1625 1 Safety Door Switch 08 0337M 1 Hydraulic Hose Lift Cylinder Supply If lift cylinder is installed 02 0934H 1 High Visibility Protective Wrap Lift Cylinder Hose If lift cylinder is installed 02 E0203 1 Hydraulic Hose Assembly Backup 55 A Side 02 1011 1 Hydraulic Hose Assembly Backup 52 B Side 02 1012 1 High Visibility Protective Wrap Backup Hydraulic Hose 02 E0204 1 JAW COMPONENTS Description Part Number Qty Required Jaw Roller 997 JR 2125 2 Jaw Pin 101 1581 2 Jaw Roller Applies only to sizes 12 3 4 to 13 5 8 997 JR 1000 2 Jaw Roller Keeper Applies only to sizes 12 3 4 to 13 5 8 101 0491 2 3 875 Flat Die Insert 13 0008 314 0 48 Wraparound Insert 3 1 2 jaw die kits only 12 2006 4 Wraparound Insert 4 jaw die kits only 12 2007 4 Wraparound Insert 4 1 2 wraparound jaw die kits only 12 2009 4 SpARe pARTS LiSTS KT LW 13
19. TV 000 M015 61 015 Single Speed M015 62 015 Two Speed Options 62 Two Speed Single Pilot 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 1S Std 1H High Speed 006 6 in3 98cc rev 007 7 in3 115cc rev 008 8 in3 131cc rev 009 9 5 in3 156cc rev 010 10 5 in3 172cc rev 011 11 5 in3 189cc rev 013 13 in3 213cc rev 015 15 in3 246cc rev 30 Keyed Shaft 31 Splined Shaft 32 Wheel Motor 34 Double Key 50 Retractable 53 API Thread Bearing Package Selection Seal Package Selection Special Code Designator 331 Breesport San Antonio Texas 78216 210 341 6333 Fax 210 341 1231 e mail sales rineer com Applications Rineer Hydraulics Inc warrants that at the time of shipment to Purchaser our product will be free of defects in the material and workmanship The above warranty is LIMITED to defective products returned by Purchaser to Rineer Hydraulics Inc freight prepaid within four hundred and fifty five 455 days from date of shipment or one 1 year from date of first use whichever expires first We will repair or replace any product or part thereof which is proved to be defective in workmanship or material There is no other warranty expressed or implied and in no event shall Rineer Hydraulics Inc be liable for consequent
20. UNC x 1 1 4 Hex Bolt 4 09 1168 H Part 1 2 Lock Washer 4 09 5110 J Part Adjusting Helix 1 1095 220 ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FAS TENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOCTITE A B C D N P K J M E F G H Q L KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 39 TechnicAL MAnuAL RigiD SLing Item Type Description Qty Part Number K Part 3 4 UNC Hex Nylock Nut 1 1429 39 02 L Part Hanger Pin 1 1095 218 M Part R Clip Pin 4 02 0981 N Part 3 8 UNC x 1 3 4 Hex Bolt 4 09 1557 P Part 3 8 Lock Washer 4 09 5124 q Part RH Bolted Hanger Weldment 1 101 1364 Part LH Bolted Hanger Weldment 1 101 1361 The following parts apply to rigid slings on CE Marked assemblies only R Weldment Rigid Sling Weldment 1 101 1360 S Part 1 2 UNC x 1 1 4 Wire Drilled Hex Bolt 4 09 1168SSD T Part Rivet 4 02 0557 U Part Mass Placard KT13625 FBU 1 CE MASS KT13625FBU V Part 3 8 UNC x 1 3 4 Wire Drilled Hex Bolt 4 09 1557SSD R V U T S The illustration on this page applies to CE Marked versions only KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 40 TechnicAL MAnuAL Leg ASSeMBLieS A B C D N
21. 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 8 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 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 9 Tighten clamping bolt on clampnut to 70 inch pounds and recheck rolling torque Apply inspectors lacquer to head of the bolt 10 Allow a minimum of 24 hrs to dry Figure 1 CUTAWAY Note The slit in the clampnut allows for loose assembly on the shaft Once in position the clampnut clamping bolt MUST be tightened to a slight drag in order to correctly engage the threads on the shaft to achieve the clamp force required FACE A CLAMPING BOLT FACE A FACE B WHEEL MOTOR SHAFT AND BEARING ASSEMBLY PROCEDURE KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 13 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion Information Bolt Torque Main Bolts 5 8 11 190 ft lbs Seal Plate 3 8 16 Wheel Motor only 45 ft lbs Grease used for bolt threads and o ring retention Pennzoil 707L RED Shaft seal assembly lube Mobilgrease special with Moly Seal Kits Standard 15 series seal kit 0150940 Standard 15 two speed seal kit 0150940 St
22. ASSEMBLY NOTE Do not neglect to install the three cage plate spacers PN 997 38B between the two cage plates during installation See exploded diagram Pp 5 30 5 31 45 Install backing pin a Thread the 3 8 UNC x 1 1 2 threaded stud PN 101 4097 into the backing pin PN 101 4042 b Insert the backing pin and stud through the bottom of the backing pin retainer installed in Step 45 e 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 c Lift the backing pin and insert into one of the two receptacles in the rear of the top cage plate 46 Install upper and lower brake band weldments PN 997 D23 29 Secure the brake bands to the top and bottom plates with one brake band retainer PN 101 0140 per side secure brake band retainers with 3 8 NC x 1 hex bolts and 3 8 lock washers Install front adjustment springs bolts and nuts 47 If not already done install the door pivot support roller components that fit within the body plates i e everything except the two pivot roller shafts 48 Install a door pivot shoulder bushings PN 101 5110 in the top plate of each of the RH door weldment PN 101 0034 and the LH door weldment PN 101 0032 ASSEMBLY NOTE Insert these bushings from the bottom of the top door plate so the shoulder rides between the door weldments and the top plate of the tong 49
23. ASTM D 2266 0 40 max Fretting wear mg ASTM D 4170 3 4 max Four ball EP kgf ASTM D 2596 Weld point 400 minimum Load wear index 50 minimum Timken OK load test lbs ASTM D 2509 50 Low temperature torque N m ASTM D 4693 1 3 max 40 C 40 F LT 37 pumpability g min 360 7 60 F 0 F 16 C 18 C Copper corrosion ASTM D 4048 1B Oil viscosity 40 C 104 F cSt 151 100 C 212 F cSt 19 2 Flash point F C ASTM 92 450 232 Use a premium quality hydraulic fluid that meets or exceeds the following specifications Typical Density kg m3 878 Viscosity cSt 40 C 68 8 cSt 100 C 8 7 Viscosity Index 97 Pour Point F C 22 30 Flash Point F C 432 222 Colour ASTM 1 5 Neutralization Number 0 40 Rust Protection Distilled Water No Rust Sea Water No Rust Hydrolytic Stability Cu Mass Loss mg cm2 0 04 Copper Corrosion Test 1A Filterability Denison Wet amp Dry Pass Afnor Wet amp Dry Pass Cincinatti Milacron Spec Approved P69 Denison HF 0 Approved Denison P 46 Piston Pump Pass Denison T6C Vane Pump Pass Vickers 35Vq25 Vane Pump Test Pass Vane pump test total ring and vane wear mg lt 10 Oxidation Stability Turbine Oil Stability Test Life hours 2500 Rotary Bomb Oxidation Test minutes 325 FzG Spur Gear Test Failure Load Stage FLS
24. BAcKup SecTion conTenTS 2 37 TechnicAL MAnuAL 2 Breaking Out A Connection Your tong and backup assembly should be properly suspended connected to a hydraulic power source and ready to make or break connections at this point a Ensure hydraulic power supply to the tong and backup is energized The master link on the rigid sling must be used to suspend the tong Do not suspend the tong directly from the rigid sling See Illustration 2 J 1 b Set the backing pin for breakout operation Lift up on the backing pin and rotate it to the breakout position which is 2 o clock as seen from the front of the tong The opening in the rotary gear must be aligned with the tong door opening in order to properly set the backing pin IllustratIon 2 j 12 settIng BacKIng pIn to BreaK out posItIon c Properly configure the load cell for making up connections see Section 2 G 3 Connect snub lines to the rear of the tong to arrest uncontrolled rotation of the assembly in the event of backup jaw slippage The snub lines must be rated for the applied torque plus whatever safety margins stated by your own operating policies The snub line connection points on the drill floor must be sturdy enough to absorb all applied forces d Unlatch and open the tong and backup doors see Illustrations 2 J 3 2 J 5 e Actuate the lift cylinder control valve to lift the assembly from the drill floor Pull the valve toward the operator
25. ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED 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 IN A LOAD BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE 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 This page intentionally left blank KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS vii TechnicAL MAnuAL Summary Of Revisions Date Section Page Description Of
26. Insert a bottom door bushing PN 101 5111 into the bottom plate of each door weldment 50 Thread a 3 8 UNC hex jam nut on to a 3 8 UNC x 1 1 2 hex bolt Thread the bolt in to the RH door weldment and lock it in place with the jam nut This will serve as a door position adjustment 51 Position the door latch weldment PN 101 0038 in front of the RH door weldment and insert two door latch springs PN 997 16 between the two weldments Insert the door latch adjustment cam PN 997 A11 14 through the top plate of the RH door weldment and the latch weldment the springs may need to be lightly compressed to facilitate the installation of the latch cam and through the bottom plate of the RH door weldment Secure the door latch cam to the top of the RH door weldment using a 3 8 UNC x 1 hex bolt and 3 8 lock washer Coat the threads of a 5 8 UNF jam nut with red Loctite and thread on to the bottom of the adjustment cam until the nut is flush with the end of the adjustment cam See Pp 5 32 5 33 for an exploded illustration of the door assembly 52 Align the door pivot holes with the pivot holes in the top and bottom plates Slide a 7 8 narrow flat washer over the end of both door pivot roller shafts PN 101 0046 and insert the shafts from the top they 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 shafts have b
27. Insert the 1 2 x 8 bolt and spacer assembly in the rear of the cage plate assemblies ensuring the backing pin spacer remains between the head of the bolt and the top of the top cage plate ASSEMBLY NOTE Do not neglect to install a cage plate spacer PN 997 38B between the two cage plates when installing this bolt See exploded diagram Pp 5 28 5 29 IllustratIon 3 I 7 tong asseMBly top shIFter BushIng InstallatIon KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 24 TechnicAL MAnuAL MAinTenAnce Assembly Procedure Continued 44 Install the cage plates continued LW13625 Tong a Install eleven cam followers 02 0016 in the lower cage plate PN 997 D2 22 using 5 8 UNF hex jam nuts and 5 8 lock washers b Install eleven cam followers in the top cage plate PN 997 D2 21 using 5 8 UNF hex jam nuts and 5 8 lock washers c Lightly grease the top and bottom slots in the rotary gear and set top cage plate in place mating the cam followers on the cage plate with the slot on the rotary gear d 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 e Secure 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
28. NOTE Make sure springs are seated in the bottom of the spring pocket in both the rotor and stator 1 Press bearing onto shaft 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 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 1 Place rotor stator cartridge onto rear housing 2 NOTE Make sure assembly marks from step 3 are lined up 1 Install dowel pins into rear housing 2 Install ballchecks into rear housings 3 Install main body o ring 1 Reverse the procedures in steps 8 thru 3 2 Screw lock nut onto shaft until all threads are engaged 3 Tighten clamp screw until 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 ASSEMBLY OF ROTOR STATOR CARTRIDGE ASSEMBLY OF FRONT HOUSING ASSEMBLY OF WHEEL MOTOR FRONT HOUSING ASSEMBLY OF MOTOR KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 12 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion WARNING RINEER RECOMMENDS FOL
29. X MOTOR BACKUP LIFT CYLINDER KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 14 TechnicAL MAnuAL SeTup amp opeRATion 2 Hydraulic Component Identification IllustratIon 2 e 5 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 01 IllustratIon 2 e 6 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 02 7 1 6 5 4 3 2 9 8 12 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 15 TechnicAL MAnuAL SeTup amp opeRATion IllustratIon 2 e 7 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 03 IllustratIon 2 e 8 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 04 10 11 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 16 TechnicAL MAnuAL SeTup amp opeRATion 3 Main 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 connection 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 IllustratIon 2 e 9 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id
30. 4 Jaw Die Kit 2 997 WJK 550 7 5 8 Jaw Die Kit 997 JDK 315 4 1 2 Jaw Die Kit 3 997 WJK 550 8 5 8 Jaw Die Kit 997 JDK 320 4 1 2 Jaw Die Kit 4 997 JDK 290 9 5 8 Jaw Die Kit 997 JDK 325 4 3 4 Jaw Die Kit 997 JDK 291 10 3 4 Jaw Die Kit 997 JDK 330 5 Jaw Die Kit 997 JDK 295 11 3 4 Jaw Die Kit 997 JDK 335 5 1 2 Jaw Die Kit 997 JDK 300 12 3 4 Jaw Die Kit 997 JDK 337 6 Jaw Die Kit 997 JDK 306 13 3 8 Jaw Die Kit 997 JDK 340 6 5 8 Jaw Die Kit 997 JDK 305 13 5 8 Jaw Die Kit 997 JDK 510 1 Wraparound jaw die kit uses insert Part 12 2006 NOTE THIS JAW IS TORQUE LIMITED TO 9000 LBS FT 2 Wraparound jaw die kit uses multi range jaw 997 WJK 550 and wraparound insert Part 12 2007 3 Wraparound jaw die kit uses multi range jaw 997 WJK 550 and wraparound insert Part 12 2009 4 Optional 4 1 2 jaw die kit uses flat jaw die insert Part 13 0008 314 0 All remaining jaw die kits use flat die Part 13 0008 314 0 DO NOT EXCEED 9000 LBS FT OF TORQUE WHEN USING THE 3 1 2 JAW DIE KIT DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED 2 Jaw Jaw Die Removal JAWS MAY PRODUCE METAL SLIVERS WEAR STURDY GLOVES WHEN REMOVING AND INSTALLING JAW DIE KITS SeTup amp opeRATion Push against the front of the jaw to cause the assembly to swivel around the pivot bolt Remove the die
31. BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FAS TENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOCTITE I 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 please refer to the relevant exploded diagrams in Section 5 TIGHTENING TORQUE GUIDE SAE GRADE 8 FINE THREAD SIZE CLAMP LOAD PLAIN PLATED 1 4 28 250 3 263 14 ft lbs 10 ft lbs 5 16 24 3125 5 113 27 ft lbs 20 ft lbs 3 8 24 375 7 875 49 ft lbs 37 ft lbs 7 16 20 4375 10 650 78 ft lbs 58 ft lbs 1 2 20 500 14 400 120 ft lbs 90 ft lbs 9 16 18 5625 18 300 172 ft lbs 129 ft lbs 5 8 18 625 23 025 240 ft lbs 180 ft lbs 3 4 16 750 33 600 420 ft lbs 315 ft lbs 7 8 14 875 45 825 668 ft lbs 501 ft l
32. Continued l Once the connection has been un threaded reverse the rotation control handle pull toward operator to release the tong jaws from the tubing see Illustration 2 J 14 IllustratIon 2 j 14 usIng Motor control to release jaws In BreaK out Mode m When tong jaws are free release the backup jaws by pulling the backup clamp control handle away from the tong toward the operator see Illustration 2 J 10 n Unlatch and open the tong door to free the assembly from the tubing Note that rig personnel may be required to stabilize the equipment as it completely releases from the tubing Guide the assembly away from the string and use the lift cylinder control to lower it to the drill floor o Use your rig s standard pipe handling procedures to remove and rack the freed tubing section or stand p Repeat steps f through p as many times as necessary to breakout and un thread the desired number of connections RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR SeTup amp opeRATion This page intentionally left blank KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 1 TechnicAL MAnuAL MAinTenAnce McCoy Completions amp Drilling 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 repla
33. FASTENERS BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT FASTENERS USED FOR MAINTENANCE OR OVERHAUL OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS LEGS MUST BE TIGHTENED TO THE PROPER TORQUE REMOVAL OF BACKUP 1 Construct a support that will when the tong and backup are lowered support the backup assembly enough to remove the weight from the front leg and rear backup support springs 2 Lift the tong and backup and lower onto structure constructed in step 1 3 Free the front leg springs by removing the 1 2 x 4 bolts and bottom spring caps from the bottoms of the legs Disconnect the rear backup support springs from the eye hooks on the bottom of the tong 4 Lift the tong and front and rear legs up and away from the backup Use caution not to lose the leg springs and top spring caps which will come loose when the tong is lifted REMOVAL OF LEG ASSEMBLIES 5 Set the tong and leg assembly onto a flat surface Ensure that the majority of the weight remains supported by the rigid sling and the crane and that there is enough clearance to remove the legs when they are freed 6 Support the rear leg weldment weight 208 lb 95 kg before disconnecting from the bottom tong plate Remove the four 1 1 4 x 8 heavy hex bolts securing the rear leg weldment Use a crane and a temporary lifting sling to remove the rear leg weldment to a secur
34. Fitting 4 02 0005 B Part 1 2 NC x 1 1 4 Hex Bolts 8 09 1168 C Part 1 2 Lock Washers 8 09 5110 D Part Pinion Bearing Cap 2 997 D15 89 E Part Cylindrical Roller Bearing 2 1234 08 01B F Part High Pinion Gear 1 997 A4 87B G Part Pinion Gear Shaft 1 997 A7 86B H Part Low Pinion Gear 1 997 A5 88 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 18 TechnicAL MAnuAL cLuTch ASSeMBLy A B C E Q D G P N M K H T U F G J L R S KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 19 TechnicAL MAnuAL cLuTch ASSeMBLy Item Type Description Qty Part Number A Part Outside Snap Ring 1 1234 00 04 B Part Drive Gear 1 997 HT 61 C Part Clutch Bearing Bushing 1 997 HT 60 D Part 10 24 x 3 4 Hex Socket Head Cap Screw 2 09 0001 E Part Cylindrical Roller Bearing 1 02 1403 F Part Bearing Retainer 1 997 HT 59 G Part Needle Roller Bearing 4 02 1404 H Part Shifting Collar 1 997 HT 62 J Part Splined Clutch Shaft 1 997 HT 50 K Part Low Clutch Gear 1 997 HT 52 L Part Clutch Spacer 1 997 99 M Part Cylindrical Roller Bearing 1 02 0014 N Part Clutch Bearing Cap 1 997 HT 54 P Part 3 8 Lock Washer 4 09 5106 q Part 3 8 NC x 1 1 4 Hex Bolt 4 09 1048 R Part 1 8 NPT Grease Fitting 1 02 0005 S Part 1 8 NPT 90 Deg Gr
35. I D ACTUAL TORQUE AND POWER 6 CID 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 500 1000 1500 2000 2500 3000 PRESSURE psid TORQUE ft lbf 0 10 20 30 40 50 60 70 POWER HP 2000 RPM 100 RPM 2000 RPM 1200 RPM 400 RPM 100 RPM 800 RPM 1600 RPM ACTUAL FLOW 6 CID 0 5 10 15 20 25 30 35 40 45 50 55 60 65 0 500 1000 1500 2000 2500 3000 PRESSURE psid FLOW gpm RPM 800 1000 1200 1400 1600 1800 2000 200 400 600 100 9 5 C I D ACTUAL FLOW 9 5 CID 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 500 1000 1500 2000 2500 3000 PRESSURE psid FLOW gpm 1500 1400 1200 1000 800 600 400 200 100 1700 ACTUAL TORQUE AND POWER 9 5 CID 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 500 1000 1500 2000 2500 3000 PRESSURE psid TORQUE ft lbf 0 10 20 30 40 50 60 70 80 90 100 POWER HP 1700 RPM 100 RPM 1700 RPM 900 RPM 300 RPM 100 RPM 500 RPM 1300 RPM RPM 11 5 C I D ACTUAL TORQUE AND POWER 11 5 CID 0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450
36. OF TONG TO SHIFT KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 8 TechnicAL MAnuAL 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 under standing of the hydraulic system If your hydraulic troubleshooting procedures involve flow and pressure tests at the power unit McCoy Completions amp Drilling recom mends construction of a test rig that can easily be connected to the main suction and discharge ports of the power unit KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 1 TechnicAL MAnuAL Assemblies and Parts Model 80 0935 4 Shown Model 80 0935 4 CE Marked Shown KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 2 TechnicAL MAnuAL ITEMS ON THE CRITICAL SPARE PARTS LIST MARKED IN RED INDICATE ESSENTIAL HEALTH amp SAFETY ITEMS FAILURE TO REPLACE DAMAGED ESSENTIAL HEALTH amp SAFETY ITEMS WILL PRESENT IMMEDIATE DANGER TO PERSONNEL OR EQUIPMENT HAVE THESE ITEMS ON HAND AT ALL TIMES STOP WORK AND QUARANT
37. Revision Approved Sep 2008 N A N A Initial Release K Isaacson Mar 2010 8 8 1 Changed item A description and part number K Duhon Jul 2011 All All Re branded amp reformatted manual S Hargreaves All All Replaced all hazard warning amp caution symbols with improved symbols amp text Intro iii Revised list of supported models 1 1 3 Revised specifications to include lightweight version if requested 2 All Moved Assembly Instructions to Maintenance section All Renumbered Setup amp Operation as Section 2 2 6 Removed hydraulic schematic tong without safety door no longer supported 2 8 2 9 Revised hydraulic schematics 2 13 Corrected list of available jaw die kits 2 16 Revised section 2 F 1 Suspension amp Restraint 2 21 Added section 2 G 3 Shifting Gears 3 All Renumbered Maintenance as Section 3 3 1 Revised section 3 A General Maintenance Safety Practices 3 1 Added Section 3 C Preventive Maintenance Practices 3 2 Replaced graphic Section 3 D 1 Lubrication Cage Plate Guide Ring 3 10 Added Section 3 E 3 Door Alignment 3 11 Added Section 3 E 4 Shifter Detent Force Adjustment 3 12 3 13 Revised Section 3 G Overhaul Procedures 3 14 3 22 Added revised Section 3 H Assembly Procedures 3 23 Added Section I Daily Power Tong Inspection amp Maintenance Checklist 3 25 Added
38. Rotate tong in high gear for 5 minutes while monitoring temperature of top and bottom bearing caps If the bearing caps are hot to the touch higher than approximately 50oC replace the applicable bearings Likewise if the tong is making unusual noises check for damaged bearings see Maintenance Manual for all bearing locations FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE SHORT TURNBUCKLES HAVING PART NUMBER 101 3086 EMPLOY HIGH STRENGTH PINS WHICH MUST BE SUPPLIED BY FARR 13 Remove hydraulic motor and rotate the gear train by hand and use a flashlight to perform a visual inspection of the gear 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 14 Inspect all jaws and dies in use for the maintenance interval Remove pin amp roller and inspect for signs of damage replace pins if necessary If the pins are welded in place amp the welds are found to be damaged remove and quarantine the jaw until 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 necessary Ensure that t
39. Section J Daily Backup Inspection amp Maintenance Checklist 3 26 Added Section K Monthly Power Tong Maintenance Checklist 3 29 Added Section L Daily Power Unit Inspection amp Maintenance Checklist 3 30 Added Section M Tubular Connection Equipment De Commissioning Checklist 3 33 Added Section N Tubular Connection Equipment Re Commissioning Checklist 4 All Renumbered Troubleshooting as Section 4 Deleted Section Storage Recommendations see Sections 3 M amp 3 N Continued on next page 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
40. access panel on the side of the tong directly adjacent to the shifter mechanism 3 Wipe excess grease or heavy oil from exposed cylinder rods 4 If applicable re connect chain sling to lifting lugs 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 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 5 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 6 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 42 TechnicAL MAnuAL 20 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
41. area port 3 is 1 8 times the area at port 1 and 2 25 times the area at port 2 Technical Features Because these valves are unbalanced operation is pressure dependent Opening and closing of the poppet are functions of the force balances on three areas 1 Port 1 100 Port 2 80 and Port 3 180 These valves are pressure responsive at all three ports therefore it is essential to consider all aspects of system operation through a complete cycle Pressure changes at any one 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 30 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion These valves have positive seals between port 3 and port 2 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 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 U S Units Metric Units Cavity T 17A Capacity 60 240 L min Area Ratio A3 to A1 1 8 1 Area Ratio
42. bolts and 1 2 lock washers 32 Install top clutch bearing retainer PN 997 HT 59 into top plate and secure with two 10 24 x 3 4 hex socket head cap screws Insert top clutch bearing PN 02 1403 over the clutch shaft into the bearing retainer followed by the clutch bearing bushing PN 997 HT 60 33 Install clutch drive gear PN 997 HT 61 on to the clutch shaft and secure with the retaining snap ring PN 1234 00 04 IllustratIon 3 I 3 tong asseMBly top plate Fasteners KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 20 TechnicAL MAnuAL Assembly Procedure Continued 34 Re install support roller shafts a Slide a 7 8 narrow flat washer on to two shorter support roller shafts PN 101 1266 and re install in the locations circled in green in Illustration 3 I 4 Slide a 7 8 narrow flat washer over the four longer support roller shafts PN 101 1268 and install where the support rollers are coincidental with the front leg weldments as shown circled in red in Illustration 3 I 4 Secure the bottom of the two shorter support roller shafts with 3 4 narrow flat washers and 3 4 UNF thin nylock nuts IllustratIon 3 I 4 tong asseMBly support roller InstallatIon 01 MAinTenAnce KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 21 TechnicAL MAnuAL 34 Re install support roller shafts cont d c Ensure the two top and two bottom brake band lug weldments top le
43. 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 A TONG WILL NOT DEVELOP SUFFICIENT TORQUE 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 1 Malfunctioning relief valve on tong hydraulic circuit See Section 4 B Relief Valve Troubleshooting 2 Directional valve is leaking Check directional valve Neutral position should return fluid directly to the reser 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 4 Poor hydraulic pressure at the tong despite ad equate pressure at the power unit or excessive back pressure in the return line Restrictions exist in line between power unit and tong Inspect integrity of self seal ing couplings to ensure they are allowing full fluid flow Check to ensure no other restrictions exist contaminated catch screens or filters for example 5 Fluid viscosity
44. cage plate Failure of the cage plate to rotate with the doors closed indicates that the safety door system has failed completely or simply requires adjustment iii Open the tong doors and fully depress the hydraulic switch to simulate the position of the switch when the doors are closed iv Keep hands clear of the cage plate assembly and attempt to rotate cage plate If the cage plate does not rotate the safety door system has failed and must be repaired before proceeding When the cage plate begins to rotate release the safety door switch The cage plate must immediately and completely stop rotating indicating that the safety door system is operational but requires adjustment If the safety door system is confirmed operational but the cage plate does not rotate with the doors closed the adjustment plate must be moved toward the RH door assembly enabling the safety door switch to be made when the doors are closed b Disconnect hydraulic power to the tong Remove the safety door guard Wire ties if applicable require removal before the fasteners securing the guard to the top plate of the door can be extracted KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 13 TechnicAL MAnuAL MAinTenAnce IllustratIon 3 F 5 saFety door swItch plate adjustMent d Tighten the socket head cap screws to secure the adjustment plate Use the four shoulder bolts to re mount the floating plate and safety door
45. control to release jaws In BreaK out Mode 2 39 IllustratIon 3 e 1 Kt13625 guIde rIng luBrIcatIon 3 2 IllustratIon 3 e 2 lw13625 caM Follower luBrIcatIon 3 3 IllustratIon 3 e 3 support roller BearIng luBrIcatIon 3 3 IllustratIon 3 e 4 rotary Idler luBrIcatIon 3 4 IllustratIon 3 e 5 pInIon Idler luBrIcatIon 3 4 IllustratIon 3 e 6 pInIon luBrIcatIon top plate 3 5 IllustratIon 3 e 7 pInIon luBrIcatIon BottoM plate 3 5 IllustratIon 3 e 8 clutch shaFt luBrIcatIon 3 6 IllustratIon 3 e 9 shIFtIng shaFt luBrIcatIon 3 6 IllustratIon 3 e 10 Motor Mount luBrIcat
46. cylinder Do not use lift cylinder if the WLL stencil has been rubbed off or intentionally removed Locate the test certificate that accompanied the cylinder to the job site or if necessary obtain a copy of the test certificate from the location at which the original certificate has been stored The lift cylinder must be clearly re marked with the WLL before it is released to an operating environment DO NOT USE A LIFT CYLINDER WITH A MISSING OR DEFACED WLL STENCIL KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 10 TechnicAL MAnuAL SeTup amp opeRATion E HYDRAULICS 1 Hydraulic Schematics Item Description Part Number Page 1 Inlet Valve DVA35 A880 10 9016 2 Relief Valve DVA35 MMRV 1 10 0010R 3 Motor Section DVA35 MA8 10 9014 4 Backup Section DVA35 DA8 SAE PORT 10 9019 5 Lift Cylinder Section DVA35 SA8 1 ORB PORT 10 9015 5A Lift Cylinder Section CE Marked Tongs Only 10 9019 6 Outlet Section DVA35 TR99 SAE PORT 10 0086 6A Outlet Section DVA35 Pressure Beyond 08 1825 7 Flow Control Valve 08 9062 8 LKHC XDN Pilot To Operate Cartridge Valve 08 1625 9 Safety Door Valve Block 101 0727 10 Safety Door Switch 08 0337 11 Check Valve 02 9022 12 Rineer GA15 15 Hydraulic Motor 87 0112 Rineer GA15 13 Hydraulic Motor Lightweight model 87 0110 IllustratIon 2 e 1 Kt13625 tong amp Farr BacKup hydraulIc scheMatIc P T 1 2 3 4 5 6
47. end of the shifting shaft PN 997 B1 71 and secure fork to shaft with a 5 8 UNF hex nut Lock the hex nut to the shifting fork with a 7 8 UNF hex jam nut Mesh the shifting fork with the shifting collar on the clutch shaft 21 Install a retainer clip PN 02 0009 into both pinion idler gears Press an idler bearing PN 02 0075 into each gear and secure with a second retainer clip 22 Slide each pinion idler half shaft through pinion gear assemblies Slide a bearing seal PN 02 0010 over the ends of each half shaft and secure with a shaft retainer clip PN 02 0008 23 Place pinion idler assemblies less the idler pads and top fasteners on top of the lower pinion gear and place them as best as possible their position may have to be adjusted slightly as the top plate is attached see Illustration 3 I 2 IllustratIon 3 I 2 tong asseMBly gear asseMBly posItIonIng KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 19 TechnicAL MAnuAL MAinTenAnce Assembly Procedure Continued 26 Carefully remove all support roller shafts using caution not to shift the position of the installed support roller assemblies or to damage the threads on the end of the shafts 27 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 opening If old dowel pins are in place remove them before installation of the top plate If the d
48. 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 Ed monton Alberta Note that many parts are transferable between FARR tongs and backups Should you need replacement parts or should you experience any difficulty not covered 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 Customer Care customerCareFarr mccoyglobal com Website http www mccoyglobal com drilling completions IllustratIon 1 a 1 Kt13625 tong amp Farr BacKup Model 80 0935 4 shown KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 1 2 TechnicAL MAnuAL SpeciFicATionS IllustratIon 1 a 2 Kt13625 tong amp Farr BacKup dIMensIons 59 1 2 32 36 1 2 76 3 8 Color Coding Green Handle or control safe to grasp or manipulate Yellow Active or potential hazard Use caution not to contact area especially when tong is rotating KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 1 3 TechnicAL MAnuAL SpeciF
49. 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 j Re inspect all hydraulic lines and connections on the tong and correct all leaks k The 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 i Keep non essential personnel clear of the unit under test This test procedure will only include two people one to run the control valve and one to operate the door ii Ensure the tong door is securely closed iii 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 d
50. is not appropriate too high or too low Ensure hydraulic fluid being used is the viscosity recommended by McCoy Drilling amp Completions Power unit pump may not prime if fluid is too heavy and the hydraulic system will overheat if fluid is too light Replace with proper viscosity fluid Hydraulic fluid viscosity is affected by environmental conditions Ensure the fluid be ing 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 Damaged bearings or gears causing excessive drag Replace or repair worn or damaged gears or bearings 8 Jaws slipping on pipe Ensure jaw dies are not worn to the point that they cannot grip Ensure the correct sized jaws are in use 9 Torque gauge is indicating incorrectly 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 Gauge has been damaged Check gauge operation and calibration on independent system Gauge has mistakenly been married to an incorrect load cell 10 Load cell is measuring incorrectly Incorrect load cell is being used Air is trapped in torque measuring circuit load cell hydraulic line or gauge Refer to torque measurement troubleshooting in Section 6 of this manual Load cell has been damaged Replace load cell or
51. retainer which is most often a flanged machine screw Remove the rear die if it does not loosen it may have to be lightly tapped out of the jaw Push against the rear of the jaw to cause the assembly to swivel the opposite way around the pivot bolt Remove the retainer for the front die and remove the front die Reverse this procedure to install new jaw dies See illustration 2 F 1 next page KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 20 TechnicAL MAnuAL Jaw Jaw Die Removal continued IllustratIon 2 F 1 jaw dIe reMoval SeTup amp opeRATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 21 TechnicAL MAnuAL IllustratIon 2 F 2 jaw reMoval Jaw Jaw Die Removal continued The tong jaws will often require removal to change jaw size or replace worn jaw die inserts Open the tong door to disable tong rota tion rotation is inhibited by safety door systems 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 see Illustration 2 F 2 Repeat for the other jaw SeTup amp opeRATion Once the jaw has been removed the jaw dies may be replaced by removing the keeper screw above the die and tap the die from jaw using a hammer Replace the die tapping it into place if necessary and repla
52. return to McCoy for repair and re calibration POSSIBLE PROBLEM SOLUTION S 11 Incorrect motor speed selected applies to 2 speed motors only Maximum torque can only be developed when LOW motor speed maximum hy draulic displacement is selected 12 Incorrect tong gear selected Maximum torque can only be developed when LOW motor gear is selected KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 2 TechnicAL MAnuAL TRouBLeShooTing B RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING d Re establish hydraulic power to your tong Ensure that no equipment functions are active e Loosen the locking nut on the pressure relief valve f Open the tong door to activate the safety door system and inhibit tong rotation g Activate motor control valve Observe the pressure displayed on the pressure indicator Adjust the relief valve until the pressure indicated is at the maximum 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 i Isolate your tong from hydraulic power and depressurize following the procedure in sectio
53. ring groove KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 3 TechnicAL MAnuAL Cage Plate Guide Rings Cam Followers Continued LW1625 Tongs See Illustration 3 E 2 Apply grease to the cam followers through the grease fittings recessed in both the top and bottom cage plates 22 locations total IllustratIon 3 e 2 lw13625 caM Follower luBrIcatIon 2 Support Roller Bearings Supply grease to these bearings through the grease fittings in the ends of the rotary roller shafts located on the top of the tong 14 locations total IllustratIon 3 e 3 support roller BearIng luBrIcatIon MAinTenAnce KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 4 TechnicAL MAnuAL MAinTenAnce 3 Rotary Idler Bearings Apply grease to these bearings through the grease fittings in the ends of the rotary idler shafts located on the left and right sides of the tong 2 locations total 4 Pinion Idler Bearings Apply grease to these bearings through the grease fittings in the ends of the idler half shafts located on the top face of the tong 2 locations total IllustratIon 3 e 4 rotary Idler luBrIcatIon IllustratIon 3 e 5 pInIon Idler luBrIcatIon KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 5 TechnicAL MAnuAL MAinTenAnce IllustratIon 3 e 6 pInIon luBrIcatIon top plate IllustratIon 3 e 7 pInIon luBrIcatIon BottoM plate 5 Pinion Bearings Apply gre
54. schematic and on page 2 7 installed on the case drain line between the motor and the main tank return line or the internal case drain protects the motor from excess pressure in the event of blockage in the tank line Inspect these connections upon activation of the power unit Leaking components must be repaired before releasing the tong to the operational environment Deactivate the power unit and de pressurize the hydraulic system according to the procedure in Section 3 D Disconnect the main hydraulic connections and inspect all four connectors two male two female for damage or debris If the connectors cannot be cleaned or easily repaired McCoy recommends replacement of the leaking connector Note that damage to one of the connectors may have caused damage to its mate Turn off power unit and depressurize hydraulic system before disconnecting the main hydraulic lines under normal working conditions See Section 3 D for hydraulic system depressurization McCoy recommends placing protective caps over the exposed connectors to protect them from water and impact damage ALWAYS TURN OFF HYDRAULIC POWER AND DEPRESSURIZE HYDRAULIC SYSTEM BEFORE DIS CONNECTING MAIN HYDRAULIC LINES IllustratIon 2 e 11 Kt13625 tong amp Farr BacKup hydraulIc connectIons 02 Make up female fitting to Marked point on male fitting KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 18 TechnicAL MAnuAL Actuating the valve handle on th
55. the clevis pin and secure the clevis pin with the two R clips v Hoist the lift cylinder and spring hanger vi Place a 1 shackle around the master lifting link on the tong sling Secure the shackle to the extending end of the spring hanger using the 1 1 8 UNC x 4 3 4 modified hex bolt and 1 1 8 UNC hex jam nut Secure the jam nut to the bolt using a 3 16 x 1 1 4 cotter pin IF USING A SPRING HANGER ITS WEIGHT MUST BE ACCOUNTED FOR WHEN CALCULATING TOTAL SUSPENDED WEIGHT KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 8 TechnicAL MAnuAL 2 Lift Cylinder Connection Inspect the hydraulic hose before connection ensuring the line is free of ruptures cracks cuts or other damage Inspect the female quick connect fitting to ensure it is free from damage Connect the female quick connect on the lift cylinder hydraulic hose to the male quick connect fitting attached to the needle valve on the tong valve bank Once the fitting has snapped into place give the hydraulic line a light tug upwards to ensure the fitting is securely seated If not already done connect the main hydraulic supply to the power tong see section 2 F for proper hydraulic connection proce dure Energize the hydraulic supply to the power tong Lift the power tong approximately three inches off the work surface and suspend the tong for approximately thirty seconds Following the suspension alternately li
56. the maintenance 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 DO NOT PERFORM MAINTENANCE UNTIL TUBULAR CONNECTION EQUIPMENT HAS BEEN COM PLETELY ISOLATED FROM HYDRAULIC POWER 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 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 see Section 3 H Overhaul 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 PRACT
57. the rear of the motor will move the shaft 1 25 inches into the motor CAUTION Retracting the shaft must be done when the motor and driven mechanism are not in operation and are unloaded RETAINING SHAFT IN RETRACTED POSITION The shaft is retained in the retracted position by inserting a 2 0 inch wide spacer between the rear housing and the knob attached to the shaft Depending on the application and mounting position of the motor the spacer design may vary Spacers are not supplied with the motor RE ENGAGING THE SHAFT This is accomplished by releasing the shaft then rotating it clockwise until the splines of the shaft line up and engage the splines of the driven mechanism CAUTION Re engaging the shaft must be done when the motor and driven mechanism are not in operation and are unloaded BEARING LOADING The 15 series Retractable is not suitable for applications which require radial or axial loading of the shaft MOUNTING The mounting position is unrestricted CAUTION The shaft extension and knob at the rear of the motor rotates when the motor is in operation KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 4 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion Performance Data Selected Displacements The above performance data was obtained at 140OF with ISO 46 DTE 25 These values must be maintained to obtain the performance indicated Contact Rineer Hydraulics Inc for additional displacements 6 C
58. the remaining three ports in the bushing as shown in illustration 3 I 7 These set screws are intended to be used as contamination barriers only Do not bottom out the set screws on the shifting shaft or the shaft will not move KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 23 TechnicAL MAnuAL MAinTenAnce Assembly Procedure Continued 37 Insert the shifter detent ball PN 02 0018 into the detent tube followed by the detent spring PN 02 0040 Thread a 7 16 UNF hex jam nut onto a 7 16 UNF x 1 1 4 hex nut then thread the 7 16 bolt into the detent tube 38 Insert two 5 16 x 7 8 dowel pins into the un threaded holes in the rear of the tong adjacent to the clutch drive gear 39 Attach motor mount PN 997 150 to top plate and secure with four 1 2 UNC x 1 3 4 hex socket head cap screws 40 Bolt the shifter lug weldment PN 101 0016 on to the top plate with four 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers 41 Insert the 5 16 x 5 16 x 2 motor gear key into the key way in the motor shaft Slide the motor gear PN 997 A10 149 on to the to the hydraulic motor shaft and secure with two 3 8 UNC x 3 8 hex socket head set screws 42 Install the hydraulic motor onto the motor mount Secure the RH side of the motor to the motor mount using two 1 2 UNC x 1 hex socket head cap screws and 1 2 lock washers Position the torque gauge holder weldmen
59. 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 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 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 IllustratIon 6 a 1 torque gauge For IllustratIon purposes only IllustratIon 6 a 3 coMpressIon load cell IllustratIon 6 a 2 tensIon load cell KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 6 2 TechnicAL MAnuAL 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 TABLE ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED B
60. vanes Each rotor vane works in each 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 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 at 100 SSU or higher Fluid temperature should not exceed 180 O F Elevated fluid temperat
61. 05 IllustratIon 2 e 10 Kt13625 tong amp Farr BacKup hydraulIc connectIons 01 Hydraulic Return 1 1 4 Hydraulic Supply 1 16 13 14 15 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 17 TechnicAL MAnuAL SeTup amp opeRATion Main Hydraulic Connections Continued 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 4 Hydraulic Circuit Description The main hydraulic power source supplies hydraulic fluid to the hydraulic valve block inlet section Item 1 on the hydraulic schematic and on page 2 7 through a 1 threaded positive shutoff connection Hydraulic fluid circulates through the inlet section the motor control section Item 3 on the hydraulic schematic and on page 2 7 and the outlet section Item 4 on the hydraulic schematic and on page 2 7 at maximum tong pressure before returning to the hydraulic fluid reservoir the tank through a 1 1 4 threaded positive shutoff connection The relief valve Item 2 on the hydraulic schematic and on page 2 7 is factory adjusted to limit the maximum operating pressure of the tong to that which will allow maximum torque Maximum operating p
62. 10 5 32 x 2 15 16 Hitch Pin 02 0981 4 BEARINGS amp BUSHINGS Description Part Number Qty Required Dumbbell Roller Bearing 02 0014 4 Bottom Clutch Roller Bearing 02 0014 1 Cam Follower LW13625 02 0016 5 Pinion Bearing 1234 08 01B 2 The following table lists parts that McCoy Drilling amp Completions FARR has identified as critical spare parts for this model of tong McCoy rec ommends that the specified quantity of each part be on hand at all times SpARe pARTS LiSTS KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 3 TechnicAL MAnuAL In addition to the critical spare parts identified earlier McCoy suggests stocking the following spare parts Even though these are not critical spares stocking these components may significantly decrease repair time in the event of long lead times from the factory MISC TONG PARTS Description Part Number Qty Recommended Backing Pin Spacer 101 4096 1 Backing Pin Stud 101 4097 1 Backing Pin Knob 02 0017 1 Shifting Yoke 997 HT 72 1 Shifting Shaft 997 B1 71 1 Door Spring Cylinder 101 0069 1 Brake Band Retainer 101 0140 2 Lined Brake Band Weldment 997 D23 29 2 BEARINGS amp BUSHINGS Description Part Number Qty Recommended Door Bushing Top 101 5110 2 Door Bushing Bottom 101 5111 2 FASTENERS amp FITTINGS Description Part Number Qty Recommended Shifter Detent Force Spring 997 0 64 1
63. 13 301S J Part 1 4 inch NPT JIC 90 degree Elbow 3 08 0284 K Part Deltrol Gauge Isolator Valve GI21S 1 08 0337M L Part 5 16 X 3 4 UNC Shoulder Bolt 4 09 0227 M Part Door Latch Plate 1 AE13 311 N Part 3 8 UNC x 1 Hex SHCS 3 09 1738 P Part Safety Door Latch Plate 1 101 0320 q Part 3 8 UNC x 3 4 Hex FHCS 3 09 4044 R Part 3 8 UNC x 1 1 2 Hex FHCS 2 09 4050 S Part 3 8 UNC x 3 4 Hex Bolt 4 09 1044 T Part Safety Door Latch Block 1 AE13 302M U Part 3 8 UNC x 1 1 2 Hex Bolt 1 09 1553 V Part Safety Door Latch Block 1 101 0319 CE Marked tongs use the following parts in place of those in the previous table Item Type Description Qty Part Number A Part 3 8 UNC x 1 Hex Bolt SS Drilled 5 09 1046SSD L Part 5 16 x 3 4 Hex Socket Shoulder Bolt UNC Drilled 4 09 0227SSD S Part 3 8 UNC x 3 4 Hex Bolt SS Drilled 4 09 1044SSD U Part 3 8 UNC x 1 1 2 Hex Bolt SS Drilled 1 09 1553SSD KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 38 TechnicAL MAnuAL RigiD SLing Item Type Description Qty Part Number A Part Master Lifting Link 1 02 0516 B Part 3 4 UNC x 9 1 2 Hex Bolt 1 09 1324 C Part 3 4 Flat Washer 1 09 5018 D Weldment Rigid Sling Weldment 1 101 1360 E Part Leveling Bolt 4 1053 C 1L F Part 3 4 Hex Nut 4 09 5818 G Part 1 2
64. 2 EFF KEY 1 0 5 000 4 998 1 250 1 248 314 316 1 2 13UNC 3 8 O RING BOSS CASE DRAIN 2 PLACES SAE STD 1 25 4 BOLT FLANGE NEAR AND FAR 15 Series Standard Motor Envelope A B 6 82 3 41 4 50 SQR 5 70 17 CENTER LINE CASE DRAIN 17 CENTER LINE CASE DRAIN PORT B PORT A 5 91 9 0 2 18 5 80 24 50 1 62 EFF KEY 1 0 5 000 4 998 1 250 1 248 313 315 7 80 PORT A 5 40 1 3 OPTIONAL SHAFT 1 8 2 2 REAR VIEW SAE 14T 12 24 PITCH FLAT ROOT SIDE FIT INVOLUTE SPLINE ALTERNATE PORT A 1 1 4 O RING BOSS ALTERNATE PORT B 1 1 4 O RING BOSS 1 2 13UNC x 1 2 DP 3 8 O RING BOSS CASE DRAIN 2 PLACES SAE STD 1 25 4 BOLT FLANGE NEAR AND FAR SAE 1 4 O RING BOSS 1 4 O RING BOSS 9 16 DIA 4 HOLES 15 Series Two Speed Envelope 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
65. 3 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 24 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 25 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 26 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 27 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 28 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 29 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion Pilot to open spring biased closed unbalanced poppet logic element Capacity 60 gpm 240 L min Functional Group Products Cartridges Corrosion Resistant Logic Element Unbalanced Poppet Pilot to open Switching Element Spring biased closed External Pilot Port 3 pilot source Model LKHC Product Description 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
66. 500 1000 1500 2000 2500 3000 PRESSURE psid TORQUE ft lbf 0 10 20 30 40 50 60 70 80 90 100 110 120 130 POWER HP 1600 RPM 800 RPM 200 RPM 100 RPM 400 RPM 1200 RPM 1600 RPM 100 RPM ACTUAL FLOW 11 5 CID 0 10 20 30 40 50 60 70 80 90 100 0 500 1000 1500 2000 2500 3000 PRESSURE psid FLOW gpm 1600 400 600 800 1000 1200 1400 100 200 RPM 15 C I D ACTUAL TORQUE AND POWER 15 CID 0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500 525 550 575 600 500 1000 1500 2000 2500 3000 PRESSURE psid TORQUE ft lbf 0 25 50 75 100 125 150 POWER HP 1500 RPM 100 RPM 1500 RPM 700 RPM 300 RPM 100 RPM 500 RPM 1100 RPM ACTUAL FLOW 15 CID 0 10 20 30 40 50 60 70 80 90 100 110 500 1000 1500 2000 2500 3000 PRESSURE psid FLOW gpm 1500 1100 1300 500 700 900 100 300 RPM KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 5 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion For durable hydraulic motors that meet your demands specify Rineer For over 35 years we have specialized in only one thing engineering the right motor for your needs Rineer delivers the performance you can count on Model Code M015 61 62 1S 015 31 B1
67. 625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 4 TechnicAL MAnuAL The following tables list parts McCoy Drilling amp Completions recommends replacing when performing a complete overhaul of your tong and backup assembly MISC TONG PARTS Description Part Number Qty Required Jaw Pivot Bolt 997 D3 28 2 Backing Pin 101 4142 1 Backing Pin Short Spacer 101 4096 1 Backing Pin Long Spacer 101 4093 1 Backing Pin Stud 101 4097 1 Backing Pin Knob 02 0017 1 Backing Pin Retainer 101 4139 1 Cage Plate Spacer 997 38B 3 Lined Brake Band Weldment 997 D23 29 2 Brake Band Retainers 101 0140 2 Door Spring Stop Cylinder 101 0069 2 Door Cylinder Post 1050 12 001 2 Door Latch Springs 997 16 2 Safety Door Latch Claw RH AE13 302M 1 Safety Door Latch Claw LH AE13 301S 1 Safety Door Load Plunger AE12 306 1 Shifting Shaft 997 B1 71 1 Shifting Yoke 997 HT 72 1 Top Shifter Bushing 101 0020 1 Dumbbell Roller Cup 997 D21 135 28 Dumbbell Roller Sleeve 997 D21 134 14 Roller Spacer 997 D21 140 28 Roller Shaft 101 1266 10 Roller Shaft Long 101 1268 2 Door Pivot Roller Shaft 101 0046 2 Drive Gear Clutch 997 HT 61 1 Shifting Collar 997 HT 62 1 High Clutch Gear 997 HT 51B 1 Splined Clutch Shaft 997 HT 50 1 Low Clutch Gear 997 HT 52 1 Motor Gear 997 A10 149 1 BEARINGS amp BUSHINGS Description Part Number Qty Re
68. 625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 43 TechnicAL MAnuAL Item Type Description Qty Part Number A Part 3 4 UNC Hex Nylock Nut 2 1429 39 02 B Part Cam Cylinder 1 1364 902 C Weldment Backup Door Weldment 1 997 05 00 D Part 1 UNC Nylock Nut 1 09 5725 E Part 1 Plain Narrow Washer 2 09 5120 F Part 1 UNC x 4 Heavy Hex Bolt 1 09 1422 G Part 1 1 4 UNC Heavy Hex Nut 2 09 5832 H Part Rear Leg Spring V Bracket 1 1483 500 00 04 J Part 3 16 x 1 1 4 Extended Prong Square Cut Cotter Pin 2 K Part Rear Leg Spring Retainer 2 1483 500 00 04B L Weldment Backup Body Weldment 1 997 521B 00 M Part Door Cylinder 1 101 0069 N Part 3 8 UNC x 1 1 2 Hex Bolt 2 09 1553 FARR BAcKup KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 44 TechnicAL MAnuAL BAcKup RoTARy ASSeMBLy A B C D S T P N R E F G H J K L M U Q V W X KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 45 TechnicAL MAnuAL 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 Long 1 101 4093 D Part Jaw Pivot Bolt 2 997 D3 28 E Part 1 2 UNC x 6 Hex Bolt 2 09 1190 F Weldment Top Cage Plate Weldment 1 101 1241 G Part Jaw Ass
69. A3 to A2 2 25 1 Maximum Operating Pressure 5000 350 bar Maximum Valve Leakage at 110 SUS 24 cSt 10 10 drops min 70 bar Pilot Volume Displacement 15 2 5 cc Series from Cavity 3 U S Patent 4 795 129 Valve Hex Size 1 1 4 31 8 mm Valve Installation Torque 150 160 200 215 Nm Seal Kits Buna 990 017 007 Seal Kits Viton 990 017 006 Option Selection LKHC X D N Preferred Options External Control Cracking Pressure Material Seal Material Standard Options X Not Adjustable N Buna N V Viton Customer specified setting stamped on hex 1 10 Related Information Explanation of Sun cartridge control options US units Explanation of Sun cartridge control options metric units Copyright 2003 Sun Hydraulics Corporation All rights reserved Terms and Conditions Statement of Privacy KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 31 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion Pilot operated balanced piston relief valve Capacity 25 gpm 95 L min Functional Group Products Cartridges Relief 2 Port Pilot Operated Balanced Piston Model RPEC LAN 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
70. ASIC 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 supplied with your equipment Please note that the parts listed in the following table are correct for accurate torque measure ment while using the equipment for which this manual is supplied Applies to KT13625 Tong amp FARR Backup Assemblies Imperial Item Type Description Qty Part Number Assembly 32 40 000 Lbs Ft Torque Measurement Assembly 1 10 0071C A Part Compression Load Cell 1 10 0008C B Part 40 000 Lbs Ft Gauge 32 Arm Length includes following 1 10 0071G Part 1 4 FNPT TEE 1 60 0364 Part 1 4 NPT Street Elbow 1 08 0023 Part 1 4 NPT Cap 1 08 0424 C Part 5 Ft Hose Assembly 1 02 0069 Applies to LW13625 Tong amp FARR Backup Assemblies Item Type Description Qty Part Number Assembly 32 30K Torque Measurement Assembly 1 10 0022C A Part Compression Load Cell 1 10 0008C B Part 30 000 Lbs Ft Gauge 32 Arm Length includes following 1 10 0022G Part 1 4 FNPT TEE 1 60 0364 Part 1 4 NPT Street Elbow 1 08 0023 Part 1 4 NPT Cap 1 08 0424 C Part 5 Ft Hose Assembly 1 02 0069 Applies to KT13625 Tong amp FARR Backup Assemblies Metric Item Type Description Qty Part Number Assembly 32 55000 Nm Torque Measurement Assembl
71. 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 the pin appears bent 4 Torque Gauge Assembly Periodic calibration of the torque gauge is recommended to assure accurate torque readings When having the torque gauge serviced and calibrated it is critical to note the arm length of the tong as indicated on page 1 3 Safety Door Adjustment continued c Remove the four shoulder bolts securing the floating plate and safety door switch to the mounting plate on the LH door assem bly Perform an initial alignment of the safety door mechanism Loosen the four hex socket head cap screws enough to lightly tap the bottom mounting plate toward the RH door assembly Only move the bottom mounting plate in very small increments at a time about one millimeter per adjustment step See Illustration 3 F 5 Loosen three socket head cap screws Tap adjustment plate in the desired direction KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 14 TechnicAL MAnuAL MAinTenAnce H 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
72. 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 lbs the calculation is 1000 x 32 12 2667 Therefore the expected indication on the torque gauge should be 2667 lbs ft 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 b Connect t
73. ENT 6 1 B TROUBLESHOOTING 6 5 C PERIODIC INSPECTION AND MAINTENANCE 1 Inspection 6 6 2 Fluid Recharge 6 6 3 Reference Checking The Torque Measurement System 6 6 4 Repair And Calibration 6 7 SECTION SEVEN HYDRAULIC COMPONENT INFORMATION TABLe oF conTenTS KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS xii TechnicAL MAnuAL LiST oF iLLuSTRATionS IllustratIon 1 a 1 Kt13625 tong amp Farr BacKup Model 80 0935 4 shown 1 1 IllustratIon 1 a 2 Kt13625 tong amp Farr BacKup dIMensIons 1 2 Illust
74. ESSURES 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 EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INJURIES D HYDRAULIC SYSTEM DE PRESSURIZATION McCoy Drilling amp Completions recommends that the hydraulic system be de pressurized prior to maintenance on any hydraulic compo nent Perform the following steps to ensure the dangers posed by hydraulic fluid under pressure are minimized ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINA TION FROM RESIDUAL HYDRAULIC FLUID 1 Rotate the tong to the open throat position Ensure 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 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 IllustratIon 3 e 1 Kt13625 guIde rIng luBrIcatIon MAinTenAnce Apply grease to top guide ring amp bottom guide
75. HIC GEAR TRAIN FAILURE IllustratIon 2 j 13 Motor control BreaK out Breaking Out A Connection Continued h Ensure tubing is roughly centered within the tong and backup jaws rig personnel are required to stabilize the tong and backup around the connection until the jaws have been clamped shut Actuate the backup clamping valve push it toward the centre of the tong see Illustration 2 J 7 to clamp the backup jaws on to the tubing below the connection point Note that the backup control is clamp and release meaning that once the backup jaws are clamped the jaws remain under clamping pressure until the operator manipulates the backup control handle to release pressure i Breakout torque is only available in low gear See Section 2 H 4 to properly set the tong to low gear Do not shift gears while the tong is rotating j Push the rotation control handle all the way in to ensure full breakout torque is being delivered to the joint k When the joint releases stop rotation and shift tong to high gear see Section 2 H 4 to properly set the tong to high gear Press motor control valve toward the centre of the tong to completely un thread the connection Do not shift gears while the tong is rotating SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 39 TechnicAL MAnuAL Breaking Out A Connection
76. ICES 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 C to 35 C ambient temperature for 10 hours per day McCoy 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 experi ence and best estimate of when your equipment is due for this maintenance Manufacturers of purchased components included with your hydraulic tubular connection equipment for example motors valves etc may specify maintenance tasks and intervals over and above what McCoy recommends as part of their recommended procedures Users of this equipment may choose to perform or ignore these additional tasks at their discretion Filtration of the hydraulic fluid must be 10 microns or better Premature fouling of particulate filters within your prime mover or ancillary hydraulic power unit requires immediate hydraulic fluid laboratory analysis to prevent premature wear of hydr
77. INE TONG UPON DISCOVERY OF DAMAGED OR DEFECTIVE HEALTH AND SAFETY COMPONENTS UNTIL PARTS CAN BE REPLACED MISC TONG amp BACKUP PARTS Description Part Number Qty Required Motor Gear 997 A10 149 1 Jaw Pivot Bolt 997 D3 28 2 Cage Plate Spacer 997 38B 3 Backing Pin 101 4142 1 Lined Brake Band Weldment 997 D23 29 1 Rigid Sling Pins 1053 C 1C 2 Upper Guide Ring KT13625 997 HT 23 TOP 1 Lower Guide Ring KT13625 997 HT 23 BOT 1 Safety Door Latch Claw RH AE13 302M 1 Safety Door Latch Claw LH AE13 301S 1 Safety Door Load Plunger AE12 306 1 Door Spring Stop Cylinder 101 0069 1 Door Latch Spring 997 16 2 Dumbbell Roller Cup 997 D21 135 4 Dumbbell Roller Sleeve 997 D21 134 2 BEARINGS amp BUSHINGS Description Part Number Qty Required Dumbbell Roller Bearing 02 0014 4 Bottom Clutch Roller Bearing 02 0014 1 Cam Follower LW13625 02 0016 5 Pinion Bearing 1234 08 01B 2 FASTENERS amp FITTINGS Description Part Number Qty Required External Snap Ring Clutch Drive Gear Retainer 1234 00 04 2 Motor Gear Set Screw 09 0106 1 Motor Gear Key 01 0317 1 Hex Bolt 1 2 UNC X 7 Cage Plate Bolt 09 1194 3 5 8 Lock Washer Cam Follower Fastener LW13625 09 5114 5 5 8 UNF Jam Nut Cam Follower Fastener LW13625 09 5514 5 3 8 UNC X 5 Flange Bolt Jaw Die Retainer 09 0229 10 5 16 UNC X 5 Countersunk Jaw Die Retainer 09 1338
78. Identification 2 14 3 Main Hydraulic Connections 2 16 4 Hydraulic Circuit Description 2 17 F TONG JAW AVAILABILITY amp INSTALLATION 1 Jaw Availability 2 18 2 Jaw Jaw Die Removal 2 19 3 Backup Jaws 2 21 G TONG RIG UP amp LEVELING 1 Suspension amp Restraint 2 22 2 Tong Leveling 2 22 3 Load Cell Configuration
79. 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 23 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi 24 Perform a visual inspection of pressurized hydraulic lines If any hydraulic fittings or hoses are leaking they must be repaired or replaced before proceeding 25 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 De energize the power unit and perform another generous lubrication of the gear train including the gear housing 26 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 27 De energize the power unit and perform a third generous lubrication of the gear train including the gear housing 28 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 29
80. IllustratIon 3 M 1 shIppIng InstructIons pallet 3 38 IllustratIon 3 M 2 shIppIng InstructIons wrappIng chaIn slIng 3 39 IllustratIon 3 M 3 shIppIng InstructIons BacKup support 3 39 IllustratIon 3 M 4 shIppIng InstructIons strappIng equIpMent to pallet 3 40 IllustratIon 4 B 1 relIeF valve trouBleshootIng teMporary gauge InstallatIon 4 2 IllustratIon 6 a 1 torque gauge For IllustratIon purposes only 6 1 IllustratIon 6 a 2 tensIon load cell 6 1 IllustratIon 6 a 3 coMpressIon load cell 6 1 IllustratIon 6 a 4 coMpressIon load cell exploded 6 3 IllustratIon 6 a 5 turn counter encoder Mount exploded 6 4 KT LW 13625 13 5 8 Tong amp FARR BAcKup
81. Ion 3 7 IllustratIon 3 e 11 door latch caM luBrIcatIon 3 7 IllustratIon 3 e 12 door stop sprIng luBrIcatIon 3 8 IllustratIon 3 e 13 Farr BacKup caM rIng caM Follower luBrIcatIon 3 8 Continued on next page KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS xiii TechnicAL MAnuAL LiST oF iLLuSTRATionS IllustratIon 3 F 1 BraKe Band adjustMent 3 9 IllustratIon 3 F 2 door latch caM adjustMent 3 10 IllustratIon 3 F 3 door alIgnMent 3 11 IllustratIon 3 F 4 shIFter detent Force adjustMent 3 12 IllustratIon 3 F 5 saFety door swItch plate adjustMent 3 13 IllustratIon 3 I 1 tong asseMBly rotary gear Inst
82. K DAILY INSPECTION amp MAINTENANCE CHECKLIST BACKUPS 3 32 L MONTHLY MAINTENANCE CHECKLIST POWER TONG 3 33 M TUBULAR CONNECTION EqUIPMENT DE COMMISSIONING amp SHIPPING 3 36 N TUBULAR CONNECTION EqUIPMENT RE COMMISSIONING PROCEDURE 3 41 Continued on next page TABLe oF conTenTS KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS xi TechnicAL MAnuAL SECTION FOUR TROUBLESHOOTING A TONG WILL NOT DEVELOP SUFFICIENT TORqUE 4 1 B RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING 4 2 C SAFETY DOOR DOES NOT OPERATE OR IS MALFUNCTIONING 4 4 D TONG RUNNING TOO SLOWLY 4 5 E FAILURE OF JAWS TO GRIP PIPE 4 6 F FAILURE OR DIFFICULTY OF TONG TO SHIFT
83. KT LW 13625 13 34 6cm 35K 25K Lbs Ft Hydraulic Power Tong amp FARR Backup Specifications Operation Maintenance Assembly 2011 McCoy Corporation All rights reserved Published by McCoy Corporation Technical Publications Department 14755 121A Avenue Edmonton AB Canada T5L 2T2 mccoyglobal com TECHNICAL MANUAL KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS iii TechnicAL MAnuAL This technical manual covers the following models oVeRALL MoDeL Tong MoDeL BAcKup MoDeL ReV DeScRipTion 80 0935 4 80 0931 3 85 0900 0 13 5 8 KT Tong 13 5 8 FARR Backup motor valve backup valve lift cylinder valve safety door 80 0935 5 80 0931 9 85 0900 1 13 5 8 KT Tong 13 5 8 FARR Backup motor valve backup valve lift cylinder valve safety door Closed centre system 80 0912 1 80 0931 3 LW 85 0900 0 13 5 8 LW Tong 13 5 8 FARR Backup motor valve backup valve lift cylinder valve safety door This technical manual applies to all CE marked versions of the models listed in the table above NOTE Some illustrations used in this manual may not exactly match your model of tong PATENTED amp PATENTS PENDING ORIGINAL INSTRUCTIONS This page intentionally left blank KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS v TechnicAL MAnuAL WARNINGS ANY REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS
84. LOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 33 34 35 36 B A 9 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 1 Install 5 8 11 bolts 2 Torque bolts to 50 ft lbs 1 Rotate shaft in both directions to assure that the shaft turns smoothly 2 Torque motor to 190 ft lbs 3 Rotate shaft again in both directions to assure that the shaft turns smoothly NOTE Spool should be oriented as shown for two speed motors with model codes 62 63 68 amp 69 NOTE Slight design variations may exist in motors manufactured either before or after the printing of this manual SPOOL ASSEMBLY FOR THE TWO SPEED MOTOR 1 Clean ALL assembly parts w lacquer thinner 2 Dip clampnut and clamping bolt separately in lacquer thinner Steps 3 thru 10 must be conducted to completion ONE assembly at a time 3 Press bearing cups into bearing housing Make sure they are pressed completely against bearing shoulders 4 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 5 Insert shaft and large cone into bearing housing 6 Coat inner race of small cone with 609 green Loctite and press small cone onto shaft 7 Apply
85. OBLEM SOLUTION S 1 Dies have become too dull to provide adequate grip Replace dies 2 Incorrect jaws are being used Double check jaw size to ensure they are rated for the diameter of pipe or casing being run 3 Incorrect dies are being used Ensure dies loaded in the jaws are appropriate for the type of pipe or casing being run 4 Brake band s is are insufficiently adjusted not allow ing jaws to cam properly 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 visibly flat spot ted or otherwise damaged KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 7 TechnicAL MAnuAL TRouBLeShooTing POSSIBLE PROBLEM SOLUTION S 1 Bent or broken shifter handle Replace shifter handle 2 Frozen or hard to move shifter handle Grease shifter shaft 3 Bent or broken shifter yoke Inspect components through inspection door Replace shifter yoke if neces sary 4 Bent or broken shifter shaft Replace 5 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 7 Tong pops out of gear Ensure that detent ball amp spring assembly has been correctly set F FAILURE OR DIFFICULTY
86. PPLIED BY MCCOY DRILLING amp COMPLETIONS MCCOY DRILLING amp COMPLETIONS DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD BEARING DEVICES UNLESS THOSE MODIFICATIONS ARE PERFORMED BY MCCOY DRILLING amp COMPLETIONS THE 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 C SLING LOAD BEARING DEVICE SAFETY Sling Angle KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 5 TechnicAL MAnuAL SeTup amp opeRATion 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
87. PT 90o Grease Fitting 1 02 0093 K Part Motor Mount 1 997 150 L Part 20 1 1 4 JIC 1 Flange Elbow 2 02 9216 M Part 0 148 x 2 938 Hitch Pin 1 N 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 UNC x 1 1 2 Hex Bolt 4 P Weldment Torque Gauge Holder Weldment 1 1500 09 04A q Part 5 16 x 5 16 x 2 Square Gear Key 1 Kit Seal kit for hydraulic motor 87 7110 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 28 TechnicAL MAnuAL hyDRAuLic ASSeMBLy C R S Q A V W D B F G L J K U N P T E M H X X KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 29 TechnicAL MAnuAL hyDRAuLic ASSeMBLy 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 90d 1 Fitting Includes seals 1 02 9206 D Part Hydraulic 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 M ORB JIC 90 DEG 3 8 F
88. Replaced illustration amp updated B O M Cage Plate Assembly KT13625 5 33 Updated B O M Cage Plate Assembly LW13625 5 37 Added addition B O M for CE specific components Tong Safety Door 5 38 5 39 Replaced illustration amp revised B O M Rigid Sling Added addition illustration and updated B O M to show CE specific components 5 40 5 41 Replaced illustration amp updated B O M Leg Assemblies 5 44 5 45 Replaced illustration amp updated B O M Backup Rotary Assembly 6 6 1 Revised section 6 A Basic Torque Measurement 6 2 Added parts information for metric torque measurement assembly 6 6 Inserted subsection 6 C 3 Reference Checking Torque Measurement System KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS x TechnicAL MAnuAL SECTION ONE INTRODUCTION Introduction amp Contact Information 1 1 Equipment Specifications 1 2 Lubricant Specifications 1 6 SECTION TWO SETUP amp OPERATION A INITIAL RECEIPT AND INSPECTION OF EqUIPMENT
89. SecTion conTenTS xiv TechnicAL MAnuAL The information presented in this document will provide setup operating and maintenance instructions for your KT13625 or LW13625 tong and backup assembly Due to the wide variety of operating 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 identifies items of the highest importance Failure to heed information identified by a HAZARD symbol may result in bodily injury death cata strophic equipment damage or any combination of these A HAZARD may also indicate the potential for dangerous envi ronmental contamination 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 HA
90. THE MOTOR AND CAGE PLATE CATASTROPHIC GEAR TRAIN FAILURE MAY RESULT IllustratIon 2 h 4 shIFtIng gears Move Shifting Handle This Direction To Shift To Low Gear Move Shifting Handle This Direction To Shift To High Gear KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 28 TechnicAL MAnuAL SeTup amp opeRATion 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 Ensure 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
91. Tong amp FARR BAcKup SecTion conTenTS 5 25 TechnicAL MAnuAL Item Type Description Qty Part Number A Part 3 8 NC x 1 Hex Bolt 2 09 1046 B Part 3 8 Lock Washer 2 09 5106 C Part 3 8 Narrow Washer 2 09 5124 D Part Brake Band Retainer 1 101 0140 E Part Brake Band Weldment With Lining 1 997 D23 29 F Part 3 8 UNF x 1 3 4 Hex Bolt 2 19 1552 G Part Brake Band Lug Weldment Left 2 101 0007 Part Brake Band Lug Weldment Right 2 101 0008 H Part 3 8 UNF Hex Nut 09 5906 BRAKe BAnD ASSeMBLy KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 26 TechnicAL MAnuAL MoToR MounT ASSeMBLy A C K G D F J E H N M L P Q B KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 27 TechnicAL MAnuAL MoToR MounT ASSeMBLy Item Type Description Qty Part Number A Weldment Torque Gauge Mount Weldment 1 1500 09 03A B Part 1 2 UNC x 1 1 4 Hex Socket Head Cap Screw 2 09 2168 C Part 1 2 UNC x 1 Hex Socket Head Cap Screw 2 09 2166 D Part 1 2 Lock Washer 4 09 5110 E Part Hydraulic Motor KT13625 Tong 1 87 0112 Part Hydraulic Motor LW13625 Tong 1 87 0110 F Part Motor Gear 1 997 A10 149 G Part 3 8 UNC x 3 8 Hex Socket Set Screw 2 09 2011 H Part 1 2 UNC x 1 3 4 Hex Socket Head Cap Screw Motor Mount 4 09 2172 J Part 1 8 N
92. 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 or optionally newton meters 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 measure ment 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 technical manual The images on
93. UPPLY 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 2 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 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 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 INJURIES KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 34 TechnicAL MAnuAL MAinTenAnce 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
94. USE A CLAMP TO CONTAIN THE ENDS OF THE CYLINDERS WHEN THEY ARE REMOVED AND RELIEVE THE SPRING TENSION GRADUALLY 12 Remove each door assembly by removing the door roller shafts Support each door assembly as the roller shaft is removed Remove the nut from the bottom of the roller shaft and use a soft alloy material e g brass rod etc to lightly tap the shaft up through the support roller assembly until it comes free at the top Use caution that the threads on the ends of the support roller shafts are not damaged NOTE The safety door switch components may remain in place on the door assemblies 13 Remove the two socket head cap screws securing the torque gauge mount and lift the gauge mount out of place 14 Remove the remaining two socket head cap screws securing the motor and lift the motor off 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 15 TechnicAL MAnuAL MAinTenAnce 21 Remove the jaw pivot bolts and the jaw assemblies 22 Remove the two front cage plate bolts and the rear cage plate bolt and the cage plate spacers The cage plates may now be removed use caution not to damage the bottom cage plate support ring or cage plate cam followers 23 Pull the top bearing cap and spacer for t
95. Y RESULT IN CATASTROPHIC GEAR TRAIN FAILURE n Push the motor control valve toward the tong to rotate the cage plate in the make up direction Gently push the rotation control valve toward the centre of the tong to slowly rotate the cage plate until the tong jaws cam on to the tubing see Illustration 2 J 8 IllustratIon 2 j 8 Motor control MaKe up Making A Connection Continued IllustratIon 2 j 7 BacKup control claMp KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 35 TechnicAL MAnuAL Making Up A Connection Continued o When the tong jaws cam on to the tubing push the rotation control handle all the way in to thread the connection together at high speed As the joint becomes fully made up the increasing torque demand will stall the motor and displayed torque will increase p Stop rotation and set motor to low speed and shift to low gear low speed high torque See Section 2 H 4 for shifting to low gear This will enable the tong to produce adequate torque to make up the joint to specification q Push the rotation control handle all the way in to complete the connection at low speed high torque Observe the torque gauge when the specified make up torque is reached stop rotation If your system is equipped with an automatic dump valve the system pressure will dump to tank when the preset torque has been reached and all rotation will stop Reverse the rotation control valve to relea
96. Y RETAIN ENERGY FROM BEING COMPRESSED USE A CLAMP TO CONTAIN THE ENDS OF THE CYLINDER WHEN IT IS REMOVED AND RELIEVE THE SPRING TENSION GRADUALLY IllustratIon 3 e 12 door stop sprIng luBrIcatIon 11 Backup Cage Plate Cam Followers Apply grease to the backup cam followers through the grease fitting on top of each cam adjustment follower 22 locations total IllustratIon 3 e 13 Farr BacKup caM rIng caM Follower luBrIcatIon KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 9 TechnicAL MAnuAL MAinTenAnce IllustratIon 3 F 1 BraKe Band adjustMent TOP AND BOTTOM BRAKE BANDS MUST BE ADJUSTED SIMULTANEOUSLY AND EQUALLY F ADJUSTMENTS 1 Brake Band 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 BRAKE BAND BRAKE BAND ADJUSTMENT BOLT AND NYLOCK NUT KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 10 TechnicAL MAnuAL MAinTenAnce 2 Door Latch Adjustment Nor
97. ZARD to operators or equipment 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 equipment 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 safety 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 Some sections of this technical manual apply only to CE Marked equipment These sections will be clearly identified by the use of the phrase applies to CE marked tongs only or by use of the CE logo within an enclosed border This identifies a section that only applies to CE Marked equipment KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 1 1 TechnicAL MAnuAL inTRoDucTion Congratulations on the purchase of your KT 13625 LW 13625 13 5 8 tong and FARR backup This unit will provide you with years of out standing performance Simple maintenance and care will extend its life and ensure years of
98. agent such as Tectyl 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 36 TechnicAL MAnuAL MAinTenAnce M TUBULAR CONNECTION EQUIPMENT DE COMMISSIONING amp SHIPPING Perform the following decommissioning procedures when removing tubular connection equipment from service 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 1 Perform an initial wash of the tool in order to remove the majority of dirt and grease bui
99. allatIon 3 17 IllustratIon 3 I 2 tong asseMBly gear asseMBly posItIonIng 3 18 IllustratIon 3 I 3 tong asseMBly top plate Fasteners 3 19 IllustratIon 3 I 4 tong asseMBly support roller InstallatIon 01 3 20 IllustratIon 3 I 5 tong asseMBly support roller InstallatIon 02 3 21 IllustratIon 3 I 6 tong asseMBly support roller InstallatIon 03 3 22 IllustratIon 3 I 7 tong asseMBly top shIFter BushIng InstallatIon 3 23 IllustratIon 3 I 8 tong asseMBly Front leg Mount weldMent InstallatIon 3 25 IllustratIon 3 I 9 tong asseMBly saFety door valve InstallatIon 3 26 IllustratIon 3 I 10 tong asseMBly levelIng Bolt InstallatIon 3 27 IllustratIon 3 I 11 tong asseMBly valve handle guard InstallatIon ce MarKed tongs 3 28
100. andard 15 wheel motor seal kit 0150936 331 Breesport San Antonio Texas 78216 210 341 6333 Fax 210 341 1231 e mail sales rineer com WHEEL MOTOR STANDARD MOTOR TWO SPEED MOTOR KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 14 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 15 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 16 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 17 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 18 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 19 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 20 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 21 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 22 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 23 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 1
101. art Idler Gear Bearing Spacer 2 997 D20 121 E Part Retainer Clip 2 02 0009 F Part Bearing Seal 2 02 0010 G Part Rotary Idler Shaft 1 997 D19 117 H Part Cylindrical Roller Bearing 1 02 0075 J Part Rotary Idler Gear 1 997 A2 119C RoTARy iDLeR ASSeMBLy KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 14 TechnicAL MAnuAL pinion iDLeR ASSeMBLy A B C D E F G H J K G L KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 15 TechnicAL MAnuAL pinion iDLeR ASSeMBLy Item Type Description Qty Part Number A Part Grease Fitting 1 02 0005 B Part 1 1 2 UNF Nylock Nut 1 09 5740 C Part 5 8 NC x 1 3 4 Hex Bolt 3 09 1232 D Part 5 8 Lock Washer 3 09 5114 E Part Pinion Idler Pad 1 997 D17 109 F Part Pinion Idler Half Shaft 1 997 D17 105B G Part Retainer Clip 2 02 0009 H Part Cylindrical Roller Bearing 1 02 0075 J Part Pinion Idler Gear 1 997 A2 119B K Part Idler Bearing Retainer 1 02 0008 L Part Bearing Seal 1 02 0010 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 16 TechnicAL MAnuAL pinion ASSeMBLy A B C D E F G H E D C B A KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 17 TechnicAL MAnuAL pinion ASSeMBLy Item Type Description Qty Part Number A Part 1 8 NPT Grease
102. ase is wiped from brake band linings and the parts of the cage plates that come into contact with the brake band linings 15 Re install access panel Install a set of pre inspected jaws that are the correct size for the pipe or casing being run 16 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 been crushed or otherwise distorted through compression 17 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen 18 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 19 Re energize power unit FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE 1 Remove all protective plastic wrapping If there are desiccant packs with the assembly they may be disposed of with the regular garbage 2 Remove the
103. ase to these bearings through the grease fittings in the pinion bearing caps which are located on the top and bottom face of the tong four locations total KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 6 TechnicAL MAnuAL MAinTenAnce 6 Clutch Shaft Apply grease to these bearings through the three grease fittings in the clutch bearing cap which is located at the bottom face of the tong IllustratIon 3 e 8 clutch shaFt luBrIcatIon IllustratIon 3 e 9 shIFtIng shaFt luBrIcatIon 7 Shifting Shaft Apply grease to the shifting shaft and shifting shaft bushings which may be accessed through the cover plate on the side of the tong Access shifter components through this panel KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 7 TechnicAL MAnuAL MAinTenAnce IllustratIon 3 e 10 Motor Mount luBrIcatIon IllustratIon 3 e 11 door latch caM luBrIcatIon 8 Motor Mount Housing Apply grease to the gears in this housing through the grease fitting on the top of the motor mount 9 Door Latch Cam Apply grease to the door latch cam through the grease fitting in the top of cam adjustment boss KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 8 TechnicAL MAnuAL MAinTenAnce 10 Door Spring Cylinders Periodically disassemble the door stop cylinders and coat the spring and cylinder with a general purpose lubricating oil THE DOOR STOP CYLINDER SPRING MA
104. aulic system due to high levels of wear metals in the fluid McCoy Drilling amp Completions recommends tracking all maintenance activity including the lubrication schedule and replacement of hydraulic hoses 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 2 TechnicAL MAnuAL E LUBRICATION 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 McCoy 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 liberal coating of grease applied to the clutch drive gears and shifting shaft Coat the jaw pins and rollers with a liberal amount of anti seize compound when installing new jaw die kits 1 Cage Plate Guide Rings Cam Followers KT1625 Tongs See Illustraton 3 D 1 Rotate the rotary gear out of the cage plate assembly Apply grease to the top and bottom guide rings and to the cage plate slots opposite the rotary gear HYDRAULIC PR
105. aximum Hydraulic Requirements LW13625 60 GPM 227 1 LPM 2500 PSI 17 237 MPa Maximum Dimensions Length Doors Closed 59 3 8 150 8 cm Height 47 119 4 cm Width 33 3 4 85 7 cm Maximum Elevator Diameter Unlimited tong comes off pipe Torque Arm Length Pipe center to anchor center 36 91 4 cm Dead Weight Approximate 2370 lbs 1077 kg Max Working Weight inc Spring Hanger 3320 lbs 1509 kg Sound Level dBa 87 dB A 1m 88 dB C 1m Jaws available inches All standard sizes from 3 1 2 to 13 5 8 See Pg 2 14 Recommended Spring Hanger 85 0106X Capacity 1800 lbs 818 kg SpeciFicATionS KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 1 6 TechnicAL MAnuAL SpeciFicATionS Use an EP synthetic grease that meets or exceeds the following specifications Thickener Lithium Complex NLGI consistency grade 2 NLGI performance grade GC LB Penetration ASTM D 217 25 C 77 F 265 295 minimum 0 1 mm worked 60 strokes Dropping point F C ASTM D2265 550 288 minimum High temperature life hours ASTM D 3527 160 minimum Oxidation stability psi ASTM D 942 100 hr 300 hr 0 3 Water washout percent ASTM D 1264 1 8 max Rust and corrosion ASTM D 1743 pass Oil separation percent loss ASTM D 1742 1 1 max 24 hours 25 C 77 F Leakage g lost ASTM D 4290 1 0 max Four ball wear test mm scar
106. backup door causing the backup door to close Ensure backup door and tong door are fully closed against the latch posts k Firmly close the tong and backup doors Ensure the tong doors are securely latched tug on the tong door handle to ensure it remains latched l Ensure tubing is roughly centered within the tong and backup jaws rig personnel are required to stabilize the tong and backup around the connection until the jaws have been clamped shut Actuate the backup clamping valve push it toward the centre of the tong to clamp the backup jaws on to the tubing below the connection point Note that the backup control is clamp and release meaning that once the backup jaws are clamped the jaws remain under clamping pressure until the operator manipulates the backup control handle to release pressure see Illustration 2 J 7 next page Pushing on the lift cylinder control valve handle toward the center of the tong will cause the equipment to lift This valve handle action applies to all CE marked tongs and is irregardless of control valve bank orientation SeTup amp opeRATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 34 TechnicAL MAnuAL SeTup amp opeRATion m Begin rotation with the tong in high gear high speed low torque See Section 2 H 4 to properly set the tong to high gear Do not shift gears while the tong is rotating SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MA
107. ble 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 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 22 Ensure main supply and return connections to the tong are fully made up Re connect the remainder of the hydraulic lines KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 35 TechnicAL MAnuAL MAinTenAnce 30 Install load cell If using a 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 31 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen 32 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
108. bs 1 12 1 000 59 700 995 ft lbs 746 ft lbs 1 14 1 000 61 125 1019 ft lbs 764 ft lbs 1 1 8 12 1 125 77 025 1444 ft lbs 1083 ft lbs 1 1 4 12 1 125 96 600 2012 ft lbs 1509 ft lbs 1 3 8 12 1 375 118 350 2712 ft lbs 2034 ft lbs 1 1 2 12 1 500 142 275 3557 ft lbs 2668 ft lbs SAE GRADE 8 COARSE THREAD SIzE CLAMP LOAD PLAIN PLATED 1 4 20 250 2 850 12 ft lbs 9 ft lbs 5 16 18 3125 4 725 25 ft lbs 18 ft lbs 3 8 16 375 6 975 44 ft lbs 33 ft lbs 7 16 14 4375 9 600 70 ft lbs 52 ft lbs 1 2 13 500 12 750 106 ft lbs 80 ft lbs 9 16 12 5625 16 350 153 ft lbs 115 ft lbs 5 8 11 625 20 325 212 ft lbs 159 ft lbs 3 4 10 750 30 075 376 ft lbs 282 ft lbs 7 8 9 875 41 550 606 ft lbs 454 ft lbs 1 8 1 000 54 525 909 ft lbs 682 ft lbs 1 1 8 7 1 125 68 700 1288 ft lbs 966 ft lbs 1 1 4 7 1 125 87 225 1817 ft lbs 1363 ft lbs 1 3 8 6 1 375 103 950 2382 ft lbs 1787 ft lbs 1 1 2 6 1 500 126 450 3161 ft lbs 2371 ft lbs REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECI FIED KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 17 TechnicAL MAnuAL MAinTenAnce Assembly Proced
109. ce the keeper screws 3 Backup Jaws The jaw die kits used in the Farr backup are identical to those used in the tong see Pg 2 19 Follow the same removal and instal lation instructions as for the tong jaw die kits KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 22 TechnicAL MAnuAL SeTup amp opeRATion G 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 to and from the connection point 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 suspension cable a single spring hanger typically applies 420 lbs 191 kg to the suspension line for every inch of thread made up a double spring hanger typically applies 840 lbs 382 kg to the suspension line for every inch of thread made up If you do not know which speci
110. cement of damaged hydraulic hoses and fittings replacement of malfunctioning pressure gauges and valves replacement of door spring stop cylinders replacement of fasteners Any replaced component must be an identical component supplied by McCoy Completions amp Drilling Replaced fasteners must be Grade 8 or equivalent or whatever fastener is specified by McCoy 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 all personal protective equipment PPE specified by your company s HSE policy and follow all of your company s safety guidelines 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 and tested If on site maintenance must be performed in other words if equipment cannot be transported to a controlled maintenance facility isolate the location of
111. cluding the door pivot rollers 14 locations total ii Install one 1 4 straight thread grease fitting PN 02 0097 into the top side of the latch adjustment cam iii Install one 1 8 NPT grease fitting PN 02 0005 into the top of each idler shaft or half shaft four locations total iv 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 v Install two 1 8 NPT 90o grease fittings PN 02 0093 in each pinion bearing cap four locations total vi Install two 1 8 NPT 90o grease fittings PN 02 0093 in clutch bearing cap two locations total vii Install one 1 8 NPT 90o grease fitting PN 02 0093 in the top of the motor mount viii LW13625 ONLY Install one 1 8 NPT grease fitting PN 02 0005 into each cam follower in the top and bottom cage plates 22 locations total ix Install one 1 8 NPT grease fitting PN 02 0005 into each cam follower in the top and bottom cage plates in the FARR backup 22 locations total 76 Install desired jaw die kit in the tong using the jaw pivot bolts PN 997 D3 28 MAinTenAnce KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 30 TechnicAL MAnuAL J 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
112. ction 6 All Complete revision of torque measurement section OCT 2011 5 Checked amp corrected part numbers for fasteners where necessary all B O M s in Section 5 DBowles SEP2012 Intro xii Inserted List of Illustrations SPanchal xiv Added CE Marked modifier statement and identification symbol 1 1 2 Corrected dimensions added hazard and safe to handle legend 1 3 Inserted illustration of additional hazard areas 1 4 Inserted illustration amp identification of FARR CE Nameplate 1 5 1 6 Corrected specifications 2 2 1 Inserted new section Initial Receipt amp Inspection of Equipment 2 4 Renumbered section 2 C Sling amp Load Bearing Device Safety 2 7 Inserted new section 2 D Lift Cylinder Installation 2 10 Renumbered section 2 E Hydraulics 2 12 2 13 Inserted CE applicable hydraulic schematics 2 16 Moved section Hydraulic Connections into Section 2 E Hydraulics 2 17 Inserted new subsection 2 E 4 Hydraulic Circuit Description 2 18 Renumbered and revised section 2 F Tong Jaw Availability amp Installation Added CE specific information 2 22 Renumbered section 2 G Tong Rig Up amp Leveling 2 25 Renumbered section 2 H Tong Operation 2 25 Inserted new subsection 2 H 1 Operator Training 2 25 Inserted new subsection 2 H 2 Operator Safety Removed subsection Initial Startup amp Break in Proc
113. d lock washers per side CE marked tongs only secure LH amp RH rigid sling mounting lugs to the top plate using two 3 8 UNC x 1 3 4 wire drilled hex bolts and 3 8 lock washers and two 1 2 UNC x 1 1 4 wire drilled hex bolts and lock washers per side 59 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 1360 using a 3 4 UNC x 9 hex bolt and 3 4 UNC nylock nut CE marked tongs only rigid sling weldment for CE marked tong PN 101 1360 CE ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE SECURED WITH RED LOCTITE KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 27 TechnicAL MAnuAL MAinTenAnce Assembly Procedure Continued 60 Use a crane to 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 61 Thread a 3 4 UNC hex nut on to each of four rigid sling leveling adjustment weldments PN 1053 C 1L Thread the leveling adjust ment weldments into each side of the rigid sling weldment mounting brackets roughly adjusting them so the rigid sling is approxi mately perpendicular to the top plate of the tong see illustration 3 I 10 IllustratIon 3 I 10 tong asseMBly levelIng Bo
114. d the poppet and spring from the relief assembly d Inspect the relief valve spring poppet and valve seat e If no debris is found in relief valve and if seat and poppet are undamaged replace relief valve spring f Reassemble relief valve g 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 POSSIBLE PROBLEM SOLUTION S 2 Relief cannot be adjusted to maximum system pres sure high fluid bypass results in low system pressure Debris on valve seat Valve spring is broken Valve spring has lost spring force due to continuous tension RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING Cont d KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 4 TechnicAL MAnuAL TRouBLeShooTing 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 malfunctioning Remove each valve Inspect seats and springs Replace valve s if damage is seen on valve seats or if spring appears to be
115. damaged or broken C SAFETY DOOR DOES NOT OPERATE OR IS MALFUNCTIONING KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 5 TechnicAL MAnuAL TRouBLeShooTing POSSIBLE PROBLEM SOLUTION S 1 Obstruction in tong hydraulic circuit preventing ad equate flow Inspect self sealing couplings to ensure they are properly engaged The main hydraulic lines supply and discharge to the tong are obstructed Remove and clean if required 2 Power unit is not producing adequate flow or pres sure Troubleshoot power unit see user s manual for your particular unit 3 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 4 Bearings in gear train and rotary section are ex cessively worn Overhaul tong See Section 3 of this manual for tong overhaul procedures 5 Shifter has malfunctioned and the tong is not shift ing to high gear Inspect and repair shift mechanism as necessary 6 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 7 By pass valve not functioning Check and repair D TONG RUNNING TOO SLOWLY KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 6 TechnicAL MAnuAL TRouBLeShooTing E FAILURE OF JAWS TO GRIP PIPE POSSIBLE PR
116. 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 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 37 TechnicAL MAnuAL MAinTenAnce depressurIzatIon procedure For storage 1 Rotate the tong to the open throat position 2 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 3 De energize th
117. dment the nuts may be accessed from the side of the door weldment Use a hex key to turn the hex head set screws either clockwise or counter clockwise to adjust the door Note that the top and bottom of the door weldment may not need to be adjusted equally each set screw should be adjusted independently until the doors are aligned FInal alIgnMent Rotate the cage plate and stop it when the inside circumference of the door is completely covered Perform three measurements see illustration next page 1 From the insides of the outer edge of each door weldment to the cage plate 2 measurements total 2 From the exact centre point where the two doors meet to the cage plate IllustratIon 3 F 3 door alIgnMent The three measurements should be equal If the centre measurement is less than the two outside measurements loosen all four locking nuts on the set screws and turn all four set screws EqUALLY clockwise until the centre measurement is equal to the two outer measurements If the centre measurement is more than the two outside measurements loosen all four locking nuts on the set screws and turn all four set screws EqUALLY counter clockwise until the centre measurement is equal to the two outer measure ments Ensure that the locking nuts are tightened when this procedure is complete Measurement 1 Measurement 1 Measurement 2 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 12 TechnicAL MA
118. draulic lines Document and correct any hydraulic fluid leaks 19 Perform a full functional test of the tong refer to section 2 I 4 20 Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low gear 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 CE marked tongs only Inspect all wire ties on drilled bolts on critical safety systems All wiring must be intact and appear tamper free Check the integrity of all guards including the rubber protective washers over the backup leg openings MAinTenAnce KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 32 TechnicAL MAnuAL MAinTenAnce K 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 Ensur
119. e adequate containment is in place to prevent environmental contamination from residual hydraulic fluid all unIts 1 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 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 or fatigued to the point it must be replaced wedge BacKup only 4 Remove access cover from top plate Perform a visual inspection ot the interior of the backup use a flashlight if necessary Premature wear where there are moving parts bare metal where there used to be paint and metal shavings in 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 ram guides door cylinder pivots and door pivots clIncher BacKup only 4 Use a flashlight to perform a visual inspection of the interior of the backup remove one side panel if necessary Premature wear where there are moving parts bare metal where there used to be paint and metal shavings in the grease are good indicators may show where a component needs to be adjusted or if necessary rep
120. e backup control section directs hydraulic fluid to the double acting backup clamping cylinder This is not proportional control meaning that actuating the control valve enables a fixed hydraulic output to the cylinder The configuration of the plumbing between the backup valve section and the backup cylinder determines the clamping action of the backup cylinder for a given valve action McCoy Drilling amp Completions FARR normally configures the plumbing on this tong so that pushing the valve control handle towards the centre of the tong clamps the backup for make up operations and pulling the valve control handle toward the operator clamps the backup for break out operations Adjustable needle valves on each backup cylinder line allows the operator to set the rate at which hydraulic fluid is supplied to the backup cylinder thus controlling the rate at which the cylinder clamps and un clamps Adjustable relief valves on each backup cylinder line allows the operator to set the clamping pressure for both make up and break out operations Hydraulic fluid at maximum tong pressure flows from the valve inlet section to the safety door switch During normal operation the plunger on the safety door switch is depressed when the tong door is closed directing a hydraulic pilot signal to both safety door relief valves Item 5 on the hydraulic schematic and on page 2 7 This pilot pressure actuates the safety door check valves allowing full system press
121. e power unit 4 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor 5 Remove the hydraulic SUPPLY line from the equipment 6 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 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 8 Disconnect the hydraulic RETURN line from the equipment 9 Disconnect remaining hoses such as case drains or lines connected to the turns counter 12 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 13 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 14 De energize the power unit and perform a third generous lubrication o
122. e spot away from the disassembly location 7 Remove the 7 16 x 3 bolts from the front leg mount weldments to remove the front leg weldments 8 Set the tong onto a sturdy flat work surface that provide adequate support but still allows access to the bottom cage plate assem bly A pair of sturdy metal horses work well in this application REMOVAL OF TOP PLATE 9 Disconnect the hydraulic connections from the motor Undo the restraints securing the inlet and outlet lines from their supports and use a crane and temporary lifting sling to hoist the hydraulic valve section away from the tong Remove the inlet and outlet support pieces 10 Support the rigid sling with a crane Remove the two hitch pins from each rigid sling pin and remove the rid sling pins The rigid sling may now be lifted away from the tong and stored in a secure location Remove both rigid sling hanger bracket weldments The heads of the fasteners securing the rigid sling hanger brackets are drilled and are constrained to the brackets using wire ties Wire ties must be removed before extracting the fasteners and removing the rigid sling hanger bracket 11 Remove the tong door stop cylinders The door stop cylinder springs may retain energy from being compressed Use a clamp to contain the ends of the cylinders when they are removed and relieve the spring tension gradually THE DOOR STOP CYLINDER SPRINGS MAY RETAIN ENERGY FROM BEING COMPRESSED
123. e 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 20 Farr recommends that chain slings be removed and stored separately Rigid slings and other rigid suspension devices may remain in place 21 Apply grease or heavy oil to all exposed cylinder rods 22 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 manufacturer data sheets for proper application and safety information DO NOT ALLOW ANTI CORROSIVE AGENTS TO CONTACT CYLINDER RODS CYLINDER ROD DAMAGE WILL OCCUR 23 Allow the anti corrosive coating ample time to dry refer to manufacturer data sheets for drying times at room temperature 24 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
124. eRATion BACKUP This is a two way direct acting valve without proportional control Pushing the valve handle forward will cause the backup to engage Pulling backward towards the operator reverses the operation IllustratIon 2 h 3 Farr BacKup control 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 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 DOWN from neutral position To shift to the low speed gear move the shift ing handle UP through the neutral detent to its HIGHEST 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 The most effective way of achieving this is to apply a small amount of pressure on to 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 see Illustration 2 I 3 next page DO NOT SHIFT TONG WHILE ROTATING
125. ead 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 and ANSI AMSE B30 26 RIGGING HARDWARE for additional information 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 COMBINATION OF PARTS AND ASSEMBLIES OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SU
126. ease Fitting 2 02 0093 T Part Clutch Spacer 1 101 3599 U Part High Clutch Gear 1 997 HT 51B KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 20 TechnicAL MAnuAL ShiFTeR ASSeMBLy A D C B H J P R S T U K Q L G F E F V N M KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 21 TechnicAL MAnuAL ShiFTeR ASSeMBLy Item Type Description Qty Part Number A Part Shifting Handle Weldment 1 1037 D 20B B Part 5 16 x 1 Clevis Pin 1 02 0020 C Part 5 16 x 1 1 2 Clevis Pin 1 09 0256 D Part 3 8 NC x 1 1 2 Hex Bolt 4 09 1553 E Part 3 8 Lock Washer 8 09 5106 F Part HITCH PIN 0930 X 1 125 Spaenaur CP 83H 2 G Part 7 16 UNF x 1 1 4 Hex Bolt 1 09 1608 H Part 7 16 UNF Hex Jam Nut 1 09 5508 J Part Detent Spring 1 01 0040 K Part Detent Ball 1 02 0018 L Part 5 8 NC x 5 8 Hex Socket Set Screw Cup Point 3 M Part Threaded Shifter Bushing 1 101 0020 N Part Shifter Lug Weldment Bolted 1 101 0016 P Part Knob Collar Pipe 1 101 0019 q Part Shifting Shaft 1 997 B1 71 R Part Shifting Fork 1 997 HT 72 S Part 5 8 UNF Hex Jam Nut 1 09 5915 T Part 5 8 UNF Hex Nut 1 09 5914 U Part Lower Shifting Shaft Bushing 1 101 0003 V Part 3 8 NC x 1 Hex Bolt 4 09 1046 KT LW 13625 13 5 8 Tong amp FARR BAcKu
127. eat steps 14 amp 15 1 Remove o ring and springs with a small screwdriver 2 Remove dowels pins 1 Place cartridge on any object which will hold it off the table 2 Remove two each 10 32 place screws 3 Remove timing plate Lift up rotor stator cartridge and remove from the rear housing DISASSEMBLY OF FRONT HOUSING AND SHAFT DISASSEMBLY OF ROTOR STATOR CARTRIDGE KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 10 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 17 21 22 23 24 18 19 20 7 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 reassembled 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 in slight flattening of vane tips which does not impair motor performance Replace vane if radius is reduced by 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
128. ection 6 C Possible Problem Internal mechanism of gauge is damaged Solution Replace gauge Possible Problem Incorrect torque gauge in use not part of the original torque gauge load cell pair Solution Replace gauge with gauge properly calibrated for the load cell in service 3 Symptom Gauge indication unexpectedly low Possible Problem Insufficient hydraulic fluid Solution 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 Possible Problem Obstruction in hydraulic hose Solutions Check hydraulic hose for kinks Replace hydraulic hose Possible Problem Snub line not at right angle to tong handle Solution Check angle of snub line and correct if necessary Possible Problem Internal mechanism of gauge is damaged Solution Replace gauge Possible Problem Incorrect torque gauge in use not part of the original torque gauge load cell pair Solution Replace gauge with gauge properly calibrated for the load cell in service 4 Symptom Gauge indication is erratic or sluggish Possible Problem Insufficient hydraulic fluid in torque measurement section Solution 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 furth
129. edure 2 25 Renumbered and revised subsection 2 H 3 Valve Operation 2 26 Added CE specific information to lift cylinder valve operation 2 27 Renumbered subsection 2 H 4 Shifting Gears 2 28 Inserted new subsection 2 H 5 Pre Operational Checks 2 29 Renumbered subsection 2 H 6 General Comments 2 40 Renumbered section 2 I Extreme Cold Weather Operations 2 32 Inserted new section 2 J Making and Breaking Connections 3 3 2 Inserted new section 3 D Hydraulic System De Pressurization 3 2 Renumbered section 3 E Lubrication Instructions 3 9 Renumbered section 3 F Adjustments 3 9 Revised subsection 3 F 1 Brake Band Adjustment 3 10 Replaced illustration subsection 3 F 2 Door Latch Cam Adjustment 3 12 Inserted new subsection 3 F 5 Safety Door Adjustment 3 13 Renumbered section 3 G Recommended Periodic Checks 3 14 Renumbered amp revised section 3 H Overhaul Procedures Disassembly Cor rected disassembly procedures and added CE specific information and warnings Continued on next page KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS ix TechnicAL MAnuAL Summary Of Revisions Continued Date Section Page Description Of Revision Approved SEP2012 3 3 16 3 29 Renumbered amp revised section 3 I Assembly Procedures Corrected assembly procedures and added CE specific information a
130. een tapped all the way through secure each with a 3 4 UNF thin nylock nut and 7 8 narrow flat washer 53 Install two mechanical door stops PN 101 0014 on the underside of the tong near the doors Secure using two 3 8 UNC x 1 3 4 bolts and 3 8 lock washers each 54 Install door cylinder mounting lugs 1050 12 001 into the threaded locations directly adjacent to the brake band lug weldments on the top plate 55 Install the door spring stop cylinder assemblies PN 101 0069 using two 1 2 x 1 2 UNC shoulder bolts Ensure the guards on door spring cylinders extend over the top of the support rollers rather than toward the edge of the tong KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 25 TechnicAL MAnuAL MAinTenAnce Assembly Procedure Continued 56 Mount the front leg mount weldments The front leg mount weldments are coincidental with two longer support roller shafts which were installed in step 34 a Secure the front leg mount weldments to the support roller shafts using one 3 4 UNF thin hex nylock nut per shaft ASSEMBLY NOTE Flat washers are not used where the support roller shafts are coincidental with the front leg mount weldments IllustratIon 3 I 8 tong asseMBly Front leg Mount weldMent InstallatIon 57 Install the safety door components see Pp 5 34 5 35 using the following procedure a Attach safety door latch plate PN 101 0320 to the LH doo
131. em 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 Jaw Pivot Bolt 2 997 D3 28 D Part 1 2 UNC x 6 Hex Bolt 2 09 1190 E Part Backing Pin Spacer Long 1 101 4093 F Part 1 2 Lock Washer 2 09 5110 G Part Top Cage Plate 1 997 HT 21 H Part Support Ring Top 1 997 HT 23 TOP J Part Jaw Assembly 13 5 8 shown 2 See Pp 2 17 K Part Cage Plate Spacer 3 997 38B L Part Rotary Gear 1 997 D1 B M Part Support RIng Bottom 1 997 HT 23 BOT N Part Bottom Cage Plate 1 997 HT 22 P Part Backing Pin Knob 1 02 0017 q Part 3 8 UNF x 2 Threaded Stud 1 101 4097 R Part Backing Pin Spacer Short 1 101 4096 S Part Backing Pin Retainer 1 101 4139 T Part Backing Pin 1 101 4142 U Part 3 8 UNC x 1 3 4 Hex Socket Head Cap Screw 22 09 2052 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 32 TechnicAL MAnuAL cAge pLATe ASSeMBLy LW13625 Tong A B C D K J L M S T P N R E F G H U Q KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 33 TechnicAL MAnuAL cAge pLATe ASSeMBLy LW13625 Tong Item Type Description Qty Part Number A Part 1 2 UNC x 8 Hex Bolt 1 09 1198 B Part Jaw Pivot Bolt 2 997 D3 28 C Part 1 2 UNC x 6 Hex Bolt 2 09 1190
132. embly 13 5 8 shown 2 See Pp 2 17 H Part 5 8 x 1 1 2 Hex Socket UNC Shoulder Screw 9 09 0116 J Part Backup Cam Gear 1 997 500 01 K Part Bottom Cage Plate 1 997 D2 22 L Weldment Backup Body Plate Weldment shown for illustration purposes only 1 M Part 1 2 UNC Thin Nylock Nut 9 09 5610S N Part Backing Pin Knob 1 02 0017 P Part 3 8 UNF x 2 Threaded Stud 1 101 4097 q Part Backing Pin Spacer Short 1 101 4096 R Part Backing Pin Retainer 1 101 4139 S Part Backing Pin 1 101 4142 T Part 1 8 NPT Grease Fitting 22 02 0005 U Part 5 8 UNF Hex Jam Nut 22 09 5514 V Part 5 8 Carbon Steel Lock Washer 22 09 5114 W Part Cam Follower 22 02 0016 X Part Cage Plate Spacer 3 997 D3 38 BAcKup RoTARy ASSeMBLy This page intentionally left blank KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 6 1 TechnicAL MAnuAL ToRque MeASuReMenT A 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 pipe or cas ing to the centre of the force being applied to the load cell
133. ent Force Adjustment 3 12 5 Safety Door Adjustment 3 12 G RECOMMENDED PERIODIC CHECKS 1 Door Stop Spring 3 13 2 Shifting Shaft 3 13 3 Backing Pin 3 13 4 Torque Gauge Assembly 3 13 H OVERHAUL PROCEDURES 3 14 I ASSEMBLY PROCEDURES 3 16 J DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER TONG 3 30
134. er fluid loss Possible Problem Loss of damping fluid in torque gauge Solution Top up or refill damping fluid NOTE Ensure leakage points in gauge are identified and repaired to prevent further loss of damping fluid Possible Problem Air bubbles in hydraulic fluid in the torque measurement system Solution Bleed air from load cell and torque gauge and top up fluid if necessary as per Section 6 C Possible Problem Internal mechanism of gauge is damaged Solution Replace 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 NOT CONTINUE AFTER RELOADING KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 6 6 TechnicAL MAnuAL ToRque MeASuReMenT C PERIODIC INSPECTION AND MAINTENANCE MAINTAIN GREATER THAN HALF FULL FLUID LEVEL IN THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO THE SYSTEM DO NOT ALLOW THE LEVEL TO FALL BELOW ONE HALF FULL 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 d Fill hand pump bowl with W15 16 hydraulic fluid e Remove the vent plug screw a
135. f the gear train including the gear housing 15 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 16 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 17 If you are using a frame mounted tool the tong must be lowered onto the backup in order to remove the risk of sudden 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 18 If any hydraulic fittings or hoses are leaking they must be repaired or replaced before proceeding 19 Wipe all excess grease from outside of equipment Replac
136. fic 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 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 sn
137. from any hydraulic cylinders that are used 21 If using a frame mounted tong and backup system raise the tong off the beams that it is resting upon Remove the beams 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 22 Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low gear 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 23 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 MAinTenAnce KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 1 TechnicAL MAnuAL TRouBLeShooTing Adequate maintenance and proper fluid selection is essential for minimizing hydraulic related failures All troubleshooting must be performed
138. ft and lower the tong slightly to confirm that lift and lower functions each operate correctly 3 Lift Cylinder Safety A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR McCoy Drilling amp Completions recommends following an industry accepted standard such as OSHA ASME B30 9 2006 or manufac turer 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 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 The Working Load Limit or Design factor may be affected by wear misuse overloading corrosion deformation intentional altera tions sharp corner cutting action and other use conditions See OSHA Regulation for Slings 1910 184 ANSI ASME B30 9 SLINGS ANSI ASME B30 10 HOOKS and ANSI AMSE B30 26 RIGGING HARDWARE for additional information IllustratIon 2 d 2 lIFt cylInder hydraulIc connectIon SeTup amp opeRATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 9 TechnicAL MAnuAL SeTup amp opeRATion Lift Cylinder Safety continued The flexible line providing hydraulic power to the li
139. ft bottom right PN 101 0007 top right bottom left PN 101 0008 are installed with the two front support roller shafts on each side as shown in Illustration 3 I 6 on the following page Note that no flat washers are used where the shafts are coincidental with the brake band lug weldments Secure the bottom of the four shafts with 3 4 UNF thin nylock nuts Assembly Procedure Continued 34 Re install support roller shafts cont d b Two rear hydraulic valve mount weldments PN 101 0011 are coincidental with the two rear support roller shafts as shown in illustration 3 I 5 ASSEMBLY NOTE Do not use 7 8 narrow flat washers on the tops of the shafts where they are coincidental with the brake band lug weldments Secure the bottoms of the shafts with 7 8 narrow flat washers and 3 4 UNF thin narrow nylock nuts IllustratIon 3 I 5 tong asseMBly support roller InstallatIon 02 MAinTenAnce KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 22 TechnicAL MAnuAL MAinTenAnce IllustratIon 3 I 6 tong asseMBly support roller InstallatIon 03 Assembly Procedure Continued 35 Coat the threads of the top shifter bushing PN 101 0020 with red Loctite Thread the top shifter bushing over the shifting shaft into the top plate until snug Thread the detent tube PN 101 0019 into the top shifter bushing as shown in illustration 3 I 7 36 Thread three 5 8 UNC x 5 8 hex socket set screws into
140. ft cylinder has been equipped with abrasion resistant high visibility protective wrap The high visibility wrap allows operators to easily see monitor the position of the hydraulic line at all times and can easily see if the line appears to become entangled or snagged IMMEDIATELY CEASE LIFT CYLINDER OPERATION IN THE EVENT OF ENTANGLEMENT OF THE HYDRAULIC LINE WITH FIXED RIG COMPONENTS OR TONG SUPERSTRUCTURE REPLACE LIFT CYLINDER HYDRAULIC LINE EVERY TWO YEARS The protective wrap also prevents wear of the hydraulic line though abrasion Do not remove the protective wrap from the lift cylin der line and replace protective wrap if it is missing torn or split Regardless of use or condition the hydraulic line supplying the lift cylinder must be replaced every two years DO NOT REMOVE THE SPEED LIMITING ORIFICE FROM THE LIFT CYLINDER BREATHER PORT The control valve section on the power tong is equipped with an internal check valve preventing sudden drop of the tong in the event of hydraulic power failure A speed limiting orifice is installed in the breather port of the lift cylinder The orifice prevents sudden drop of the lift cylinder in the event of a ruptured hydraulic line limiting the speed at which the cylinder extends and the tong drops to a safe rate Do not remove the speed limiting orifice and only replace with an identical orifice supplied by McCoy The working load limit WLL is clearly stenciled on to the side of the lift
141. g Suspension 2 G 2 Tong Rig up and Leveling Leveling Your tong and backup assembly should be properly suspended connected to a hydraulic power source and ready to make or break con nections at this point 1 Making A Connection a Ensure hydraulic power supply to the tong is energized The master link on the rigid sling must be used to suspend the tong Do not suspend the tong directly from the rigid sling THESE OPERATING PROCEDURES ASSUME THE USER HAS PROPERLY SET UP AND PREPARED THE EQUIPMENT FOR OPERATION AS PER SECTIONS 2D 2E AND 2F OF THIS MANUAL THE MASTER LINK MUST BE USED TO SUSPEND THE TONG ASSEMBLY IllustratIon 2 j 1 rIgId slIng Master lInK SeTup amp opeRATion b Ensure the backing pin is in the makeup position From the front of the tong the backing pin correctly configured for makeup will be in the 10 o clock position see Illustration 2 J 2 next page If it is not simply lift up and place in the correct position see Illustration 2 next page The cage plate opening must be aligned with the door opening when setting the backing pin position Set the position of the backing pin on the backup in exactly the same fashion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 31 TechnicAL MAnuAL Making A Connection Continued IllustratIon 2 j 2 settIng BacKIng pIn to MaKe up posItIon c Properly configure the load cell for making up connections see Sect
142. g installation Connect the rotation control valve on the DVA35 valve assembly to the safety door block 67 Connect the safety door switch to the safety door block and hydraulic valve assembly Refer to hydraulic schematic or call McCoy Drilling amp Completions Farr engineering department for assistance 68 Install the two front leg weldments PN 997 917 00B in the front leg mounts and secure each with a 1 2 UNC x 4 1 2 hex bolt 1 2 UNC hex nut and two flat washers CE marked tongs only Install the valve handle guard weldment PN CE HANDLE 3 over the valve handles while securing the valve bank to the supports see illustration 3 I 11 IllustratIon 3 I 11 tong asseMBly valve handle guard InstallatIon ce MarKed tongs MAinTenAnce 1 2 UNC x 5 1 2 Lock Washer 1 2 UNC x 4 1 2 1 2 UNC x 5 1 2 Narrow Flat Washer 1 2 UNC Thin Nylock Nut KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 29 TechnicAL MAnuAL Assembly Procedure Continued 69 Place the rear leg weldment PN 997 915 00 on a flat section of the floor adjacent to the tong assembly Use a crane to lift the tong assembly from its assembly base and lower on to the leg assembly ensuring all the weight remains suspended by the crane Secure with four 1 1 4 NC x 8 heavy hex bolts and nylock nuts 70 Support backup assembly about waist high off floor ensuring the backup supports d
143. he hand pump to the check valve fitting c Elevate the load cell so it is higher than the torque gauge and hand pump ONLY QUALIFIED DESIGNATED PERSONNEL ARE PERMITTED TO PERFORM MAINTENANCE ON THE TORQUE MEASUREMENT SYSTEM KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 6 7 TechnicAL MAnuAL Reference Checking Your Torque Measurement System continued Tension Load Cell continued e Perform a simple calculation continued Calculations for a metric torque measurement system using tension load cell are as follows KNOWN WEIGHT in 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 lbs ft Compression 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 e
144. he jaw rollers rotate freely 15 Inspect backing pin s If cracked broken or bent it they must be replaced 16 Inspect top and bottom brake band linings replace if lining is found to be flaking or is missing pieces of material 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 17 Inspect door springs Ensure the springs retain sufficient strength to be able to assist the opening of the door and to keep the door open The springs should also help to snap the door shut 18 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 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 20 Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have visi
145. he lift cylinder control valve handle toward the centre of the tong supplies hydraulic pressure to the lift cylinder retracting the cylinder and causing the equipment to lift while pulling on the lift cylinder control valve handle toward the operator will cause the equipment to lower This valve handle action applies to all CE marked tongs and is irregardless of control valve bank orientation A speed limiting orifice is installed in place of a breather on all CE marked lift cylinders This orifice limits the rate at which the equipment will lower in the event of equipment failure a ruptured hydraulic hose for example Hydraulic Circuit Description continued Actuating the valve handle on the lift cylinder section directs hydraulic fluid to the lift cylinder which is connected to the master link on the rigid sling and provides raising and lowering functions to the tong and backup assembly Although the lift cylinder is designed to be a double acting cylinder normally only the lift side is connected to hydraulic pressure from the lift cylinder valve Actuating the lift cylinder valve in the lower direction provides a path to tank for the hydraulic fluid in the lift cylinder and allows the load suspended on the lift cylinder to force the hydraulic fluid from the cylinder through the valve In other words the lowering action is a function of gravity not active hydraulics The position of the lift cylinder valve controls t
146. he 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 24 Remove the 1 1 2 nuts and pads for the rotary idler gears and the 1 1 2 nuts 5 8 bolts and half moon pads from the pinion idler gears 25 Remove the bottom roller shaft nuts 26 Carefully remove the remaining twelve support roller shafts A soft alloy material e g brass rod etc may be required to lightly tap the shafts up through the support roller assembly until they come free at the top Use caution not to misplace the brake band lug weldments or the two hydraulic valve mounting posts that will come free with this step 27 Remove the hex head bolts around the perimeter of the tong which secure the top plate to the gear case housing 28 Remove the countersunk socket head screws around the perimeter of the tong 29 With all the above steps taken the top tong plate can be lifted off providing access to the inside of the gear case 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 OR PERSONAL INJURY TO THE MECHANIC IF THE BEARING REMAINS ATTACHED TO THE GEAR SHAFT AFTER THE BEARING CAP IS PULLED MCCOY DRILLING am
147. he rate at which the cylinder lowers the tong and backup assembly An adjustable needle valve on the pressure line to the lift cylinder allows an operator to set the rate at which hydraulic fluid is supplied to the lift cylinder thus controlling the rate at which the cylinder raises and lowers A breather port installed in the opposite side of the lift cylinder allows the cylinder to breathe as the piston in the lift cylinder moves The configuration of the plumbing between the lift cylinder valve section and the cylinder determines the action of the lift cylinder for a given valve action McCoy Drilling amp Completions FARR normally configures the plumbing on this tong so that pulling the valve control handle towards the operator supplies hydraulic pressure to the lift cylinder which causes the cylinder to retract thus providing a lifting action Conversely pushing the valve control handle towards the centre of the tong allows a path back to tank which allows gravity to extend the cylinder and lowers the equipment Allowing the handle to go to neutral stops all hydraulic fluid movement to or from the lift cylinder USE OF ALUMINUM DIES IS FORBIDDEN ON CE MARKED EQUIPMENT SeTup amp opeRATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 19 TechnicAL MAnuAL Jaw Availability continued Description Part Number Description Part Number 3 1 2 Jaw Die Kit 1 997 WJK 350 7 Jaw Die Kit 997 JDK 310
148. ial or special damages Dismantling the product operation of the product beyond the published capabilities or for purposes other than that for which the product was designed shall void this warranty Limited Warranty Policy KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 6 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion Standard Motor Two Speed Motor HYDRAULICS INC HYDRAULICS INC R M A N U F A C T U R E R O F H Y D R A U L I C M O T O R S 15 Series Repair Manual 331 BREESPORT SAN ANTONIO TX 78216 210 341 6333 FAX 210 341 1231 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 7 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 8 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 1 2 3 4 5 6 7 8 5 1 Remove snap ring WARNING Use caution when removing snap ring If released accidentally it can become an airborne hazard 1 Pry out shaft seal plate 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 Loosen and remove 8 each 3 8 bolts w
149. icATionS IllustratIon 1 a 3 Kt13625 tong amp Farr BacKup hazard areas ce MarKed Model shown THIS PAGE ILLUSTRATES THE SAFE TO HANDLE AND HAZARD AREAS OF THIS EQUIPMENT In addition to the HAZARD areas of this equipment that are coated YELLOW a rotating cage plate assembly and backup clamp cylinders pose significant hazards when the equipment is active Keep hands clear of the cage plate and backup clamp cylinders when equipment is energized SAFE areas to handle while the equip ment is energized are indicated by GREEN coating Keep hands clear of cage plate when equipment is energized TORQUE GAUGE MOUNTS IN THIS LOCATION SYSTEM PRESSURE GAUGE KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 1 4 TechnicAL MAnuAL Torque Table Standard Tong Pressure High Gear Low Gear PSI MPa Lbs ft Nm Lbs ft Nm 1500 10 34 3530 4786 17640 23917 2000 13 79 4970 6738 24840 33679 2500 17 24 6410 8691 32040 43440 2750 18 96 7130 9667 35640 48321 MAXIMUM RATED TORQUE 35000 LBS FT 47450 Nm Speed Table Flow US GPM LPM Low Gear RPM High Gear RPM 10 37 9 1 6 8 20 75 71 3 2 16 40 151 4 6 4 32 60 227 1 9 6 48 Specifications KT13625 CE compliant Conforms with the essential requirements of the applicable Conformit Europ enne directives EU Explosive Atmosphere certified II Equipment Group surface non
150. ing or pipe you are running 8 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 9 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 10 Inspect backing pin s If cracked broken or bent it they must be replaced 11 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 12 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 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 2 depressurIze hydraulIc systeM In preparatIon For MaInte
151. ion 2 G 3 Connect snub lines to the rear of the tong to arrest uncontrolled rotation of the assembly in the event of backup jaw slippage The snub lines must be rated for the applied torque plus whatever safety margins stated by your own operating policies The snub line connection points on the drill floor must be sturdy enough to absorb all applied forces When making up joints the snub line is attached to the driller s side of the tong which is the left side of the tong as seen from the rear For accurate torque measurement the snub line must be perpen dicular to the vertical and perpendicular to the centre line of the tong d Grasp the green tong door latch handle on the right hand door assembly on the left hand side as seen from the front and pull the door to release the latch and open the door See Illustration 2 J 3 Opening the tong door will activate the safety door system and prevent rotation of the cage plate SeTup amp opeRATion IllustratIon 2 j 3 openIng rh tong door KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 32 TechnicAL MAnuAL SeTup amp opeRATion Making A Connection Continued e Grasp the green tong door handle on the left hand door assembly on the right hand side as seen from the front and pull the door completely open See Illustration 2 J 4 IllustratIon 2 j 4 openIng lh tong door f Grasp the green tong door handle on the backup door weldment and pull the d
152. ipment PPE specified by your company s HSE policy and follow all of your company s safety guidelines Inspect anti tamper devices on safety door components before beginning job Equipment showing signs of tam pering on any safety system must be immediately removed from service and tested Anti tamper devices must be restored before allowing equipment to be released to an operating environment 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 illustrations on the following pages demonstrate the type and effect of the hydraulic valves with which this tong is may be equipped KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 26 TechnicAL MAnuAL SeTup amp opeRATion TONG MOTOR This is a proportional valve Pushing the valve handle forward will cause the tong motor to rotate in a clockwise direction as seen from the top of the tong This is the desired direction of rotati
153. ith 5 16 socket head wrench 1 Press shaft out of bearing box 2 Proceed to step 9 disregarding steps 11 amp 12 1 Loosen clamp screw in lock nut 2 Unscrew lock nut and remove Lift up on the bearing box to remove from motor 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 of the motor REMOVAL OF SHAFT SEAL REMOVAL OF WHEEL MOTOR SEAL PLATE AND BEARING BOX DISASSEMBLY OF WHEEL MOTOR BEARING BOX KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 9 TechnicAL MAnuAL hyDRAuLic coMponenT inFoRMATion WARNING RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 9 10 11 12 13 14 15 16 6 1 Remove front housing 2 Note Two 5 16 ball checks and one main body o ring may be dislodged and fall free 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 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 bearing 1 Replace plate on rotor stator cartridge 2 Turn rotor stator cartridge over 3 Rep
154. itting 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 Part Hydraulic Outlet DVA35 PB55 Closed Centre Tongs Only 1 08 1825 T Part DVA35 DA8 4WAY SAE Ports 1 10 9019 U Assembly Handle Assembly 3 01 0409 Part Hydraulic Valve Handle 1 01 0409 HANDLE Part Valve Handle Link 2 01 0409 LINK Part Hydraulic Handle Pin 2 01 0409 PIN1 Part Hydraulic Handle Auxiliary Pin 1 01 0409 PIN2 Part Valve Handle C Clip 2 01 0409 CIRCLIP Part Cotter Pin 2 01 0409 COTTER V Part DVA35 SA8 Valve 1 ORB PORT 1 10 9015 W 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 SEAL KIT Seal kit for DVA35 Valve 02 9133 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 30 TechnicAL MAnuAL cAge pLATe ASSeMBLy KT13625 Tong A B C D K J L M N T U Q P S E F G H U R KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 31 TechnicAL MAnuAL cAge pLATe ASSeMBLy KT13625 Tong It
155. ke band retainer lug weldments and the front leg assemblies 8 occurrences backup ready or 6 occurrences stand alone tong KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 10 TechnicAL MAnuAL SuppoRT RoLLeR DooR piVoT A B D J C F E C D E H G F G KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 11 TechnicAL MAnuAL SuppoRT RoLLeR DooR piVoT Item Type Description Qty Part Number A Part 1 4 24 NF Grease Fitting 1 02 0097 B Part Support Roller Shaft 1 101 0046 C Part 7 8 Narrow Washer 2 09 5123 D Part Roller Cap Spacer 2 997 D21 140 E Part Metric B062M Inside Snap Ring 2 02 0013 F Part Cylindrical Roller Bearing KT13625 Tongs 2 02 0014 Part Ball Bearing Roller Bearing LW13625 Tongs 2 02 0101 G Part Roller Cup 2 997 D21 135 H Part Door Roller Sleeve 1 997 D21 134 J Part 3 4 UNF Thin Hex Nylock Nut 1 09 5718 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 12 TechnicAL MAnuAL RoTARy iDLeR ASSeMBLy A B C D E F G H J F E D C B KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 13 TechnicAL MAnuAL 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 02 5740 C Part Rotary Idler Pad 2 997 D20 125 D P
156. laced 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 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 Farr style BacKup only 4 Inspect cam ring gear for broken teeth 5 Lubricate the cam follower array 6 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 7 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 c
157. ld up Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease 2 Remove the access panel on the side of the tong directly adjacent to the shifter mechanism 3 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 4 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 5 Inspect all fasteners and fastener safety wires Replace any missing fasteners use Grade 8 bolts only Re torque all external fasteners to SAE specifications 6 Inspect backing pin s If cracked broken or bent it they must be replaced 7 Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc
158. lt InstallatIon 62 Install hydraulic inlet support base PN 101 1138 to the top plate between the RH pinion idler and RH rotary idler using two 3 8 UNC x 1 hex bolts and 3 8 lock washers Attach a adjustment plate PN 101 0022 to the support base using two 3 8 UNC x 1 hex bolts 3 8 narrow flat washers and 3 8 UNC hex nylock nuts 63 Attach the outlet coupling support weldment mount PN 101 0021 to the top plate to the RH side of the motor mount using four 3 8 UNC x 1 hex socket head cap screws Attach the outlet coupling support PN 101 0023 to the weldment mount using two 3 8 UNC x 1 hex bolts and 3 8 lock washers Attach a second adjustment plate PN 101 0022 to the support base using two 3 8 UNC x 1 hex bolts 3 8 narrow flat washers and 3 8 UNC hex nylock nuts KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 28 TechnicAL MAnuAL Assembly Procedure Continued 64 Use a crane and a temporary lifting sling to transport the hydraulic valve assembly to the top of the tong Attach to the valve mount weldments using two 1 2 UNC x 5 hex bolts and 1 2 narrow flat washers 65 Attach two 20 1 1 4 1 JIC flange elbows PN 02 9216 to the motor using 20 split flange kits PN 02 9217 66 Connect the safety door valve block PN 101 0727 directly to the flange elbows on the hydraulic motor the block will sit on top of the motor followin
159. mal 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 alignment remove the 3 8 bolt and turn the cam with a wrench When the door has been adequately aligned replace the 3 8 bolt 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 IllustratIon 3 F 2 door latch caM adjustMent DOOR LATCH ADJUSTMENT CAM KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 11 TechnicAL MAnuAL MAinTenAnce 3 Door Alignment Each door weldment is equipped with two set screws along with jam nuts to lock position to align the door when it is in the closed position InItIal alIgnMent Ensure tong doors are closed and inspect how one door aligns with the other at the point at which they meet If misalignment is seen choose one or the other door to adjust Use a box end wrench to loosen the lock nuts on the insides of the door wel
160. mining 2 Equipment Category high level of protection Gc Gas Group Acetylene amp Hydrogen Certified for use in an acetylene hydrogen environment T6 Maximum surface temperature of 85 oC IllustratIon 1 a 4 Farr ce naMeplate II 2 G c T6 SpeciFicATionS KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 1 5 TechnicAL MAnuAL These are ideal values Actual achieved torque is highly dependant upon tong efficiency final posi tion of rotary gear when full torque load is reached and the motor with which the tong is equipped Torque Table Lightweight Tong Pressure High Gear Low Gear PSI MPa Lbs ft Nm Lbs ft Nm 1000 6 895 1696 2299 8482 11500 1500 10 34 2866 3886 14332 19432 2000 13 79 4036 5472 20181 27362 2400 16 55 4972 6741 24861 33707 MAXIMUM RATED TORQUE 25000 LBS FT 33895 Nm Speed Table Flow US GPM LPM Low Gear RPM High Gear RPM 10 37 9 1 8 9 2 20 75 71 3 7 18 5 40 151 4 7 4 36 9 60 227 1 11 1 55 4 Specifications LW13625 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 ONLY USE SPRING HANGER SUPPLIED BY MCCOY IF USING SPRING HANGER REFER TO SEC TION 2 H FOR PROPER RIGGING INSTRUCTIONS Maximum Hydraulic Requirements KT13625 60 GPM 227 1 LPM 3000 PSI 20 684 MPa M
161. n 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 I 5 k Continued on next page IllustratIon 4 B 1 relIeF valve trouBleshootIng teMporary gauge InstallatIon POSSIBLE PROBLEM SOLUTION S 1 Relief pressure set too low resulting in in sufficient tong torque Adjust setting See following procedure Relief pressure set too high resulting in 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 D c Tee in a temporary indicator at the safety door supply pressure port Ensure all hydraulic connections are performed by a qualified hydraulic technician Connect a temporary 0 3000 PSI pressure indicator at this location KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 4 3 TechnicAL MAnuAL TRouBLeShooTing PROCEDURE a Isolate your tong from hydraulic power and depressurize following the procedure in section 3 D b Loosen the locking nut on the pressure relief valve c Use a large flat head screwdriver to completely un threa
162. n Step 3 and have the opening in the rotary gear oriented as shown in the following illustration IllustratIon 3 I 1 tong asseMBly rotary gear InstallatIon 6 Install support roller assemblies in the locations exposed by the opening in the rotary gear Continue to rotate the rotary gear installing 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 Do not install the two door pivot support roller assemblies at this time 7 Press pinion bearing PN 1234 08 01B into bottom pinion bearing cap and install bearing cap into bottom plate of tong using four 1 2 UNC x 1 1 4 hex bolts and 1 2 lock washers 8 Press lower clutch bearing PN 02 0014 into bottom clutch bearing cap and install bearing cap into bottom plate of tong using four 3 8 UNC x 1 1 4 hex bolts and 3 8 lock washers 9 Install a retainer clip PN 02 0009 into both rotary idler gears Press an idler bearing PN 02 0075 into each gear and secure with a second retainer clip 10 Lightly grease the larger circumference of the two rotary idler shafts and slide them through the bearing and gears assemblies centering the gear on the shaft 11 Slide two bearing seals PN 02 0010 over each end of the idler shafts and press against the retainer clips KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 18 TechnicAL MAnuAL MAinTenAnce
163. n 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 IllustratIon 2 g 3 load cell conFIguratIon MaKe up IllustratIon 2 g 4 load cell conFIguratIon BreaK out Load cell configured for make up operations Load cell configured for break out operations KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 25 TechnicAL MAnuAL 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 2 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
164. nance 1 Rotate the tong to the open throat position Ensure 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 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 MAinTenAnce KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 31 TechnicAL MAnuAL 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 13 Perform a complete greasing of the tong refer to Maintenance section of the technical manual 14 Ensure main supply and return connections to the tong are fully made u
165. nation of Sun cartridge control options US units Explanation of Sun cartridge control options metric units Two piece floating cartridge construction Copyright 2006 2007 Sun Hydraulics Corporation All rights reserved Maximum Valve Leakage at 110 SUS 24 cSt 2 in min 1000 psi 30 cc min 70 bar Response Time Typical 10 ms Series from Cavity Series 1 Valve Hex Size 7 8 in 22 2 mm Valve Installation Torque 30 35 lbf ft 45 50 Nm Adjustment Screw Hex Socket Size 5 32 in 4 mm Adjustment Nut Hex Size 9 16 in 15 mm Adjustment Nut Torque 108 lbf in 12 Nm Seal Kits Buna 990 010 007 Seal Kits Viton 990 010 006 RPEC LAN Control Adjustment Range External Material Seal Material Preferred Options L Standard Screw Adjustment A 100 3000 psi 7 210 bar 1000 psi 70 bar Standard Setting W 150 4500 psi 10 5 315 bar 1000 psi 70 bar Standard Setting N Buna N Standard Options C Tamper Resistant Factory Set F Hex Head Screw with Locknut B 50 1500 psi 3 5 105 bar 1000 psi 70 bar Standard Setting C 150 6000 psi 10 5 420 P Stainless Buna N V Viton W Stainless Viton
166. nd Stat O Seal Items C and D on Illustration 6 A 4 or item H on Illustration 6 A 5 to allow trapped air to escape f 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 i Disconnect the hand pump from the torque gauge j Replace the brass cap on 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 drill 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 lbs 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 c Suspend the load cell piston side up from a crane capable of supporting the known weight in Step 3a d
167. nd warnings SPanchal 3 30 Renumbered Section 3 J Daily Inspection amp Maintenance Checklist Power Tong Added CE Specific information 3 32 Renumbered Section 3 K Daily Inspection amp Maintenance Checklist Backups 3 33 Renumbered Section 3 L Monthly Inspection amp Maintenance Checklist Power Tong 3 36 Renumbered Section 3 M Tubular Connection Equipment De Commissioning Revised section to add packaging and shipping instructions and retitled Tubular Connection Equipment De Commissioning amp Shipping 3 41 Renumbered Section 3 N Tubular Connection Equipment Re Commissioning 4 4 1 Revised section 4 A Troubleshooting Tong Will Not Develop Sufficient Torque 4 2 Inserted new section 4 B Troubleshooting Relief Valve 4 4 Inserted new section 4 C Troubleshooting Safety Door 4 5 Renumbered section 4 D Troubleshooting Tong Running Too Slowly 4 6 Renumbered section 4 E Troubleshooting Failure of Jaws to Grip Pipe 4 7 Renumbered section 4 F Troubleshooting Shifting 5 5 2 Inserted list of critical spare parts 5 3 Inserted list of recommended spare parts 5 4 Inserted list of parts needed for complete overhaul Removed Images and B O M s Tong Body Assembly 5 22 5 23 Inserted new illustration amp B O M Hydraulic Valve Assembly Supports 5 26 5 27 Replaced illustration amp updated B O M Motor Mount Assembly 5 30 5 31
168. nents including 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 Minimum Allowable Chain Link Thickness at Any Point Nominal Chain Size Minimum Thickness Inches MM Inches MM 7 32 5 5 0 189 4 80 9 32 7 0 239 6 07 5 16 8 0 273 6 93 3 8 10 0 342 8 69 1 2 13 0 443 11 26 5 8 16 0 546 13 87 3 4 20 0 687 17 45 7 8 22 0 750 19 05 1 26 0 887 22 53 1 1 4 32 1 091 27 71 Refer To ASME B30 9 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 6 TechnicAL MAnuAL SeTup amp opeRATion 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 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 Test Examination tIMe Interval lIFtIng tests1
169. ng when cleaning tong parts in cold weather THE SNAP BREAK METHOD IS HAZARDOUS TO PERSONNEL AND EQUIPMENT 6 General Operational Comments a Position rotary gear in contact with both idler gears when breaking out joints 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 30 TechnicAL MAnuAL J MAKING AND BREAKING CONNECTIONS Set up and prepare your equipment for operation as per Section 2 of this manual Refer to the following sections 2 D Lift Cylinder Installation 2 E 3 Hydraulic Connections 2 F Tong Jaw Installation 2 G 1 Tong Rig up and Levelin
170. nicAL MAnuAL 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 McCoy Drilling amp Completions does not guarantee the accuracy of the information contained in this section All original copyrights claimed by the manufacturer s apply KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 2 TechnicAL MAnuAL Eight fixed displacement motors ranging from 6 in3 to 15 in3 Starting and stall torques equal to 90 94 of theoretical torque Speed to 2 000 RPM continuous Up to 75 HP continuous Conforms to SAE C mounting specification Weighs 43 lbs Features of the 15 Series Standard Motor Standard Motor 3000 PSI Code 61 MOTOR SELECTION GUIDE POWER to be the Best CROSS SECTION Made in USA PUBLICATION DS151005 8 03 HYDRAULICS INC HYDRAULICS INC R M A N U F A C T U R E R O F H Y D R A U L I C M O T O R S KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 3 TechnicAL MAnuAL 1 38 SAE 14T 12 24 PITCH FLAT ROOT SIDE FIT INVOLUTE SPLINE OPTIONAL SHAFT 6 81 3 41 4 51 5 70 9 16 DIA 4 HOLES 17 17 CENTER LINE CASE DRAIN CENTER LINE CASE DRAIN 5 91 5 69 7 17 2 18 5 87 24 51 1 6
171. non destructIve exaMInatIon nde oF lIFtIng poInts thorough vIsual exaMInatIon suFFIx to Be MarKed on plate attached to unIt Initial Certification By Farr Superior YES YES YES T Interval Not Exceeding 12 Months At the discretion of inspection body At the discretion of inspection body YES T or VN3 Interval Not Exceeding 60 Months At the discretion of inspection body YES YES T or VN Following Substantial Repair or Alteration YES YES YES T 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 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 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 sh
172. nt 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 strap ping Before tightening strapping place strapping protectors wherever the metal strapping comes into contact with the equipment IllustratIon 3 M 3 shIppIng InstructIons BacKup support KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 40 TechnicAL MAnuAL MAinTenAnce 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 lbs 454 kg or less 3 4 x 0 029 metal strapping 3320 lbs 1509 kg tensile strength Minimum two straps Assemblies weighing more than 1000 lbs 454 kg or less 1 1 4 x 0 031 metal strapping 5500 lbs 2500 kg tensile strength Minimum two straps for assemblies weighing less than 5000 lbs 2273 kg Minimum three straps for assemblies weighing more than 5000 lbs 2273 kg Before tightening strapping place strapping protectors wherever the metal strapping comes into contact with
173. nuAL MAinTenAnce 4 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 achieved 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 F 4 shIFter detent Force adjustMent 5 Safety Door Adjustment The safety door system is the prime protective measure separating the operator from the rotary gear and must be in working condi tion when operating tong The safety door switch is designed to interrupt hydraulic power to the motor when the tong door is opened or even slightly ajar This is a critical safety system and proper adjustment is necessary to maintain the intended function KEEP HANDS CLEAR OF SAFETY DOOR LATCH CLAWS PAINTED YELLOW WHEN CLOSING DOOR If the rotary gear does not stop immediately and completely stop rotating when the door is opened remove the tong from service and perform the following adjustments a Perform a preliminary assessment to ensure the safety door switch is functioning i Connect the tong to hydraulic power in a controlled environment ii Attempt to rotate the
174. 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 23 TechnicAL MAnuAL SeTup amp opeRATion Tong Leveling continued 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 front or rear adjusting bolt equally on each hanger lug until tong hangs level front to back Lock adjusting bolts in place with the jam nuts IllustratIon 2 g 2 tong levelIng Front to BacK IllustratIon 2 g 1 tong levelIng sIde to sIde ONLY USE THE MASTER LINK TO SUSPEND THE TONG ASSEMBLY THE RIGID SLING IS DESIGNED TO BE USED FOR VERTICAL LIFTING ONLY Rotate helix using flat 3 4 nylock nut may require loosening KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 24 TechnicAL MAnuAL SeTup amp opeRATion 3 Load Cell Configuration The backup is directly coupled to the compression load cell via the backup body paddle The load cell 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 i
175. o not obstruct front leg and rear leg areas 71 Lift tong and rear leg assembly and lower onto backup so that the front legs lower through openings in backup A small amount of maneuvering may be necessary to position the load cell weldment between the two rear leg plates as the tong is lowered over the backup Continue to lower tong assembly so that roughly half the lengths of the front legs protrude through the bottom of the backup CE marked tongs only place a rubber protective washer PN 101 5733 on the top plate of the backup over each front leg opening The front legs will be inserted through these protective washers 72 Slide a top spring cap PN 1302 905 03B over each leg followed by the front leg springs PN 997 906 02 and the bottom leg spring caps PN 1302 905 03A Secure in place with a 1 2 NC x 4 1 2 hex bolt nut and two flat washers Note that the position of these bolt assemblies and the bottom spring cap may have to be adjusted when leveling the backup 73 Attach two rear support springs PN 1302 905 06 to the rear suspension bracket on the backup and the U Bolt spring holder links on the bottom plate of the rear leg 74 Lift tong and backup assembly high enough so that the backup supports can be removed Lower assembly until it rests on its legs 75 Install grease fittings i Install one 1 4 straight thread grease fitting PN 02 0097 into the top side of each support roller shaft in
176. of the motor seal A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE TONG ROTATION IN ORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL 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 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 i 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
177. omponents 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 unIt 10 Perform a visual inspection of pressurized hydraulic lines document and correct any hydraulic fluid leaks 11 Perform a full functional test of the backup Document and correct hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are in use on the backup KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 33 TechnicAL MAnuAL MAinTenAnce L MONTHLY MAINTENANCE CHECKLIST POWER TONG The following maintenance checklist is intended as a guideline rather than a definitive maintenance schedule Your equipment 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 in the rotary gear faces towards the rear of the tong 3 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 solven
178. 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 interval are Normal Service yearly Severe Service monthly to quarterly Special Service as recommended by a qualified person 1 Inspection Of Slings McCoy 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 compo
179. on 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 Releasing the valve handle will cause the tong to immediately stop rotation LIFT CYLINDER CONTROL VALVE 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 Pushing on the lift cylinder control valve handle toward the center of the tong will cause the equipment to lift while pulling on the lift cylinder control valve handle toward the operator will cause the equipment to lower This valve handle action applies to all CE marked tongs and is irregardless of control valve bank orientation LIFT CYLINDER NEEDLE VALVE See illustration 2 H 2 This needle valve regulates hydraulic fluid flow to the lift cylinder Closing the needle valve rotating the knob clockwise will increas ingly restrict the flow rate of the fluid resulting in slower actuation of the cylinder in both directions lifting amp lowering IllustratIon 2 h 1 Motor control valve IllustratIon 2 h 2 lIFt cylInder control valve Lift Cylinder Needle Valve KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 27 TechnicAL MAnuAL SeTup amp op
180. oor completely open See Illustration 2 J 5 As the backup door is opened the kicker bar which is a component of the door weldment will swing into the rotary opening This kicker bar mechanically causes the backup door to swing shut as the tong and backup assembly is moved on to a pipe string IllustratIon 2 j 5 openIng BacKup door KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 33 TechnicAL MAnuAL RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR IllustratIon 2 j 6 lIFt cylInder control raIse non ce MarKed tongs Making A Connection Continued g Actuate the lift cylinder control valve to lift the assembly from the drill floor Pulling on the valve handle toward the operator will retract the lift cylinder to lift the assembly see Illustration 2 J 4 below Note that rig personnel are required to stabilize the tong and backup as it is being lifted so it does not swing and collide with other rig equipment h Manually engage the threads of the tubing connection being made up Ensure threads are not cross threaded i Move the tong and backup assembly on to the tubing joint Use the lift cylinder to ensure the assembly is at the correct height so that the backup jaws are located below the connection point and the tong jaws are located above the connection joint j As the assembly is moved on to the joint the pipe will contact the kicker bar on the rear of the
181. oor 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 Ensure wire ties where applicable on safety door components are present and secure and do not show signs of tampering DO NOT OPERATE TONG WITH A MALFUNCTIONING OR NON OPERATING SAFETY DOOR SYSTEM KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 29 TechnicAL MAnuAL SeTup amp opeRATion I 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 hydraulic fluid that is compatible with expected climatic conditions 4 Allow hydraulic 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 fluid has reached operating temperature as specified by hydraulic fluid data sheet 5 Allow for adequate drying of moisture prior to lubricati
182. ort Roller Assembly Pp 5 4 5 5 8 J Assembly Door Door Pivot Roller Assembly Pp 5 6 5 7 2 K Part Rotary Gear 1 997 D1 B KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 8 TechnicAL MAnuAL SuppoRT RoLLeR A B D J C F E C D E H G F G KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 9 TechnicAL MAnuAL SuppoRT RoLLeR Item Type Description Qty Part Number A Part 1 4 24 UNF Grease Fitting 1 02 0097 B Part Support Roller Shaft See Note A 1 101 1266 101 1268 C Part 7 8 Narrow Washer See Note B 2 09 5123 D Part Roller Cap Spacer 2 997 D21 140 E Part BS 3673 Metric B062M Retaining Ring 2 02 0013 F Part Cylindrical Roller Bearing KT13625 Tongs 2 02 0014 Part Ball Bearing Roller Bearing LW13625 Tongs 2 02 0101 G Part Roller Cup 2 997 D21 135 H Part Support Roller Sleeve 1 997 D21 134 J Part 7 8 UNF Thin Hex Nylock Nut 1 09 5722 NOTE A Where the support roller is coincidental with the front leg assembly shaft number 101 1268 is used 4 occurrences NOTE B Upper washers are not used where the support roller assembly is coincidental with the brake band retainer lug weldments and the hydraulic valve mount post weldments 6 occurrences Lower washers are not used where the support roller assembly is coincidental with the bra
183. ortened 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 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 McCoy 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 McCoy recommends that an anti corrosive agent such as Tectyl 506 be applied to all external surfaces Refer to manufac turer data sheets for proper application and safety information Allow the anti corrosive coating ample time to dry refer to manufacturer da
184. owel pins are in any way damaged or deformed McCoy recommends replacing them with new 3 8 x 1 1 2 hardened dowel pins If necessary clean the dowel pin holes and do not insert dowel pins until after the top plate has been installed 28 Use a temporary lifting sling and crane to maneuver the top plate PN 101 0025 into position and place on to the side body Insert the three positioning dowel pins PN 09 0092 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 Secure the top plate with eighteen 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers and two 3 8 UNC x 1 hex socket head cap screws as shown in illustration 3 H 3 Do not install fasteners at the rigid sling hanger locations indicated by the red circles or the door cylinder mounting lug locations indicated by the green circles 29 Install half moon idler pads 9PN 997 D17 108 over the end of each pinion idler shaft and secure each with three 5 8 UNC x 1 3 4 hex bolts and 5 8 lock washers followed by a 1 1 2 UNF nylock nut 30 Slide the remaining rotary idler pads PN 997 D20 125 over the end of the two rotary idler shafts and secure each with 1 1 2 UNF nylock nuts 31 Press the remaining pinion bearing PN 1234 08 01B into the top pinion bearing cap and install over the top of the pinion gear shaft secure with four 1 2 UNC x 1 1 4 hex
185. p SecTion conTenTS 5 22 TechnicAL MAnuAL hyDRAuLic VALVe SySTeM SuppoRTS B C D E L C J H K F G D M N K A KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 23 TechnicAL MAnuAL hyDRAuLic VALVe SySTeM SuppoRTS Item Type Description Qty Part Number A Assembly DVA Valve Assembly 1 See Pp 2 10 2 14 B Part 3 8 UNC x 1 1 2 Hex Bolt 2 09 1553 C Part 3 8 Narrow Flat Washer 4 09 5124 D Part 3 8 Thin Nylock Nut 4 E Part Hydraulic Outlet Support Base 1 101 0023 F Part Hydraulic Support Mount Block 1 101 0021 G Weldment Hydraulic Inlet Support Base 1 101 1138 H Part 1 2 UNC x 5 Hex Bolt 2 09 1186 J Part 1 2 Lock Washer 2 09 5110 K Part Adjustable Support Plate 2 101 0022 L Part 3 8 UNC x 1 Hex Bolt 6 09 1046 M Part 3 8 Lock Washer 6 09 5106 N Weldment Hydraulic Valve Mounts 2 101 0011 P Part 1 2 UNC x 4 1 2 Hex Bolt 1 09 1184 q Weldment Valve Handle Guard Weldment 1 CE HANDLE 3 R Part 1 2 Narrow Flat Washer 1 09 5010 S Part 1 2 Thin Nylock Nut 1 09 5610S G H P S Q G H R The illustration on this page applies to CE Marked versions only KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 24 TechnicAL MAnuAL BRAKe BAnD ASSeMBLy C D A G B F H E KT LW 13625 13 5 8
186. p COMPLETIONS SERVICE PERSONNEL RECOMMENDS LEAVING IT IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED Removal of Top Plate Continued 15 Remove the motor mount by removing the four socket head cap screws The motor mount can be lifted out of place Take care not to lose the two position dowels one or both may come off with the mount 16 Remove the snap ring that secures the top clutch gear Remove the top clutch gear and top clutch bushing Remove the 10 x 3 4 socket head cap screws securing the bearing retainer to the top plate and remove the bearing retainer 17 Remove the clevis pin connecting the shifting shaft handle to the shifting shaft Back off the shifter position detent spring and ball assembly as much as possible without removing the detent assembly 18 Remove the access panel on the body side adjacent to shifter assembly Remove the 5 8 fine thread nut and 5 8 fine thread jam nut from the shifting shaft to loosen the shifting fork The shifting shaft may now be carefully rotated and pulled out of the top shifter bushing 19 Loosen the top brake band See page 3 3 by backing off the brake band adjustment bolts until the nut is flush with the end of the bolt 20 Remove the backing pin assembly but leave the rear cage plate bolt in place KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 16 TechnicAL MAnuAL MAinTenAnce ALL FASTENERS USED DURING REASSEMBLY OF LOAD
187. p 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 NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR 15 Perform a visual inspection of the load cell If using a tension load cell 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 hydraulic line fittings and diaphragm seals for fluid leaks 16 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 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 17 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi 18 Perform a visual inspection of pressurized hy
188. quired Dumbbell Roller Bearings 02 0014 28 Idler Bearing 02 0075 4 Pinion Bearing 1234 08 01B 2 Ball Bearing Bottom Clutch Bearing 02 0014 1 Needle Bearing Clutch Shaft 02 1404 4 Ball Bearing Top Clutch Bearing 02 1403 1 Cam Follower LW13625 02 0016 22 Door Bushing Top 101 5110 2 Door Bushing Bottom 101 5111 2 oVeRhAuL pARTS LiST KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 5 TechnicAL MAnuAL ITEMS ON THE CRITICAL SPARE PARTS LIST MARKED IN RED INDICATE ESSENTIAL HEALTH amp SAFETY ITEMS FAILURE TO REPLACE DAMAGED ESSENTIAL HEALTH amp SAFETY ITEMS WILL PRESENT IMMEDIATE DANGER TO PERSONNEL OR EQUIPMENT HAVE THESE ITEMS ON HAND AT ALL TIMES STOP WORK AND QUARANTINE TONG UPON DISCOVERY OF DAMAGED OR DEFECTIVE HEALTH AND SAFETY COMPONENTS UNTIL PARTS CAN BE REPLACED FASTENERS amp FITTINGS Description Part Number Qty Required Idler Seal 02 0010 6 Idler Retainer 02 0009 8 1 4 Straight Thread Grease Fitting 02 0097 16 1 8 NPT Grease Fitting 02 0005 5 1 8 NPT 90o Grease Fitting 02 0093 7 Snap Ring Clutch Shaft 1234 00 04 1 Motor Gear Set Screw 09 0106 2 Motor Key 01 0317 1 7 8 Narrow Flat Washer Support Roller Washer 09 5123 18 7 8 UNF Thin Nylock Nut Support Roller Fastener 09 5722 12 3 4 UNF Thin Nylock Nut Door Pivot Support Roller Fastener 09 5718 2 Hex Bolt 1 2 UNC X 7 Cage Plate Bolt
189. r weldment using three 3 8 UNC x 1 hex socket head cap screws b Attach safety door latch block PN 101 0319 to the RH door weldment using two 3 8 UNC x 1 1 2 socket head countersunk cap screws and one 3 8 UNC x 1 1 2 hex bolt and lock washer c Attach safety door latch block PN AE13 301S to safety door latch plate PN AE13 311 using three 3 8 NC x 1 flat head countersunk cap screws d Attach the assembly from step iii to the safety door latch plate PN 101 0320 using four 5 16 x 3 4 shoulder bolts CE marked tongs only attach assembly from Step 56c to the safety door latch plate PN 101 0320 t using four 5 16 x 3 4 UNC wire drilled shoulder bolts e Attach safety door latch block PN AE13 302M to the safety door latch block PN 101 0319 using four 3 8 UNC x 3 4 hex bolts CE marked tongs only attach safety door latch block PN AE13 302M to the safety door latch block PN 101 0319 using four 3 8 UNC x 3 4 wire drilled hex bolts f Insert load plunger PN AE12 306 into LH safety door latch block PN AE13 301S KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 26 TechnicAL MAnuAL MAinTenAnce Assembly Procedure Continued 57 Install the safety door components continued g 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 in illustration 3 I 9 and secure the
190. ratIon 1 a 3 Kt13625 tong amp Farr BacKup hazard areas ce MarKed Model shown 1 3 IllustratIon 1 a 4 Farr ce naMeplate 1 4 IllustratIon 2 B 1 Kt13625 tong amp Farr BacKup Major coMponent IdentIFIcatIon 01 2 1 IllustratIon 2 B 2 Kt13625 tong amp Farr BacKup Major coMponent IdentIFIcatIon 02 2 2 IllustratIon 2 B 3 Kt13625 tong amp Farr BacKup Major coMponent IdentIFIcatIon 03 2 3 IllustratIon 2 c 1 slIng angle 2 4 IllustratIon 2 d 1 lIFt cylInder amp sprIng hanger InstallatIon 2 7 IllustratIon 2 d 2 lIFt cylInder hydraulIc connectIon 2 8 IllustratIon 2 e 1 Kt13625 tong amp Farr BacKup hydraulIc scheMatIc 2 10 IllustratIon 2 e 2 Kt13625 tong amp Farr BacKup hydraulIc closed centre 2 11 IllustratIon 2 e 3 Kt13625 tong amp Farr BacKup hydraulIc scheMatIc ce MarKed 2 12 Ill
191. 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 in protec tive wrap and placing in a separate wooden crate 2 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 tong accessories IllustratIon 3 M 1 shIppIng InstructIons pallet KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 39 TechnicAL MAnuAL MAinTenAnce shIppIng InstructIons contInued 3 Use a crane 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 M 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 independe
192. 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 ALWAYS WEAR APPROVED PERSONAL PROTECTIVE EQUIPMENT PPE WHEN OPERATING HYDRAULICALLY 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 The area surrounding the tong operating area must be clutter 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 equ
193. ressure and maximum torque are listed in the specifications on page 1 3 Actuating the valve handle on the motor control section directs hydraulic fluid to the hydraulic motor Item 9 on the hydraulic sche matic and on page 2 7 through the safety door relief valve block Items 5 amp 6 on the hydraulic schematic and on page 2 7 causing rotation of the motor During normal operation pilot pressure from the safety door switch Item 7 on the hydraulic schematic and on page 2 8 directs pilot pressure to actuate the safety door check valves allowing full hydraulic power to the motor The configuration of the plumbing between the motor valve section and the motor determines the direction of rotation for a given valve action McCoy Drilling amp Completions FARR normally configures the plumbing on this tong so that pushing the valve control handle towards the centre of the tong supplies hydraulic pressure to the clockwise rotation side of the motor which is the desired direction of rotation for making up a tubular connection Conversely pulling the valve control handle towards the operator supplies hydraulic pressure to the counter clockwise rotation side of the motor which is the desired direction of rotation for breaking out a tubular connection Releasing the valve handle enables the valve to go to a neutral position directing all hydraulic fluid to the outlet section and back to tank A check valve Item 8 on the hydraulic
194. rt Helical Flexible Encoder Shaft Coupling 1 60 0130N C Part Internal Retainer Ring 2 1376 13 D Part Bearing 2 1376 05 E Part 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 6 5 TechnicAL MAnuAL ToRque MeASuReMenT 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 1 Symptom No indication on gauge Possible Problem Obstruction in hydraulic hose Solutions Check hydraulic hose for kinks Replace hydraulic hose Possible Problem Loss of hydraulic fluid Solution 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 Possible Problem Internal mechanism of torque gauge is damaged Solution Replace gauge 2 Symptom Gauge indication unexpectedly high Possible Problem Excessive hydraulic fluid Solutions Completely drain hydraulic fluid from torque gauge load cell system Recharge following the procedure in S
195. rubbing bare metal where there used to be paint is a good indication of wear 10 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 11 Visually inspect all load bearing welds Any weld that is cracked or separating must be repaired and repainted before returning the tong to service 12 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 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 DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CONNECT ED TO ANY HYDRAULIC POWER S
196. safety door valve to the safety door latch block using the valve lock nut IllustratIon 3 I 9 tong asseMBly saFety door valve InstallatIon h Attach the front safety door guard plate weldment PN 101 0387 to the LH tong door weldment using two 3 8 UNC x 1 hex bolts and lock washers Attach the rear safety door guard plate weldment PN 101 0386 to the safety door latch plate PN 101 0320 using a single 3 8 UNC x 1 hex bolt and lock washer Secure the top guard plate to the front and rear plates using four 3 8 UNC x 3 4 hex bolts and lock washers Note that a safety door adjustment may be necessary to obtain proper operation refer to 3 F 5 CE marked tongs only Attach the front safety door guard plate weldment PN 101 0387 to the LH tong door weldment using two 3 8 UNC x 1 wire drilled hex bolts and lock washers Attach the rear safety door guard plate weldment PN 101 0386 to the safety door latch plate PN 101 0320 using a single 3 8 UNC x 1 wire drilled hex bolt and lock washer Secure the top guard plate to the front and rear plates using four 3 8 UNC x 3 4 wire drilled hex bolts and lock washers Note that a safety door adjustment may be neces sary to obtain proper operation refer to 3 F 5 58 Install the LH amp RH rigid sling mounting lugs LH PN 101 1361 RH PN 101 1364 using two 3 8 UNC x 1 3 4 hex bolts and 3 8 lock washers and two 1 2 UNC x 1 1 4 hex bolts an
197. se the tong jaws from the tubing see Illustration 2 J 9 IllustratIon 2 j 9 usIng Motor control to release jaws In MaKe up Mode r When tong jaws are free release the backup jaws by pulling the backup clamp control handle away from the tong toward the operator see Illustration 2 J 10 next page COMPRESSION ENERGY STORED IN THE BACKUP SUPPORT SPRINGS MAY CAUSE THE TONG TO JUMP SLIGHTLY WHEN TONG JAWS ARE RELEASED SeTup amp opeRATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 36 TechnicAL MAnuAL SeTup amp opeRATion IllustratIon 2 j 10 usIng BacKup control to release BacKup jaws Pulling on the lift cylinder control valve handle toward the operator will cause the equipment to lower This valve handle action applies to all CE marked tongs and is irregardless of control valve bank orientation Making Up A Connection Continued s Unlatch and open the tong door to free the assembly from the tubing Note that rig personnel may be required to stabilize the equipment as it completely releases from the tubing Guide the assembly away from the string Push the lift cylinder control valve toward the centre of the tong to lower the equipment to the drill floor IllustratIon 2 j 11 usIng lIFt cylInder control to lower asseMBly non ce MarKed tongs only t Repeat steps e through p until the desired number of connections are made up KT LW 13625 13 5 8 Tong amp FARR
198. see calculations next page KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 38 TechnicAL MAnuAL MAinTenAnce calculatIon oF requIred desIccant 1 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 approxi mate volume of 113500 in3 or 66 ft3 1 87 m3 2 Multiply the calculated air volume in cubic feet by the recommended amount of desiccant per cubic foot Carrying forth the example used in the previous step the required desiccant charge would be 3 5 g x 66 ft3 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 envi ronment 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
199. sher 4 09 5124 K Part Door Stop Spacer 4 997 13B L Assembly Door Cylinder Assembly 2 101 0069 M Weldment Left Hand Door Weldment 1 101 0032 N Part 3 8 NC x 1 1 2 Hex Bolt 2 09 1553 P Part Door Cylinder Mounting Lug 2 1050 12 001 q Part Shoulder Bushing 4 101 0045 R Weldment Door Latch Weldment 1 101 0038 S Part Door Latch Spring 2 997 16 T Part 3 8 NC x 1 3 4 Hex Bolt 1 09 1557 U Part 3 8 NC Hex Nut 1 09 5806 V Part 5 8 NC Hex Jam Nut 1 09 9141 Tong DooR ASSeMBLy KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 36 TechnicAL MAnuAL SAFeTy DooR coMponenTS B C A D E F K H M B P G J A B L Q R N S T U B V A B rear swItch guard wall Is secured at the BottoM By one 3 8 unc x 1 hex Bolt whIch threads Into part 101 0320 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 5 37 TechnicAL MAnuAL SAFeTy DooR coMponenTS Item Type Description Qty Part Number A Part 3 8 UNC x 1 Hex Bolt 7 09 1046 B Part 3 8 Carbon Steel Lock Washer 11 09 5106 C Part Switch Guard Plate 1 101 0384 D Weldment Rear Switch Guard Wall Weldment 1 101 0386 E Weldment Front Switch Guard Wall Weldment 1 101 0387 F Part Load Plunger 1 AE12 306 G Part 15 16 Valve Lock Nut 1 09 0278 H Part Safety Door Latch Block 1 AE
200. ssembly IllustratIon 2 B 2 Kt13625 tong amp Farr BacKup Major coMponent IdentIFIcatIon 02 SeTup amp opeRATion 12 13 14 15 6 7 8 11 9 10 16 18 17 19 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 3 TechnicAL MAnuAL Item Description 16 Tong Door Latch 17 Hydraulic Valve Assembly 18 Manual Shift Assembly 19 Inspection Panel 20 Torque Gauge Mounting Plate 21 Backup Clamp Cylinder 22 Backup Cam Ring Assembly 23 Hydraulic Fluid Inlet quick Connect Coupling 24 Hydraulic Fluid Outlet quick Connect Coupling 25 Backup Backing Pin Assembly 26 Backup Jaws c w Dies 27 Backup Door SeTup amp opeRATion IllustratIon 2 B 3 Kt13625 tong amp Farr BacKup Major coMponent IdentIFIcatIon 03 23 24 21 22 20 26 25 27 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 4 TechnicAL MAnuAL SeTup amp opeRATion IllustratIon 2 c 1 slIng angle 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 overh
201. 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 3 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 4 Remove the access panel on the side of the tong directly adjacent to the shifter mechanism 5 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 complete 6 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 7 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 cas
202. switch to the mounting plate on the LH door assembly e Test the safety door system Connect hydraulic power to the tong Ensure the door is closed and all personnel are clear Attempt to rotate the cage plate If the cage plate does not rotate further adjustment of the switch is required Repeat steps c d amp e f When the cage plate rotates with the door closed re test the system to ensure power to the motor is interrupted when the door is open the cage plate should immediately and completely stop when the doors are opened g If adjustment limits have been reached before safety door function has been established further troubleshooting of the safety door system is required before the tong is placed into service Some components may be worn past their useful lives and replacement of those components is necessary to restore proper safety door function G 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 Door stop spring fatigue will result in sluggish latch operation Replace the latch spring inside the cylinder when this occurs 2 Shifting Shaft The shifting yoke is secured to the shifting shaft by one hex jam nut and one locknut on the bottom of the yoke Check these nuts after each job Do this by removing the clutch inspection plate and ensuring a snug fit prior to lubrication 3
203. t 8 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less than 350 psi 9 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 10 Perform a thorough inspection of all seals Any seal that is leaking or weeping must be replaced before the equipment is returned to service 11 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 12 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 13 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 14 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 gre
204. t PN 1500 09 04A on the LH side of the motor and secure the weldment and the motor to the motor mount using two 1 2 UNC x 1 1 4 hex bolts and 1 2 lock washers 43 Secure the shifting handle weldment PN 1037 D 20B to the shifting lug weldment and the shifting shaft using one 5 16 x 1 clevis pin and one 5 16 x 1 1 2 clevis pin Secure the clevis pins with small R hitch pins or cotter pins 44 Install the cage plates KT13625 Tong a Pre grease the support ring slot in the lower cage plate 997 HT 22 Install the lower support ring PN 997 HT 23 BOT in the lower cage plate using eleven 3 8 x 1 3 4 socket head cap screws b Pre grease the support ring slot in the rotary gear Install the upper support ring PN 997 HT 23 TOP in the rotary gear using eleven 3 8 x 1 3 4 socket head cap screws c Pre grease the support ring slot in the top cage plate and set top cage plate in place mating the support ring slot with the support ring attached to the rotary gear d Secure the bottom cage plate to the top cage plate using two 1 2 UNC x 6 hex bolts at the front and temporarily install two jaw pivot bolts PN 997 D3 28 at the rear of the cage plate assembly to provide support e 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 backing pin retainer PN 101 4139 over the backing pin spacer f
205. t 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 4 Remove the access panel on the side of the tong directly adjacent to the shifter mechanism 5 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 6 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 7 Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc 8 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 9 Inspect tong for signs of premature wear or moving parts that are
206. ta 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 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 7 TechnicAL MAnuAL SeTup amp opeRATion IllustratIon 2 d 1 lIFt cylInder amp sprIng hanger InstallatIon D LIFT CYLINDER INSTALLATION The lift cylinder is not orientation specific that is the lift cylinder will function the same way independent of which end is connected to the crane and which end is connected to the main lifting lug of the tong or the spring hanger if used However McCoy recommends orient ing the lift cylinder with the hydraulic hose connection at the bottom of the cylinder to ensure the hose is not stressed when cylinder is at full extension TEST LIFT CYLINDER BEFORE INSTALLATION REFER TO THE LIFT CYLINDER TECHNICAL MANUAL FOR DETAILED TESTING AND OPERATING PROCEDURES AND DETAILED SAFETY GUIDELINES 1 Installation Procedure i Use a crane to hoist the lift cylinder by the shackle ensuring the hydraulic hose connection is at the bottom of the cylinder when it is hoisted ii Remove the two R clips securing the clevis pin and remove the clevis pin iii Orient the spring hanger so the piston will extend down during thread make up preventing water and debris from gathering around the seal iv Place the welded U connection inside the clevis Replace
207. 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 x 0 029 metal strapping see Illustration 3 M 4 If it is not practical to place larger loose items in 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 completely 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 IllustratIon 3 M 4 shIppIng InstructIons strappIng equIpMent to pallet KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 3 41 TechnicAL MAnuAL MAinTenAnce N 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 7 Energize power uni
208. to retract the lift cylinder to lift the assembly see illustration 2 J 6 Note that rig personnel are required to stabilize the tong and backup as it is being lifted so it does not swing and collide with other rig equipment RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR f As the assembly is moved on to the joint the pipe will contact the kicker bar on the rear of the backup door causing the backup door to close Ensure backup door and tong door are fully closed against the latch posts Use the lift cylinder to ensure the assembly is at the correct height so that the backup jaws are located below the connection point and the tong jaws are located above the connection joint g Firmly close the tong and backup doors Ensure the tong doors are securely latched tug on the tong door handle to ensure it remains latched Pushing on the lift cylinder control valve handle toward the center of the tong will cause the equipment to lift This valve handle action applies to all CE marked tongs and is irregardless of control valve bank orientation SeTup amp opeRATion KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 2 38 TechnicAL MAnuAL SeTup amp opeRATion Gently push the rotation control valve toward the centre of the tong to slowly rotate the cage plate until the tong jaws cam on to the tubing SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROP
209. ub lines by dividing the maximum torque of the tong by the tong s torque arm expressed in feet For example a 35 000 lbs ft tong with a 36 inch 3 ft torque arm will generate 11667 lbs 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 be leveled side to side and front to rear before placing into service The following guidelines wil assist you when leveling your tong FAILURE TO PROPERLY LEVEL TONG MAY RESULT IN JAW SLIPPAGE OR FAILURE OF JAW COMPONENTS i 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
210. 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 33 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 34 Perform a full functional test of the tong including if applicable backup components lift cylinder and float frame compo nents refer to Section 2 I 4 Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used 35 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 36 Farr recommends that an anti corrosive
211. ure apply a thIn layer oF grease to the surFace oF each MovIng part durIng asseMBly to aId In the asseMBly process 1 Position the tong body gear case on a suitable stationary support ensuring that the bottom body plate remains accessible A set of sturdy metal horses works well in this application 2 Press support roller bearings into the support roller cups and secure with retaining rings 28 total KT 13625 Tongs Press roller bearing PN 02 0014 into a support roller cup 997 D21 135 and secure with an inside retaining ring 02 0013 Repeat for all remaining roller cup assemblies LW 13625 Tong Press ball bearing PN 02 0101 into a support roller cup 997 D21 135 and secure with an inside retaining ring 02 0013 Repeat for all remaining roller cup assemblies 3 Use the roller cup assemblies to assemble five support roller assemblies as shown on Pp 5 4 5 5 but at this time use only items B D E F G amp H i e all the support roller components that reside between the top and bottom plates of the tong plus the support roller shaft 4 Install five support roller assemblies plus shafts along one side of the body case Insert shafts through the bottom plate but do not install the bottom nylock nuts or where used the narrow flat washers 5 Install rotary gear PN 997 D1 B making sure the backing pin slots are on the side facing up Ensure one side is supported by the support rollers installed i
212. ure to the motor when the motor control valve is manipulated Releasing the plunger on the safety door switch by opening the tong door diverts all hydraulic fluid from the safety door switch to the tank line interrupting pilot pressure to the safety door check valves The relief valves close immediately inhibiting system pressure to the motor Full hydraulic power to the motor cannot be restored until the plunger on the safety door switch is depressed by fully closing the tong door F TONG JAW AVAILABILITY amp INSTALLATION 1 Jaw 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 McCoy can custom engineer and manufacture any size of jaw within the range of the tong Jaw systems are available 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 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 All CE marked tongs are configured so that pushing t
213. ure 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 O 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 37 Series Publication DS371003 57 Series Publication DS571003 125 Series Publication DS1251003 Technical Information Retractable Shaft Motor RETRACTING THE SHAFT The shaft is spring loaded into the engaged position Pulling on the knob attached to the shaft at
214. 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 This 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 operation 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 equip ment integrity KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS viii TechnicAL MAnuAL Summary Of Revisions Continued Date Section Page Description Of Revision Approved Jul 2011 5 All Renumbered Assemblies amp Parts as Section 5 SHargreaves 5 2 5 3 Revised graphics amp BOM Gear Train Layout 5 30 5 31 Added graphic amp BOM Cage Plate Assembly Lightweight Tong 6 All Renumbered Torque Measurement as Se
215. ustratIon 2 e 4 Kt13625 tong amp Farr BacKup hydraulIc closed centre ce MarKed 2 13 IllustratIon 2 e 5 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 01 2 14 IllustratIon 2 e 6 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 02 2 14 IllustratIon 2 e 7 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 03 2 15 IllustratIon 2 e 8 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 04 2 15 IllustratIon 2 e 9 Kt13625 tong amp Farr BacKup hydraulIc coMponent Id 05 2 16 IllustratIon 2 e 10 Kt13625 tong amp Farr BacKup hydraulIc connectIons 01 2 16 IllustratIon 2 e 11 Kt13625 tong amp Farr BacKup hydraulIc connectIons 02 2 17 IllustratIon 2 F 1 jaw dIe reMoval 2 20 IllustratIon 2 F 2 jaw reMoval 2 21 IllustratIon 2 g 1 tong levelIng sIde to sIde
216. valves are accurate have low pressure rise vs flow they are smooth and quiet and are moderately fast Download Technical Features Will accept maximum pressure at port 2 suitable for use in cross port relief circuits If used in cross port relief circuits consider spool leakage Main stage orifice is protected by a 150 micron stainless steel screen Not suitable for use in load holding applications due to spool leakage Back pressure on the tank port port 2 is directly additive to the valve setting at a 1 1 ratio All 2 port relief cartridges except pilot reliefs are physically and functionally interchangeable same flow path same cavity for a given frame size 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 Incorporates the Sun floating style construction to minimize the possibility of internal parts binding due to excessive installation torque and or cavity cartridge machining variations Technical Data U S Units Metric Units Model Weight 0 30 lb 0 14 kg Cavity T 10A Capacity 25 gpm 95 L min Adjustment Number of Clockwise Turns to Increase Setting 5 Factory Pressure Settings Established at 4 gpm 15 L min Maximum Operating Pressure 5000 psi 350 bar KT LW 13625 13 5 8 Tong amp FARR BAcKup
217. xactly 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 lbs the calculation is 500 x 32 12 1333 3 Therefore the expected indication on the torque gauge should be approximately 1333 lbs ft If you are using a metric torque measure system calculations are as follows KNOWN WEIGHT 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 4 Repair And Calibration Return the load cell and indicator gauge to the authorized repair facility for repairs and calibration This page intentionally left blank KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 7 1 Tech
218. y 1 10 0071C M A Part Compression Load Cell 1 10 0008C B Part 55000 Nm Gauge 32 Arm Length includes following 1 10 0071G M Part 1 4 FNPT TEE 1 60 0364 Part 1 4 NPT Street Elbow 1 08 0023 Part 1 4 NPT Cap 1 08 0424 C Part 1 5 m Hose Assembly 1 02 0069 KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 6 3 TechnicAL MAnuAL ToRque MeASuReMenT IllustratIon 6 a 4 coMpressIon load cell exploded 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 A B C D E F G H Compression Load Cell 8 in2 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 UNC x 3 4 Hex Socket Head Cap Screw G Part Street Elbow D Part Retainer Ring H Part 1 4 NPT Brass Plug KT LW 13625 13 5 8 Tong amp FARR BAcKup SecTion conTenTS 6 4 TechnicAL MAnuAL ToRque MeASuReMenT IllustratIon 6 a 5 turn counter encoder Mount exploded 2 74 2 75 J A B C D E D C F G H Item Type 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 Pa

KT13625 w/ McCoy Backup - Texas International Oilfield Tools LTD

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