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Technical Manual - Texas International Oilfield Tools LTD

1. Section Two Sling Load Bearing Device Safelty oii ima 2 1 Major Component Identification Hydraulic Schematic Hydraulic Valve Identification sisse seen 2 8 la Miel mien oon T 211 Tong Backup Jaw Availability amp Installation Tong Rig UD amp Eu 2 13 HOPED MEM P 2 17 Extreme Cold Weather Operation Procedures Making amp Breaking Connections eee nri anna tk nti ua raga E 2 21 General Maintenance Safety Practices M Preventive EIE Lubrication Iu E Recommended Periodic Checks rein ttn e aaa Disassembly amp Overhaul Procedures Assembly Instr clions orta tere e Daily Inspection amp Maintenance Checklist Power
2. 0150402 STATOR GA 15 0150403 STATOR GA 9 5 3 0150404 STATOR CA 8 0 gt 0150407 STATOR 6 0150408 STATOR 10 5 25 0150414 STATOR 11 5 25 0150419 STATOR B5 0150300 ROTOR Q 0150313 ROTOR VANE 0150320 ROTOR VANE SPRING OUTER eo 0150321 ROTOR VANE SPRING INNER e 10150410 STATOR VANE 0150420 STATOR VANE SPRING 0150429 DOWEL PINS REAR 0150720 NEEDLE BEARING 0150841 REAR HOUSING TS 62 0150842 HOUSING TS 63 0150843 REAR HOUSING TS 64 co onal Zn cO X lt 5 SERIES MODEL CODE 015 62 15 015 30 31 B1 TB 5 E 15 exetopen STANDARD TWO SPEED z RECORD DATE 8 RINEER HYDRAULICS REFERENCE 819 00 2 x ic d zi CORPUS CHRISTI TEXAS ju 0150044 U 5 5 gt 2 gt SL4500 4 1 Tone Hyprautic Motor WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION REMOVAL OF SHAFT SEAL 1 Remove snap ring WARNING Use caution when removing snap ring If released accidentally it can become an airborne hazard 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 Lift up on the bearing
3. c Pre set the backup pressure before beginning your job See Step 1 d of these operating procedures for detailed instruc tions for setting backup clamping pressure d Ensure the load cell is configured for break out operation See Section 2 F 3 of the SL 4500 Technical Manual for detailed instructions for configuring the load cell on your equipment e Transfer the snub line to the off driller s side of the tong the right hand side as seen from the rear f Unlatch and open the tong door see Illustration 2 1 6 g Actuate the lift cylinder control valve to lift the assembly from the drill floor Pushing the valve toward the center of the tong will retract the lift cylinder to lift the assembly see illustration 2 1 7 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 AND BACKUP AS IT IS LIFTED FROM THE DRILL FLOOR h 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 i Close the tong door Ensure the door is securely latched tug on the door handle to ensure it remains latched DRILLING amp 2 30 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBA
4. DRILLING amp AACCCOY TECHNICAL MANUAL 5 29 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Front LEG ASSEMBLY wg DRILLING amp 5 30 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Front LEG ASSEMBLY SL4500 4 1 Sum Tone Item Type Description Qty Part Number A Part 3 8 NC x 3 1 2 Hex Cap Screw 4 09 1060 B Weldment Front Leg Weldment 2 101 3661 C Part 3 8 Lock washer 8 09 5106 D Part 3 8 NC Hex Nut 8 09 5806 E Part 1 5 8 Plain Narrow Flat washer 2 101 4446 F Part Leg Spring 2 02 0920 G Part Bottom Spring Support 2 101 4339 H Part 3 8 NC x 2 Hex Cap Screw 2 09 1054 DRILLING amp AACCCOY TECHNICAL MANUAL 5 31 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank Torque MEASUREMENT SL4500 4 1 Sum Tone A BASIC TORQUE MEASUREMENT Basic torque measurements are performed using a simple hydraulic measurement system A hydraulic load cell connects to a cali brated 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 casing to the centre of the force being applied to the load cell Two load cell o
5. TECHNICAL MANUAL SL 4500 4 1 11 43cm 8K Lbs Ft Slim Hydraulic Power Tong amp Backup Specifications Operation e Maintenance Assembly 2011 McCoy Corporation All rights reserved Published by McCoy Corporation Technical Publications Department m ccoyg lo 212 14755 121A Avenue Edmonton AB Canada 5 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone This manual covers the following models MODEL DESCRIPTION 80 2001 6 4 1 2 6500 Ib ft Slim Tong with integrated backup amp support structure standard 2 arm sling motor valve backup valve amp safety door 80 2001 8 4 1 2 8000 Ib ft Slim Tong with integrated backup amp support structure standard 2 arm sling motor valve backup valve lift valve amp safety door 80 2001 10 4 1 2 8000 Ib ft Slim Tong with integrated backup amp support structure short 2 arm sling motor valve backup valve lift valve amp safety door 80 2001 13 4 1 2 8000 Ib ft Slim Tong with integrated backup amp support structure standard 2 arm sling motor valve backup valve lift valve safety door amp dump valve NOTE CE Marking available for all models except 80 2001 10 Some illustrations used in this
6. Door Assembly Rigid Sling ASSOIMDIY Ie PIC Rear Leg Assembly Front Leg Assemblies aca eet ad ee 5 30 Measureme t X Section Six Hydraulic Component Information siiccisiciecesitenceatvsieiacexczatectedecesisdieesedesctatesscedievededassbeiensebavadedessscizsncuadsietacenso diizigs Section Seven DRILLING amp SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD List oF ILLUSTRATIONS SL4500 4 1 Sum Tone Illustration 1 1 514500 amp Backup retrahit n ran tinea pia 1 1 Iustration 1 A 2 SL4500 DIMONSIONS 1 2 Illustration 2 A 1 Sling 2 1 Illustration 2 B 1 Component Identification 01 e 2 4 Illustration 2 B 2 Component Identification 02 2 5 Illustration 2 B 3 Component Identification 2 6 Illustration 2 4 Component Identification 04 wee 2 6 Illustration 2 B 5 Component Identification 05 2 7 Illustra
7. S Aw 5 331 Breesport San Antonio Texas 78216 210 341 6333 Fax 210 341 1231 e mail 5 5 rineer com DRILLING amp AACCCOY TECHNICAL MANUAL 7 15 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone VALVES Inlets 2500 psu End Inlet Iz M NON PORNTED Se en Adjustable Relief Valve Cartridges For Intets and Mid section inlets Coda Description VASA poe tinge SOTHO Factus SO SO gor CVA range 200 2500 pss Factory aet 2500 B ras echan i a y S Posbon i Spog DAS Double Acting Siacbo AW y Peden Spon Cylngar SA8 EC Section B Way Poron Hou in Pein CCQOY MOVING GLOBAL ENERGY FORWARD 7 16 SECTION CONTENTS TECHNICAL MANUAL VALVES Outlets Tank Return Type ease _ Sem Son Section G Page 32 far Port Plugs Brief Circuit Descriptions Series Circuli mi CH AZ amen ay Parallel Circuits Va dors eee Pea aue fee mor bn mobis SQM mcam
8. Step amp Install Tie Balts Slide the Oodle casing cac ipse na Than dicht prit o init llaton Place he vale segnors o phe mc bolts proper sequence ace Mep 1 page 4 Timing hy hami engage severe threads a VG aries mut ta either end iud albos Tongue Vid Le ipiis ii Creer patter Tie Balt Torque Valuas VA20 29 lbs 348 in I4 VG20 42 ft ibis 504 Ibs VAJS 34 lbs 408 Ibi VG35 75 ft 900 im Iba 150 1800 in 6 COY TECHNICAL MANUAL 7 27 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Hyprautic VALVES Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Pinched blown or missing Replace section seal Section seal leaks between sections Sted fasteners nat correctly Replace section seals and re ronque torqued Mounting pime ner level Loosen mounting bolts and shim as required Clean seal groove replace section Oil leaks at either end Over pressunized tank core Corect high back pr ssurt of spool senditien Wom or damaged spool seals Replace seuls and seal retainers Broken centering spring Replace centerng spring Spring centered spinli of operating Check Imkage for mot return to neutral linkage binding
9. DRILLING amp AACCCOY TECHNICAL MANUAL 2 27 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Setup amp OPERATION Making A Connection continued n When system pressure and torque begin to rise switch to low speed Do not release the rotation control Grasp the speed control knob and firmly push it down to the low speed setting Motor speed decreases by 50 percent and available torque doubles 1 E E nj S ILLUSTRATION 2 1 12 SwitcHinG Motor speen Switch To LOW SPEED Observe the tubing in the backup as the joint is approaches the specified make up torque If the tubing begins to slip in the backup increase the backup pressure in 50 psi increments until the tubing stops slipping Makeup torque must be reached without any tubing rotation in the backup When that has been achieved record the backup pressure for future reference As you gain experience with your equipment make up a pressure vs tubing size chart that can be referred to when making future connections ensuring proper backup pressure settings without risking crushed tubing p When proper makeup torque has been reached reverse the rotation control valve to release the tong jaws from the tubing ILLUSTRATION 2 1 13 REVERSING ROTATION To FREE JAws TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 2 28 Section CONTENTS SETUP amp OPERATION SL4500 4 1 Sim
10. 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 ROTOR Normal wear results in polishing of rotor faces which does not impair motor performance Examine the rotor vane slots closely Polishing down in the slots is normal but if there is any indication of a pocket forming in the wall of the slot the rotor should be replaced STATOR Normal wear results in polishing of cam form which does not impair motor performances Noticeable wear may be apparent along the corner of one side of the staor vane slot This does not necessarily require replacement of the stator but may slightly affect volumetric efficiency Note Measure the rotor and stator length to the fourth decimal point and supply measurement when ordering rotor stator or vanes AACCCOY MOVING GLOBAL ENERGY FORWARD HvoRAULIC Motor ASSEMBLY OF ROTOR STATOR CARTRIDGE 25 1 Reverse the procedures in steps 17 16 15 and 14 2 NOTE Make sure that the radiused edge of each stator vane points to the rotor and the radiused edge of each rotor vane points to the stator 3 NOTE Make sure Springs are seated in the bottom of the spring pocket in both the rotor and stator ASSEMBLY OF FRONT HOUSING 2 Install snap ring Press shaft and bearing assembly into front h
11. sisse esee enean rane ernst entes 2 32 Illustration 2 1 19 Releasing Tong Jaws Following Break Out amp Un threading 22200000 1 000000000000 2 32 Illustration 2 1 20 Un clamping Backup Jaws 2 33 Illustration 2 1 21 Lowering Assembly Using Lift Cylinder 2 33 Illustration 3 0 1 Cage Plate Roller 3 2 Illustration 3 D 2 Idler Shaft Bearing Lubrication is x2 Illustration 3 0 3 Reduction Gear Bearing Lubrication 3 3 Illustration 3 D 4 Door Pivot Shaft Lubrication einen nien inan annii aya o 3 3 Illustration 3 0 5 Door Latch amp Post Lubrication ex ud Ill stration 3 D 6 Jaw Assembly L brication iei sinet 3 4 lllustration 3 D 7 Load Cell L brication iier rn Itin rina nhan aan aaa ean avus 3 5 Illustration 3 E 1 Brake Band Adjustment ix X Illustration 3 E 2 Safety Door Plunger Adjustment 01 sisse 3 6 Illustration 3 E 3 Safety Door Plunger Adjustment 02 3 6 Illustration 3 E 4 Safety Door Plunger Adjustment 03 jas ud Illustration 3 H 1 Gearbox
12. the approprinke work oon imber Ser Sep i Arwwil Fi Valen E and hagk uz nag 1 be baard Step 6 Transition Check The efseck 14 et Ie bottom center of tae work section heus Carefully chen the wark ero n Be sr Do cod Dami d tnc maimai aurfuve Remorse Ue check valye cap Fig 10 and st sea Fig wen d li npn 12 1 and eheekeralve popper Fig 1 mnm 121 STE Only work secibtium parts blocked ecotrul have a tremsition check sections have only plug 7 22 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD Hyprautic VALVES SL4500 4 1 Sim Tone 5 Valve Disassembly Instructions Spool Disassembly Spring Centered Spool Tee apring maembe be senio ved rom Hi nla ewe quarts us he Chee i free of che wort secnian be harsdled carefully irt cias Plage lie vertically in vise the MaL ele rs and rere the Peg 1 iter boi wrench lap the sniper woh hoanmes anil a punch tio help break va Caueus af hear mas te free he
13. Commi ion urs on een Foreign particles in system Clean valve and system Cylinder leaking or wom Check cylinder repair Js Load will not held Port relief vulve mot holding Remove and clean or replace Spool ar housing scored Replace section Wom Lad drops when spoal Dirt or forcign particles Disassemble clean moved from neutral lodged bermween chack valve amp reassemble poppet and seal Scored or sticking check poppet valve poppet 2 Worn pump Check Now amp pressure Detective cylinder or motor Repair replace Low reservedr ail level Add oi to specifications No mation show or Clogged suction Clean or replace ers sten pera biam Relief valve not properly sect Check pressure setting HH Relief valve poppet or Replace relief m seat scared amp sticking open valve E alve spon got Check spac linkage to full stroke travel DRILLING amp 7 28 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic VALVES SL4500 4 1 2 Sum Tone Capacity 30 Pilot to open check valve with standard pilot gpm 120 L min Functional Group Model Products Cartridges Pilot to Open Check Valve 3 Port Non Vented Standard CKEB Pilot Steel Seat Product Description This valve is a pilot to open check valve It has a non sealed pilot a steel seat and is non vented It
14. Haar cnn ba snami ewm med argon ur mons dni aoenaled al tea wama Erma lih thu hee id pue bct Hur fed war pec eee has s wem Ina cruda Rows Pena he ope cart n when al spocds dry T hera reo paesi in EM VEO Gem He tappa from trae imam park Posen Dn n opm Boe Pre mco chos fo nip Dow kan lux oen ener lar siti dry Poise cd s ioc med pr shade ert iha Eire of nd thin Sf ofa cere pam and pees Ihe para iuga Cu ver peach at ine narras e Dnensimam cum be ares nc tances TCI Tom m moneri 18 ilis don pressum qr nal scat Thon or rap verve SL4500 4 1 Sum Tone Tandem Cireults anda progeny farum Are amp Ownedmm d nied Ponty oF creed orca fej Diis rS arenis Tare pete lewd Irzen ther cem san aires eee fud thus 75 Ina iian areae and amp nod Fide Cic TP
15. before bene reasserhiy Pag special any of dese exigi replace dle Minor ameni tothe mumber sid kenem martel ac the puris sires damage rhe cana spisal ani check poppei en he in Step any marks are remosed during cleaning re quoad ess ead ah e eda fine o ry 2 he hilos ol the lar 3 Clem adhesive norm tiureagls ul spes stripper and hars Wir Cause secun cup geris amd hes with nine Ligh sone 0 rymove amy rough spots Reme CAUTION A relief aren extends the O ring face of the valve housing This should mat he Sioned ground of DRILLING amp AACCCOY TECHNICAL MANUAL 7 23 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone VALVES Valve Assembly Instructions 7 Preparation of Parts CAUTION Failure to follow the Spray Marec of the mew bali Fig 2 14 recommended assembly instructions tapped iireaded pool ead ail screws and screw nalis on can result in poor performance or both hussin Primer Grade praduct malfunctian Product should BT 306 1e dry be thoroughly tested to ensure proper operation before the valve is placed back into service Spring Center Spool Assembly
16. Step 1 Spool Assembly Spring Centered lain ibe fat dew end al the spaci wi a tafi jawed tise Apply Parker Superai Liabe qo the spool weal alie 2 anm ad the from Sid on ee back ring reviines plare hee enc be sa rhar they do wall the nes duree nod allerw the O ring ath ilie chap edge ar the s posl noches Step 2 Attach Spring Guides and Spring Apply 1 3 2274 ia adhesive meer the middle af the female the spon Assemble the spring gules 1 mem Ei cenperigg i Fr bera 15 and supper Fay ines 14 jain the apl id hien 7 Tongue the smpper bolita 73 im he 3 CAUTION Care man betaken to ensure that rie retainer no pinched onder the chander fult daring avsemh y This con result burrs thar panl binding Check for binding by compresims he spring and guides or by rotating ibr spring the bouring CAUTION Fallisw ihe adhesive matifaciurer s imsiructioas for proper cloning und curing Failure prepare parti pruperly ln acm failure veu ike cenierng spring wah lay Temperature grens po pecv nt
17. 2 7 De energize the power unit and perform a third generous lubrication of the gear train including the gear housing DRILLING amp AACCCOY TECHNICAL MANUAL 3 19 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE 2 8 Re energize power unit and extend all hydraulic cylinders Inspect cylinder rods for signs of mechanical damage flaking or rust Farr recommends that damaged cylinders be replaced 2 9 Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines If a seal line or fitting begins to leak while tong is rotating it must be replaced before the equipment is returned to service Rotate tong in high gear for 5 minutes while monitoring temperature of top and bottom bearing caps If the bearing caps 30 hot to the touch higher than approximately 50 C replace the applicable bearings Likewise if the tong is making unusual noises check for damaged bearings see Maintenance Manual for all bearing locations Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted 37 components including links and chains If using a compression load cell replace component that has been crushed or otherwise distorted through compression 3 2 If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal dist
18. 3 7 tong must be removed from service until the mechanism is repaired Repeat the test while operating the tong in the opposite direction If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR Farr recommends that an anti corrosive agent such as Tectyl amp 506 be applied to all external unpainted surfaces and 3 8 chain slings EXCEPT cylinder rods jaw rollers 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 DRILLING amp 3 20 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone 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 recom mends that all hydraulic lines are fully disconnected and residual hydraulic pressure is bled off Ensure adequate containment is in plac
19. Do not release the rotation control Grasp the speed control knob and firmly pull it all the way up to the high speed setting see Illustration 2 1 18 Release the rotation control handle when the connection completely un threads DRILLING amp AACCCOY TECHNICAL MANUAL 231 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone SETUP amp OPERATION Breaking A Connection continued ILLUSTRATION 2 1 18 SwitcHinc Motor SPEED To HIGH SPEED m Release the jaws from the tubing after the connection has been broken and un threaded Push the rotation control handle toward the centre of the tong to rotate the cage plate in the makeup direction and release the jaws from the tubing ILLUSTRATION 2 1 19 RELEASING Jaws FoLLowinG BREAK Our UN THREADING DRILLING amp 2 32 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sim Tone n When tong jaws are free release the backup jaws by pulling the backup clamp control handle away from the tong toward the operator Breaking A Connection continued ILLUSTRATION 2 1 20 Un cLAmPING BAckuP JAWS o 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 th
20. MENT IS USED TO GUARD AGAINST PRESSURE INJURIES Clean the exterior of the tool thoroughly using either water if using a pressure washer ensure a low pressure wash 3 wand is used or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and cleaning agents 4 Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental con 5 tamination 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 C 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 Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet am
21. Sim Description Qty Part Number A Part Grease Fitting 1 4 straight thread 1 02 0097 B Part Thrust Washer 2 02 E0001 C Part Gear Shaft 1 101 3296 D Part Inner Ring 1 x 1 1 4 x 1 3 35 2 02 9027 Needle Roller Bearing Drawn Cup 1 1 4 x 1 5 8 x 1 5 55 2 02 9009 F Part Bearing Spacer 1 101 3812 G Part Reduction Gear 1 101 3291 DRILLING amp AACCCOY comprenons TecHNicAL MANUAL 5 7 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone 5 8 SECTION CONTENTS GEAR 55 LARGE TECHNICAL MANUAL CCQOY MOVING GLOBAL ENERGY FORWARD GEAR ASSEMBLY LARGE SL4500 4 1 Sum Tone Item Type Description Qty Part Number A Part Grease Fitting 1 4 straight thread 1 02 0097 B Part Thrust Washer 2 02 E0001 C Part Gear Shaft 1 101 3296 D Part Needle Roller Bearing Drawn Cup 1 1 4 x 1 5 8 x 1 5 55 2 02 9009 E Part Inner Ring 1 x 1 1 4 x 1 3 35 2 02 9027 F Part Bearing Spacer 1 101 3812 G Part Reduction Gear 1 101 3292 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TEcHNICAL MANUAL SECTION CONTENTS 5 9 SL4500 4 1 Tone Rorary ASSEMBLY DRILLING amp 5 10 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS
22. actuator and push pull assembly to the top plate and remove the entire actuator assembly 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 17 Remove the four cage plate bolts washers and nuts and the four cage plate spacers The cage plates may now be removed There is no need to remove the backing pin assembly from the top cage plate unless maintenance on the backing pin is required 18 Remove the two 3 8 x 3 1 2 bolts from the center of the tong just behind the cage plate opening Note that one of these two bolt sets secures the brake band retainer to the bottom plate 19 Remove the three 3 8 x 5 hex bolts 3 8 lock washers and 3 8 hex nuts that secure the bottom gearbox cover to the top plate DRILLING amp 3 8 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Overhaul Procedures continued 20 Remove the remainder of the 3 8 nuts and bolts from around the perimeter of the tong Once the bolts are removed the top and bottom plate may be split apart use caution to pull the top plate straight up from the bottom plate so that there is no binding on the dowel pins used for positioning 21 For additional access to
23. aub it MOTOR SELECTION GUIDE 15 Series Two Speed Weight 51 Ibs available displacements of standard motor Spool valve shift from full to partial displacement B Standard shift ratio is 2 1 Some special ratios available Shift on the run Typical applications winch track and wheel drives Cross Section Two Speed Motor AU HA 28 S AACCOY 2388S 5 13 TEcHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Technical Information All Styles iE 7 4 Motor 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 ha
24. or if using a diesel power supply ensure that the engine is locked out or the starting mechanism otherwise disabled DiEsEL ONLY 1 Check engine oil levels add if necessary 2 Check diesel fuel tank fill if necessary 3 Visually inspect all fan belts 4 C Activate mechanical shut off device ensure that shut off switch on engine is engaging when manual shut off switch s is actuated ELECTRIC ONLY Visually inspect all electrical lines and visible connections If your unit is NOT explosion proof open the electrical 1 enclosure and VISUALLY inspect contacts and connections for signs of corrosion or arcing Do not open explosion proof enclosures NEVER PLACE HANDS INSIDE AN ELECTRICAL ENCLOSURE UNLESS YOU HAVE CON FIRMED THAT THE POWER HAS BEEN DISCONNECTED AND LOCKED OUT 2 Visually inspect main electrical line between main power source and power unit ALL Units 5 Perform a visual inspection of all parts Check to ensure there are loose or missing fasteners 6 C Check hydraulic fluid level ensure cold level is approximately half way up the sight glass on the hydraulic fluid reservoir 7 Perform a visual inspection to ensure there no hydraulic fluid leaks correct if necessary 8 Check that the main supply and return lines on the hydraulic fluid reservoir are both fully open 9 C Apply grease to any grease fittings that your power unit may have Apply grease to each f
25. 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 2 the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers INBOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INJURIES 3 Perform an initial wash of the tong in order to remove the majority of dirt and grease build up Ensure adequate contain ment 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 Use a flashlight to perform a visual inspection of the gear train through the access panel and the opening of the rotary 5 gear If gear damage or chips of metal are seen the tong should be removed from service and overhauled to avoid
26. 2 1 Making amp Breaking A Connection 3 1 Revised Section 3 A General Maintenance Safety Practices 3 1 Inserted Section 3 C Preventive Maintenance Practices 3 6 Inserted Subsection 3 E 2 Safety Door Switch Adjustment 3 316 Daily Power Tong Inspection amp Maintenance Checklist to Maintenance section December 2011 3 318 Monthly Power Tong Inspection amp Maintenance Checklist to Maintenance section 3 3 21 es Daily Backup Inspection amp Maintenance Checklist to Maintenance sec 3 3 22 Daily Power Unit Inspection amp Maintenance Checklist to Maintenance section 3 323 Tubular Connection Equipment De commissioning Checklist to Mainte nance section 3 3 26 Moved Tubular Connection Equipment Re commissioning Checklist to Mainte nance section 4 1 4 6 Revised Troubleshooting section ALL Complete revision of torque measurement section DRILLING amp AACCCOY TECHNICAL MANUAL vii MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone TABLE OF CONTENTS Introduction mcg Section One Introduction amp Contact 1 1 8 8 1 2 Lubrication Specifications 1 4 Setup amp Operation
27. 22000 0 0000000000 0000 3 16 Monthly Inspection amp Maintenance Checklist Power Tong Daily Inspection amp Maintenance Checklist 200000002 10000000000000 3 21 Daily Inspection amp Maintenance Checklist Power Unit sessi eese 3 22 Tubular Connection Equipment De commissioning Procedures Tubular Connection Equipment Re commissioning 22 2 20000000000000000000000000 3 26 HOC M Tong Will Not Develop Sufficient Torque Failure OF Jaws TO Grip de PLE HM RE ne ERR TONG RUNNING TOO SIOWY m Assemblies seccsisiscsctsesssssscsizsuesssanstiostsondenasessteitesessenionscsdadessneresstdonssieetsnies edseseeiiodcssatesindsaden od ressiesdcauedseys Idler Assemblies Reduction Gear Assembly Reduction Gear Assembly ireann Rotary Assembly Rotary Gear ASS MDIY TONG Hydraulic 5 Brake
28. 3 hex cap screws indicated by green and 3 8 NC x 5 hex cap screws indicated by red and 3 8 NC hex nuts and 3 8 lock washers ILLUSTRATION 3 H 5 Main FASTENER PLACEMENT 17 Position the lower cage plate PN 101 3304 against the bottom side of the rotary gear assembly ensuring the groove in the cage plate engages with the lower rollers Place four cage plate spacers PN 101 3333 on the inside of the bottom cage plate DRILLING amp 3 12 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Mechanical Assembly Procedures continued 18 Place the top cage plate PN 101 3303 over the top of the rotary gear assembly ensuring the groove in the cage plate engages the rollers on the top of the rotary gear Secure the top and bottom cage plates with four 3 8 NC x 4 1 2 hex cap screws lock washers and hex bolts 19 Attach the motor gear to the motor shaft Orient the motor gear so that the smaller diameter of the gear is toward the motor rather than the end of the motor shaft The gear should be positioned 7 16 from the flat end of the motor shaft secure with two 1 4 NC x 3 8 cone point hex socket head set screws 20 Slide the motor thrust washer PN 02 E0009 over the end of the motor shaft Mount the motor to the top plate the end of the motor shaft should rest within the circular cutout in the
29. 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 Stat O Seal and tighten securely h Remove load cell from containment vessel and wipe clean Reclaim the hydraulic fluid if it is clean or dispose of all waste materials according to governmental or your company s proscribed environmental protection regulations Disconnect the hand pump from the torque gauge J Replace the brass cap on the torque gauge check valve fitting 3 Repair And Calibration Load cell and indicator gauge should be returned to authorized repair facility for any repairs or calibration required DRILLING amp AACCCOY TECHNICAL MANUAL 6 7 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank SL4500 4 1 Sum Tone AACCQDY MOVING GLOBAL ENERGY FORWARD FARR Section 7 Hydraulic Component Information The manufacturer information contained in this section has been obtained from publicly available web sites and has been provided for information purposes only Farr Canada Corp does not guarantee the accuracy of the infor mation contained in this section original copyrights claimed by the manufacturer s apply DRILLING amp AACCCOY comprenons TECHNICAL MANUAL 71 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank SL4500 4 1 Sum Tone 0
30. AACCCOY TECHNICAL MANUAL 7 29 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone VALVES use counterbalance valves cavities same flow path for a given frame size However cartridge extension dimensions from the mounting surface may vary e Stainless steel cartridge options P or W e Incorporates the Sun floating style are intended for use within corrosive construction to eliminate the effects of environments with all external internal parts binding due to excessive components manufactured in stainless installation torque and or steel or titanium Internal working cavity cartridge machining variations components remain the same as the standard valves Technical Data avit Series from Cavit EIE alve Hex Size alve Installation Torque Model Weight 990 202007 Viton 990 202 006 Typical Pressure Drop Option Selection Preferred Options External Control Cracking Pressure Material Seal Material X Standard Pilot C 30 psi 2 bar N Buna N Standard Options L Manual Load Release A 4 psi 0 3 bar P Stainless Buna B 15 psi 1 bar N D 50 psi 3 5 bar M Viton E 75 psi 5 bar W Stainless Viton F 100 psi 7 bar DRILLING amp 7 30 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic VALVES SL4500 4 17 Sim Tone Capacity Pilot to open spring biased closed unbalanc
31. C Energize power unit and rotate the tong for a final time one minute in one direction stop and reverse the direction of rotation for another minute this time ending with the rotary gear the open throat position 1 6 Extend all hydraulic cylinders and inspect cylinder rods for signs of mechanical damage flaking or rust Farr mends that damaged cylinders be replaced prior to storage If you are using a frame mounted tool the tong must be lowered onto the backup in order to remove the risk of sudden and catastrophic movement when pressure is removed from the float cylinders Cover the top of the backup with pro tective cloth to protect the paint on the backup Place two wooden beams across the top of the tong ensuring that the 17 beams 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 flat contact with the bottom of the tong away from bearing caps brake bands or other protrusions on the bottom of the tong Ensure that the tong hanger chains are loose but not dangling into contact with the hangers or top plate of the tong DEPRESSURIZATION PROCEDURE 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 an
32. DRAIN AND CROSS PORT LEAKAGE The combined case drain and cross port leakage of the 15 Series Two Speed Motor is approximately 1 GPM per 1 000 PSI This will vary with the oil viscosity OTHER INFORMATION All other information as specified under Techinal Information also applies to the 15 Series Two Speed Motor See page 5 9 16 DIA 4 HOLES CENTER LINE CASE DRAIN SAE 14T 12 24 OPTIONAL SHAFT FLAT ROOT SIDE FIT INVOLUTE SPLINE TECHNICAL MANUAL SECTION CONTENTS SL4500 4 17 Sim Tone 7 5 SL4500 4 1 Tone Performance Data selected Displacements Motor ACTUAL TORQUE AND POWER 6 CID 2000 RPM 100 RPM 2000 RPM 1600 RPM 1200 RPM 800 RPM 400 RPM 100 RPM 1500 2000 PRESSURE psid ACTUAL FLOW 6 CID 11 5 1500 2000 PRESSURE psid ACTUAL TORQUE AND POWER 11 5 CID 42 40 1600 RPM 37 100 RPM 1600 RPM 1200 RPM 800 400 RPM 200 RPM 100 RPM POWER HP 130 120 110 100 90g 80 70 x 60 508 40 30 20 10 0 1500 2000 2500 3000 PRESSURE psid ACTUAL FLOW 11 5 CID a FLOW gpm B 7 6 1500 2000 PRESSURE psid SECTI
33. H 2 DRILLING amp 3 10 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Mechanical Assembly Procedures continued a5 simi iar Dni ILLUSTRATION 3 H 2 IDLER GEAR INSTALLATION 11 Assemble rotary gear assembly gear as shown in Illustration 3 H 3 Refer to assembly drawing on page 5 12 for further informa ILLUSTRATION 3 H 3 RorARY GEAR ASSEMBLY DRILLING amp AACCCOY TECHNICAL MANUAL 3 11 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE Mechanical Assembly Procedures continued 12 Install eight button guides PN 101 3389 into the bottom plate using one 1 4 NC x 1 2 hex socket flat head machine screw per button Install the remaining eight button guides on the underside of the top plate 1r ILLUSTRATION 3 H 4 Button INSTALLATION 13 Install rotary gear assembly over the button guides in the lower plate Ensure the rotary gear is installed with the backing pin slots facing up 14 Insert three 3 8 x 1 dowel pins into their respective locations in the lower body plate 15 Lower the top plate into position over the bottom plate Ensure the plate is lowered as horizontally as possible to prevent binding on the dowel pins 16 Secure the top plate to the bottom plate and gear box with 3 8 NC x
34. Part PTFE Shoulder Bushing 38 02 E0075 E Part Roller Shaft 19 101 4655 F Part Plain Bushing 19 02 E0074 G Part Rotary Gear 1 101 3301 DRILLING amp AACCCOY comprenons TECHNICAL MANUAL 5 13 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone ASSEMBLY ABCDD E DRILLING amp 5 14 Section CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD ASSEMBLY 514500 4 1 Sim Tone Item Type Description Qty Part Number A Assembly Door Assembly See 5 22 5 23 B Part External Snap Ring 4 02 E0004 C Part Shoulder Bushing 2 02 E0003 D Part Door Post 2 101 3306 E Part 3 8 NC x 3 Hex Cap Screw 15 09 1058 F Part 3 8 NC x 3 1 2 Hex Cap Screw 11 09 1060 G Assembly Rigid Sling Assembly See Pp 5 24 5 25 1 H Assembly Motor Assembly See Pp 5 18 5 19 1 J Assembly Hydraulic Valve Assembly See Pp 5 16 5 17 1 K Part 3 8 NC x 5 Hex Cap Screw 4 09 1066 L Part Top Plate 1 101 3361 M Part Body Spacer 2 101 3333 N Part Bottom Plate 1 101 3362 P Part Gearbox Cover 1 101 3317 Q Part 3 8 Lock washer 44 09 5106 R Part 3 8 NC Hex Nut 30 09 5806 S Part Wear Button 16 101 3389 T Part 1 4 NC x 1 2 Hex Socket FHCS 16 09 4003 U Part Leg Plate typ welded to front leg weldment shown for illustration 2 101 4034 V Weldment Lined Brake band Weldment Se
35. Procedures continued 34 Attach the front leg weldments to the tong using two 3 8 NC x 3 1 2 hex cap screws 3 8 lock washers and 3 8 NC hex nuts per side 35 Support the backup on a structure that will support its complete weight at least 16 inches 40 cm off the floor 36 Set the tong and leg assembly down over the backup guiding the front legs through the front leg holes on the backup and guid ing the rear paddle on the backup between the uprights in the rear leg weldment Before the front legs reach the floor slide a large 1 5 8 washer over the bottom of each leg followed by a front leg spring PN 02 0920 and a bottom spring support PN 101 4339 Secure the leg springs with a 3 8 NC x 2 hex cap screw and 3 8 NC hex nut 37 Insert two backup support plate weldments PN 101 3885 between the uprights in the rear leg weldment so that they oppose each other see exploded diagram Pp 6 28 6 29 Insert two rear leg springs PN 997 13 between the two support plates and insert the rear leg support rod PN 101 3891 beneath the two plates Secure the rod with two small hitch pins 38 Lift the tong and backup assembly away from any supporting structures and place flat on a sturdy surface 39 Pre mount the main valve bank to the valve mount weldment PN 101 4101 using three 1 2 NC x 4 1 2 hex bolts 1 2 narrow flat washers and 1 2 NC thin nylock nuts 40 Install the valve mount weldment on the
36. TESTS LIFTING POINTS EXAMINATION To UNIT Initial Certification By YES Farr Superior 5 Interval Not Exceeding At the discretion of At the discretion of YES 12 Months inspection body inspection body Interval Not Exceeding At the discretion of 60 Months inspection body Following Substantial YE YES YES T Repair or Alteration 1 Lifting test as per S 7 3 BS EN 12079 or DNV 2 7 1 May 1995 T Proof Test non destructive examination non destructive examination and visual examination V visual examination Dependant upon whether non destructive examination has been carried out 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 IF MECHANICAL DAMAGE IS SEEN OR SUSPECTED ON A LOAD BEARING DEVICE OR IF THE LOAD BEARING DEVICE HAS BEEN OVERLOADED IT MUST BE REMOVED FROM SERVICE AND QUARANTINED UNTIL RECERTIFIED Written records of the most recent periodic inspection shall be maintained and shall include the condition of the sling 2 Proper Use Of Load Bearing Devices Whenever any load bearing device is used the following practices shall be observed Load bearing devices that are damaged or defective shall not be used Slings shall not be shortene
37. Tone Making A Connection continued q When tong jaws are free release the backup jaws by pulling the backup clamp control handle away from the tong toward the operator ILLUSTRATION 2 1 14 Un cLAmPING BAckuP JAWS 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 ILLUSTRATION 2 1 15 LOWERING AssEMBLY UsinG CYLINDER CONTROL s Repeat steps e through until the desired number of connections are made up DRILLING amp AACCCOY TECHNICAL MANUAL 2 29 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Setup amp OPERATION 2 Breaking A Connection 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 1 1 b Setthe 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 Backing pin shown in the break out ILLUSTRATION 2 1 16 SETTING BAckiNG Pin
38. a hammer to lightly tap the guide block toward the front of the tong Adjust the block approximately 1 8 of an inch and retighten the mounting bolts ILLUSTRATION 3 E 4 SAFETY DooR PLUNGER ADJUSTMENT 03 10 Repeat steps 5 through 8 11 Make another adjustment of the guide block Once the adjustment block can no longer be adjusted further adjustment must be made using the cable positioning nuts see Step 4 12 Repeat steps 5 through 11 as many times as necessary to properly adjust the safety door switch Once the switch has been satisfactorily adjusted the tong my be returned to service F RECOMMENDED PERIODIC CHECKS 1 Backing Pin Perform a visual inspection of the backing pin after each job Replace the pin if stress cracks or excessive wear is found or if either pin is bent 2 Torque Gauge Periodic calibration of the torque gauge is recommended 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 in the Specifications section Farr recom mends that the torque gauge assembly be calibrated yearly DRILLING amp AACCCOY TecHNicAL MANUAL 37 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone OVERHAUL PROCEDURES The tong may be overhauled following the disassembly instructions in the following proceddure Access to the gear train is possible by removing the top plate o
39. allows free flow from the valve port 2 to the load port 1 and blocks flow the opposite direction Pressure at the pilot port 3 will open the valve from port 1 to port 2 Pilot pressure needed at port to open the valve is directly proportional to the load pressure at port L 1 Pressure at port 2 directly opposes pilot pressure LOCATING SHOULDER L 2 81 71 4 1 38 35 1 X 1 38 35 1 INSTALLED B 1 38 35 1 E 1 38 35 1 1 38 35 1 2 CAVITY rrrj gt M LOAD HEX DIMENSION t ACROSS FLATS 1 1 8 28 6 2 PILOT VALVE in ram Technical Features e Provides hose break protection e Standard unsealed pilot allows air prevents loads from drifting and trapped in the pilot line to be purged positively locks pressurized loads from the circuit e Extremely low leakage The seat and e Optional external porting out of the hex poppet are heat treated for long life If end of the cartridge is available for the load drifts due to the valve the seat external piloting In this configuration has probably been damaged by port 3 is blocked See Control options contamination and the valve should be E and P replaced e Pilot to open check cartridges are e This 3 port pilot to open check valve locking valves not motion control and 3 port counterbalance valves are valves For motion control applications physically interchangeable i e same DRILLING amp
40. between the load cell and torque gauge are repaired to prevent further fluid loss Obstruction in hydraulic hose Check hydraulic hose for kinks Replace hydraulic hose Snub line not at right angle to tong handle Check angle of snub line and correct if necessary Internal mechanism of gauge is damaged Replace gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication is erratic or sluggish Insufficient hydraulic fluid in torque measurement section Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Loss of damping fluid in torque gauge Top up or refill damping fluid NOTE Ensure leakage points in gauge are identified and repaired to prevent further loss of damping fluid Air bubbles in hydraulic fluid in the torque measurement system Bleed air from load cell and torque gauge and top up fluid if necessary as per Section 6 C Internal mechanism of gauge is damaged Replace gauge DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL Torque MEASUREMENT SL4500 4 1 Sim Tone PERIODIC INSPECTION AND MAINTENANCE 1 Inspection The torque measurement system supplied with your equipment is designed and built to pro
41. further damage Replace access panel when inspection is complete Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp outlet 6 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 as soon as possible Inspect the jaws and dies Inspect the jaw roller pins for signs of damage replace pins if necessary If the pins are 7 welded in place replace the entire jaw assembly Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely Check to ensure the size of the loaded jaws match the size of casing or pipe you are running Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal 8 2 etc replace damaged part s before placing tong in service Also inspect all chains master links turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service 9 C Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is good indication of wear 10 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicate
42. if signs of potential failure are identified 1 3 C 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 the rotary gear Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the 1 4 brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands Ensure that all grease is wiped from brake band linings 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 the correct size for the pipe or casing being run Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted 16 components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 17 C If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression 1 8 C load cell only If the integrity of the weld has been compromised the tong must be removed from service until the weld is
43. increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 1 6 C Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is less 5 than 350 psi 17 Perform visual inspection of pressurized hydraulic lines Document correct any hydraulic fluid leaks 1 8 Perform full functional test of the tong Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used Perform a visual inspection of the load cell If using a tension load cell replace any cracked broken or distorted com 19 ponents including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 20 C If applicable inspect the load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression 21 C 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 Test safety door feature if eq
44. manual may not exactly match your model of tong PATENTED amp PATENTS PENDING DRILLING amp AACCCOY TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD This page intentionally left blank SL4500 4 1 Sum Tone WARNINGS A LOAD BEARING DEVICE IS A CHAIN SLING RIGID SLING SPREADER BAR ASSEMBLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH THIS MANUAL HAS BEEN PRODUCED THE LOAD BEARING DEVICE SUPPLIED BY MCCOY DRILLING amp COMPLETIONS IS DESIGNED TO SUP PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL MCCOY DRILLING amp COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEM BLY OR COMBINATION OF PARTS AND ASSEMBLIES MCCOY DRILLING amp COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD BEARING DEVICE OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SUPPLIED BY MCCOY DRILLING amp COMPLETIONS WHEN RE ASSEMBLING LOAD BEARING DEVICES CHAIN SLINGS RIGID SLINGS BACKUP LEGS ETC NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE OF FASTENER SEE SECTION 3 OVERHAUL ANY THREADED FASTENER A LOAD BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE ANY REPLACEMENT FASTENER B
45. nuts per lug secure bolts from underneath the tong 30 Slide the backing pin retainer PN 101 4040 over the backing pin center pivot spacer PN 101 4038 and secure the pivot spacer to the top cage plate using a 3 8 NC x 2 1 2 hex cap screw and 3 8 flat washer 31 Thread 3 8 NC x 1 1 2 threaded stud PN 101 4058 into the backing pin PN 101 4039 Attach the backing pin to the backing pin retainer using the backing pin knob PN 02 0017 32 Attach the rigid sling weldment to the rigid sling brackets using one rigid sling pin PN 02 E0008 per side Secure each rigid sling pin with a 0 125 x 2 5 hitch pins Ensure a 3 4 flat washer is installed between the rigid sling weldment and each rigid sling lug total of four 33 Setthe rear leg weldment PN 101 3883 on a flat concrete surface in a clear area as close to the tong assembly as possible Lift the tong with a crane and lower it on to the rear leg weldment ensuring most of the weight remains supported by the crane Secure the rear leg weldment to the tong using two 3 4 NC x 5 hex bolts 3 4 lock washers and two 3 4 hex nuts through the two mounting holes in the rear one 3 4 NC x 3 1 2 hex bolt and 3 4 lock washer one 3 4 NC x 2 1 2 hex bolt and 3 4 lock washer DRILLING amp 3 14 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Mechanical Assembly
46. parts list on page Zand 3 fur work section detail Step 1 Valve Bank Tid a orcad dise disassembly procedure D be chaociv creare titel Uni valvi Bank propery after repairs lave boei inse Wib witeit quick drying marker mark exch cages sequential dumber Start by ile miler cacti with the and finish by aking the ouer el dfi number Next mark the bosi closest bici cip on ect work wih a B fer back eni hen mark the port boss closest the ppan levis each work sein 7 fase chee nm emi valves ens the valve tank be rposrked wii tha al Gaming asd pan cr C they were rere Init and relier vales are marked number onky Step 2 Tie Bolts rue leur ne bole jaa eld the bark And separe the beet ona BOTE vales tle bolis nie the casting VG valve tic inlis pass rheengh tee entire bank requiri washers and let mite fastened ar al doe Dall Step 3 Section Seals mici brillet each parade erork hac Fig 14 2 tating fie Serie Work sectione and the
47. 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 DRILLING amp 3 26 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone 2 0 Perform a full functional test of the equipment including if applicable backup components and float frame components Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used If using a frame mounted tong and backup system raise the tong off the beams that it is resting upon Remove the 2 1 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 Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low 2 2 gear in both directions makeup and breakout If cage plate begins rotating the safety door mechanism is not func tional and the tong must be removed from service until the safety door mechanism 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
48. the gear train the bottom gearbox cover may be removed by removing the remaining fasteners securing it to the bottom plate H ASSEMBLY PROCEDURES Assembly of Farr Hydraulic Power Tongs is simple and can be accomplished without the use of special tools The instructions on this page are presented as a guide only and are similar to the assembly sequence our technician would use while assembling the tong in our plant REFER TO THE FOLLOWING TORQUE SPECS WHEN TIGHTENING HEX BOLTS AND HEX HEAD CAP SCREWS SAE GRADE 8 FINE THREAD CLAMP LOAD PLATED 3 263 10 ft Ibs 5 113 20 ft Ibs 7 875 37 ft Ibs 10 650 58 ft Ibs 14 400 90 ft Ibs 18 300 129 ft Ibs 23 025 180 ft Ibs SIZE 1 4 28 250 5 16 24 3125 3 8 24 375 7 16 20 4375 1 2 20 500 9 16 18 5625 5 8 18 625 3 4 16 750 7 8 14 875 1 12 1 000 1 14 1 000 1 1 8 12 1 125 1 1 4 12 1 125 1 3 8 12 1 375 1 1 2 12 1 500 33 600 315 ft Ibs 45 825 501 ft Ibs 59 700 746 ft Ibs 61 125 764 ft Ibs 77 025 1083 ft Ibs 96 600 1509 ft Ibs 118 350 2034 ft Ibs 142 275 2668 ft Ibs SAE GRADE 8 COARSE THREAD CLAMP LOAD PLAIN 2 850 12 ft Ibs 4 725 25 ft Ibs 6 975 44 ft Ibs 9 600 70 ft Ibs 1 2 13 500 12 750 106 ft Ibs 80 ft Ibs 9 16 12 5625 16 350 153 ft Ibs 115 ft Ibs ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS
49. the need to manipulate gears in a gear train Simply rotate the speed valve to change the speed of the motor The simplicity of this system is particularly useful when making up or breaking out a joint A ILLUSTRATION 2 G 4 Motor SPEED CONTROL DRILLING amp AACCCOY TECHNICAL MANUAL 2 19 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone SETUP amp OPERATION 4 GENERAL 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 engagement and then quickly pulling the throttle valve control lever allowing the tong to snap into its loaded or high torque condition Although this method is very effective in breaking out joints the extremely high stress placed on the gear train frequently causes gear breakage THE SNAP BREAK METHOD IS HAZARDOUS TO RIG PERSONNEL H EXTREME COLD WEATHER OPERATION PROCEDURES 1 Consult the power unit engine oper
50. top plate to the left of the motor Secure with four 3 8 NC x 1 hex bolts and 3 8 lock washers 41 Install grease fittings as follows i Install two 1 4 UNF straight thread grease fittings PN 02 0097 into the top cage plate i Install a 1 4 UNF straight thread grease fitting PN 02 0097 in the top end of each gear shaft located on the the top side of the tong 5 locations total iii Install 1 4 UNF straight thread grease fitting PN 02 0097 in the end of the door pivot shaft DRILLING amp AACCCOY comprenons TECHNICAL MANUAL 3 15 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER TONG Farr recommends that the following inspection and maintenance procedures be performed before each use and at least once per day when the tong is in steady use in the order in which they are listed 1 Rotate cage plate rotary gear until the opening in the rotary gear faces towards the rear of the tong DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON NECTED 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 CONTAMI NATION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HYDRAULIC SYSTEM IN PREPARATION FoR MAINTENANCE 1 Rotate the tong to the open throat
51. 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 DRILLING amp AACCCOY TECHNICAL MANUAL 2 13 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Setup amp OPERATION Suspension amp Restraint continued 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 estab lished 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 snub lines by dividing the maximum torque of the t
52. 0 3 1 2 Jaw Die Kit SL4500 JDK 3500 3 5 8 Wrap Around Jaw Die Kit SL4500 WJDK 3625 3 5 8 Jaw Die Kit SL4500 JDK 3625 4 Wrap Around Jaw Die Kit SL4500 WJDK 4000 3 668 Jaw Die Kit SL4500 JDK 3668 4 1 2 Wrap Around Jaw Die Kit SL4500 WJDK 4500 4 Jaw Die Kit SL4500 JDK 4000 5 Wrap Around Jaw Die Kit SL4500 WJDK 5000 4 1 2 Jaw Die Kit SL4500 JDK 4500 All jaw die kits except Wraparound use flat die P N 12 1003MOD Contact Farr Sales for Wraparound dies 2 12 If necessary the entire jaw may be removed Support the jaw from the bottom and remove the jaw retainer bolt The jaw may then be slid out of and away from the cage plate Reverse this procedure to replace the jaw assemblies SECTION CONTENTS ILLUSTRATION 2 E 1 Jaw REMOVAL TECHNICAL MANUAL NACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS 5 Setup amp OPERATION SL4500 4 12 To release dies from a jaw assembly remove the retaining bolts and slide dies out Repeat this procedure in reverse to install new dies 5 Wraparound Style Jaw Standard Style Jaw ILLUSTRATION 2 E 2 Jaw Die REPLACEMENT 2 Backup Jaws The jaw die kits used in the Farr backup are identical to those used in the slim tong see previous page Follow the same removal and installation instructions as for the tong jaw die kits 3 Tong
53. 04 specific tension load cells C Part 1 4 NC x 1 2 Binding Head Machine Screw 1 09 0045A D Part Stat O Seal 1 02 0307 E Part O Ring 1 02 0350 F Part O Ring 1 08 0596 G Part Load Cell Piston 1 LC99 101 H Part Load Cell End 1 LC99 003 J Part Flange Gasket 1 02 0073 K Part Load Cell Rod 1 LC99 002 L Part Wiper 7 08 1558 N M Part 3 8 NC x 3 8 Cup Point Hex Set Screw 2 09 0106 K Seal Kit Replacement Seal Kit 4 08 in Tension Load Cell 02 4578 ILLUSTRATION 6 4 TENSION Loan CELL ExPLODED DRILLING amp AACCCOY TECHNICAL MANUAL 6 3 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone TORQUE MEASUREMENT This is the standard hydraulic com pression load cell supplied by McCoy Drilling amp Completions Farr Contact our sales department for information about optional application specific compression load cells Electronic compression load cells are used for some WinCatt applications Item Type Description Qty Part Number Assembly Compression Load Cell 8 in 1 10 0008C A Part 5 16 UNC x 1 Hex Socket Head Cap Screw 1 09 2026 B Part Load Plate 1 E360 A C Part 5 16 UNC x 3 4 Hex Socket Head Cap Screw 6 09 2024 D Part Retainer Ring 1 E360 8 E Part Diaphragm 1 E358 2 F Part Diaphragm Casing 1 E360 C G Part Street Elbow 1 H Part 1 4 NPT Brass Plug 1 ILLUSTRATION 6 A 5 CouPRESSION Loan CELL EXPLO
54. 1 Sim Tone ILLUSTRATION 2 B 5 COMPONENT IDENTIFICATION 05 Item Description 18 Compression Load Cell 19 Rear Backup Float Spring Assembly 20 Load Cell Spacer DRILLING amp AACCCOY comprenons TecHNicAL MANUAL 2 7 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Setup amp OPERATION C HYDRAULIC SCHEMATIC amp VALVE IDENTIFICATION The following hydraulic schematic illustrates the hydraulic controls of a fully equipped tong and backup assembly Your specific equip ment may or may not have all hydraulic controls as illustrated TONG MOTOR BACKUP 9 OPTIONAL OPTIONAL je 18 PTIONAL TO LIFT Ef JO SA I A ATA RRA enden en s e Luis pene cent go 9 1 I G9 1 1 1 i m 4 1 1 1 i oS gt T 1 COO i 20 OPTIONAL OPTIONAL ILLusrRATION 2 C 1 HypRAULIC 01 Item Description Part Number Page 1 Inlet Valve c w safety door cartridge 101 3927A 2 10 2 Relief Valve type varies with model 2 10 3 Pilot To Open Valve Sun LKHC XDN 08 1625 2 11 4 Motor Section DVA35 MA8 4 WAY SAE PORTS 10 9014 2 10 5 Backup Sec
55. 3 25 MOVING GLOBAL ENERGY FORWARD 514500 4 12 Tone 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 1 C 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 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 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 4 inspect all chains master links and turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service If your company requires yearly certification of lifting equipment ensure that the most recent test date falls within the past year Perform recertification if necessary Perform a liberal lubrication of the equipment refer to Maintenance
56. 5cc rev 011 11 5 in3 189cc rev 50 Retractable 1S Std 008 8 in 131cc rev 013 13 in 213cc rev 53 API Thread 1H High Speed 009 9 5 in 156cc rev 015 15 in 246cc rev Applications 63 Two Speed Single Pilot Closed During Crossover 65 Two Speed Double Pilot Open During Crossover 67 Two Speed Double Pilot Closed During Crossover DRILLING 8 AACCCOY comprenons TECHNICAL MANUAL 77 MOVING GLOBAL ENERGY FORWARD 15 Series Standard Motor Two Speed Motor 331 BREESPORT SAN ANTONIO TX 78216 210 341 6333 FAX 210 341 1231 DRILLING amp 7 8 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 7 9 ISERIES 15 STD TWO SPEED EXP VIEW ITEM PART NO DESCRIPTION 0150111 SEAL PLATE SNAP RING 0150135 SEAL PLATE 1250161 SEAL SHAFT TCN NOT USED 0150114 SEAL PLATE O RING 0150730 SNAP RING BEARING 0150710 BALL BEARING 0150701 SHAFT KEYED 0150702 SHAFT SPLINED 0150901 BOLT 0150102 FRONT HOUSING INTERNAL 0150428 DOWEL PINS FRONT 0150610 O RING 0150902 BALL CHECKS 0150620 PLATE SCREW 0150609 PLATE TWO SPEED 0150401 STATOR GA 15 2 9 gt Li O 72 E o z Q E
57. 7 C 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 Inspect backup springs if applicable The rear extension springs should be equally extended and the front leg 1 8 C 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 have been over compressed and still retain enough spring strength to support the front of the backup 1 9 Extend all hydraulic cylinders and inspect cylinder rods for signs of mechanical damage flaking or rust Farr recom mends that damaged cylinders be replaced prior to storage Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have 20 visible signs of wear from contact with a rigid object If your tong is equipped with rigid hydraulic lines replace line that is dented or appears to be stressed or cracked 21 C Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear Perform full lubrication refer to Maintenance section of manual to determine lubrication points 2 2 Ensure main supply and return connections to the tong are fully made Re c
58. AD CELL CONFIGURATION NALCO Y MOVING GLOBAL ENERGY FORWARD 2 16 SECTION CONTENTS TECHNICAL MANUAL SETUP amp OPERATION SL4500 4 1 Sim Tone G TONG OPERATION 1 Operator Training Many companies set qualification standards that must be met before equipment is may be operated without supervision McCoy Drilling amp Completions recommends operator training which typically consists of operation of the equipment under the supervi sion 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 Initial Start up and Break in Procedure YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY HOWEVER WE ADVISE INSPECTION AND TESTING OF YOUR NEW TONG AFTER TAKING POSSESSION IN ORDER TO ELIMINATE THE POSSIBILITY OF SHIPPING DAMAGE McCoy Drilling amp Completions recommends that the following pre operating tests be performed after receipt from the factory or after extended storage prior to releasing the tong to operations Perform a complete inspection of all fasteners to ensure none have loosened during transport Connect the tong to the power unit and apply full hydraulic pressure Inspect and correct any lea
59. AL ENERGY FORWARD SL4500 4 1 Sum Tone CatcuLaTion Or 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 approximate volume of 113500 in or 66 18 1 87 m 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 3 equaling 231 g Several manufactur ers 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 stor age environment Farr recommends that for equipment stored in a salt water maritime or exposed dusty environment repeat steps 9 through 24 monthly For equipment stored in isolated storage in a non maritime environment repeat steps 9 through 24 quarterly Re place desiccant packs at this time depleted desiccant packs may be treated as regular dunnage DRILLING amp AACCCOY comprenons TECHNICAL MANUAL
60. ATION 3 H 7 Door DETENT INSTALLATION 25 Position the door amp latch assembly assembled in Step 22 in its location and insert the door pin from the top through the door the shoulder bushings and the top and bottom plate Secure the door pin with two 3 4 external snap rings PN 02 E0004 to the insides of the shoulder bushings 26 Attach the safety door cable guide holder PN 101 4235 and cover PN 101 4237 to the top plate with one 3 8 NC x 1 3 4 hex cap screw and 3 8 lock washer and one 3 8 NC x 4 1 2 hex cap screw and lock washer Note that the second fastener extends through the top and bottom plates and is secured on the bottom with a 3 8 lock washer and 3 8 NC hex nut 27 Connect the two brake band weldments together using a 3 8 NC x 3 1 4 hex cap screw 3 8 lock washer and 3 8 NC hex nut Ensure that a Belleville 8 washer assembly PN 101 3272ASSEM is placed between the head of the cap screw and the brake band weldment 28 Secure the brake band assembly to the bottom plate using two 3 8 x 16 25 shoulder bolts at the brake band pivots and the brake band retainer 101 3975 Secure the brake band retainer to the bottom plate using a 3 8 NC x 3 1 2 hex cap screw inserted from the top plate a 3 8 lock washer and a 3 8 NC hex nut 29 Secure four rigid sling lifting lugs to the top plate using two 3 8 NC x 3 1 2 hex cap screws two 3 8 lock washers and two 3 8 NC hex
61. BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FASTENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOC DRILLING amp AACCCOY TECHNICAL MANUAL 3 9 MOVING GLOBAL ENERGY FORWARD SIZE 1 4 20 250 5 16 18 3125 3 8 16 375 7 16 14 4375 PLATED 9 ft Ibs 18 ft Ibs 33 ft Ibs 52 ft Ibs SL4500 4 1 Sum Tone MAINTENANCE 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 meta 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 1 Position the tong body gear case on a suitable stationary support such that the bottom body plate is accessible 2 Assemble seven inner ring needle bearing assemblies press seven inner rings into seven needle bearings 3 Pressone of the bearing assemblies assembled in step 2 into large reduction gear PN 101 3292 followed by a bearing spacer PN 101 3812 and a second bearing assembly 4 Orient the gear assembly from step so that the smaller gear is facing up Slide gear shaft PN 101 3296 into the gear assem bly making sure the threaded hole in the top of the shaft is facing up centering in the gear assembly as
62. Bing Set aside Tei i Fus niam hoe Afer curing fea the smpper holt dp make en wittisund 25 ol breskaenis DRILLING amp 7 24 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic VALVES SL4500 4 1 Sum Tone Valve Assembly Instructions Detent Spool Assembly Step 1 Spool Assembly Detant Apply Parker Super Labem Ie ihe spool seal Fii iem 8 and it the spool Slide the back up ring Fig 7 ime plate Erg ose the pend Potitien these einusthe span thas they do interfere Wib the mocha during asscnibly Do nor allow ibe Uring in come ic ccm sed exi he exime Of Uie npn ntti Apply 2 2 drops of 28274 ar an equivalent anaerobic pdhesrve Te moddle of the female ibreads im speuil CAUTION F lle tf adherve manufserurer instructons for raper cleaning and curring Failure to and prepare properly may Wesidt auyepahly Falluce Step 2 Spool Assembly Detent ike ball reram Fig 2 20 ana Be Tongue dilereni me i 175 Fi lha m bee This can be acenmgilishesd by vang a ache be of the and the sposi try inserting n rou
63. CALLY INCLUDING WEARING OF EYE PROTECTION 1 Rotate shaft in both directions to assure that the shaft turns smoothly 2 Torque motor to 190 ft Ibs 3 Rotate shaft again in both directions to assure that the shaft tums smoothly 1 Install dowel pins into rotor stator cartridge 2 Pour a small amount of Clean oil into the cartridge 3 Install front housing onto rotor stator cartridge 4 Make sure alignment marks are lined up SPOOL ASSEMBLY FOR THE 1 Install 5 8 11 bolts TWO 2 Torque bolts to 50 ft Ibs SPEED MOTOR NOTE Spool should be oriented as shown for two speed motors with model codes 62 63 68 amp 69 NOTE Slight design variations may exist in motors manufactured either before or after the printing of this manual WHEEL MOTOR SHAFT AND BEARING ASSEMBLY PROCEDURE Clean ALL assembly parts w lacquer thinner Dip clampnut and clamping bolt separately in lacquer thinner Steps 3 thru 10 must be conducted to completion ONE assembly ata time Press bearing cups into bearing housing Make sure they are pressed completely against bearing shoulders Coat inner race of large cone with 609 green Loctite and press cone onto the shaft Make sure the cone is completely against the shoulder of the shaft Insert shaft and large cone into bearing housing Coat inner race of small cone with 609 green Loctite and press small cone onto shaft Apply 272 red Loctite to the clampnut threads of the s
64. Cover 3 10 Illustration 3 H 2 Idler Gear Installation netiis i ER uo aaa Eae 3 11 Illustration 3 H 3 Rotary Gear Assembly so 22271 Illustration 3 H 4 Button Guide 3 12 Illustration 3 H 5 Body Fastener Placement 3 12 Illustration 3 H 6 Door Latch Weldment Installation TEE VE Illustration 3 H 7 Door Detent Installation aee rerit ren rnit rn ente paa nas 3 14 Illustration 6 A 1 Torque Gatige isset ea ced da ed s base ex 6 1 Illustration 6 A 3 Compression Load Cell 6 1 6 2 Tension Load ennt retenta theta tasa taria 6 1 Illustration 6 A 4 Tension Load Cell Exploded tasse 6 3 Illustration 6 A 5 Compression Load Cell Exploded 6 4 Illustration 6 A 6 Turn Counter Encoder Mount 6 5 DRILLING amp AACCCOY TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone The informati
65. DED 6 4 CONTENTS TEcHNICAL MANUAL AACCCOY MOVING GLOBAL ENERGY FORWARD ToRQUE MEASUREMENT N Sa N A 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 Part 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 104 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 ILLUSTRATION 6 6 Turn Counter Mount ExPLODED NALCO Y MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone TECHNICAL MANUAL SECTION CONTENTS 6 5 SL4500 4 1 Tone 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 6 6 Symptom Possible Problem Solutions Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solutions Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solution Po
66. Handles Tong handles may be supplied as an accessory with this tong They may be removed for operational needs and requirements F TONG RIG UP amp LEVELING 1 Suspension amp Restraint Suspend the tong and backup from a location as near to the centre of the drill rotary as possible and from a location high enough on the mast to ensure easy handling The lower the point from which the tong is suspended the more effort will be required to move the tong 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 e a single spring hanger typically applies 420 Ibs 191 kg to the suspension line for every inch of thread made up e a double spring hanger typically applies 840 Ibs 382 kg to the suspension line for every inch of thread made up If you do not know which specific spring hanger is in use check the specification page in this manual for information on the recommended spring hanger for this application McCoy Drilling amp Completions will not guarantee or specify spring hangers other than
67. L ENERGY FORWARD Setup amp OPERATION SL4500 4 1 Sum Tone Breaking A Connection continued k 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 1 8 The motor speed control valve may be in one of three positions UP High speed selected MIDDLE Neutral position DOWN Low speed selected Breakout torque is only available in the low speed mode If the motor speed control is not already in the low speed position grasp the motor speed control valve and firmly push down until it latches into its detent position Gently pull the rotation control valve toward the operator to slowly rotate the cage plate until the tong jaws grip the tubing ILLUSTRATION 2 1 17 ROTATION CONTROL BREAK OUT Pull the rotation control handle all the way out to ensure full breakout torque is being delivered to the joint When the joint releases switch to high speed to completely un thread the connection
68. LOBAL ENERGY FORWARD SL4500 4 1 Tone SLING ASSEMBLY A I uim DRILLING amp 5 24 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Sting ASSEMBLY SL4500 4 1 Sim Tone Item Type Description Qty Part Number A Weldment Rigid Sling Weldment 1 101 4137 B Part 0 148 x 2 938 Hitch Pin 2 02 0028 C Part 3 4 Narrow Washer 4 09 5013 D Part Rigid Sling Pin 2 02 E0008 E Part 3 8 NC x 3 1 2 Hex Cap Screw 8 09 1060 F Part Rigid Sling Leveling Bolt 4 02 E0038 G Part 1 2 NC Hex Nut 4 09 9124 H Part Rigid Sling Lifting Lug 4 101 3337 J Part Rigid Sling Adjustment Bolt Spacer 4 101 4138 K Part 3 8 Lock washer 8 09 5106 L Part 3 8 NC Hex Nut 8 09 5806 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL Section CONTENTS 5 25 SL4500 4 1 Tone Backup ASSEMBLY ABC EFC p 1 DCC KQR ST I c DRILLING amp 5 26 TECHNICAL MANUAL AACCCOY MOVING GLOBAL ENERGY FORWARD Backup ASSEMBLY SL4500 4 1 Sum Tone Item Type Description Qty Part Number A Assembly Hydraulic Cylinder Assembly 1 101 4336 B Part Cylinder Pin 1 101 3676 C Part External Retaining Ring 4 02 E0036 D Part 3 4 Narrow Flat washe
69. LY gt Oo gt DRILLING amp 5 18 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor ASSEMBLY SL4500 4 1 Sum Tone Item Type Description Qty Part Number A Part 20 1 1 4 Split Flange Kit 2 02 9217 Part O Ring 2 Part 20 1 1 4 Split Flange 4 Part 7 16 Lock washer 8 Part 7 16 NC x 1 1 2 Hex Bolt 8 B Part Flange Fitting 1 02 E0022 C Part RINEER GA 15 13 6 5 2 SPEED Hyaraulic Motor 1 87 0008 D Part 1 2 Lock washer 4 09 5110 E Part 1 2 NC x 1 1 2 Hex Cap Screw 4 09 1170 F Part 90 Degree Flange Fitting 1 02 9216 G Part 1 4 NC x 3 8 Hex Socket Set Screw 2 09 0107 H Part Motor Gear 1 101 4011 J Part Thrust Washer 1 02 E0009 K Part Square Motor Key 5 16 x 5 16 x 1 3 4 Not Shown 1 DRILLING amp AACCCOY TECHNICAL MANUAL 5 19 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Brake BANDS DRILLING amp 5 20 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Brake BANDS SL4500 4 1 Sum Tone a Item Type Description Qty Part Number A Part 3 8 NC Hex Nut 1 09 5806 B Part 3 8 Lock washer 1 09 5106 C Weldment Lined Brake band Weldment 2 101 3393 D Assembly Belleville
70. MENT FOR OPERATION AS PER SECTION 2 OF THE TECHNICAL MANUAL 1 Making Up A Connection 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 ILLUSTRATION 2 1 1 TONG SUSPENSION MASTER LINK THE MASTER LINK MUST BE USED TO SUSPEND THE TONG ASSEMBLY 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 If it is not simply lift up and place in the correct position see Illustration 2 1 2 next page The cage plate opening must be aligned with the door opening when setting the backing pin position DRILLING amp AACCCOY TECHNICAL MANUAL 2 21 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Making A Connection continued Setup amp OPERATION ILLUSTRATION 2 1 2 SETTING BAckiNG To MAKE UP c Ensure the load cell is properly configured for making up connections See Section 2 F 3 of the SL 4500 Technical Manual for correctly configuring your equipment d McCoy Drilling amp Completions recommends that backup pressure be pre set for the size of tubing before starting the job no tubing is required for this procedure Backup clamping pressure is only displayed when the backup jaws are closed in the clamp position Close th
71. MOVING GLOBAL ENERGY FORWARD Rotary ASSEMBLY SL4500 4 1 Sum Item Type Description Qty Part Number A Part 3 8 UNC x 2 1 2 Hex Cap Screw 1 09 1056 B Part 3 8 Flat Washer 1 09 5006 C Part 3 8 UNC x 4 1 2 Hex Cap Screw 4 09 1064 D Part 3 8 X 1 UNC Shoulder Bolt 2 09 1118 E Part 3 8 X 1 2 UNC Shoulder Bolt 2 09 9179 F Part 2 211 O Ring 2 02 0340 G Part Top Cage Plate 1 101 3303 H Part Cage Plate Spacer 4 101 3333 J Assembly Jaw Die Kit 2 3 8 shown see Pg 2 8 2 K Assembly Rotary Gear Assembly See Pp 5 12 5 13 1 L Part Bottom Cage Plate 1 101 3304 M Part 3 8 Lock washer 6 09 5106 N Part 3 8 UNC Hex Nut 4 09 5806 P Part Knob 1 02 0017 Q Part 3 8 UNC Stud 1 101 4058 R Part Backing Pin Bolt Spacer 1 101 4038 S Part Backing Pin Retainer 1 101 4040 T Part Backing Pin 1 101 4039 U Part 1 4 Straight Thread Grease Fitting 2 02 0097 DRILLING amp AACCCOY TecHNicAL MANUAL 5 11 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Rotary GEAR ASSEMBLY DRILLING amp 5 12 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Rotary GEAR ASSEMBLY SL4500 4 1 Sim Tone Item Type Description Qty Part Number A Part 7 16 Hex Jam Nut 38 02 E0005 B Part PTFE Thrust Washer 38 02 E0073 C Part Cam Roller 38 101 4019 D
72. OLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED DRILLING amp AACCCOY comprenons TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD This page intentionally left blank SL4500 4 1 Sum Tone Copyright 2009 2011 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 consid ered 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 informa tion is either complete or accurate in every respect and the user of the manual should consult with its McCoy sales representative for any clarifications and updates The user of the manual shall protect indemnify and hold harmless McCoy and its directors officers employees and agents from and against all liability for personal injury death or property damage resulting directly or indirectly from the use of the information c
73. ON CONTENTS TECHNICAL MANUAL ACTUAL TORQUE AND POWER 9 5 CID 1700 RPM 100 RPM 1 700 RPM 1300 RPM 900 RPM 500 RPM 300 RPM 1500 2000 PRESSURE psid ACTUAL FLOW 9 5 CID 100 RPM FLOW gpm 2000 1500 PRESSURE psid ACTUAL TORQUE AND POWER 15 CID 1500 RPM 100 RPM 1500 RPM 1100 RPM a 700 RPM 500 RPM POWER 300 RPM 100 RPM 1500 2000 PRESSURE psid ACTUAL FLOW 15 CID 2000 PRESSURE psid The above performance data was obtained at 140 F with ISO 46 DTE 25 These values must be maintained to obtain the performance indicated Contact Rineer Hydraulics Inc for additional displacements AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS Hyprautic Motor SL4500 4 1 Sim Tone Model Code M015 61 62 15 015 31 1 TV 000 Special Code Designator Seal Package Selection M015 61 015 Single Speed M015 62 015 Two Speed Options 62 Two Speed Single Pilot Open During Crossover Bearing Package Selection 30 Keyed Shaft 31 Splined Shaft 32 Wheel Motor 006 6 in3 98cc rev 010 10 5 in3 172cc rev 34 Double Key 007 7 in3 11
74. OSSIBLE PROBLEM Incorrect tong gear selected SOLUTION Maximum torque can only be developed when tong is in low gear Ensure tong is low gear FARR CANADA CORP GUARANTEES CALIBRATION OF A LOAD CELL TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR FARR CANADA CORP SUGGESTS THAT THE LOAD CELL TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE CALIBRATION ON A YEARLY BASIS AACCCOY 4 2 SECTION CONTENTS TECHNICAL MANUAL TROUBLESHOOTING SL4500 4 1 Sum Tone B FAILURE OF JAWS TO GRIP PIPE 1 POSSIBLE PROBLEM Dies have become too dull to provide adequate grip SOLUTION Replace dies 2 POSSIBLE PROBLEM Incorrect jaws are being used SOLUTION Double check jaw size to ensure they are rated for the diameter of pipe or casing being run 3 POSSIBLE PROBLEM Incorrect dies are being used SOLUTION Ensure dies loaded in the jaws are appropriate for the type of pipe or casing being run 4 POSSIBLE PROBLEM Brake band s is are insufficiently adjusted not allowing jaws to cam properly SOLUTION Adjust brake bands to give proper resistance to cage plates 5 POSSIBLE PROBLEM Jaw roller broken or worn SOLUTION Remove jaw assembly and inspect Replace rollers that are visibly flat spotted or otherwise damaged DRILLING amp AACCCOY comprenons TecHNicAL MANUAL 4 3 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone TROUBLESHOOTING 44 C TONG RUNNING TOO SLO
75. OY MOVING GLOBAL ENERGY FORWARD 2 14 SECTION CONTENTS TEcHNICAL MANUAL SETUP amp OPERATION SL4500 4 1 Sum Tone i Place a level lengthwise front to back along the tong ensuring that it is parallel with the surface of the tong Loosen the 1 2 locking nuts on the adjusting bolts on rigid sling brackets Completely loosen the adjusting bolts Turn each adjusting bolt equally until tong hangs level front to back Lock adjusting bolts in place with the lock nuts Loosen locking nut before I rotating adjustment bolt Leveling adjustment bolt ILLUSTRATION 2 F 2 TonG LEVELING DRILLING amp AACCCOY comprenons TECHNICAL MANUAL 2 15 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone 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 in its slot on the paddle and in normal operation does not need to be adjusted or removed The assembly in the first of the following two illustrations has been configured in the make up configuration to convert the assembly to the break out con figuration simply lift the load cell holder spacer assembly off the paddle rotate it 180 and replace no tools are required for this operation Load Cell Makeup Configuration Load Cell Breakout Configuration ILLUSTRATION 2 F 3 Lo
76. THIS MANUAL HAS BEEN SPECIFIED OR DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS DOCUMENT FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEMBLY OR COMBINA TION OF PARTS AND ASSEMBLIES OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SUPPLIED BY FARR CANADA CORP FARR CANADA CORP DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD BEARING DEVICES UNLESS THOSE MODIFICATIONS ARE PERFORMED BY FARR CAN ADA CORP McCoy Drilling amp Completions recommends following an industry accepted standard such as OSHA ASME B30 9 2006 or manu facturer 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 e Only grade 80 or grade 100 alloy chain should be used for overhead lifting applications e 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 new condition and when the load is uniformly and directly applied The WLL must never be exceeded e 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 e The Working L
77. TIONS MOVING GLOBAL ENERGY FORWARD GEAR TRAIN LAYouT SL4500 4 1 Sum Item Type Description Qty Part Number A Part Rotary Gear Assembly See Pp 5 12 5 13 1 B Assembly Idler Gear Assembly See Pp 5 4 5 5 3 C Part Motor Gear 1 101 4011 D Assembly Reduction Gear Assembly See Pp 5 6 5 7 1 E Assembly Reduction Gear Assembly See Pp 5 8 5 9 1 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL 5 3 SL4500 4 1 Tone 5 4 SECTION CONTENTS IDLER ASSEMBLY TECHNICAL MANUAL CCQOY MOVING GLOBAL ENERGY FORWARD IDLER ASSEMBLY SL4500 4 1 Sum Tone Item Type Description Qty Part Number A Part Grease Fitting 1 4 straight thread 1 02 0097 B Part Thrust Washer 2 02 E0001 C Part Shaft 1 101 3297 D Part Inner Ring 1 x 1 1 4 x 1 3 35 1 02 9027 E Part Needle Roller Bearing Drawn Cup 1 1 4 x 1 5 8 x 1 5 55 1 02 9009 Idler Gear 1 101 3293 DRILLING amp AACCCOY comprenons TecHNicAL MANUAL 55 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sim Tone Repuction Gear 5 SMALL A X B DRILLING amp 5 6 SECTION CONTENTS TECHNICAL MANUAL AACCOCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Gear AssEMBLY SMALL 14500 4 1
78. VASES ama inbes have ilira sean pe sends The dos nsincam mating face Fig 1 Thee sae be discal COY TECHNICAL MANUAL 7 21 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Hyprautic VALVES Valve Disassembly Instructions 5 Step 4 Valve Back Cap Using n lates reece thuc senews Fry 1 4 which ius back to tie work section Lighity top the dod of he handle wiih a hammer bo break mheara Reeve ibe back LFrg 1 item 5 Step 5 Control Spool and Seals rage spring at rhe wii lint free pall he os A meting motion Generally ihe renr plate Tig em hacksap rm gem 7 ard spen seni T coma deat wiih CAUTION For detentod spool modata nol fo remeve the delenl poppet Fig 2 itam 17 unless tt is ta serviced Phillips Besd ierewdnyes remove the scies Fig 1 5 fron spol of the werk section Lughitiy tap end of the Immie with a hammer break The adheuwe Remove the neta plates Pag backup iing Fi 1 T imd ke Fue V iem A Tag or mark
79. WLY POSSIBLE PROBLEM Obstruction in tong hydraulic circuit preventing adequate flow SOLUTION Inspect self sealing couplings to ensure they are properly engaged SOLUTION The main hyaraulic lines supply and discharge to the tong are obstructed Remove and clean if required POSSIBLE PROBLEM Power unit is not producing adequate flow or pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit POSSIBLE PROBLEM Tong motor is excessively worn and is leaking hydraulic fluid past the vanes SOLUTION Replace motor or rebuild as per Section 7 of this manual POSSIBLE PROBLEM Bearings in gear train and rotary section are excessively worn SOLUTION Overhaul tong See Section 3 of this manual for tong overhaul procedures POSSIBLE PROBLEM Shifter has malfunctioned and the tong is not shifting to high gear SOLUTION Inspect and repair shift mechanism as necessary POSSIBLE PROBLEM Two speed hydraulic motor if equipped is not set to correct speed SOLUTION Check motor and set to the correct speed if required POSSIBLE PROBLEM Safety door system is not properly adjusted hydraulic fluid leak past Deltrol valve SOLUTION Check and adjust safety door system POSSIBLE PROBLEM Hyaraulic fluid viscosity too high SOLUTION Ensure hydraulic fluid meets McCoy Drilling amp Completions specifications SOLUTION Ensure hyaraulic fluid is appropriate for climatic conditions especially during cold weather ope
80. Washer Assembly 8 101 3272 E Part 3 8 NC x 3 1 4 Hex Cap Screw 1 09 1059 F Part Brake band Retainer 1 101 3975 G Part 3 8 x 5 8 Shoulder Bolt 2 02 E0045 AACCOY MOVING GLOBAL ENERGY FORWARD DRILLING amp Techical MANUAL 5 21 SL4500 4 1 Tone Door ASSEMBLY 1 FGHJKLMN S TECHNICAL MANUAL NCCOY MOVING GLOBAL ENERGY FORWARD Door ASSEMBLY SL4500 4 1 Sum Tone Item Type Description Qty Part Number A Part Cable Guide Holder 1 101 4235 Al Part Safety Door Plunger 1 101 4360 A2 Part Push Pull Control Cable 1 02 E0026 A2 Part 7 16 UNF Hex Jam Nut 1 09 5508 B Part Cable Guide Guard 1 101 4237 C Part 3 8 Lock washer 2 09 5106 D Part 3 8 NC x 1 3 4 Hex Cap Screw 1 09 1557 E Part 3 8 NC x 4 1 2 Hex Cap Screw 1 09 1064 F Part 1 4 Straight Thread Grease Fitting 1 02 0097 G Part Shoulder Bushing 2 02 E0003 H Part Detent c w button 1 02 0899 J Part Top Plate shown for illustration 1 101 3361 K Part 3 8 NC Hex Nut 2 09 5806 L Part External Snap Ring 4 02 E0004 M Part Door Post 2 101 3306 N Weldment Door Weldment 1 101 4300 P Part Compression Spring 1 C0460 0050 1125 Q Part Wave Spring 1 02 9267 R Part Latch Weldment 1 101 3530 5 Part 3 8 x 3 4 Shoulder Bolt 1 09 0223 DRILLING amp AACCCOY MANUAL 5 23 MOVING G
81. While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 23 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 AACCCOY MOVING GLOBAL ENERGY FORWARD MANUAL 3 27 This page intentionally left blank TROUBLESHOOTING SL4500 4 17 Sum Tone 1 Adequate maintenance and proper fluid selection is essential for minimizing hydraulic related failures All troubleshooting must be per formed 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 10 Malfunctioning relief valve on tong hydraulic circuit a POSSIBLE PROBLEM Relief pressure set too low SOLUTION Increase setting To check block the oil line beyond the relief valve and determine pressure with a gauge b POSSIBLE PROBLEM Relief valve is stuck SOLUTION Check for contamination of oil that may inhibit the way the valve actuates Remove valve and clean ensuring that the valve
82. Y FORWARD SHIFTING METHOD Selecting between full and partial displacement is accomplished by shifting the two position spool valve incorporated in the motor Motors are available in either single or double pilot configurations SINGLE PILOT Single pilot motors require a pilot line to be connected to port C When port C is pressurized the spool shifts the motor to partial displacement When port C is vented to tank an internal spring shifts the spool returning the motor to full displacement DOUBLE PILOT Double pilot motors require two pilot lines One line is connected to port C while the other line is connected to port D The motor is in full displacement when port D is pressurized and port C is vented to tank The motor is in partial displacement when port C is pressurized and port D is vented to tank 15 Series Two Speed Envelope 9 0 7 80 1 4 O RING BOSS SAE 1 4 O RING ALTERNATE BOSS PORT 1 1 4 O RING BOSS REAR VIEW DRILLING amp COMPLETIONS 3 8 O RING BOSS CASE DRAIN 2 PLACES PILOT PRESSURE A minimum of 100 PSI over case drain pressure is required to shift the spool The maximum allowable pressure to port C or D is 3 500 PSI SHIFT ON THE RUN The 15 Series Two Speed Motor may be shifted on the run while loaded or unloaded MAXIMUM SPEED Maximum rated speed is the same for either full or partial displacement as stated in the performance data CASE
83. accurately represent the torque gauge and load cell that have been supplied with your equipment THE IMAGES DISPLAYED ARE SUPPLIED FOR ILLUSTRATION PURPOSES ONLY ILLUSTRATION 6 A 2 TENSION LoAD CELL ILLUSTRATION 6 A 1 ToRQUE GAUGE FoR ILLUSTRATION Purposes ONLY ILLUSTRATION 6 4 3 Compression Loan CELL Torque gauges and load cells are supplied as a matched calibrated pair Substituting one or the other will render the calibration inaccurate even if the actual model numbers appear to be identical The serial numbers of matching load cell and torque gauges are clearly identified on the calibration certificate Should you suspect the accuracy of your torque measurements or wish to replace either component the pair should be returned to the factory for re calibration before placing into service TORQUE GAUGES AND LOAD CELLS ARE FACTORY SUPPLIED SUPPLIED AS MATCHED CALI BRATED PAIRS IF REPLACING EITHER COMPONENT THE LOAD CELL AND TORQUE GAUGE MUST BE RETURNED TO THE FACTORY FOR RE CALIBRATION BEFORE PLACED INTO SERVICE DRILLING amp AACCCOY TecHNicaL MANUAL 6 1 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone BASIC TORQUE MEASUREMENT Continued The images on the preceding page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supplied with your equipment Please note that the parts listed in the following table are correct fo
84. age plate and rotary gear grooves in which the cam followers ride should be lightly greased When the cage plate is rotated as a unit the cam followers are exposed and can be greased Continue rotating the cage plate assembly until all cam followers top and bottom are greased ILLUSTRATION 3 D 1 CAGE PLATE RoLLER LUBRICATION Idler Shaft Bearings Apply grease to these bearings through the grease fittings in the ends of the idler shafts located on the top of the tong to the inside of each rigid sling weldment 3 locations total j Fr ILLUSTRATION 3 D 2 IDLER SHAFT BEARING LUBRICATION SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone 3 Reduction Gear Bearings Apply grease to these bearings through the grease fittings in the ends of the reduction gear shafts located on the top of the tong directly under the main hydraulic support and behind the motor 2 locations total ILLUSTRATION 3 D 3 REDUCTION GEAR BEARING LUBRICATION 4 Tong Door Pivot Shaft Apply grease to the tong door pivot shaft through the grease fitting in the end of the shaft ILLUSTRATION 3 D 4 Door Pivot SHAFT LUBRICATION COY TECHNICAL MANUAL 3 3 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE 5 Door Latch Apply a thin layer of grease to the tong door latch claws and the top and bottom of the door latch p
85. and the crane Remove the two 3 4 x 5 hex bolts lock washers and 3 4 nuts securing the rear of the rear leg assembly and the two 3 4 x 3 1 2 hex bolts and lock washers securing the front of the rear leg assembly 9 Remove the fasteners securing each front leg mount to the bottom plate 10 Liftthe tong up and away from the legs ensure that none of the leg assemblies or weldments topple over when the tong is lifted away Place the tong on a suitable surface that will support the entire weight of the tong and allow access to the bottom of the tong 11 Remove the two eight 3 8 x 3 1 2 cap screws lock washers and nuts securing the rigid sling assembly to the top plate four per side The entire rigid sling assembly may now be lifted away from the tong REMOVAL OF TOP PLATE 12 If not already done complete the disconnection of all hydraulic lines from the motor Remove the four 1 2 cap screws securing the motor to the top plate and lift the motor and motor gear away 13 If not already done remove the two jaw assemblies from the tong 14 Remove the two external snap rings from the door pivot shaft Remove the door pivot shaft if necessary use a hammer and a soft metal drive to tap the shaft out Remove the door assembly 15 Remove the door latch shaft the same way the pivot shaft was removed 16 Ensure the safety door push pull cable has been freed at the hydraulic valve end Remove the fasteners securing the safety door
86. 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 Website http www mccoyglobal com index php arilling completions ILLUSTRATION 1 1 SL4500 amp Backup DRILLING 8 AACCCOY TECHNICAL MANUAL 1 1 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone SPECIFICATIONS C L 8b 39 7 8 0c ILLUSTRATION 1 A 2 SL4500 DimENSIONS PLEASE NOTE AREAS SHOWN HIGHLIGHTED ARE POTENTIAL PINCH HAZARD AREAS EXERCISE CAUTION AROUND THESE AREAS DURING TONG OPERATION DRILLING amp 1 2 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SPECIFICATIONS SL4500 4 1 Sim Tone Torque Table Low Torque Pressure PSI Hi Speed Ibs ft Lo Speed Ibs ft 1000 660 2300 1500 1060 3700 2000 1485 5200 2500 1885 6500 MAXIMUM RATED TORQUE 6500 LBS FT _ EE T E wil Speed Table Low Torque Flow US GPM Lo Speed RPM Hi Speed RPM 10 8 28 20 16 55 40 32 111 60 48 166 Torque Table H
87. ase or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove residual solvent 2 0 Farr recommends that chain slings be removed and stored separately Rigid slings and other rigid suspension devices may remain in place 2 1 Apply grease or heavy oil to all exposed cylinder rods 2 2 Farr recommends that an anti corrosive agent such as Tectyl8 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 2 3 Allow the anti corrosive coating ample time to dry refer to manufacturer data sheets for drying times at room tem z perature 2 4 a 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 DRILLING amp 3 24 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOB
88. ase that meets or exceeds the following specifications Penetration ASTM D 217 25 C 77 F Dropping point F C ASTM 02265 High temperature life hours ASTM D 3527 Oxidation stability psi ASTM D 942 Water washout percent ASTM D 1264 Rust and corrosion ASTM D 1743 Oil separation percent loss ASTM D 1742 Four ball wear test mm scar ASTM D 2266 Timken OK load test los ASTM D 2509 Low temperature torque N m ASTM D 4693 Disc brake wheel bearing specifications Hydrolytic Stability Cu Mass Loss mg cm2 Cincinatti Milacron Spec Approved Vane pump test total ring and vane wear mg Turbine Oil Stability Test Life hours Rotary Bomb Oxidation Test minutes FZG Spur Gear Test Failure Load Stage FLS SPECIFICATIONS Thickener Lithium Complex NLGI consistency grade 2 NLGI performance grade GC LB 265 295 minimum 0 1 mm worked 60 strokes 550 288 minimum 160 minimum 100 hr 300 hr 0 3 1 8 max pass 1 1 max 24 hours 25 C 77 F Leakage g lost ASTM D 4290 1 0 max 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 50 1 3 40 40 F LT 37 pumpability g min 360 7 60 F 0 F 16 C 18 C Copper corrosion ASTM D 4048 1B Ford ESA M1C 198A Yes Chrysler MS 3701 Yes 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 qualit
89. ator s manual for all cold weather operating procedures and precautions 2 Select gear and bearing lubricants that are compatible with expected climatic conditions 3 Select hyaraulic fluid that is compatible with expected climatic conditions 4 Allow 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 lubricating when cleaning tong parts in cold weather AACCCOY MOVING GLOBAL ENERGY FORWARD 2 20 SECTION CONTENTS TECHNICAL MANUAL SETUP amp OPERATION SL4500 4 1 Sum Tone MAKING AND BREAKING CONNECTIONS Set up and prepare your equipment for operation as per Section 2 of the SL 4500 Technical Manual Refer to the following sections 2D Hydraulic Connections 2 E Tong amp Backup Jaw Installation 2 1 Tong Rig up and Leveling Suspension 2 F 2 Tong Rig up and Leveling Leveling 2 Tong Rig up and Leveling Load Cell Configuration 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 THIS PROCEDURE ASSUMES THE USER HAS PROPERLY SET UP AND PREPARED THE EQUIP
90. best as able 5 Place a thrust washer PN 02 E0001 over each end of the gear shaft and then place the bottom non threaded end of the gear shaft into the gear box cover PN 101 3317 6 Place three 3 8 x 3 4 dowel pins in to their respective locations in the side wall of the gearbox cover and fasten the gearbox cover to the bottom of the bottom plate with four 3 8 NC x 2 1 2 hex cap screws and 3 8 lock washers ILLUSTRATION 3 H 1 GEARBOX COVER INSTALLATION 7 Press one of the bearing assemblies assembled in step 2 into the smaller reduction gear PN 101 3291 followed by a bearing spacer PN 101 3812 and a second bearing assembly 8 Orient the gear assembly from step 7 so that the smaller gear is facing down Slide gear shaft PN 101 3296 into the gear as sembly making sure the threaded hole in the top of the shaft is facing up centering in the gear assembly as best as able 9 Placeathrust washer PN 02 E0001 over each end of the gear shaft and then place the bottom non threaded end of the gear shaft into the gear box cover PN 101 3317 10 Press one bearing assembly assembled in Step 2 into each of the three idler gears PN 101 3293 Slide an idler gear shaft PN 101 3297 through each idler gear assembly and center in the gear assemblies as well as able Slide a thrust washer PN 02 E0001 over each end and place the bottom un threaded ends of the shafts through the bottom plate see Illustration 3
91. ble lists all jaw die kits that are available as standard stocked sizes for this model of tong McCoy Drilling amp Completions Farr offers a good selection of standard jaw sizes However please note that we can custom engineer and manufacture any size of jaw within the range of the tong Jaw systems are 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 aluminium and wrap around fine tooth dies are available for specialized applications Please refer to our website for complete information http www mccoyglobal com index php dies inserts Description Part Number Description Part Number 1 9 Jaw Die Kit SL4500 JDK 1900 1 9 Wrap Around Jaw Die Kit SL4500 WJDK 1900 2 063 Jaw Die Kit SL4500 JDK 2063 2 3 8 Wrap Around Jaw Die Kit SL4500 WJDK 2375 2 3 8 Jaw Die Kit SL4500 JDK 2375 2 7 8 Wrap Around Jaw Die Kit SL4500 WJDK 2875 2 7 8 Jaw Die Kit SL4500 JDK 2875 3 Wrap Around Jaw Die Kit SL4500 WJDK 3000 3 Jaw Die Kit SL4500 JDK 3000 3 1875 Wrap Around Jaw Die Kit SL4500 WJDK 31 87 3 068 Jaw Die Kit SL4500 JDK 3068 3 1 2 Wrap Around Jaw Die Kit SL4500 WJDK 350
92. bottom plate Secure the motor to the top plate with four 1 2 NC x 1 1 2 hex cap screws and 1 2 lock washers 21 Insert the door latch pin PN 101 3306 into its location and secure on the insides of the top and bottom plate with two external snap rings PN 02 E0004 22 Attach the door latch weldment to the door weldment see Illustration 3 H 6 i Insert a positioning 1 4 x 3 4 dowel pin into the front of the door weldment ii Slide the latch spring CO460 0050 1 125 over the pin welded to the front of the bottom door plate in the door weldment iii Attach the latch weldment PN 101 3530 to the door weldment with a 3 8 x 3 4 hex socket shoulder bolt Ensure a wave spring PN 02 9267 is inserted between the latch weldment and the door weldment when the latch weldment is being at tached Positioning Dowel Pin Wave Compression Spring ILLUSTRATION 3 H 6 DooR LATCH WELDMENT INSTALLATION 23 Insert a shoulder bushing PN 02 E0003 into the top of the top plate and the bottom of the bottom plate where the door pin is located DRILLING amp AACCCOY TECHNICAL MANUAL 3 13 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Mechanical Assembly Procedures continued 24 Thread the door detent into the bottom of the top plate until the spring loaded button protrudes through the top plate Secure the detent from the bottom with a 3 8 NC hex nut ILLUSTR
93. box 1 Pry out shaft seal plate to remove from motor with two screw drivers 2 Remove seal plate o ring from groove in bearing bore REMOVAL OF WHEEL MOTOR SEAL PLATE AND BEARING BOX 1 Loosen and remove 8 each 10 32 bolts 2 Pry off seal plate with screw driver 1 Loosen clamp screw in lock nut 2 Unscrew lock nut and remove Loosen and remove 8 1 Press shaft out of each 3 8 bolts with 5 16 bearing box Socket head wrench 2 Proceed to step 9 disregarding steps 11 amp 12 Y DRILLING amp 7 10 Section CONTENTS TECHNICAL MANUAL MCCO COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic Motor SL4500 4 1 2 Sim DISASSEMBLY OF FRONT HOUSING AND SHAFT 1 Mark one side of the motor for proper assembly paying careful attention that the cartridge will not be installed upside down 2 Secure the motor prior to loosening the 5 8 11 bolts 1 Remove front housing 2 Note Two 5 16 ball checks and one main body o ring may be dislodged and fall free 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 DRILLING amp COMPLETIONS AACCOY MOVING GLOBAL ENERGY FORWARD WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION DISASSEMBLY OF ROTOR STATOR CARTRIDGE Lift up rotor
94. ce 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 the rear of the die clean and free of debris before insert ing clincher die If die are already installed ensure fasteners 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 condi tion 8 Inspect clincher cylinders for hydraulic fluid leaks once the system pressure has been restored FanR SrvLE Backup ONLY 4 Inspect cam ring gear for broken teeth 5 Lubricate the cam follower array Inspect the jaws and dies Inspect the jaw roller pins for signs of damage replace pins if necessary If the pins are 6 welded in place replace the entire jaw assembly Ensure dies are secure in the jaw replace worn dies if necessary 5 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 parts that are broken cracked or bent 8 Inspect rear spring hanger assembly Ensure all eye bolts shackles and cotter pins place and good condi tion 9 C Open the backup door and inspect the condition of the latch Repair or replace damaged
95. 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 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 hydraulic system due to high levels of wear metals in the fluid McCoy Completions amp Drilling recommends tracking all maintenance activity including the lubrication schedule This may be a simple as keeping a paper log or using a software based maintenance tracking utility A maintenance log is a valuable tool that can be used for easily retrieving maintenance history or identifying trends that require correction DRILLING amp AACCCOY TECHNICAL MANUAL 3 1 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone 3 2 2 MAINTENANCE 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 1 Cage Plate Rollers The cage plate cam followers are sealed units and do not require lubrication However the c
96. d extend the remote backing pin ramp if equipped retract and extend the float cylinders Leave all cylinders except for the door cylinders in their fully retracted position The general idea is to have as little of the chrome cylinder rods exposed as possible 3 De energize the 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 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 equipment 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 18 If any hydraulic fittings or hoses are leaking they must be repaired or replaced before proceeding Wipe all excess grease from outside of equipment Replace the access door panel Use a solvent based cleaner on 19 rags to wipe all external surfaces to remove residual gre
97. d residual hydraulic pressure is bled off Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid DEPRESSURIZATION PROCEDURE IN PREPARATION FoR STORAGE 1 2 3 4 5 7 8 10 11 12 13 NAA A le Sy de AH 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 De energize the power unit Repeatedly actuate the tong motor control valve lever INBOTH DIRECTIONS to dissipate any residual pressure in the valve and motor Remove the hydraulic SUPPLY line from the equipment Repeatedly actuate the remaining control valve levers INBOTH DIRECTIONS to dissipate any residual pressure in the remain der of the hydraulic control system Disconnect the hydraulic RETURN line from the equipment 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 EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INDUCED INJURIES Perform an initial wash of the tool in order to remove the majority of dirt and g
98. d 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 e 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 Farr recommends observing the following practices e 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 e Farr 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 data sheets for drying times at room temperature e Store in a c
99. e 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 SHORT TURNBUCKLES HAVING PART NUMBER 101 3086 EMPLOY HIGH STRENGTH PINS WHICH MUST BE SUPPLIED BY FARR Rotate the gear train by hand and use a flashlight to perform a visual inspection of the gear train through the access 1 3 C panel and the opening of the rotary gear while the gear train is being rotated If gear damage or chips of metal are z seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is complete Inspect all jaws and dies in use for the maintenance interval Inspect the jaw roller pins for signs of damage replace 14 pins if necessary If the pins are welded place remove and quarantine the jaw until the weld is repaired Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely 15 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the 16 i brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands 1
100. e 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 loose or missing fasteners replace if necessary 3 C Check to see if backup is parallel to the tong if the backup is resting at an angle one of the front leg springs is likely 8 broken fatigued to the point it must replaced Backup ONLY Remove access cover from top plate Perform a visual inspection ot the interior of the backup use a flashlight if neces 4 sary Premature wear where there are moving parts bare metal where there used to be paint and metal shavings the grease are good indicators may show where a component needs to be adjusted or if necessary replaced 5 Inspect latch mechanism to ensure the door latch plate completely engages the door Adjust or replace if necessary 6 Grease UC 300 slider pads guides door cylinder pivots door pivots CLiNCHER Backup ONLY Use a flashlight to perform a visual inspection of the interior of the backup remove one side panel if necessary Prema 4 C ture wear where there are moving parts bare metal where there used to be paint and metal shavings in the grease are good indicators show where a component needs be adjusted if necessary replaced Repla
101. e Pp 5 20 5 21 2 101 3393 3 8 NC x 2 1 2 Hex Bolt 4 09 1056 DRILLING amp AACCCOY TECHNICAL MANUAL 5 15 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Hyprautic ASSEMBLY DRILLING amp 5 16 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Hyprautic ASSEMBLY SL4500 4 1 Sim Tone Item Type Description Qty Part Number A Part 1 4 NC x 3 4 Hex Cap Screw 2 09 1005 B Part 1 2 NC Thin Nylock Nut 3 09 5610S 1 2 Narrow Washer 3 09 5119 D Part Cable Guide Holder 1 101 4236 Part Cable Guide Holder Retainer 2 02 E0025 E Part Safety Door Valve 1 08 0337 Part 1 4 NPT 90 Degree Fitting 6 08 0284 F Weldment Valve Mount 1 101 4101 G Weldment Torque Gauge Mount 1 101 4403 H Assembly DVA35 Valve Assembly 1 VARIES J Part 1 2 NC x 4 1 2 Hex Cap Screw 3 09 1184 K Part HITCH PIN 148 X 2 938 1 1 L Part 1 4 Narrow Washer 4 09 1119 M Part 1 4 NC Nylock Nut 4 09 5701 N Part Valve 1 10 9024A P Part 1 4 NC x 2 Hex Cap Screw 2 09 1015 Q Part 3 8 NC x 1 Hex Cap Screw 4 09 1046 R Part 3 8 Lock washer 6 09 5106 S Part 3 8 NC x 2 Hex Cap Screw 4 09 1054 T Part Valve Body 1 08 1327 DRILLING amp AACCCOY TECHNICAL MANUAL 5 17 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Motor ASSEMB
102. e backup jaws using the backup control handle ILLUSTRATION 2 1 3 BACKUP CONTROL DRILLING amp 2 22 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION SL4500 4 1 Sum Tone Making A Connection continued d Setting backup pressure continued Observe the backup pressure as indicated on the CLAMP pressure gauge ILLUSTRATION 2 1 4 CLAMP Pressure GAUGE ON GAUGE PANEL Hydraulic pressure on the clamp cylinders must be relieved before the clamping pressure can be adjusted Relieve pres sure by pulling back on the backup control handle enough to actuate the relief but not enough to retract the cylinder Use the backup pressure control knob to adjust the pressure Turning the knob clockwise increases clamping pressure and turning the control knob counter clockwise decreases clamping pressure ILLUSTRATION 2 1 5 BAckuP PRESSURE CONTROL VALVE Turn the knob in small increments i e 1 4 turn at a time and check clamping pressure after every pressure adjustment Ensure the pressure on the clamp cylinders is relieved before re adjusting pressure DRILLING amp AACCCOY TECHNICAL MANUAL 2 23 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Setup amp OPERATION Making A Connection continued d Setting backup pressure continued f pressure data from previous jobs is unavailable McCoy recommends sett
103. e drill floor ILLUSTRATION 2 1 21 LOWERING AssEMBLY UsiNcG Lift CYLINDER CONTROL Use your rig s standard pipe handling procedures to remove and rack the freed tubing stand D q Repeat steps g through p as many times as necessary to breakout and un thread the desired number of connections DRILLING amp AACCCOY TECHNICAL MANUAL 2 33 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank SL4500 4 1 Sim Tone 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 e replacement of damaged hydraulic hoses and fittings e replacement of malfunctioning pressure gauges and valves e replacement of door cylinders e 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 perf
104. e 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 i Close the tong door Ensure the door is securely latched tug on the door handle to ensure it remains latched j snub line is a length of wire rope that connects the pad eye on the centre rear of the tong body to a sturdy post on the drill floor The snub line prevents the tong body from spinning in the opposite direction of the cage plate when torque begins to build in the joint The wire rope and shackles or connectors that make up the snub line must be appropriately rated for the applied torque see Section 2 F 1 The snub line connection point on the drill floor must be sturdy enough to absorb all applied torque when making up the joints 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 k 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 t
105. ecessary POSSIBLE PROBLEM Worn or damaged tong motor causing slippage SOLUTION Replace or repair worn or damaged motor POSSIBLE PROBLEM Damaged bearings or gears causing excessive drag SOLUTION Replace or repair worn or damaged gears or bearings POSSIBLE PROBLEM Jaws slipping on pipe SOLUTION Ensure jaw dies are not worn to the point that they cannot grip Ensure the correct sized jaws are in use POSSIBLE PROBLEM Torque gauge is indicating incorrectly SOLUTION 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 SOLUTION Gauge has been damaged Check gauge operation and calibration on independent system POSSIBLE PROBLEM Load cell is measuring incorrectly SOLUTION Incorrect load cell is being used SOLUTION Air is trapped in torque measuring circuit load cell hydraulic line or gauge Refer to torque measurement trouble shooting in Section 6 of this manual SOLUTION Load cell has been damaged Replace load cell or return to McCoy for repair and re calibration DRILLING amp AACCCOY comprenons TecHNicAL MANUAL 4 1 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone TROUBLESHOOTING TONG WILL NOT DEVELOP SUFFICIENT TORQUE Cont d 11 POSSIBLE PROBLEM Incorrect motor speed selected SOLUTION Maximum torque can only be developed when motor is in the lowest speed Ensure motor is in low speed 12 P
106. ed 60 gpm 240 L min poppet logic element Functional Group Products Cartridges Corrosion Resistant Logic Element Unbalanced Poppet Model Pilot to open Switching Element Spring biased closed External Pilot Port 3 LKHC pilot source 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 area port 3 is 1 8 times the area at port 1 and 2 25 times the area at port 2 LOCATING SHOULDER xX 1 81 45 0 1 81 46 0 X CONTROL SHOWN INSTALLED T 17A CAVITY d HEX DIMENSION 2 ACROSS FLATS 1 1 4 31 8 PILOT PORT in mm Technical Features e Because these valves are unbalanced e These valves are pressure responsive operation is pressure dependent at all three ports therefore it is Opening and closing of the poppet are essential to consider all aspects of functions of the force balances on three system operation through a complete areas 1 Port 1 100 Port 2 80 cycle Pressure changes at any one and 180 port may cause a valve to switch from closed to an open position or vice versa All possible pressure changes in the compl
107. ete circuit must be considered to assure a safe functional system design DRILLING amp AACCCOY TECHNICAL MANUAL 731 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone VALVES These valves have positive seals e Stainless steel cartridge options P or W between port 3 and port 2 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 e Incorporates the Sun floating style construction to eliminate the effects of internal parts binding due to excessive installation torque and or cavity cartridge machining variations Technical Data U S Units Metric Units Capacity Area Ratio A3to A1 181 AreaRatio A3toA2 X 2251 Series from Cavity 23 2 U S Patent 49 9 alve Installation Torque 200 215 Nm SealKits 9900707 Seal Kits Viton 990 017 006 Full Open Da Full Cr piri n E 5 m T 2 il 7 Option Selection Preferred Options External Material Seal Control Cracking Pressure Material Standard Options X Not Adjustable N Buna N Viton DRILLING amp 7 32 TecHNICAL MANUAL AACCOY MOVING GLOBAL ENERGY FORWARD HypRAULic VALVES SL4500 4 1 Sum Tone Capacity 12 gp
108. f the tong ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED REPLACEMENT FASTENERS BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT 1 Disconnect all hydraulic lines from the hydraulic valve assemble including main motor lines backup safety door and drains 2 Remove the four 3 8 hex cap screws securing the valve assembly to the top plate and lift valve assembly away 3 If not already done disconnect and remove load cell and load cell spacer weldment REMOVAL OF BACKUP 4 Construct a support that will support the entire weight of the backup assembly 5 Lift the tong and backup and lower onto structure constructed in step 1 until the weight of the backup is completely removed from the front leg and rear support springs 6 Free the front leg springs by removing the 3 8 hex cap screw that supports the bottom spring spacers Remove the cotter pins securing the rear leg support rod and remove the support rod 7 Liftthe tong and front and rear legs up and away from the backup Use caution not to lose the springs and top spring washers which will come loose from the front legs when the tong is lifted REMOVAL OF LEG ASSEMBLIES 8 Setthe tong and leg assembly onto a flat surface Ensure that the majority of the weight remains supported by the rigid sling
109. fui ence an adhesive was var dering im CAUTION Tao much heat may distort the spend s ihe stripper bolr reads the spring Fig 2 14 guck 2 wall mired abrupil iom ihe spud Detent Spool The delem ameet noe be renamed from he spem these parts ngad repos M rap the deism sieeve Fig 2 eim TT wli tein lint ec gjah np the sleeve and dimly AS the lee mones backend he detent balls Phy 2 iem 581 and ibo spring Fig 2 10 wall The eure jars preveri thes clamp ihe kara sun vise asa verme the poppe retainer Eig 2 yem am bar dejem ball bore i verse ai a wrench giis tap the detent papper nemaner wih and punch e holp break her ades eee Cautious applicdtion af may be required again simce an arkaenahic adhesive was alu aed retaines CAUTION Too much haat may distort tha spoa l CLEANING INSPECTION AND REPAIR i Pre check sur ans spexil 3 paris 3 sabvent section for d en poeta or cran wear
110. g 1 Hh ami ide spl ring 7 Push both itema th coauner turre uatil rhe wis resumes plases Fog 1 inem n using the Pho Fig i item 9 hack maine plates fer proper alignment Tighasn ia final hs 2 les Step 3 Back cap Lucia back cap cue was Miser sere i 4 Tighten to final torque of 34 im bi 2 im Caution Excessive torque will damage the hock cap COY MOVING GLOBAL ENERGY FORWARD 7 26 SECTION CONTENTS TECHNICAL MANUAL Hyprautic VALVES SL4500 4 1 Sim Tone 29 Valve Assembly Instructions Step 4 Install Transition Check check componens for cleanliness click pepper Fig 1 inem 133 indo tee trans tice Align the cheek pring Fig iiem 12 dhe popped ien zasefully place the cheek cap lure and pring Turne by sapane te a final tongue afri fi 1 Step 5 Relief Valves al relief valves iher paper priims and 73 fl Ital new setim aale Plc secti aem Fig d ires 2 m Fe poper groceees ceram ambs oiber
111. g the valve orifice results in proportionally higher hydraulic output to the controlled device The following illustration demonstrates the type and effect of the hydraulic valves with which this tong is may be equipped TONG MOTOR This is a proportional valve Pushing the valve handle forward will cause the tong motor to rotate in a clockwise direction as seen from the top of the tong This is the desired direction of rotation for making up a joint Pulling the valve handle in the opposite direction results in counter clockwise rotation which is the desired direction of rotation for breaking out a joint 1 Motor LIFT CYLINDER This is a direct acting valve Pushing the valve handle forward will cause the lift cylinder to lift the tong vertically Pulling the valve handle in the opposite direction will cause the lift cylinder to lower the tong 2 6 2 Lift CYLINDER CONTROL NALCO Y MOVING GLOBAL ENERGY FORWARD SECTION CONTENTS TECHNICAL MANUAL SETUP amp OPERATION SL4500 4 1 Sum Tone 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 G 3 BAckuP CLAMP CONTROL TONG SPEED The motor speed valve offers safe and smooth adjustment of the tong speed without
112. haft Apply 242 blue Loctite to the threads of the clamping bolt and install in the clampnut Spin clampnut onto shaft with the B face towards bearings After the nut threads are fully engaged but prior to the nut contacting the bearings 1 tighten the clamping bolt until there is drag on the clamping nut see note Fig 1 Tighten the nut until a 20 to 30 inch pound rolling torque is achieved Tighten clamping bolt on clampnut to 70 inch pounds and recheck rolling torque Apply inspectors lacquer to head of the bolt Allow a minimum of 24 hrs to dry 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 the shaft to achieve the clamp force required Figure 1 DRILLING amp 7 14 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor SL4500 4 1 Sim Tone Information Bolt Torque Seal Kits Main Bolts 5 8 11 190 ft Ibs Standard 15 series seal kit Seal Plate 3 8 16 0150940 Wheel Motor only 45 ft Ibs Standard 15 two speed seal kit Grease used for bolt threads 0150940 and o ring retention Standard 15 wheel motor seal kit Pennzoil 707L RED 0150936 Shaft seal assembly lube Mobilgrease special with Moly ave Y NG UME
113. he operator manipulates the backup control handle to release pressure see Illustration 2 1 8 DRILLING amp AACCCOY MANUAL 2 25 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone SETUP amp OPERATION Making A Connection continued ILLUSTRATION 2 1 8 BAckuP CONTROL 1 The motor speed control valve may be one of three positions UP High speed selected MIDDLE Neutral position DOWN Low speed selected A Control ILLUSTRATION 2 1 9 Moron SPEED CONTROL If not already in the high speed position grasp the motor speed control valve and firmly lift up until it latches into its detent position Gently push the rotation control valve toward the centre of the tong to slowly rotate the cage plate until the tong jaws grip the tubing see Illustration 2 1 10 next page NALCO Y 2 26 SECTION CONTENTS TECHNICAL MANUAL vilae iteratis SETUP amp OPERATION SL4500 4 1 Sum Tone Making A Connection continued ILLUSTRATION 2 1 10 RoTATION CONTROL MAKEUP m When the tong jaws grip 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 system pressure and displayed torque will increase ILLUSTRATION 2 1 11 ToRQUE amp PRESSURE GAUGES ON GAUGE PANEL
114. hich the paint has been damaged must be repaired prior to storage Prepare areas to be painted to ensure they are free of grease dirt or solvent Touch up using a solvent based acrylic paint McCoy Grey is paint number RAL7015 Allow sufficient time for paint to dry before proceeding Perform a liberal lubrication of the equipment refer to Maintenance section of manual to determine lubrication points Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear Connect the equipment to a hydraulic power unit Ensure all lines are fully made up to prevent equipment damage from excessive back pressure Do not neglect to connect the motor drain Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of the rotary gear facing the gear train De energize the power unit and perform another generous lubrication of the gear train including the gear housing Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of the rotary gear facing the gear train DRILLING amp AACCCOY TECHNICAL MANUAL 3 23 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE 14 De energize the power unit and perform a third generous lubrication of the gear train including the gear housing 1 5
115. ic governor and increase the engine speed to as high as maximum RPM e Arestriction in the return line will result in high pressure within the power unit and the tong hydraulic system causing engine speeds as high as maximum RPM and possible failure of the motor seal Following inspection of the hoses start the engine and allow it to idle until warm Allow hydraulic fluid to circulate for approxi mately 10 minutes then slowly close the Bypass Valve to allow hydraulic fluid to circulate through the hoses and to the tong circulating pressure should not exceed 200 psi Place the tong gear shifter in low gear and rotate the tong slowly forward and then reverse with the throttle valve control lever Once this has been done and the proper size jaws have been installed the tong is then ready to run pipe DRILLING amp AACCCOY TECHNICAL MANUAL 2 17 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Setup amp OPERATION 3 2 18 Valve Operation 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 for ward 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 openin
116. igh Torque 2500 Pressure PSI Hi Speed Ibs ft Lo Speed Ibs ft 1000 1400 2800 1500 2300 4600 2000 3150 6300 4000 8000 MAXIMUM RATED TORQUE 8000 LBS FT ae Speed Table High Torque a These are ideal values Actual achieved torque is highly dependant upon tong efficiency and final position of rotary gear when full torque load is reached Max Hydraulic Requirements 60 GPM 227 1 LPM 3000 PSI 20 684 MPa Max Hydraulic Fluid Temp Operating Temperature Length Overall Width Height Torque arm length Weight Approximate Jaw Range Jaws available inches Max Sound Level NACCOY MOVING GLOBAL ENERGY FORWARD Flow US GPM Lo Speed RPM Hi Speed RPM 10 6 13 20 13 25 40 26 51 82 20 C 40 C 20 50 8 39 7 8 101 3 cm 48 1 2 123 2 cm 24 3 4 inches 62 9 cm Tong only Center Line of Pipe Center Line of Anchor Handle 18 inches 45 7 cm Tong amp Backup 600 Ib 273 kg Tong Only 1000 Ib 444 4 kg Tong amp Backup 1 90 48 25 mm 5 00 127 mm Diameter Pipe See Pp 2 13 97 96 dB C Q 1m DRILLING amp COMPLETIONS REPLACEMENT FASTENERS BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED TECHNICAL MANUAL SECTION CONTENTS 13 SL4500 4 1 Sum Tone Use an EP synthetic gre
117. ile Screws 2 387 1433 1 18 381 143 34002 a 11 12 1158 10 Check Valve 1 381 0551 044 291 0551 044 358 1t 0585 0gb Gr Valve Gap Fl 1 301 2251 015 3E81 2281 015 cen e 11 Ring Seal 4 381 88 204 395 2581 204 331 2881 24077 12 Check Spring 1 381 358 1 7 1 31 381 38281 713 351 3581 778 Chock Valve 1 30 2414 381 2283 081 Sealing Face Includes and refr eri hot in Sections AACCCOY MOVING GLOBAL ENERGY FORWARD 2 3 ne shown TECHNICAL MANUAL SECTION CONTENTS 7 19 HypRAULic VALVES SL4500 4 1 Sum Tone Spool Spring Centered and Detent Spool Operators See Figure 2 14 Stripper 1 381 1432 022 391 1432 021 381 1402 452 15 Centering Spring 1 391 3581 B08 291 3581 832 391 3581 330 18 Guides 2 391 1642445 391 1642 013 391 1842 161 17 Detent Sienve 1 301 3283 015 3 1 32 3 008 301 3384 310 18 Detent Balls 2 391 0282 010 391 0282 008 391 0282 011 19 Detent Spring 391 3581 130 391 3581 015 391 3581 316 20 Detent Poppat Retainer 381 2583 008 381 2583 006 301 3384 311 21 Datent Spacer 1 391 3782 208 7 20 Section 5 TECHNICAL MANUAL AAC COY DRILLING amp MOVING GLOBAL ENERGY FORWARD COMPLETIONS Hyprautic VALVES SL4500 4 1 Sum Tone 4 Valve Disassembly Instructions Reference exploded view und
118. ing be required to restore the brake lining Replace the brake band if the thickness is less than 10 2 5mm at any effective portion of the brake lining Brake Band Adjustment S Nut amp Bolt a Y A m EUN gt a ILLUSTRATION 3 E 1 BRAKE BAND ADJUSTMENT DRILLING amp AACCCOY TECHNICAL MANUAL 35 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE 2 Safety Door Switch Adjustment The safety door switch is intended 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 If the rotary gear does not immediately and completely stop rotating when the door is opened remove the tong from service and perform the following adjustments 1 Set the tong up in a controlled testing environment without connecting hydraulic power 2 Open the tong door and check operation of the safety door switch plunger Depress and allow it spring back several times to ensure smooth operation If the plunger binds or jams remove the control cable guide mount at the door end remove the control cable and plunger and thoroughly clean and lubricate the plunger and control cable before reinstalling 3 Test the control cable after cleaning and reinstallation The cable end should spring back when depressed If the cable does not sm
119. ing the initial backup pressure to 1900 PSI and increase the pressure incrementally if required If pressure data is available set the final backup pressure to the pres sure required for the job Due to a wide variety of tubing wall thicknesses it is impossible to recommend optimum backup pressure settings from the factory for each size of tubing Retract clamp cylinders once backup pressure has been satisfactorily set e Openthe tong door If your equipment is equipped with a safety door opening the door will inhibit rotation of the cage plate ILLUSTRATION 2 1 6 UNLATCHING amp OPENING Door f Manually engage the threads of the tubing connection being made up Ensure threads are not cross threaded NALCO Y 2 24 Section 5 TECHNICAL MANUAL E Setup amp OPERATION SL4500 4 1 Sim Tone Making A Connection continued g Actuate the lift cylinder control valve to lift the assembly from the drill floor Pushing the valve toward the center of the tong will retract the lift cylinder to lift the assembly see illustration 2 1 7 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 RIG PERSONNEL MUST STABILIZE THE TONG AND BACKUP AS IT IS LIFTED FROM THE DRILL FLOOR ILLUSTRATION 2 1 7 Lirr CYLINDER CONTROL h Move the tong and backup assembly on to the tubing joint Use th
120. ining variations U S Units Metric Units Cavity T 162A Capacity 12 45 L min Adjustment Number of Clockwise Turns to Increase Setting 5 Factory Pressure Settings Established at 4 15 L min Maximum Operating Pressure 5000 psi 350 bar 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 0 Valve Hex Size 3 4 in 19 1 Valve Installation Torque 25 30 Ibf ft 35 40 Nm Adjustment Screw Internal Hex Size 5 32 in 4mm Adjustment Nut Hex Size 9 16 in 15 mm Adjustment Nut Torque 108 Ibf in 12 Nm Model Weight 0 30 Ib 0 14 kg Seal Kits Cartridge Seal Kits Cartridge DRILLING amp COMPLETIONS Buna 990 162 007 Viton 990 162 006 TEcHNICAL MANUAL SECTION CONTENTS 7 33 SL4500 4 1 Tone VALVES Typical Pressure Rise 5000 5 OEE 300 250 200 150 100 Typical Pressure Rise LI LLL 50 5 77710 15 20 Flow GPM P RPCC KAN External Material Seal Control Adjustment Range Material 75 3000 psi 5 210 K Handknob bar 1000 psi 70 bar 0 00 Buna N 0 00 Standard Setting DRILLING amp 7 34 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD
121. itting until grease is visibly 2 displaced from bearing or as recommended by your power unit manual 10 Ensure supply return connections at the power unit at the equipment in use are fully made up FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE 11 C Check hydraulic fluid filter back pressure must be done while fluid is circulating If needle on indicator gauge is in the red zone the filter should be changed the next time the unit is shut down DRILLING amp 3 22 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sim Tone M TUBULAR CONNECTION EQUIPMENT DE COMMISSIONING PROCEDURE 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 an
122. ks Operate the tong at full speed and in high gear for a duration of one half hour Hot bearing caps may indicate impending bear ing failure Switch to low gear and operate for an additional one half hour at full speed Run the backup through several clamp un clamp sequences to ensure functionality Inspect all components and hydraulic fittings for possible defects following completion of the tests All FARR Tongs have been thoroughly tested at the factory prior to shipping but shipping damage must be identified before running the tong in an operational environment Carefully inspect the safety door components and test to ensure that the safety device on each door is operating correctly before releasing the tong to the operating environment TONG DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE THE POWER UNIT IS STARTED IN ORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL Ensure adequate lube oil and hydraulic oil levels before starting engine Use start up procedures as recommended by the power unit engine 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 IMPROPERLY SECURED HYDRAULIC CONNECTIONS WILL INTERRUPT HYDRAULIC FLUID FLOW AND COULD RESULT IN THE FOLLOWING FAILURES e Arestriction in the pressure supply hose will result in high pressure within the power unit hydraulic system which will activate the hydraul
123. latch components If latch appears to be in good condition close the door then tug firmly 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 L Perform a full functional test of the backup Document and correct hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are in use on the backup DRILLING amp AACCCOY TECHNICAL MANUAL 3 21 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE L DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER UNIT Farr recommends that the following inspections and maintenance procedures be performed before each use and at least once per day when the equipment is in steady use in the sequence in which they are listed Rigorous inspection and maintenance especially lubrication is essential in order to ensure that your equipment always meets specifications and to prevent catastrophic failures that can severely damage your equipment and cause worker injury If using a stand alone power unit perform the following inspection and maintenance procedures before each use and at least once per day when the power unit is in steady use Do not perform any maintenance while the power unit is energized electric or if the engine is running diesel Ensure the electrical supply is locked out
124. lean dry location When returning to service note that a full inspection of the device must be performed DRILLING amp AACCCOY TECHNICAL MANUAL 23 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Setup amp OPERATION B MAJOR COMPONENT IDENTIFICATION ILLUSTRATION 2 B 1 COMPONENT IDENTIFICATION 01 Item Description 1 Rigid Sling 2 Tong 3 Backup 4 Front Leg Assembly 5 Hydraulic Valve Assembly amp Mounting Plate 6 Rear Leg Assembly DRILLING amp 24 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION SL4500 4 1 Sim Tone ILLUSTRATION 2 B 2 COMPONENT IDENTIFICATION 02 Item Description 7 Backing Pin Assembly 8 Cage Plate Assembly 9 Tong Jaws with Die Inserts 10 Safety Door Plunger amp Guard 11 Tong Door Latch 12 Tong Door 13 Tong Leveling Adjustment DRILLING amp AACCCOY TecHNicAL MANUAL 25 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone 2 6 SECTION CONTENTS Setup amp OPERATION ILLUSTRATION 2 4 COMPONENT IDENTIFICATION 04 17 Item Description 14 Safety Door Valve 15 Hydraulic Motor 16 Brake Band 17 Brake Band Adjustment TEcHNICAL MANUAL AACCCOY MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION SL4500 4
125. m 45 L min Pilot operated balanced piston relief valve Model RPCC KAN Functional Group Products Cartridges Relief 2 Port Pilot Operated Balanced Piston Product Description Pilot operated balanced piston relief cartridges are normally closed pressure regulating valves When the pressure at the inlet port 1 reaches the valve setting the valve starts to open to tank port 2 throttling flow to regulate the pressure These valves are accurate have low pressure rise vs flow they are smooth and quiet and are moderately fast FONT Technical Features MOVING GLOBAL ENERGY FORWARD 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 Minimum setting is 75 psi 5 bar for all spring ranges 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 Technical Data The main stage orifice is protected against contamination All 2 port relief cartridges except pilot reliefs are physically and functionally interchangeable same flow path same cavity for a given frame size ncorporates the Sun floating style construction to minimize the possibility of internal parts binding due to excessive installation torque and or cavity cartridge mach
126. n 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 prop erly cleaned Ensure that cleaning solvents and chemicals are captured to prevent environmental contamination and dispose of all materials according to your company s proscribed environmental protection regulations C PREVENTIVE MAINTENANCE PRACTICES Regular maintenance programs are necessary and must be established to assure safe dependable operation of your Hydraulic Tubular Connection System and to avoid costly breakdown maintenance The following maintenance procedures provide 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 McCoy has also provided recommended maintenance check lists The intervals in the maintenance checklists 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 or in conjunction with your maintenance foreman s experience and best estimate of when your equip ment is due for this maintenance Purchased
127. nd eel rad cr amp ewaiiniver ihmugh the hide in the ball retninger Step J Detent Balls and Spring Une balls Eig 2 inem IE derent 2 ier 19 and entire diameter 91 ibe sleeve Fig 2 UT wath press ilie leteni sgh enge itr iier libe di detent hall nziamer Place balls on the ends of ihe spn Camaras the halls and eprom then ili on ibe desent sleeve Sure Whe detent sleeve mi ermine eng end of the sleeve has a lead in TT Tender fice ihe clev wleen ocean Move ihe deser dew qo ibe neural ae maddie ioo ho prevent ihe Mon separmrime sequal scope COY TECHNICAL MANUAL 7 25 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Hyprautic VALVES Valve Assembly Instructions 3 Step 1 Spool Subassembly Apply 2 3 dropi al 2629 oc equivalent bio ihe Filis sere nales an Tcu erus al thie hemis Apply Bids maung af clean hidrauli ail ps lbe valve seen Curtieliy Inscrit the pool zisembly the Vise canman amay bus careful rit vo toll dauid sure ihe spoil and housing ave in he proper meranen Step p ge Step 2 Spool Seal and Back up Apply Paster Superd 1 be T to ibe acal Fi
128. ndition Replace missing hardware if necessary All hardware must be free of rust and corrosion 5 4 80 6 07 6 93 8 69 11 26 13 87 17 45 19 05 Additional inspections shall be performed during sling use where service conditions warrant Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on e Frequency of use of the load bearing device e Severity of service conditions e Nature of lifts being made e Experience gained on the service life of load bearing devices used in similar circumstances Guidelines for the interval are e Normal Service Yearly e Severe Service Monthly to quarterly e Special Service As recommended by a qualified person DRILLING amp 2 2 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION SL4500 4 1 2 Sim Tone 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 Non DESTRUCTIVE THOROUGH Surrix To BE MARKED NDE oF VISUAL On PLATE ATTACHED TIME INTERVAL LIFTING
129. oad Limit or Design factor may be affected by wear misuse overloading corrosion deformation intentional al terations sharp corner cutting action and other use conditions e Shock loading and extraordinary conditions must be taken into account when selecting alloy chain slings e See OSHA Regulation for Slings 1910 184 ANSI ASME B30 9 SLINGS ANSI ASME B30 10 HOOKS ANSI AMSE B30 26 RIGGING HARDWARE for additional information 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 ILLUSTRATION 2 1 SLING ANGLE DRILLING amp AACCCOY TECHNICAL MANUAL 21 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Setup amp OPERATION 1 Inspection Of Slings Farr Canada Corp 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
130. on presented this document will provide setup operating and maintenance instructions for your SL4500 tong 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 op erating authority ies IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS INSTALLATION GUIDE Farr Canada Corp uses three indicators to describe items of three degrees of importance A HAZARD to operators or equipment is represented by an exclamation point within a red triangle and identifies items of the highest importance Failure to heed information identified by a HAZARD symbol may result in bodily injury death catastrophic equipment damage or any combination of these A HAZARD may also indicate the potential for dangerous environmental contamination This identifies a HAZARD to operators or equipment A WARNING is represented by an exclamation point within an orange triangle and contains information that will alert per sonnel to a potential safety hazard that is not life threatening A WARNING may also serve to alert the user to information critical to the correct assembly or operation of the equipment in use This identifies a WARNING to users A CAUTION is represented b
131. ong by the tong s torque arm expressed in feet For example an 8 000 Ibs ft tong with an 18 inch 1 5 ft torque arm will generate 5333 Ibs of force against the snub line Select your snub lines based upon the total force and the margins of safety dictated by the policies of your company and by established engineering practices Ultimately calculating the force on the snub line and selection of the snub line is the complete responsibility of the customer Snub lines must be securely connected to the rear of the tong and backup assembly and tied off to a suitable anchor FARR CANADA CORP 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 SUS PENSION AND SNUB LINES MUST BE RATED FOR THE CALCULATED FORCES 2 Leveling The tong must be leveled side to side and front to rear before placing into service The following guidelines will assist you when leveling your tong Lift the tong by the main lifting link Place a level axially side to side across the tong ensuring that it is parallel with the surface of the tong If the tong is not hanging level move the main link to an adjacent notch on the hanger to move the tong closer to the level position THE MASTER LINK MUST BE USED TO SUSPEND THE TONG ASSEMBLY c Master Link ILLUSTRATION 2 F 1 MASTER Link AACCC
132. onnect 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 If using a stand alone power unit start it now refer to the power unit technical manual for startup procedures Listen to power unit for a moment to see if there are any unusual mechanical sounds rubbing grinding excessive pump noise If using a diesel unit allow sufficient time for the engine to reach operating temperature before increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 2 3 C Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is 5 less than 350 psi 2 4 C Perform a visual inspection of pressurized hydraulic lines If any hydraulic fittings or hoses are leaking they must be repaired or replaced before proceeding Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening 25 of the rotary gear facing the gear train De energize the power unit and perform another generous lubrication of the gear train including the gear housing 2 6 Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending 2 with the opening of the rotary gear facing the gear train
133. ontained 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 equipment integrity Summary Of Revisions Date Section Page Description Of Revision May 2009 N A N A Initial Release Sep 2009 Intro 1 2 amp 1 3 Corrected dimensions on the specification pages May 2010 Varies Varies 2 to represent updated jaw retention mechanism June 2010 Varies Varies Updated manual to comply with CE marking September 2010 Appendixes Varies Revised appendixes All All Added table of illustrations 2 2 13 Revised subsection 2 F 1 Tong Rig Up amp Leveling Suspension amp Restraint 2 2 17 Inserted subsection 2 G 1 Tong Operation Operator Training 2 221 Removed Sections 2 4 amp 2 Up A Joint and Breaking Out A Joint inserted section
134. oothly spring back replace the control cable 4 Following reinstallation the plunger should extend 3 4 of an inch from the end of the control cable guide mount ILLUSTRATION 2 Door PLUNGER ADJUSTMENT 01 Adjust plunger position using the positioning nut and locking nut on the control cable before proceeding Loosen the locking nut and adjust the positioning nut until the plunger extension measures approximately 3 4 When position of the plunger is set tighten the locking nut Note that although the following illustration shows the tong door closed the plunger extension must be performed with the door open ILLUSTRATION 3 E 3 SAFETY DooR PLUNGER ADJUSTMENT 02 DRILLING amp 3 6 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Safety Door Switch Adjustment Cont d 5 Connect hydraulic power to the tong 6 Ensure the door is closed and all personnel are clear Begin rotating the cage plate Open the tong door the cage plate should immediately and completely stop 7 Release all controls and close the tong door again Ensure the cage plate rotates with the door closed If cage plate continues to rotate with the door open further adjustment of the safety door switch is necessary Remove hydraulic power from the tong 9 Adjust the guide block first Slightly loosen the two mounting bolts and use
135. ormed only by designated qualified maintenance personnel Wear approved eye wear and footwear 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 activation Notify operations when maintenance procedures are complete and equipment functionality is restored Isolate the location of the maintenance under way to prevent unaware personnel from inadvertently exposing themselves to a hazard Use tape rope or signage to clearly indicate off limits area Replacement of large heavy individual parts and or heavy structural components must be performed using an approved lifting device of sufficient lifting capacity Use care when attaching the lifting device and safeguard area to avoid endangering personnel or equipment All spare parts must meet or exceed OEM specifications in order to maintain equipment integrity especially protective equipment McCoy recommends that disconnection of hydraulic connectors be performed with the power unit off and the hydraulic circuit depres surized 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 protectio
136. ortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compres 3 3 sion 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 3 4 C 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 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 3 5 need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved Refer to the maintenance section of the manual for instructions on properly adjusting brake bands Perform a full functional test of the tong including if applicable backup components lift cylinder and float frame 3 6 components Report and correct hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used Test safety door feature if equipped Begin rotating the tong at low speed and open the tong door s If rotation does not immediately stop this is an indication that the safety door mechanism is not operating correctly and the
137. ost to enable smooth latch ing action ILLUSTRATION 3 D 5 Door amp Post LUBRICATION 6 Jaw Lubrication Apply a thin layer of grease to the metal to metal contact surfaces of the tong and backup jaws to enable them to slide smoothly ILLUSTRATION 3 0 6 Jaw ASSEMBLY LUBRICATION DRILLING amp 3 4 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone 7 Backup Load Cell Lubrication Grease must be added to both sides of the interface of the load cell and the rear leg of the backup _ WES pr ILLUSTRATION 3 D 7 LoAD CELL LUBRICATION E ADJUSTMENTS 1 Brake Band Adjustment See Illustration 3 E 1 The 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 Do not over tighten as this causes excessive wear to the brake bands If excessive tightening is required for tong operation remove the brake band and inspect for wear or foreign debris excessive grease Clean
138. ousing 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 AACCCOY MOVING GLOBAL ENERGY FORWARD 1 Press bearing onto shaft SL4500 4 1 Sum Tone WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION ASSEMBLY OF WHEEL MOTOR FRONT HOUSING 29 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 nuttums with a slight drag 4 Tighten lock nut until desired rolling drag of bearing is obtained see procedure Page 9 5 Tighten clamp screw 6 Tighten all seal plate bolts 1 Install dowel pins into rear housing 2 Install ballchecks into rear housings 3 Install main body o ring 1 Place rotor stator cartridge onto rear housing 2 NOTE Make sure assembly marks from step 3 are lined up 1 Install main body o ring into front housing 2 Install ball checks into front housing 3 Place a small amount of grease over ball checks and o ring 4 Wipe off excess grease TECHNICAL MANUAL SECTION CONTENTS 7 13 SL4500 4 1 Tone Hyprautic Motor WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFI
139. p Gohltrol carae tid ras eden Ihe epus x cea Pa gu de pd 2 22 Illustration 2 1 4 CLAMP Pressure Gauge Gauge sss sesenta 2 23 Illustration 2 1 5 Backup Pressure Control Valve 2 23 Illustration 2 1 6 Unlatching amp Opening DOOT 2 erento rin itio tnn nebenan 2 24 Ill stration 2 L 7 Lift Cylinder Control iriure exei ere ut OH a eae a 2 25 Illustration 2 1 8 Backup Control 2 26 Ill stration 2 19 Motor Speed Gonltrol iei ceder eiae eta ai i edad d treo EUR da e Rak HR Re ea R Ea 2 26 Illustration 2 1 10 Rotation Control 2 27 Illustration 2 1 11 Torque amp System Pressure Gauges on Gauge Panel ee 2 27 Illustration 2 1 12 Switching Motor speed Switch To LOW 2 28 Illustration 2 1 13 Reversing Rotation To Free Tong 2 28 Illustration 2 1 14 Un clamping Backup Jaws 2 29 Illustration 2 1 15 Lowering Assembly Using Lift Cylinder Control 2 29 Illustration 2 1 16 Setting Backing Pin To Break out 2 30 Illustration 2 17 Rotation Control Break out i 291 Illustration 2 1 18 Switching Motor Speed Control To HIGH SPEED
140. p outlet 8 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 as soon as possible 9 C Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is good indication of wear Inspect all paint locations in which the paint has been damaged must be repaired prior to the tong being returned to 1 0 service Prepare areas 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 contact Farr sales for paint number for custom paint plications Allow sufficient time for paint to dry before proceeding 11 Inspect all external welds weld that is cracked or separating must be repaired and repainted before returning the tong to service DRILLING amp 3 18 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone 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 turn 1 2 C buckles again if any damage is noted replace the damaged part s before placing the tong in servic
141. ptions are available A tension load cell is typically used with a suspended stand alone tong This application requires that the load cell be attached to the rear of the tong as part of the restraint line that opposes the force generated when the tong makes up or breaks out a joint A compression load cell is used in a tong and backup assembly and is typically located on the rear of the backup between the backup and a stationary frame The load cell must be located in the centre of the compression force vector generated between the backup and the frame Hydraulic force generated by a load cell is transmitted to the torque gauge via a reinforced flexible hydraulic line The hydraulic force is displayed as torque in units of Ft Lbs The torque gauge has a red peak torque indicator that tracks with the torque gauge needle to the point of highest torque and remains at the point of highest torque until manually reset Note that every model of tong and tong and backup assembly has a unique arm length and the torque gauge must be calibrated for that arm length Torque gauges that are not calibrated for the arm length of the tool in service will not display correct torque To ensure correct torque measurement ensure the arm length or handle as displayed on your torque gauge matches the arm length of the tool in service as listed on the specifications page of the technical manual The images on this page are for illustration purposes only and may not
142. quarantined from service until it can be properly repaired or replaced Removal Criteria A load bearing device shall be removed from service if conditions such as the following are present Missing or illegible sling identification Cracks or breaks Evidence of tampering is seen sling tag has been modified or obscured or tamper proof nuts are missing Signs of impact on load bearing components including spreader bars lifting lugs rigid slings amp rigid sling weldments and legs amp leg mounts Broken or damaged welds e 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 MM Inches 0 189 0 239 0 273 0 342 0 443 0 546 0 687 0 750 0 887 22 53 1 091 27 71 Refer To ASME B30 9 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 e 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 co
143. r 1 09 5013 E Weldment Backup Body Weldment 1 101 4337 F Assembly Jaw Die Kit 2 3 8 shown see Pg 2 13 2 G Part Cylinder Pin 1 101 4329 H Part Jaw Retainer Bolt 2 101 4264 J Part 3 8 x 1 UNC Socket Head Shoulder Screw 1 09 1118 K Part External Retaining Ring 2 02 E0037 L Part Lever Pin 1 101 4330 M Part 3 8 x 1 2 UNC Socket Head Shoulder Screw 1 09 9179 N Part 2 213 O Ring 1 02 0347 1 1 4 Plain Narrow Washer 2 02 E0043 Cam Arm 1 101 3672 Q Part Compression Load Cell CC 108 1 10 0008C R Weldment Load Cell Holder Weldment 1 101 4340 5 5 16 Narrow Flat washer 2 02 E0044 T Part 5 16 NC x 4 Hex Cap Screw 2 09 1024 DRILLING amp AACCCOY TECHNICAL MANUAL 5 27 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Rear LEG ASSEMBLY DRILLING amp 5 28 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Rear Lec 55 SL4500 4 1 Sim Tone Item Type Description Qty Part Number A Part 3 4 Lock washer 4 09 5118 B Part 3 4 NC x 3 1 2 Hex Cap Screw 1 09 1300 C Part Rear Leg Spring 2 997 13 D Weldment Backup Support Plate 2 101 3885 E Part 3 4 NC x 5 Hex Cap Screw 1 09 1306 F Weldment Rear Leg Weldment 1 101 3883 G Part 3 4 Hex Nut 2 09 5818 H Part 0 093 x 1 125 Hitch Pin 2 02 E0046 J Part Support Rod 1 101 3891
144. r accurate torque measurement while using the equipment for which this manual is supplied THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE THE PART NUMBERS LISTED IN THE FOLLOWING TABLES ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH TORQUE MEASUREMENT THIS MANUAL IS SUPPLIED Item Type Description Qty Part Number Assembly 24 Arm 8000 Lbs Ft Torque Gauge Tension Load Cell Assembly 1 10 0025T 1 Part 24 Arm 8 000 Lbs Ft Torque Gauge 1 10 0025G 2 Part Tension Load Cell 4 08 in 1 10 0008T 3 Part Hydraulic Hose 1 02 0069 Item Type Description Qty Part Number Assembly 18 Arm 4K 8 5K Torque Gauge Comp Load Cell Assembly 1 10 0025C 1 Part 18 Arm 8 500 Lbs Ft Torque Gauge 1 10 0025G 2 Part Compression Load Cell 8 in 1 10 0008C 3 Part Hydraulic Hose 1 02 0069 MCCOY 5115 6 2 Section CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD Torque MEASUREMENT SL4500 4 1 Sum Tone Item Type Description Qty Part Number This is the standard tension load cell sup Assembly Tension Load Cell 4 08 in 1 10 0008T lied by McCoy Drilling amp Comp letions Farr Contact our sales department for A Part O Ring 1 02 0800 information about optional application B Part Load Cell Body 1 LC99 1
145. ration POSSIBLE PROBLEM By pass valve not functioning SOLUTION Check and repair DRILLING amp SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING SL4500 4 1 Sum Tone D 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 understanding 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 DRILLING amp AACCCOY comprenons TecHNicAL MANUAL 4 5 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank Parts amp Assemblies Model 80 2001 8 Shown Model 80 2001 10 Shown DRILLING amp AACCCOY TecHNicAL MANUAL 5 1 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone Gear Train Layout DRILLING amp 5 2 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLE
146. rease build up Ensure adequate contain ment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental con tamination 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 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 con tamination from residual hydraulic fluid dirty grease and cleaning agents Inspect all fasteners and fastener safety wires Replace any missing fasteners use Grade 8 bolts only Re torque all external fasteners to SAE specifications Inspect backing pin s If cracked broken or bent it they must be replaced Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Inspect all paint locations in w
147. rewire AM sarum arr drm 94 tm res dr nest nur ineat wen planus Bre Sere y al ind pcr Typical Work Section Schematics inier NALCO Y MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL Section CONTENTS 7 17 SL4500 4 1 Tone VALVES VA VG Valve Service Instructions INTRODUCTION Thas has been prepared to assisi you im the proper maintenance of the V AZOTMAPA 3579 and VGZUTV VG3SIM VORO directional control valves Before any work is done we sues that you read the assembly and dissssembly msiructions completely The first rule of good maintenance is cleanliness which meludes a clean environment MARE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT A CLEAN AREA Dirt is the natural enemy of any hydraulic system GENERAL INFORMATION The V and V model valves are updated versions Of eur proven 2 and 5 units The VG models are cast from compacted graphite high strength iron alloy which allows the valve to rated to 1500 VA models are cast from ion and rated al 2500 These open center directional control valves are available in parallel tandem and series circuitry As needed ihe sectional stack fype construction provides flexibility forthe addition of subtraction of work Sections to existing valve bank This design al
148. s four stator cavities and 10 rotor 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 Technical Information Two Speed Motor ae DISPLACEMENT CHANGE When a motor is shifted from full to partial displacement the motor is changed to 50 35 or 28 of its original displacement depending on its shift ratio STANDARD SHIFT RATIO The standard 15 Series displacemen
149. s that the 11 brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands 1 2 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 1 3 Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have z visible signs of wear from contact with a rigid object DRILLING amp 3 16 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sim Tone 14 Perform complete greasing of the tong refer to Maintenance section of the technical manual 1 5 C Ensure main supply and return connections to the tong are fully made up Re connect the remainder of the hydraulic lines and if applicable the electrical line to the turns counter FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE 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 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
150. section of manual to determine lubrication points 5 Generously 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 excessive back pressure Do not neglect to connect the motor drain FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE 7 Energize power unit 8 Ensure that supply pressure is at 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 1 0 Perform thorough inspection of all seals Any seal that is leaking or weeping must be replaced before the equipment s is returned to service Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines If a seal line or fitting 11 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 1 2 Inspect all flexible hydraulic lines for signs of wear blistering or any other signs of potential failure replace
151. so permits the combination of parallel tandem and series circuitry a single bank The internal conny of each valve section delermines ifs circuitry and the number of gasket seals required All with optional features such as port relief valves crossover relief valves and anti eavitatian checks are dimensionally larger when measured from the top of the to the battam of the housing These are referred to as Iu hay Those without work per options can use the low profile castings Which are called lo boy sectis 7 18 SECTION CONTENTS TECHNICAL MANUAL REPLACEMENT PARTS The illustratiens and instructions in this manual apply only ta the V A VG series assemblies subassemblies and components All valve except for spaols and housings nre available as replacement parts subasstmblies Spools lionce Fitied to their individual housings oo damage to either of these components means the entire section must be replaced We recommend that you usc only genuine V A VG series replacement parts in your service program Manufaetured the same exacting and quality controls as the original equipment genuine replacement parts may help prevent premature component failure and costly downtime Service parts and asseniblics available through yor orginal eguipanent dealer or amy authorized distributor MAINTENANCE Valves are offen used im hazardo
152. spring operates smoothly c POSSIBLE PROBLEM Relief valve is leaking SOLUTION Check valve seat for scouring Check oil seals Check for particles stuck under the valve system POSSIBLE PROBLEM Directional valve is leaking SOLUTION Check directional valve Neutral position should return fluid directly to the reservoir Replace or repair valve to en sure correct operation POSSIBLE PROBLEM Power unit is malfunctioning SOLUTION Troubleshoot power unit see user s manual for your particular unit POSSIBLE PROBLEM Poor hyaraulic pressure at the tong despite adequate pressure at the power unit or excessive back pressure in the return line SOLUTION Restrictions exist in line between power unit tong Inspect integrity of self sealing couplings to ensure they are allowing full fluid flow Check to ensure no other restrictions exist contaminated catch screens or filters for example POSSIBLE PROBLEM Fluid viscosity is not appropriate too high or too low SOLUTION Ensure hyaraulic 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 SOLUTION Hyaraulic fluid viscosity is affected by environmental conditions Ensure the fluid being used is suitable for high or low temperatures Replace with proper viscosity fluid for the operating conditions if n
153. ssible Problem Solutions Possible Problem Solution Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solution Possible Problem Solution Possible Problem Solution Possible Problem Solution SECTION CONTENTS TORQUE MEASUREMENT IF TROUBLESHOOTING REVEALS THAT THERE 15 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 No indication on gauge Obstruction in hydraulic hose Check hydraulic hose for kinks Replace hydraulic hose Loss of hydraulic fluid Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Internal mechanism of torque gauge is damaged Replace gauge Gauge indication unexpectedly high Excessive hydraulic fluid Completely drain hydraulic fluid from torque gauge load cell system Recharge following the procedure in Section 6 C Internal mechanism of gauge is damaged Replace gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication unexpectedly low Insufficient hydraulic fluid Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system
154. stator cartridge and remove from the rear housing 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 1 Remove o ring and Springs with a small screwdriver 2 Remove dowels pins 1 Replace plate on rotor stator cartridge 2 Turn rotor stator cartridge over 3 Repeat steps 14 amp 15 TECHNICAL MANUAL Section CONTENTS 7 11 5 SL4500 4 12 Stim TONG WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 7 12 Motor 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 SECTION CONTENTS TECHNICAL MANUAL
155. te 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 DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON NECTED 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 CONTAMINA TION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HYDRAULIC SYSTEM IN PREPARATION FoR MAINTENANCE 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 2 the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers INBOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP
156. tion 2 C 1 Hydraulic Schemalic 01 2 8 Illustration 2 2 Hydraulic Component Identification 01 we 29 Illustration 2 C 3 Hydraulic Component Identification 002 2 9 Illustration 2 C 4 Hydraulic Component Identification 03 2 10 Illustration 2 D 1 Hydraulic Connections 01 a 20201 Illustration 2 D 2 Hydraulic Connections 02 enata saei 2 11 Ill stration 2 E 1 Tong Jaw Removal eiie dit etri enne idR 2 12 Illustration 2 E 2 Tong Jaw Die Replacement 2 13 lll stration 2 F 1 Master LINK X E 2 14 Mustration 2 F 2 TONG Levellers Et 2 15 Illustration 2 F 3 Load Cell Configuration s 210 lll stration 2 6 1 COMON sites 2 18 Illustration 2 G 2 Eift Cylinder Control 2 rase rite 2 18 Illustration 2 G 3 Backup Clamp Control 2 19 Illustration 2 6 4 Motor Speed Control ssiri esiisaks daa Fe ka aS RR Aa na Ro 2 19 Illustration 2 1 1 Tong Suspension Master Link eese ssiiseseseea seen 2 21 Illustration 2 1 2 Setting Backing Pin to Make up e 2 22 Illustration 2 L 3 Backu
157. tion DVA35 DA8 SAE PORTS 10 9019 2 10 6 Lift Cylinder Section DVA35 SA8 1 ORB PORT 10 9015 2 10 7 Outlet Section DVA35 TR99 SAE PORT 10 0086 2 10 8 Flow Control Valve Parker N800S Not Shown 08 9062 Not Shown 9 Safety Door Switch 08 0337 2 11 10 Motor Shift Valve Bailey ED Series 220 906 10 9035 2 10 11 Check Valve 08 9022 2 11 12 Rineer GA15 13 6 5 Hydraulic Motor High Torque Version 87 0008 2 11 Rineer GA15 10 5 3 Hydraulic Motor Low Torque Version 87 0010 2 11 13 DVA35 Transition Plate 101 3935 2 10 14 3000 psi Pressure Gauge 02 0246 Not Shown 15 Valve Body 08 1327 2 11 16 Pilot To Open Check Valve Sun CKEB XCN 08 0481 2 11 17 Relief Valve Sun RPCC KAN 08 1749 Not Shown 18 Relief Valve Block Sun AAI 08 1750 Not Shown 19 Backup Clamp Cylinder Inside Backup 101 4336 2 10 DRILLING amp 2 8 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION SL4500 4 1 Sum Tone ILLUSTRATION 2 C 3 HYDRAULIC COMPONENT IDENTIFICATION 02 DRILLING amp AACCCOY TECHNICAL MANUAL 2 9 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Sum Tone Setup amp OPERATION ILLUSTRATION 2 C 4 HyDRAULIC COMPONENT IDENTIFICATION 03 DRILLING amp 2 10 SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION SL4500 4 1 Sim Tone D HYDRAULIC CONNECTIONS A pair of h
158. ts of 15 13 9 5 8 7 and 6 CID are available in the 15 Series Two Speed with a shift ratio of 2 1 For example a 15 CID motor shifted to partial displacement becomes a 7 5 CID motor SPECIAL SHIFT RATIOS There are two special displacements available in the 15 Series Two Speed which offer higher shift ratios the 10 5 and the 11 5 CID The 10 5 CID motor has a shift ratio of 3 5 1 which when shifted becomes a 3 CID motor The 11 5 CID motor has a shift ratio of 2 875 1 which when shifted becomes a 4 CID motor SECTION CONTENTS TECHNICAL MANUAL 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 F Elevated fluid temperature will adversely affect seal life while accelerating oxidation and fluid breakdown Fire resistant fluids may be used with certain limitations Contact Rineer for additional information CASE DRAIN The 15 Series Motor is designed for either internal or external case drain Two case drain ports are supplied When using internal case drain simply plug the two ports When using external case drain use the port at the highest elevation We recommend case drain pressure of 35 PSI or less when using the standard seals CASE DRAIN CIRCULATION Fluid should be circulated thro
159. ugh the case when a temperature differential exists between the motor and the system in excess of 50 F Should this occur contact a Rineer Application Engineer MOUNTING The mounting position is unrestricted The shafts pilots and mounting faces should be within 002 TIR INTERMITTENT CONDITIONS Intermittent conditions are to be less than 10 of every minute OTHER AVAILABLE MOTORS For information on additional Rineer Motors request one of the following publications IMONE Publication DS371003 57 Series Publication 05571003 125 Series Publication DS1251003 OPEN DURING CROSSOVER SPOOLS Open during crossover spools allow port A to be directly connected to port B when the spool is shifting between full and partial displacement Motors with 62 or 65 designations are open during crossover WARNING IN SOME WINCH APPLICATIONS OPEN DURING CROSSOVER SPOOLS 62 or 65 ARE NOT RECOMMMENDED CLOSED DURING CROSSOVER SPOOLS Closed during crossover spools do not allow port A to be directly connected to port B when the spool is shifting between full and partial displacement Motors with 63 or 67 designations are closed during crossover These motors contain an internal factory preset relief valve This valve protects the motor during shifting only and is not a system relief valve NALCO Y MOVING GLOBAL ENERGY FORWARD HvoRAULIC Motor AACCOY MOVING GLOBAL ENERG
160. uipped Open the tong door s and attempt to rotate the cage plate at low speed low 22 gear in both directions makeup and breakout If cage plate begins rotating the safety door mechanism is not func tional and the tong must be removed from service until the safety door mechanism be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR 2 3 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper action is achieved DRILLING amp AACCCOY TECHNICAL MANUAL 3 17 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone MAINTENANCE J 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 maintenance procedures be performed monthly or in conjunction with your maintenance foreman s experience and best estima
161. us environments Inspect them frequently for damage due te improper use cortoesin or normal wear If needed repairs should be made immediately Always refer to the machine manual for the proper procedure to remove the valve from the machine Remove the valve bank from the equipmeni disconnecting all hoses eonim handles and linkage connectors thal might be attached to the valve Plug all ports and thoroughly clean the exterior of the valve bunk ren the poi plugs eun be NALCO Y MOVING GLOBAL ENERGY FORWARD VALVES SL4500 4 1 Sim Tone Exploded View of Work Section Parts List For Work Section Description V VGZD Part Parallel Section See Figure 1 1 Square Sea s 3 353 2891 206 301 2883 200 331 2881 433 2 Seal 1 384 7881 200 2BB 2281 22881 57D Seres Saala 1 Square Deals 2 364 2884 206 3631 2RR1 200 3 Square Saal 1 354 2854 827 383 2Rh1 508 Parallel and Series Section Component Parts See Figure 1 4 Back Soa z WiU 4 301 140 088 d Lock wirsh ara eg i 381 7 Wi ge 5 Back 1 347 6001 1 GR 541506850589 B Plates 3 38 1 2183 0CH 393 2 183 D058 351 2183 157 7 Back up Hings 391 2581 3 8 21 268126 391 25HT 2H5 Speo Fork 2 Jai THEE J81 2887 212 23 1 268 1096 7 Retina P
162. vide 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 the hand pump to the check valve fitting c Elevate the load cell so it is higher than the torque gauge and hand pump UN CONTAINED SPILLAGE OF THE HYDRAULIC FLUID IN THIS SYSTEM MAY CONTRAVENE GOVERNMENTAL ENVIRONMENTAL REGULATIONS OR THE ENVIRONMENTAL REGULATIONS AND POLICIES OF YOUR COMPANY MCCOY DRILLING amp COMPLETIONS 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 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 e Remove the vent plug screw and Stat O Seal Items C and D on Illustration 6 A 4 or item on Illustration 6 A
163. y 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 e all descriptions information and instructions set out in this manual e 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 e any legal or other mandatory regulation in force governing accident prevention or environmental protection DRILLING amp X SECTION CONTENTS TECHNICAL MANUAL AACCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD INTRODUCTION SL4500 4 1 Sim Tone Congratulations the purchase of your FARR SL4500 4 1 2 Slim tong This unit will provide you with years of outstanding perfor mance Simple maintenance and care will extend its life and ensure years of excellent performance and reliability The setup operating and maintenance instructions in this manual will assist you in giving your equipment the care it requires Please carefully read the manual before installing and using your equipment Replacement parts are readily available from McCoy Drilling amp Completions FARR in Edmon ton Alberta Note that many parts
164. y 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 0 04 Copper Corrosion Test 1A Filterability Denison Wet amp Dry Pass Afnor Wet amp Dry Pass P69 Denison HF 0 Approved Denison P 46 Piston Pump Pass Denison T6C Vane Pump Pass Vickers 35VQ25 Vane Pump Test Pass 104 105C Vane Pump Test No Data Available lt 10 Oxidation Stability 2500 325 12 AACCOY 2 COMPLETIONS 14 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION SL4500 4 1 Sim Adequate setup and proper hydraulic connections are essential in ensuring reliable operation of your tong For best results and long term reliability read and obey the start up instructions in this section DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR A SLING LOAD BEARING DEVICE SAFETY THE SUPPLIED LOAD BEARING DEVICE CHAIN SLING RIGID SLING SPREADER BAR ASSEM BLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT DESCRIBED IN
165. ydraulic 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 THE INLET amp OUTLET HYDRAULIC HOSES ANTI WHIPLASH LANYARDS MUST BE ATTACHED TO THE TONG WITH ANTI WHIPLASH LANYARDS 1 Hydraulic Inlet 1 1 4 Hydraulic Outlet ILLUSTRATION 2 0 1 HyDRAULIC CONNECTIONS 01 These hose couplings are self sealing and care should be taken to ensure complete engagement to prevent partial closure of the check valve in the coupling Ensure that the nut female side is completely made up onto the male connector there is a line on the male fitting that indicates complete make up Snug the female fitting right up to the line Make up female fitting to Marked point on male fitting ILLUSTRATION 2 0 2 CONNECTIONS 02 DRILLING amp AACCCOY TECHNICAL MANUAL 211 MOVING GLOBAL ENERGY FORWARD SL4500 4 1 Tone TONG JAW AVAILABILITY amp INSTALLATION 1 Jaw Availability Setup amp OPERATION The following ta

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