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KT20000 - McCoy Global Inc.

1. 3 10 ILLUSTRATION 3 E 6 SHIFTER DETENT ADJUSTMENT 3 11 ILLUSTRATION 1 CAM FOLLOWER INSTALLATION BOTTOM PLATE 3 14 ILLUSTRATION 3 H 2 ROTARY GEAR amp SUPPORT ROLLER INSTALLATION 4 15 ILLUSTRATION 3 H 3 TURN COUNTER ENCODER amp ROTARY IDLER INSTALLATION 3 16 ILLUSTRATION 3 H 4 CAM FOLLOWER INSTALLATION PLATE 3 17 ILLUSTRATION 3 H 5 PLATE FASTENER EXCLUSIONS 3 17 ILLUSTRATION 3 H 6 INSTALLATION OF HORIZONTAL CAM FOLLOWERS AND GUIDES 3 18 ILLUSTRATION 7 SUPPORT ROLLER BRAKEBAND WELDMENT INSTALLATION 3 18 ILLUSTRATION 3 H 8 SHIFTER LUG WELDMENT INSTALLATION 3 19 ILLUSTRATION 3 H 9 amp BOTTOM CAGEPLATE INSTALLATION 3 20 ILLUSTRATION 3 H 10 DOOR CYLINDER POST INSTALLATION 3 20 ILLUSTRATION 3 H 11 SAFETY DOOR VALVE NSTALLATION 3 21 Technical Manual Section Contents xi 20000 50 KT20000 50K Tong This page intentionally left bl
2. 5 18 Brakeband FS SOR MN 5 22 c r E 5 24 5 26 FAV LAIN PNG SONI Var Savin ddr ard tere as 5 28 Door Base Ase A X rrr 5 30 a a NT 5 32 COSTOS ASSET qr Pr doen gt Dr RP Ae ada adt d 5 34 X Technical Manual Section Contents FARR AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCQOY MOVING GLOBAL ENERGY FORWARD Table Of Illustrations KT20000 50K Tong Table of Contents Continued Torque Measurement Section s Section 6 Hydraulic Component Information Section 7 TABLE ILLUSTRATIONS LLUSTRATION 1 1 KT 20000 TONG s a t ee ede 1 1 ILLUSTRATION 1 2 KT 20000 TONG DIMENSIONS 1 2 ILEOSTRATION 2 1 SLING EORR 2 1 ILLUSTRATION 2 B 1 COMPONENT IDENTIFICATION 01 2 4 ILLUSTRATION 2 B 2 COMPONENT IDENTIFICATION 02 2 5 ILLUSTRATION 2 B 3 COMPONENT
3. m m ON Li k hd LL al Toe T TE LS OE 5 E M cadem xs LI LI L LI EM HEN DE 5 2 s 5 01 8 2 45 h AE C LI w ten oes 5 4 zx Citas ru uS Am LET 5 D s m 1 E LI LI pet a xe 1 ir Zr a 5 x zx De x x o ER 5 135 ce pane a x Tees lt RCM 1 j a zx on n An p if Ios 84 4 a s mu 4 det os m iot cH m ae a UN Nm ww n D j 3 i pana a DA IE E NM ze x WW ari T T M Pes F D z z PS LI m E oE as at 4 a AE 2 Vs e m mm rmm xm I a Ls n d a LI Lu
4. with 4 distributor valves Use H prefix code as noted 10 be specified when requiring specify hollow shats through habe 0 26 2 1 03 dia Hollow are 7204 main port connection shaft with HIS Ofindrical 14 splines to ES 3550 shaft to DIN 54 80 WTO x 3 x 22 x Thi Female 24 splines ES 3550 Long tapered keyed shaft X Short tapered keyed shaft where sul is perfil apwanfespecfy ey Sur Pun level aet pur i FARR AACCQOY MOVING GLOBAL ENERGY FORWARD hollaw shafts type HP 5 or S04m G bom UNF flange Staffa original valvis housingi 2 GS animum cea iam nod Mu drew ow gut Ser crea DRIWE T original acho deve T1 for Hohner 3000 be ondened separabelyl if not required and when specifying shaft types H NUMBER 3 SERIES te change Installation amd performance denis remain unaltered for design numbers 30 to 39 inclusive El sPecia FEATURES PL non catalogued features port connectors shart variants reduced capacities Spitti eignen cus
5. High pesson seals ane qvatlable 6 HYDRAULIC FLUIDS position Elli suitable fluids include Anithevear Phoaphabe estera fluids Water fluids a HFB fluids a oll in w ber emulsions fiic a Viscosity limits when using amy fluid excep oil in water 505 emulsions Bre Max cSt iz TO SUSI Max laad 150 c51 695 SUS ptimur 50 232 SUS Minimum 25 c51 119 SUS PETROLEUM OIL RECOMMENDATIONS The fluid should be good hydraulic grade petroleum It shouki contain anti cxidant anti foam contain anter EP additives 7 TEMPERATURE LIMITS Ambient min 3080 22 F Ambient max TC 158 F Max operating bermperature range Petroleum Water Min 20 C F 10 C 50 Max GM Sr C oon sero bake ei cwnponents 65 amp aoe Weide ere 8 FILTRATION Full flow filtration open circuit or Tull ensure sysiem cleanliness of 540 4406 1986 code 18 14 deiner 65 7 DIN 70 throughout the continuous operating Where nome iB factor instalbson resonances can be reduced Dy mejor ty means Tram the siructure and the return line installation Potential retum line resonances o
6. TECHNICAL MANUAL 20 50 8cm 50K Hydraulic Power Tong BJ SPEC opecifications Operation Maintenance Assembly mccoyglobal com 2010 McCoy Corporation All rights reserved Published by McCoy Corporation Technical Publications Department 14755 121A Avenue Edmonton Canada T5L 272 MONIS MOVING GLOBAL ENERGY FORWARD FARR 20000 50K Tong This manual covers the following models TONG MODEL REV DESCRIPTION 80 1304BJ 5 Tong is equipped with Staffa 080 motor motor valve lift cylinder valve chain sling dump valve and BJ type safety door system NOTE Some illustrations used in this manual may not exactly match your model of tong Technical Manual Section Contents iii 20000 50 KT20000 50K Tong This page intentionally left blank AACCOY MOVING GLOBAL ENERGY FORWARD FARR KT20000 50K Tong WARNINGS A LOAD BEARING DEVICE IS A CHAIN SLING RIGID SLING SPREADER BAR ASSEM BLY 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 DE SIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL MCCOY WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEMBLY OR COMBINATION OF PARTS AND ASSEMBLIES MCCOY WILL NOT GUARANTEE
7. EE is macie E Hug and are furnished with plastic closures T B ae ET Bee Page 32 for inlet port plugs P utlets Tank Return Tank Return Type Code DVA3 TR55 1 1 4 11 4 DVA3S TRSS s NON PORTED HOUSING NOTE See Section 32 far Port Plugs Double Acting Section 4 Way Float in Neutral Motor Spoal Adjustable Relief Valve Cartridges For Inlets and Mid section Inlets Description DVA35 MRW 1 Main R V pressure range 800 2000 psi Factory set 1500 psi 50 gpm DVA35 MRV Main pressure range 2001 2500 psi Factory set 2500 psi 50 gpm DVA35 MRWVP Main valve plug 7 12 Technical Manual Section Contents Hydraulic Components AACCQOY MOVING CLOBAL ENERGY FORWARD FARR KT20000 50K Tong Hydraulic Components Lo Boy Work Sections Parallel Circuits E E d E Qnem as mim ere m T E t i d T M s n JE 1 ww LI E 7 Pret sins Bow oie a e 1 4 LE LI LI in D 2 4
8. 20000 50 Tong 5 26 Motor amp Motor Mount lt Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Motor amp Motor Mount 20000 50K Tong Pa 09 _ Reguler Carton 91 moso 00 Fat e UNC x2 14 Hex Socket Head Cap Screw ___ HMB080 S S05 70Stafa Motor Oen MotorMount 0 Weldment Shifter Pivot Lug Weldment See Pp 5 16 5 17 a Upper Motor Spacer 1037 D 38S Thrust Washer 101 3289 Technical Manual Section Contents 5 27 KT20000 50K Tong q Hydraulic Assembly ABC DE Description A 1 Hydraulic Line Supply 1 Dust Cup 1 Quick Coupler Fitting NEN E F MNPDFENPTSOdFHing __ 1 um LE D Pat DVAS amp SABVaveSecion 10908 ____ 5 28 Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Hydraulic Assembly KT20000 50K Tong Th 4 FIC SU S The hydraulic assembly on these pages are intended for use as a general assembly guide For an exact listing of the hydraulic components in your system please refer to the hydraulic sche matic bill of materials and hydraulic component identification guide in Section 2 E Flow Control Valve Lift Cylinder Outlet Section DVA35
9. 3 2 ILLUSTRATION 3 0 2 ROTARY GEAR LUBRICATION 3 2 ILEUSTRATION 3 D 39 SUPPORT ROLLER LUBRICATION d a 3 3 ILLUSTRATION 3 D 4 Door ROLLER LUBRICATION 3 3 JFEUSTRATION 3 D 5 ROTARY IDLER 3 4 ILLUSTRATION 3 D 5 PINION IDLER rien ac ko Roe 3 4 ILEUSTRATION 3 D 6 PINION LUBRICATION 3 5 LLUSTRATION 3 D 7 CLUTCH LUBRICATION 3 9 ILLUSTRATION 3 0 8 SHIFTER COMPONENT LUBRICATION ACCESS 3 6 LLUSTRATION 3 D 9 Jaw ROLLER LUBRICATION ERU REPE ERE EURO E EORR E 3 6 ILLUSTRATION 3 D 10 DOOR CYLINDER Rom 3 7 ILLUSTRATION 3 E 1 BRAKEBAND ceed eee bees 3 7 ILLUSTRATION 3 E 2 DOOR LATCH ADJUSTMENT CAMS REARS 3 8 ILLUSTRATION 3 E 3 DOOR ALIGNMENT MEASUREMENT 5 3 9 ILLUSTRATION 3 E 4 DOOR ALIGNMENT ADJUSTMENT SET SCREWS 3 9 ILLUSTRATION 3 E 5 SHIFTER DETENT ADJUSTMENT
10. as stated in ASME 30 10 Other conditions including visible damage that cause doubt as to the continued use of the sling Inspect all lugs and fixing points for signs of elongation and or bending or for material build up around the hole Repair replace components that appear distorted Ensure all hardware is tight and in good condition Replace missing hardware if necessary All hardware must be free of rust and corrosion Aaditional inspections shall be performed during sling use where service conditions warrant Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on Frequency of use of the load bearing device Severity of service conditions Nature of lifts being made Experience gained on the service life of load bearing devices used in similar circumstances Guidelines for the interval are Normal Service yearly Severe Service monthly to quarterly Special Service as recommended by a qualified person Technical Manual Section Contents AACCODY MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD FARR Setup amp Operation KT20000 50K Tong Units designed and manufactured in accordance with EN 12079 and DNV 2 7 1 should be tested and examined in accor dance 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 typ
11. MOVING GLOBAL ENERGY FORWARD FARR Setup amp Operation KT20000 50K Tong m ILLUSTRATION 2 C 4 HyDRAULIC COMPONENT IDENTIFICATION 03 10 ILLUSTRATION 2 C 5 HyDRAULIC COMPONENT IDENTIFICATION 04 Technical Manual Section Contents 2 9 Setup amp Operation KT20000 50K Tong T ILLUSTRATION 2 C 6 HyDRAULIC COMPONENT IDENTIFICATION 05 D HYDRAULIC CONNECTIONS A pair of hydraulic lines a 1 1 4 supply line and a 1 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 con nection 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 small er than the return side 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 m Hydraulic Supply 1 LS 4 Hydraulic Return 1 1 4 gt ILLUSTRATION 2 0 1 HyDRAULIC CONNECTIONS
12. 5 E 24 Du Id 9 ONITHAA Most codes outside the shaded area can be made from codes inside the area and kits on page 33 Solenoids ane with apade connectors Codes outside of the shaded area may require increased lead fime Machining instructions fer standard housings are included in solenoid kita See Section 33 for section seal kits AO 3N3 ONIAOW AOD2VNV 7 13 Technical Manual Section Contents KT20000 50K Tong Brief Circuit Descriptions Series Circuit Available in OVA20 sections only If a machine s work cycle requires simul taneous as well as Separate operation of individual hydraulic work functions a circuit right tor tha job As with the other circuits the all flows through the open center when all sponds are in neutral There is no parallel nassaga In standard sections They directly from th open center pas I than spool ia operated pump flow goes first to Ih section closest to the inlet Return flow from first agction is hed back inte the open center for usa by downstream sections Downstream aections can be series Parallel or Tandem Will in genes with the upstream section In series circuits operaling prassune is cumulabw
13. FARR MOVING CLOBAL ENERGY FORWARD Shifter Assembly 20000 50K Tong Part Number 1037 D 20B 101 5116 1037 C 20A Weldment Top Shifter Bushing Weldment Typically Welded To Top Plate 101 1286 Weldment Shifting Fork Weldment 1037 D 27 A Part 4 Part 7 16 UNC Thin Hex Nylock Nut Shifting Link Shifting Shaft FARR Bottom Shifter Bushing 1037 C 21B 3 8 NC x 1 Hex Bolt 4 09 1170 101 5114 Weldment Shifter Lug Weldment 3 8 Lockwasher 09 5106 3 8 x 1 1 2 NC Shoulder Bolt C K L M 3 4 UNC x 2 3 4 Hex Socket Head Cap Screw 3 4 Lockwasher 271711 9706 _ Fe 09480 AACCOY MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 5 17 Tong Body Assembly 20000 50 Tong dev SNOILA IdINOO ONITIIeC AO 3N3 ONIAOW NODWN Technical Manual Section Contents 5 18 FARR AACCOY MOVING CLOBAL ENERGY FORWARD Tong Body Assembly 20000 50K Tong 4 Fat Shite Pvot Lug See Fp 516 617 M Assembly Suppons See 520 520 Reson Balaban Assembly See Pe 7227 Fa _ O oa far Awemby Door Assenby See Po 26 3 Q emw _ S
14. KT20000 50K Tong Measurement 2 eee nem Vieasurement 1 ILLUSTRATION 3 E 3 DooR ALIGNMENT MEASUREMENT POINTS The three measurements should be equal If the centre measurement is less than the two outside measurements loosen all four locking nuts on the set screws and turn all four set screws EQUALLY clockwise until the centre measurement is equal to the two outer measurements If the centre measurement is more than the two outside measurements loosen all four locking nuts on the set screws and turn all four set screws EQUALLY counter clockwise until the centre measurement is equal to the two outer measurements Ensure that the locking nuts are tightened when this procedure is complete FARR MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 3 E 4 DooR ALIGNMENT ADJUSTMENT SET SCREWS Technical Manual Section Contents 3 9 KT20000 50K Tong 4 3 10 5 Detent Adjustment Over time wear to the shifting shaft wear to the detent ball and loss of spring tension in the detent spring may result in a loose or sloppy fit within the top shifter bushing The detent pressure may be increased or otherwise adjusted by loosen ing the 7 16 UNF locking jam nut and turning the 7 16 UNF detent bolt Should adequate detent action not be achieved the shifting shaft detent ball or detent spring or possibly all three may need to be replaced see Pp 5 16 5 17 1 4 4 ILLUSTRATION 3 E 5 SHIFT
15. di Quin 10 11 wow Gm ge come onm El enr UMS 6 T 2740 LORS dpi eB 5 7 8 Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Hydraulic Components 20000 50K Tong MOTORS WITH F2 FM2 1 SAE PORT CONNECTION See drawing of front mount model for details of types and SAMO port connection D 1890 P5 dei x dp ng ICD then hoe ee able 5m pod Pob ir UM boli Ss dr E Din mud ned iter peri mnNoma mem Eun 17 i05 GROS 255013 ge 3 1 4 P Beck red plate are 1 Beary Pelis T MH L umm 185 5 Pii j E Z oS O LC vei ba Y 22011 20 orar uiuit nn d Ba lael auf pe X applicable ES in pud gt Wi 22 2 amp gt a CY U Mode _ appe um gt Fr pi O Sa Zh Z Technical Manual Section Contents 7 9
16. 10 17 18 19 20 2I E m LI ILLUSTRATION 3 H 3 TuRN COUNTER ENCODER amp ROTARY IDLER INSTALLATION Slide low pinion gear PN 1037 D 32 over bottom end of pinion gear shaft PN 1037 D 15 and place end of pinion gear shaft into pinion bearing and bearing cap installed in Step 6 Ensure the gear keys PN 1037 D 15A are placed into the pinion gear shaft before installing gear two keys per gear Install a retaining ring PN 02 0009 into each of the two pinion idler gears PN 1037 D 1 Press one each of the idler bearings PN 02 0011 into each of the pinion idler gears followed by a second retainer ring in each Slide each pinion idler gear and bearing assembly over an idler shaft PN 1050 D5 117 and centre as well as you are able Slide a bearing seal PN 02 0010 over each end of the pinion idler shafts ensuring that the lip on the seals are towards the centre bearing followed by an idler spacer PN 1050 D5 121 over each end of the shafts Install each pinion idler in their respective locations in the bottom plate NOTE when the pinion idler assemblies are placed vertically the bearing seal and idler spacer on the bottom side will have to be held in place by hand as the assembly is lowered through the bottom plate Once the assembly is through the bottom plate place an idler pad PN 997 D20 125 over the bottom end of each shaft and secure the pads with a 1 1 2 UNF h
17. 2 10 CAU Iii PPS 2 15 ON OMIM EC RR 2 17 4 General Operational 2 17 Making and Breaking Connections MARINO CONMCCHON 2 18 2 Breaking CONNCCHON sx sacs ato d ace c 2 23 Extreme Cold Weather Operation Procedures 2 25 us oaa cy WR ne Section 3 General Maintenance Safety 3 1 3 1 Preventive C d f Tor sq Prec 2 2 Adjustments a Brakeband SUI MMC 3 7 CN Laleh 3 8 3 D r MP P E M 3 8 Sitter Delent AOIUSITIBUL Lee che a eap Fb ia e RC Rea UP Ode ap KOR Reo ee Bede RR RR Re dede 3 10 D eae Door ssi les er EE B dir cea e dna ica a ir dud er 2 10 Recommended Periodic CHECKS e cac anc ha 3 11 Disassembly amp Overhaul PIOCCOUIES C doa _ 312 D pas sisia _ 3 14 Daily Tong Inspection a
18. Cylinder D A Motor Cylinder Cylinder Standard Series Parallel Parallel Parallel Tandem Tank Flaturn Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components KT20000 50K Tong VA VG Valve Service Instructions INTRODUCTION This manual has been prepared to assist you in the proper maintenance of the VA UTMAV A 15TM and VG201M V 35TM VCG80TM directional contro valves Before any work is done we suggest that you read the assembly and disassembly instructions completely The first rule of good maintenance is cleanliness which includes a clean environment MAKE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT IN A CLEAN AREA Dart 15 the natural enemy of any hydraulic system GENERAL INFORMATION The VA and VG model valves are updated versions of our proven A2O and A35 units VG models are cast from compacted graphite high strength iron alloy which allows the valve to be rated to 3500 psi V A models are cast from grav iron and rated at 2500 These open center directional control valves are available in parallel tandem and series circuitry As needed the sectional stack type construction provides flexibility for the addition of subtraction of work sections to an existing valve bank This design also permits the combinatio
19. Many applications use a lift cylinder for aadjusting 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 forces upon the suspension line must be considered when calculating necessary strength of the suspension line The weight of the tong the weight of the lift cylinder the weight of the spring hanger and the force imparted on the suspension line by the spring hanger must all be added together in order to arrive at the total force supported by the suspension line Select your suspension line based upon the total force and the margins of safety dictated by the policies of your company and by established engineering practices Ultimately calculating the force on the suspension line and selection of the sus pension 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 in use Calculate the force on the snub lines by dividing the maximum torque of the tong by the tong s torque arm expressed feet For example an 50 000 Ibs ft tong with 52 inch 4 333 ft torque arm will generate 11 540 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 calc
20. Torque Gauge 0 60 000 ft Ibs 10 0023G Tie Off Shackle Assembly 101 0078 Hose Assembly 02 0069 Technical Manual Section Contents 6 1 KT20000 50 Tong 6 2 Torque Measurement Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR AACCQOY MOVING GLOBAL ENERGY FORWARD FARR Torque Measurement KT20000 50K Tong _ 1 9909 _ ar Flange Gasket 1 fw om 02 Aw om _ Technical Manual Section Contents 6 3 KT20000 50K Tong A TROUBLESHOOTING Torque Measurement Under normal operating conditions and with proper maintenance the torque gauge and load cell system are designed to give lasting trouble free performance Faulty indication on the gauge will very often define a fault within the gauge 1 PROBLEM POSSIBLE SOLUTIONS 2 PROBLEM POSSIBLE SOLUTIONS 3 PROBLEM POSSIBLE SOLUTIONS 4 PROBLEM POSSIBLE SOLUTIONS 6 4 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 hose Loss of hydraulic fluid Gauge internal mechanism damaged Gauge indication too high Excessive hydraulic fluid Inte
21. 07 and shafts will transmit the maximu given on page 4 However customers should enaure in their applicason iuri Pes 1508 EA OUS 1 n d SA gt between par AS ah Lr rong cr cage be Technical Manual Section Contents KT20000 50K Tong SHAFT T MODEL CODE POSITION 15 36 715 Pm 60 nz ml Le onze 2 4115 4 la s m AF 1081 pr M SHAFT TYPE X MODEL CODE POSITION El Chip pisie 2 Bois M12 x 1 bec tha and equi XL D ED bd _ e EROS men 13 1 n PED TES aie 1 l rr Sc 404747 400 RE 4 0 2080000 2048 123 4 S Pin ME O48 11 08 7 11 KT20000 50K Tong Inlets 2500 psi End Inlet pe E DVA35 A980 SAE 16 DVAS5 A000 NON PORTED HOUSING For mipis with section NOTE inlets are machined for main R V
22. FARR Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp 6 outlet supports tong legs shifter handle pivot lugs Tighten replace loose or missing fasteners Farr mends that damaged or missing body parts br 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 size of the loaded jaws match the size of casing or pipe you are running Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong service Also inspect all chains master links and turn buckles again if any damage is noted replace the damaged part s before placing the tong in service 9 Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be is a good indication of wear 10 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brakeband linings replace if necessary Unequal wear of the brakebands indicates that 7 7 the brakeband tension is not evenly
23. POSSIBLE PROBLEM Jaw roller broken or worn SOLUTION Remove jaw assembly and inspect Replace rollers that are visibly flat spotted or otherwise damaged Technical Manual Section Contents 4 3 KT20000 50K Tong Troubleshooting C TONG RUNNING TOO SLOWLY 44 POSSIBLE PROBLEM Obstruction in tong hydraulic circuit preventing adequate flow SOLUTION Inspect self sealing couplings to ensure they are properly engaged SOLUTION The main hydraulic 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 geartrain 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 sa
24. SANT Roe SHS Wor Mean O O mem T Fat 94 Lockwasher Motor amp Motor Moun osme _ w Aem Torque Gauge Hower _ Technical Manual Section Contents 5 19 ne 20000 50 5 20 Tong Body Assembly Hydraulic Supports amp Hangers Technical Manual Section Contents FARR AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCQOY MOVING GLOBAL ENERGY FORWARD Tong Body Assembly Hydraulic Supports amp Hangers KT20000 50K Tong tem Tye Fatum 78 fa Hyeraute met Suppor Pate owe posz met Suppor Pate mersupon ese _ fm e a Pan Outer Suppor Pae f _ far Outer Support Acustment Pato Technical Manual Section Contents 5 21 Brakeband Assembly KT20000 50K Tong dev IdINOO 9 ONITIIeC Ao 3N3 IVgO 19 ONIAOW NODWN Technical Manual Section Contents 5 22 MOVING GLOBAL ENERGY FORWARD FARR Brakeband Assembly 20000 50K Tong tm Wwe 4 Pan Support Roler Shafi Shown For Mustain Purposes 4
25. The shifting shaft may now be carefully rotated and pulled out of the top shifter bushing 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 OH PERSONAL INJURY TO THE MECHANIC 13 Remove the jaw pivot bolts and the jaw assemblies 14 Remove the 3 8 hex bolt connecting the backing pin to the rear cage plate bolt Remove the backing pin 15 Remove the two front cage plate bolts and the rear cage plate bolt and the cageplate spacers The cage plates may now be removed Use caution not to damage the cam followers while removing the cageplates 16 Pull the top bearing cap and spacer for the pinion drive gear by removing the four 5 8 bolts which secure the bearing cap Thread two of the removed bolts into the extra holes on top of the bearing cap and use them as lifting lugs to lift the bearing cap out of place FARR IF THE BEARING REMAINS ATTACHED TO THE GEAR SHAFT AFTER THE BEARING CAP IS PULLED FARR SERVICE PERSONNEL RECOMMENDS LEAVING IT IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED 17 Remove the two 1 1 4 x 8 load cell anchor bolt assemblies from the rear of the tong 18 Remove the top 1 1 2 nylock nuts and pads for the rotary and pinion idler gears 19 Remove the top roller shaft thin nylock nuts and washers Note that the top brakeband lug weldments will
26. lockwashers 2 each per base Attach the chain sling to the four chain sling hangers using one shackle and bolt set PN 02 9063 per hanger DO NOT EXCEED THE SPECIFIED LENGTH OF ANY FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED 3 22 Technical Manual Section Contents AACCODY MOVING GLOBAL ENERGY FORWARD FARR Maintenance ___ 20000 50K Tong I DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER Farr recommends that the following inspection and maintenance procedures be performed before each use and at least once per day when the tong 15 in steady use in the order in which they are listed 7 Rotate cageplate 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 HYDRAU LIC LINES ARE FULLY DISCONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINATION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HyDRAULIC SvsrEM 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 cyli
27. the electrical 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 Ensure that supply pressure is at or above 5 specified operating pressure and that the return pressure 5 is less than 350 psi 2 4 Perform a visual inspection of pressurized hydraulic lines If any hydraulic fittings or hoses are leaking they must z 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 geartrain De energize the power unit and perform another generous lubrication of the geartrain including the gear housing 26 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 geartrain 2 7 De energize the power unit and perform third
28. 01 2 10 Technical Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation KT20000 50K Tong Make up female fitting to Marked point on male fitting ILLUSTRATION 2 D 2 HyDRAULIC CONNECTIONS 02 E TONG JAW AVAILABILITY AND INSTALLATION 1 Available Jaws The following table lists all jaw die kits that are available as standard sizes for this model of tong If your desired size is not listed Farr can engineer custom jaw sizes contact sales for further information 9 7 8 Jaw Die Kit 1037 JDK 547 K Standard 4 Heplacement Die 12 1004 2 Jaw Hemoval amp Die Replacement FARR AACCOY MOVING GLOBAL ENERGY FORWARD Support tong jaw assembly Remove the jaw pivot bolt Slide the jaw towards the centre of the rotary assembly to free the jaw from the cageplates Technical Manual Section Contents 2 11 20000 50K Tong Setup amp Operation Jaw Removal amp Die Replacement Cont d Remove the flanged retaining bolts to remove the dies jaw dies may require light tapping with a hammer to free them from their slots Reverse this procedure to install new jaw dies Note that if space allows the entire jaw assembly does not need to be removed to replace the jaw dies ILLUSTRATION 2 E 1 Jaw REMOVAL Once the jaw has been removed the jaw dies may be replaced by removing the keeper screw above the die and tap the die from
29. 053990 _ Brakeband Lug RH Top LH Bottom _ 2 101636 Wetiment Lug Wetdment LH Top RH 2 101 1687 E Pat 09897 _ Pat 4 m _ Los p 8 Regular Carbon 5 09505 Kk m _ Technical Manual Section Contents 5 23 20000 50 Tong 5 24 Cageplate Assembly Technical Manual Section Contents FARR MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD Cageplate Assembly KT20000 50K Tong Part 3 8 NC x 1 Hex Bolt 1 Part 3 8 Regular Carbon Steel Lockwasher 1 Part 3 8 Narrow Washer 1 Pari Jaw Pivot Bolt 2 2 1 Type Part 1 2 NC x 8 Hex Part Top Cageplate 1 101 1580 Part 7 8 UNF Thin Hex Jam Nut 50 Part 7 8 Regular Carbon Steel Lockwasher 50 Part Cam Follower 50 Assembly Jaw Die Kit 20 shown See Pg 2 11 Part Cageplate Spacer Part Rotary Gear Part Bottom Cageplate Part Backing Pin Knob Part Backing Retainer Part Backing Pin Part Rear Cageplate Bolt 1 Part Cam Follower 10 art 10 24 x 1 1 2 Hex SHCS 20 Part 7 16 UNF Thin Nylock Nut 10 Part Horizontal Cam Follower Guide 10 Mem o Technical Manual Section Contents 5 25
30. Tong Pinion Idler Assembly B ei oc 5 10 Technical Manual Section Contents FARR AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD Pinion Idler Assembly 20000 50K Tong Technical Manual Section Contents 5 11 KT20000 50K Tong Pinion Assembly Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR MOVING CLOBAL ENERGY FORWARD FARR Pinion Assembly 20000 50K Tong 1 A gt gm 14 1037 D 15 1037 D 32 1037 C 33 Bottom Pinion Bearing Cap Technical Manual Section Contents 5 13 20000 50K Tong Clutch Assembly lt Wi AC PA FARR AACCQOY MOVING CLOBAL ENERGY FORWARD 5 14 Technical Manual Section Contents Clutch Assembly 20000 50K Tong Wm Top Clutch Bearing 5 8 Lock Washers 09 5114 Clutch Bearing Cap 1037 C 17 02 0105 1037 D 40 02 0104 5 8 NC x 1 1 2 Hex Bolts 09 1230 Low Clutch Gear Clutch Bearing art FARR AACCQOY MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 5 15 KT20000 50K Tong 5 16 Shifter Assembly Technical Manual Section Contents
31. 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 Varsol Ensure adequate ment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and cleaning agents 4 Remove the access panel on 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 envi 5 ronmental contamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the geartrain cavity if shavings or metal pieces are seen the tong must be overhauled before it is returned to service 6 Inspect all fasteners and fastener safety wires if equipped Replace 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 v
32. WHEN OPERATING THE TONG AT SPECIFIED TORQUE A CLOSED DOOR ALSO ENSURES SAFETY OF OPERATING PERSONNEL Identical adjustment cam is located on bottom of door weldment 3 8 ILLUSTRATION 3 2 DooR LATCH ADJUSTMENT CAMS Door Alignment Each door weldment is equipped with two set screws along with jam nuts to lock position to align the door when it is in the closed position Initial Alignment Ensure tong doors are closed and inspect how one door aligns with the other at the point at which they meet If misalign ment is seen choose one or the other door to adjust Use a box end wrench to loosen the lock nuts on the insides of the door weldment the nuts may be accessed from the side of the door weldment Use a hex key to turn the hex head set screws either clockwise or counter clockwise to adjust the door Note that the top and bottom of the door weldment may not need to be adjusted equally each set screw should be adjusted independantly until the doors are aligned Final Alignment Rotate the cageplate and stop it when the inside circumference of the door is completely covered Perform three measure ments see illustration below 1 From the insides of the outer edge of each door weldment to the cageplate 2 measurements total 2 From the exact centre point where the two doors meet to the cageplate Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR
33. WITH A MALFUNCTIONING SAFETY DOOR SYSTEM IN SERVICE RECOMMENDED PERIODIC CHECKS 1 DOOR STOP SPRING The spring inside the actuator cylinder must be of sufficient strength to enable the door latch mechanism to snap closed properly and to hold the door in the open position when opened Door stop spring fatigue will result in sluggish latch opera tion Replace the latch spring inside the cylinder when this occurs 2 BACKING PIN Perform a visual inspection of the backing pin after each job Replace the if stress cracks or excessive wear 15 found or if either pin is bent 3 SHIFTING SHAFT The shifting yoke is secured to the shifting shaft by one hex jam nut above the shifting yoke and one locknut on the bot tom of the yoke Check these nuts after each job Do this by removing the clutch inspection plate and ensuring a snug fit prior to lubrication 4 TORQUE GAUGE ASSEMBLY Periodic calibration of the torque gauge is recommended to assure accurate torque readings When having the torque gauge serviced and calibrated it is critical to note the arm length of the tong as indicated in the Specifications section Farr recommends that the torque gauge assembly be calibrated yearly Periodically check to ensure the load cell is filled with oil see Section 6 MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 3 11 20000 50K Tong Maintenance G OVERHAUL PROCEDURES The tong may be overhauled following the
34. adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brakebands MOVING GLOBAL ENERGY FORWARD 1 2 Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have i visible signs of wear from contact with a rigid object Technical Manual Section Contents 3 23 20000 50K Tong Maintenance 1 3 Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or s have visible signs of wear from contact with a rigid object 14 Perform a complete greasing of the tong refer Maintenance section of technical manual 1 5 C Ensure main supply and return connections to the tong are fully made up Re connect the remainder of the hy 7 draulic 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 unti
35. 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 or if using a diesel power supply ensure that the engine is locked out or the starting mechanisn 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 Activate mechanical shut off device ensure that shut off switch on engine is engaging when manual shut off i switch is actuated ELECTRIC ONLY Visually inspect all electrical lines and visible connections If your unit is NOT explosion proof open the electri 1 cal enclosure and VISUALLY inspect contacts and connections for signs of corrosion or 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 Check hyaraulic fluid level ensure cold level is approximately half way up the sight glass on hydraulic fluid reservoir f Perform a visual inspection to ensure there are no hydraulic fluid leaks c
36. be released 20 Remove the top plate fasteners hex head bolts amp socket head cap screws around the perimeter of the tong which secure the top plate to the gear case housing Note that the rear door cylinder mounting lugs must also be removed to release the top plate 21 Use a soft alloy material e g brass rod etc to lightly tap the remaining support roller shafts down through the support roller assemblies until they are roughly flush with the top plate of the tong Use caution that the threads on the ends of the support roller shafts are not damaged 22 With all the above steps taken the top tong plate can be lifted off providing access to the inside of the gear case Use this opportunity to inspect the cam follower array mounted on the top plate replace damaged cam followers AACCOY MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 3 13 KT20000 50K Tong Maintenance 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 assem bling the tong in our plant REFER TO PAGE 3 11 FOR TORQUE SPECS WHEN TIGHTENING HEX BOLTS AND HEX HEAD CAP SCREWS ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQ
37. bent it they must be replaced 7 Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Inspect all paint locations in which the paint has been damaged must be repaired prior to storage Prepare areas 8 to be painted to ensure they are free of grease dirt or solvent Touch up using solvent based acrylic paint Farr Blue is paint number RAL 5005 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 9 points Generously fill the geartrain housing with grease through the access panel and also through the opening the rotary gear 1 0 Connect equipment to a hydraulic power unit Ensure lines are fully made up to prevent equipment damage from excessive back pressure Do not neglect to connect motor 11 Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening 7 2 of the rotary gear facing the geartrain De energize the power unit and perform another generous lubrication of the geartrain including the gear housing Technical Manual Section Contents 3 29 KT20000 50K Tong 1 3 Energize power unit Rotate tong for one minute stop and reverse direction of rotation for another minute end i
38. breakanway torque 7 21 KT20000 50K Tong Hydraulic Components Valve Assembly Instructions Detent Spool Assembly step 1 Spool Assembly Detent Apply Parker Super Lube to the spool seal Fig em 5 and slide it onto the spool Slide the back up Fig 1 aem 7 and one retainer plate Fig nem onto the spool Position these onto the spool they do noc interfere wiih the spool operator mechanism during assembly Do not allow the O ring bo come im contact with the sharp edge of the spool notches Apply 2 5 drops of Loctire 26274 or equivalent anaerobic adhesive near the muddle of the female threads in the spool CAUTION Follow the adhesive manufacturer s instructions for proper cleaning and curing Failure to clean and prepare parts properly may result in assembly failure Step 2 Spool Assembly Detent Thread the ball remmer Fig 2 20 into the end Torque the detent ball retainer 175 m Iba i 4 im Iba This can be sooompliahed by using a erows foo socket on the ef the amd bolding the spool by inserting round steel rod or screwdriver tee an the ball Step 3 Detent Balls and Spring lightly the balls Fig 2 item 13 deteni spring Fig 2 wer 9p amd entre makke daxmeter of the detent sJeeve Fig 7 item 171 with high temperature gres Insert ihe d
39. casing i Breakout torque is only available when tong is in low gear See Section 2 G 3 for instructions on shifting your tong to low gear Do not shift gears while the tong is rotating AACCQOY MOVING GLOBAL ENERGY FORWARD SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGEPLATE MAY RESULT IN CATASTROPHIC GEARTRAIN FAILURE Technical Manual Section Contents 2 23 KT20000 50K Tong Setup amp Operation Breaking A Connection Continued J the motor control valve toward the operator to rotate the cageplate in the break out direction ILLUSTRATION 2 H 9 ConTROL BREAK OuT When the tong jaws cam on to the tubing pull the rotation control handle all the way out to break the connection m When the connection breaks stop rotation and shift to high gear see Section 2 G 3 to shift to high gear This will enable the tong to completely unthread the connection at high speed n Pull the rotation control handle all the way out to completely unthread the connection Reverse the rotation control handle push toward tong to release the tong jaws from the tubing see lllustration 2 H 10 ILLUSTRATION 2 H 10 RELEASING TONG Jaws FoLLowiNG BREAK OUT amp UNTHREADING 2 24 Technical Manual Section Contents MOVING GLOBAL ENERGY FORWARD FARR Setup amp Operation 20000 50K Tong Breaking A Connection Continued o p q 1 2 3 4 FARR 5 AACCOY
40. cell has been damaged Replace load cell or return to McCoy for repair and recalibration 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 POSSIBLE PROBLEM Incorrect tong gear selected SOLUTION Maximum torque can only be developed when tong is in low gear Ensure tong is in low gear MCCOY COMPLETIONS amp DRILLING GUARANTEES CALIBRATION OF A LOAD CELL TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR MCCOY SUGGESTS THAT THE LOAD CELL TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE CALIBRATION ON A YEARLY BASIS Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Troubleshooting 20000 50K Tong 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
41. disassembly instructions in the following procedure Access to the gear train is pos sible by removing the top plate of the tong ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED REPLACEMENT FASTENERS BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTH ERWISE SPECIFIED TIGHTENING TORQUE GUIDE SAE GRADE 8 FINE THREAD SAE GRADE 8 COARSE THREAD 5 16 18 3125 18 ft Ibs 7 16 14 4375 52 ft Ibs 9 16 12 5625 115 ft Ibs AACCODY MOVING GLOBAL ENERGY FORWARD 5 8 11 625 20 325 212 ft Ibs 159 ft Ibs 3 4 10 750 30 075 376 ft Ibs 282 ft Ibs 7 8 9 875 41 550 606 ft Ibs 454 ft Ibs 11 8 7 1 125 966 ft Ibs 1 1 4 7 1 125 1363 ft Ibs 1 3 8 6 1 375 1787 ft Ibs 1 1 2 6 1 500 2371 ft Ibs 3 12 Technical Manual Section Contents FARR Maintenance KT20000 50K Tong Disassembly Procedures Continued 1 Remove load cell assembly and load cell pin while tong is suspended if equipped Securely support tong from the bottom Ensure the supports are capable of supprting the entire weight of the tong Remove the chain sling assembly Disconnect hydraulic connections from the motor Undo the restraints securing the inlet and outlet lines from their supports a
42. gt lt Technical Manual Section Contents 5 33 20000 50 Tong 5 34 Chain Sling Assembly Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Chain Sling Assembly Master Link Part Hammer Lock Connector 4 per chain Part Part 25 Link Chain Set Front Part 23 Link Chain Set Rear Part Turnbuckle 4 Qty 1 16 4 20000 50K Tong Part Number 02 0517 02 0607 101 0377 101 0376 02 6506 Part 4 Link Chain Set 101 0378 Part Shackle Assembly 02 9063 LOCTITE Technical Manual Section Contents ALL FASTENERS USED DURING REASSEMBLY OF LOAD BEARING COMPONENTS CHAIN SLINGS RIGID SLINGS BACKUP LEGS MUST BE TIGHTENED TO THE CORRECT TORQUE THREADED FASTENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED 5 35 20000 50 KT20000 50K Tong This page intentionally left blank MOVING GLOBAL ENERGY FORWARD FARR Torque Measurement KT20000 50K Tong This is the typical load cell and torque gauge sold with this tong Torque measurement systems in different ranges for this torque arm up to the maximum rated torque are available contact our sales office for more information Assembly Load Cell Torque Gauge Assembly 52 Torque Arm 60000 Ft Lbs Gauge Face fo Tension Load Cell 4 08 10 0008T
43. 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 CALCULATION OF REQUIRED DESICCANT 1 Calculate the trapped air volume by measuring the outside dimensions of the tool to be stored and treat that as the volume to be stored For example the external dimensions of a KT20000 20 power tong are 80 25 x 50 5 x 28 which calcu lates to an approximate volume of 113500 or 66 ff 1 87 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 ff equaling 231 g Several manufacturers offer silica gel desiccant in packaged quantities of 125 grams per bag so two packages of desiccant would be required Please keep in mind that this is a guideline only more or less desiccant may be required in extreme environmental conditions For best corrosion resistance the equipment should be removed from storage and exercised on a regular basis depending on the storage environment Farr recommends that for equipment stored in a salt water maritime or exposed dusty environment repeat steps 9 through 24 monthly For equipment stored in isolated storage in a non maritime environm
44. nut and bolt set as shown in the illustration below Do not over tighten as this causes excessive wear to the brake bands Ensure top and bottom brakebands are adjusted at the same time TOP AND BOTTOM BRAKEBANDS MUST BE ADJUSTED SIMULTANEOUSLY FARR Brakeband Adjustment Mechanism MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 3 E 1 BRAKEBAND ADJUSTMENT Technical Manual Section Contents 3 7 20000 50K Tong Maintenance 2 Door Latch Adjustment Normal operation of the tong may cause wear of the door latch which will cause the door to develop a loose fit at the latch Two latch cam plates are located on the right hand door assembly one on the top of the weldment and one on the bottom see Illustration 3 E 2 next page The cam plates have eight positioning holes located on a 360 degree bolt circle The latch cam shaft extends down through the door and is secured at the top by a 3 8 hex head bolt To make adjustments in door alignment remove the 3 8 bolt and turn the cams with a wrench When the door has been adequately aligned replace the 3 8 bolt ADJUST BOTH DOOR LATCH CAMS SIMULTANEOUSLY ROTATE BOTH LATCH CAMS THE SAME AMOUNT IN THE SAME DIRECTION THE DOOR IS AN IMPORTANT PART OF THE STRUCTURAL INTEGRITY OF THE TONG IT IS IMPERATIVE TO KEEP A SECURE FIT AT THE DOOR IN ORDER TO MAINTAIN PROPER GEAR ALIGNMENT AND TO MINIMIZE THE POSSIBILITY OF DAMAGE TO THE GEARTRAIN
45. plate so that guides rollers and gears can be properly cleaned Ensure that cleaning solvents and chemicals are captured to prevent environmental contamination and dispose of all materials according to your company s proscribed environmental protection regulations C PREVENTIVE MAINTENANCE Regular maintenance programs are necessary and must be established to assure safe dependable operation of your Hydraulic Tubular Connection Systemm and to avoid costly breakdown maintenance The following maintenance procedures provides information required to properly maintain your equipment Your equipment may require more or less maintenance depending upon the frequency of use and the field conditions under which your equipment operates These maintenance procedures are designed for equipment operating at 10 C 35 ambient temperature for 10 hours per day McCoy recommends that the inspection and maintenance procedures in this section be performed as recommended in the maintenance checklists see Appendices or in conjunction with your maintenance foreman s experience and best estimate of when your equipment is due for this maintenance Purchased components included with your hydraulic tubular connection equipment for example motors valves etc may specify 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 the
46. seals should be removed and discarded MOVING CLOBAL ENERGY FORWARD 7 18 Technical Manual Section Contents MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components KT20000 50K Tong Valve Disassembly Instructions Technical Manual Section Contents Step 4 Valve Back Cap Using a large Phallips bead screwdriver nemove the cap screws Fig 1 dem 4 which Fasten the back cap to the work section Lightly tap the end of the handle woth hammer break adhesive Remove the back cap Fig 1 item 5 Step 5 Control Spool and Seals Grasp the spring end of the spool woth a lint free cloth and pull the spool out of the housing using a twisdipg meotbon Generally the rear retainer plate Fig 6 back up Fig 1 mem 7 and spool seal Fog 1 will comme with the spool CAUTION For detented spool models be careful not t remove the detent poppet sleeve Fig 2 itam 17 unless it is to be serviced Lung large Phillips head serewdrier remove me twi screws Fig from the end of the work section Lightly tap the end of the screwdriver handle with a hammer to break the mdbesive Rensove the retainer plaies Fig mem 6 the back up ming Fog item the spool seal Fig 1 item 8 Tag mark wh the appropriate work section lentification mumbe
47. 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 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 2 POSSIBLE PROBLEM Directional valve is leaking SOLUTION Check directional valve Neutral position should return fluid directly to the reservoir Replace or repair valve to ensure correct operation 3 POSSIBLE PROBLEM Power unit is not producing adequate pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit 4 POSSIBLE PROBLEM Poor hydraulic 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 and 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 5 POSSIBLE PROBLEM Fluid viscosity is not appropriate too high or too low SOLUTION Ensure hydraulic fluid being used is the viscosity recommended by McCoy Drilling amp Completions Power unit pump may not prime if fluid is too heavy and th
48. support roller inner spacer PN 1037 C 134 into each support dumbell roller Press two support roller bear ings PN 02 0094 into each end of each support roller 16 assemblies total Once the assembly of the support rollers is complete temporarily slide the support roller shafts into each assembly for assistance in correctly positioning each support roller NOT do not include the two door pivot rollers in this step only perform this action with the fourteen body rollers Place rotary gear on bottom plate over the cam followers installed in Step 2 Note that the backing pin grooves are in the top side of the rotary gear Rotate the rotary gear so that the opening in the gear faces the first three support roller positions closest to the mouth of the tong do not include door pivot rollers at this point Install three support roller assemblies including shafts but not including fasteners in the locations exposed in the rotary gear opening Continue to rotate rotary gear around the tong installing the support roller assemblies as the gear is rotated Finish with the rotary gear aligned with the opening in the bottom plate 10 ILLUSTRATION 3 H 2 RorARY GEAR amp SUPPORT ROLLER INSTALLATION Press pinion bearing PN 02 0106 into bottom pinion bearing cap PN 1037 C 33 and install bearing cap into bottom plate of tong using four 5 8 SS lockwashers and four 5 8 NC x 1 1 2 hex cap screws Press lower clutch bearing PN
49. the top plate directly behind the RH pinion idler using two 3 8 UNC x 1 hex bolts and 3 8 lockwashers iii Attach the coupling support plate PN 101 1946 to the hydraulic support baseplate using two 3 8 UNC x 1 hex bolts two 3 8 narrow washers and two 3 8 UNC thin nylock nuts iv Attach the dump valve coupling support weldment PN 101 4850 to the top plate using two 3 8 NC x 1 hex bolts and 3 8 lockwashers v Attach the adjustable coupling support plate 101 1775 to the dump valve coupling support weldment using four 3 8 UNC x 1 hex bolts four 3 8 narrow washers and four 3 8 UNC thin nylock nuts Attach torque gauge holder weldment PN 101 1694 to the rear of the top plate behind the motor mount using two 3 8 NC x 1 hex bolts and S 8 lockwashers Slide the torque gauge mount weldment PN 101 2865 on to the holder weldment and secure with a 0 148 x 3 hitch pin Bolt the hydraulic valve assembly to the hydraulic valve support posts installed in step 54 i using two 1 2 NC x 4 1 2 hex bolts and 1 2 lockwashers Secure the inlet and outlet plumbing to the support assemblies installed in Step 54 Install tong hangers i Attach four tong hanger bracket weldments PN 101 3985 to the bottom plate using 3 8 NC x 2 1 2 hex bolts and 3 8 lockwashers 2 each per weldment ii Attach four tong hanger bracket bases PN 101 4006 to the top plate using 3 8 NC x 2 1 2 hex bolts and 3 8
50. to service Finish this step with the rotary gear opening facing the geartrain 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 if signs of potential failure are identified 1 3 Inspect geartrain housing If the amount of grease is inadequate liberally grease the geartrain through the ac cess panel and through the opening in the rotary gear Inspect top and bottom brakeband linings replace if necessary Unequal wear of the brakebands indicates that the 1 4 brakeband tension is not evenly adjusted Refer to the maintenance section the manual for instructions on prop erly adjusting brakebands Ensure that all grease is wiped from brakeband linings and the parts of the cageplates that come into contact with the brakeband linings 15 Re install access panel Install a set of pre inspected jaws that are the correct size for pipe or casing being 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 1 7 If applicable inspect load cell anchor pins tension load cell only Replace the anchor pins if cracking or metal distortion is seen If applicable the weld s
51. 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 lllustration 2 H 3 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 AS IT IS LIFTED FROM THE DRILL FLOOR FARR MOVING GLOBAL ENERGY FORWARD TONG LIFT HI LO c o i ILLUSTRATION 2 H 3 CYLINDER CONTROL RAISE Technical Manual Section Contents 2 19 KT20000 50K Tong 1 Setup amp Operation Making A Connection Continued e 7 9 J 2 20 Grasp the tong door latch and pull to open the RH door After the latch side RH door is open grasp the handle on the LH door and swing open Since your equipment is equipped with safety doors opening the door will inhibit rotation of the cageplate OPEN THIS SIDE SECOND OPEN THIS SIDE FIRST ILLUSTRATION 2 H 4 OPENING Doors Manually engage the threads of the tubing connection being made up Ensure threads are not cross threaded Move the tong on to the tubing joint Use the lift cylinder to ensure the tong jaws are at the correct location above the connection joint Firmly close the LH tong door followed by the RH tong door Tug firmly on the LH door handle to ensure the latch is firmly engaged Ensure tubing is roughly centered wi
52. 0 1 3 max 360 7 1B Yes Yes 151 19 2 450 232 Use a premium quality hydraulic fluid that meets or exceeds the following specifications Typical Density kg m Viscosity cSt 40 cSt 100 T Viscosity Index Pour Point F Flash Point F lt Colour ASTM Neutralization Number Rust Protection Distilled Water Sea Water Hydrolytic Stability Cu Mass Loss mg cm Copper Corrosion Test Filterability Denison Wet amp Dry Afnor Wet amp Dry Cincinatti Milacron Spec Approved Denison HF 0 Denison P 46 Piston Pump Denison T6C Vane Pump Vickers 35VQ25 Vane Pump Test 104 105 Vane Pump Test Vane pump test total ring and vane wear mg Oxidation Stability Turbine Oil Stability Test Life hours Rotary Bomb Oxidation Test minutes FZG Spur Gear Test Failure Load Stage FLS 1 4 878 68 8 8 7 97 22 30 432 222 1 5 0 40 No Rust No Rust 0 04 1A Pass Pass P69 Approved Pass Pass Pass No Data Available lt 10 2500 325 12 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation EE 20000 50K Tong 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 DE
53. 00 cmar 5 76 to 415 in capaciby The nugged wall proven design incorporates hydrostatic balancing techniques to achieve high torque and smooth running capability Various features and options are Uu match compelitor The HMBOSO capable of terque outputs up fo S950 4350 ff and io 200 r min with a connues eutput of up 100 KW 134 hp The Kuwasaki Stalfa range also dispiacement motors plus malching bralgrs and gearboxes fo extend The 2 FUNCTIONAL SYMBOLS All model types with variants model code position Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Hydraulic Components 3 MODEL CODE Features shown in brackets 1 may be left blank according to requirements other features must be specified F MHM BOB0 H V 3 7 Elman CONNECTIONS Blank Petroleum Models with 21 distributor valves Phoaphate ester HPD fluid 2 SAE 1 4 bol UNG flanges FII Waler based fluids HFA SAE 17 d bolt metric with 3 distributor valve mone 503 6 UNF flange Blank Standard original vale housing UK specification F3 4 UNG 453 1081 HMM langes R Dual mount er rear FM3 SAE 1 4 4 beit metic Elsuarr
54. 02 0105 into bottom clutch bearing cap 1037 C 17 and install bearing cap into bottom plate of tong using four 5 8 SS lockwashers and four 5 8 NC x 1 1 2 hex cap screws Install a retaining ring PN 02 0009 into each of the two rotary idler gears one each of PN 1037 D59 amp 1037 059 Press one each of the idler bearings PN 02 0011 into each of the rotary idler gears followed by a second retainer ring in each Slide each rotary idler gear and bearing assembly over an idler shaft PN 1050 D5 117 and centre as well as you are able Slide a bearing seal PN 02 0010 over each end of the rotary idler shafts ensuring that the lip on the seals are towards the centre bearing followed by an idler spacer PN 1050 D5 121 over each end of the shafts Attach the turn counter encoder PN 1482 59 01 and encoder spacer PN 101 1712 to the RH rotary idler gear stack using three 1 4 NC x 1 hex SHCS Place each rotary idler assembly in their respective locations in the bottom plate meshed with the rotary gear and secure with an idler pad PN 997 D20 125 and 1 1 2 UNF hex nylock nut NOTE as the rotary idler assemblies are placed vertically the bearing seal and idler spacer on the bottom side will have to be held in place by hand as the assembly is lowered through the bottom plate Technical Manual Section Contents 3 15 20000 50K Tong Maintenance Assembly Procedures Cont d 12 13 14 19
55. 1433 009 342 6000 100 391 2183 005 391 2081 4265 391 2887 212 391 1433 002 381 0581 044 3B81 2781 D15 391 2881 301 3581 713 291 2481 069 Technical Manual Section Contents Hydraulic Components VGBO Part 14 4 391 2881 433 391 28816 70 391 1402 391 3783 039 341 0585 099 391 2183 157 381 2681 285 391 2881 096 381 1402 015 391 0585 099 mE 391 2881 2497 391 3581 778 191 2483 091 MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components KT20000 50K Tong Spring Centered and Detent Spool Operators See Figure 2 14 Stripper Bolt 1 15 Centering Spring 1 16 Spring Guides 2 17 Datent Sleeve 1 18 Detent Balls 2 19 Detent Spring 1 20 Detent Poppet Retainer 1 21 Detent Spacer 1 Technical Manual Section Contents 391 1432 022 391 3581 608 391 1642 045 391 3283 015 391 0282 010 391 3581 130 391 2583 008 391 1432 021 391 3581 633 391 1642 013 301 3283 008 391 0282 009 391 3581 015 391 2583 006 391 1402 452 391 3581 330 391 1642 161 391 3384 310 391 0282 011 391 3581 316 391 3384 311 391 3782 208 7 17 KT20000 50K Tong Hydraulic Components Valve Disassembly Instructions Reference exploded view and parts list on page 2 and 4 for work section detail Ec Step 1 Valve B
56. 20000 50K Tong las qaare i5 On HEN pem mW its b ohm Nw 24 UMP RE 67 P IR pad neces dor Ar Zo aug ad un das a SHAFT TYPES P AND HP MODEL CODE POSITION E supplied 270 7084 was x d 2220 4208 ars 2708593 qe AS m P 50 20 0NE 20 1120 t Falli cepi hai HEC 0 252 du hie molor 10 7 10 Hydraulic Components 4 VALVE HOUSING WITH FLANGE 5047 IN FLO M94 57 24 160 t gos 2201125 te 220 ET SHAFT TYPES 5 AND H5 MODEL CODE POSITION EJ Cylindrical shafi with 14 seines BS 3550 1963 SHAFT TYPES 2 AND HZ MODEL CODE POSITION Ell Cylindrical shat with splines to DIN 5480 LT d xp de hole molor 671 a 2425 Sos LASS UT EET 9070 T ihr eT Sed DM 0 WP ee 1 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components SHAFT TYPES Q AND MODEL CODE POSITION Female shaft with 24 splines to BS 3550 Mote The
57. 50K Tong q Troubleshooting H GENERAL COMMENTS The following factors generally contribute to poor hydraulic operation and premature wear of equipment fs 2 3 4 Contaminated hydraulic fluid due to overuse overheating or inadequate fluid filtration Unsuitable hydraulic fluid especially in extreme climatic conditions Defective packing or seals in components of the hydraulic system Poor or incomplete hydraulic system training Users must be fully qualified to operate the equipment and have com plete understanding of the hydraulic system If your hydraulic troubleshooting procedures involve flow and pressure tests at the power unit McCoy Completions amp Drilling recommends construction of a test rig that can easily be connected to the main suction and discharge ports of the power unit 4 6 Technical Manual Section Contents FARR MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD Parts amp Assemblies T LL Technical Manual Section Contents 20000 50K Tong 5 1 KT20000 50K Tong 5 2 Geartrain Layout Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD FARR Geartrain Layout 20000 50K Tong Part Number 87 0210B assembly Door Pivot Roter Assembly 54 5 2_ Assembly Rotary Idler Assembly With T
58. ACTIVATED 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 ASSEMBLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT DESCRIBED IN THIS MANUAL HAS BEEN SPECIFIED OR DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS DOCUMENT FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEMBLY OR COMBINATION OF PARTS AND ASSEMBLIES OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SUPPLIED BY MCCOY MCCOY DRILLING amp COMPLETIONS DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD BEARING DEVICES UNLESS THOSE MODIFICATIONS ARE PERFORMED BY MCCOY McCoy Drilling amp Completions recommends following an industry accepted standard such as OSHA ASME B30 9 2006 or manufacturer s guidelines when performing any rigging and overhead lifting Use by untrained persons is hazardous Improper use will result in serious injury or death Do not exceed rated capacity Slings will fail if damaged abused misused overused or improperly maintained Only grade 80 or grade 100 alloy chain should be used for overhead lifting applications Working Load Limit WLL is the maximum allowable load in pounds which may be applied to the lo
59. ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INJURIES 1 Perform an initial wash of the tool in order to remove the majority of dirt and grease build up Ensure adequate tainment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease 2 Remove the access panel on side of 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 envi 3 ronmental contamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the geartrain 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 4 solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environ mental contamination from residual hydraulic fluid dirty grease and cleaning agents 5 Inspect all fasteners and fastener safety wires Heplace any missing fasteners use Grade 8 bolts only He torque d all external fasteners to SAE specifications 6 Inspect backing pin s If cracked broken or
60. AUTION shallow milled relief area oxtends across the O ring face of the valve housing This should not be stoned or ground off 7 20 3 Wash all parts thoroughly in a cleaning solver and blow dry before beginning reassembly Pay special attention to the number letters masked on the parts in Seep 1 If any marks are removed during cleanimg re mark immediately a Clean adhesive from threads of spool stripper hosing cap screws and hex nat with Loctite M Chisel Gasket Reniover Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components KT20000 50K Tong Valve Assembly Instructions Preparation of Parts Spray the threads of the new sinpper bali Fig 2 item 14 tapped ihreaded spool end all screws and screw holes on both ends of the housing with LOCCQUIC Primer Grade NF and let dry Spring Center Spool Assembly CAUTION Follow the adhesive manufacturer s instructions for proper cleaning and curing Failure fo ckan amd prepare parts properly may result in assembly failure Technical Manual Section Contents CAUTION Failure to follow the recommended assembly instructions can result in poor performance or product malfunction Product should be thoroughly tested to ensure proper operation before the valve is placed back into service Step 1 Spool Assemb
61. ER DETENT ADJUSTMENT Safety Door Switch Adjustment The safety door switch should interrupt hydraulic power to the motor when the tong door is opened or even slightly ajar This 15 a critical safety system and proper adjustment is necessary to maintain the intended function If the rotary gear does not stop immediately and completely stop rotating when the door is opened remove the tong from service and per form the following adjustments 2 Set the tong up in a controlled testing environment without connecting hydraulic power 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 switch and thoroughly clean and lubricate the plunger before reinstalling Test the switch plunger after cleaning and reinstallation The plunger should spring back when depressed If the plunger does not smoothly spring back replace the switch Connect hydraulic power to the tong Ensure the door is closed and all personnel are clear Begin rotating the cageplate Open the tong door the cage plate should immediately and completely stop Release all controls and close the tong door again Ensure the cageplate rotates with the door closed If cageplate continues to rotate with the door open further adjustment of the safety door switch is necessary Hemove hydraulic power from the tong Adjust the position of the
62. ER NOMENCLATURE OF IMPORTANCE USED IN THIS INSTALLATION GUIDE McCoy Drilling amp Completions uses three indicators to describe items of three degrees of importance A HAZARD to operators or equipment is represented by an exclamation point within a red triangle identifies items of the highest importance Failure to heed information identified by a HAZARD symbol may result in bodily injury death catastrophic equipment damage or any combination of these AHAZARD may also indicate the potential for danger ous environmental contamination This identifies a HAZARD to operators or equipment A WARNING 15 represented by an exclamation point within an orange triangle and contains information that will alert personnel to a potential safety hazard that is not life threatening A WARNING may also serve to alert the user to infor mation critical to the correct assembly or operation of the equipment in use This identifies a WARNING to users A CAUTION is represented by an exclamation point within a yellow triangle and highlights information that may aid the user during assembly or operation of your equipment CAUTIONS are also used to ensure common errors are not made during assembly or operation of your equipment This identifies a CAUTION to users Observance of the following is the full responsibility of the user all descriptions information and instructions set out in this manual any regulation or requirement issued by an authorit
63. IDENTIFICATION 3 2 5 ILLUSTRATION 2 4 COMPONENT IDENTIFICATION 04 2 6 ILLUSTRATION 2 7 ILLUSTRATION 2 C 2 HYDRAULIC COMPONENT IDENTIFICATION 2 8 ILLUSTRATION 2 C 3 HYDRAULIC COMPONENT IDENTIFICATION 02 2 8 ILLUSTRATION 2 C 4 HYDRAULIC COMPONENT IDENTIFICATION O8 2 9 ILLUSTRATION 2 C 5 HYDRAULIC COMPONENT IDENTIFICATION 2 9 ILLUSTRATION 2 C 6 HYDRAULIC COMPONENT IDENTIFICATION 05 2 10 ILLUSTRATION 2 0 1 HYDRAULIC CONNECTIONS 0 1 EIC ORE ESOS 2 10 ILLUSTRATION 2 D 2 HYDRAULIC CONNECTIONS arr HO CROCO RC TERR RECO 2 11 JS TRATION 2 E 1 Jaw REMOVAL anaa 2 12 ILLUSTRATION 2 F 1 TONG SUSPENSION RELATIVE TO AXIAL CENTRE 2 13 ILLUSTRATION 2 F 2 TONG SUSPENSION RELATIVE TO VERTICAL CENTRE 2 13 ILLUSTRATION 2 F 3 LEVELING TONG USING TURNBUCKLES 2 14 ILLUSTRATION 2 G 1 TONG ROTA
64. LUSTRATION 1 A 2 20000 Tonc DIMENSIONS Specifications 1 2 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR Specifications Torque Table Pressure PSI MPa 1000 6 895 1500 10 342 4400 5965 28500 2000 13 79 6200 8406 40200 2500 17 237 8000 10846 51800 20000 50K Tong 2600 3525 16900 Lbs ft 22913 38640 54504 70231 MAXIMUM RATED TORQUE 50000 LBS FT 67790 NM Speed Table 10 37 9 Flow USGPM LPM High Gear 3 40 151 6 60 227 4 m m 3 8 17 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 Hydraulic Requirements max Max Length Height Staffa Motor Height Rineer Motor FARR Overall Width Space Required on Pipe Maximum Elevator Diameter Torque Arm Length Recommended Spring Hanger Weight Approximate Casing Jaws Available inches AACCOY MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 60 US GPM 1000 psi 227 LPM 6 894 MPa 10 US GPM 9 2500 psi 38 LPM 17 237 MPa 80 25 inches 203 8 cm doors closed 28 71 1 cm chain sling not included 25 3 8 64 5 cm chain sling not included 50 5 inches 128 3 cm 10 25 4 cm N A 52 inches 132 1 cm Centerline of pipe to Centerline of anc
65. LUSTRATION 3 0 1 CAGEPLATE CAM FOLLOWER LUBRICATION Rotate the rotary gear into the mouth opening as illustrated below Apply grease to the top and bottom cageplate grooves Continue to rotate the rotary gear and lubricate the grooves until the gear is well lubricated Apply grease to top amp bottom rotary gear grooves AACCQOY MOVING CLOBAL ENERGY FORWARD cnn ILLUSTRATION 3 D 2 RorARY GEAR LUBRICATION 3 2 Technical Manual Section Contents FARR Maintenance KT20000 50K Tong 2 Support Roller Bearings Lubricate support roller bearings through the grease fittings in the bottom ends of the rotary support roller shafts located on the bottom face of the tong ILLUSTRATION 3 D 3 SUPPORT ROLLER LUBRICATION The safety door cam weldments must be removed to lubricate the door pivot support roller bearings Remove the two 3 8 x 1 hex bolts amd 3 8 lock nuts securing the cam weldment to the door weldment then remove the cam weldment to expose the support roller shaft Lubricate support roller bearings through the grease fittings in the top end of the support roller shafts Repeat for the other door pivot roller FARR MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 3 0 4 Door Pivot ROLLER LUBRICATION Technical Manual Section Contents 3 3 20000 50K Tong Maintenance 3 Rotary Idler Bearings Apply grease to these bearings through the grease fittings in the ends of t
66. MOVING GLOBAL ENERGY FORWARD When the tong jaws disengage align the opening in the rotary gear with the mouth of the tong and open the tong door to free the tong from the arill string 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 arill floor if desired ILLUSTRATION 2 H 11 LowerRinGc UsiNc CYLINDER CONTROL Use your rig s standard pipe handling procedures to remove and rack the freed tubing stand Repeat steps through as many times as necessary to break out and unthread the desired number of connec tions H EXTREME COLD WEATHER OPERATION PROCEDURES Consult the power unit engine operator s manual for all cold weather operating procedures and precautions Select gear and bearing lubricants that are compatible with expected climatic conditions Select hyaraulic fluid that is compatible with expected climatic conditions Allow hyaraulic fluid to circulate for approximately 20 minutes after starting the power unit prior to activating the bypass valve to allow fluid to circulate to tong If the power unit is equipped with an oil temperature gauge ensure that the fluid has reached operating temperature as specified by hydraulic fluid data sheet Allow for adequate drying of moisture pri
67. PM 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 approximately 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 2 VALVE OPERATION 4 way proportional valves control operation of hydraulic devices on the tong assembly such as hydraulic motors and cyl inders When any one valve is centered or in the detent position there is no hydraulic output from the valve When the valve is pushed forward there is an effect and when the valve is pulled back there is an opposite effect These valves feature proportional control which means that further extension of the valve handle thereby further opening the valve orifice results in proportionally higher hydraulic output to the controlled device FARR The following illustration demonstrates the type and effect of the hydraulic valves with which this tong is may be equipped AACCQOY MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 2 15 20000 50K Tong Setup amp Operation TONG MOTOR This i
68. 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 WHEN RE ASSEMBLING LOAD BEARING DEVICES CHAIN SLINGS RIGID SLINGS BACKUP LEGS ETC NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE OF FASTENER SEE SECTION 3 OVERHAUL ANY THREADED FASTENER A LOAD BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE ANY REPLACEMENT FASTENER BOLTS NUTS CAPSCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT Technical Manual Section Contents V 20000 50 KT20000 50K Tong This page intentionally left blank MOVING GLOBAL ENERGY FORWARD FARR 20000 50K Tong Copyright 2008 Farr Canada A Division Of McCoy Corporation all rights reserved This document is the property of Farr Canada and 15 supplied as reference information for users of our products This document and the contents within are considered confidential information not to be disclosed copied transmitted transcribed in any form or stored on any type of data storage media without the express written consent of Farr Canada While continually striving to maintain accuracy Farr Canada hereby states that the infor
69. TION MOTOR CONTROL iss RE RERO Ree OG 2 16 LLUSTRATION 2 2 TONG LIFT CYLINDER 1 RC ROS 2 16 ILLUSTRATION 2 H 1 MASTER LIFTING LINK ddd ee RODA 2 18 ILLUSTRATION 2 H 2 SETTING BACKING PIN To MAKE UP POSITION 2 19 ILLUSTRATION 2 H 3 Lirr CYLINDER CONTROL RAISE 2 19 ILLUSTRATION 2 H 4 OPENING TONG DOORS 2 20 ILLUSTRATION 2 H 5 MOTOR CONTROL 2 21 ILLUSTRATION 2 H 6 MoTOR CONTROL RELEASING JAWS 2 21 ILLUSTRATION 2 H 7 LIFT CYLINDER CONTROL LOWER 2 22 ILLUSTRATION 2 H 8 SETTING BACKING PIN To BREAK OUT POSITION 2 23 ILLUSTRATION 2 H 10 RELEASING TONG JAWS FOLLOWING BREAK OUT amp UNTHREADING 2 24 ILLUSTRATION 2 H 9 ROTATION CONTROL BREAK OUT 2 24 ILLUSTRATION 2 11 LoweRING TONG UsiNcG LIFT CYLINDER CONTROL eee 2 25 ILLUSTRATION 3 0 1 CAGEPLATE CAM FOLLOWER LUBRICATION
70. TION Cont d 2 6 ILLUSTRATION 2 B 4 COMPONENT IDENTIFICATION 04 Hem Description 9 Backing Pin Assembly _______ __ 2 Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR FARR AACCOY MOVING GLOBAL ENERGY FORWARD Setup amp Operation 20000 50K Tong C HYDRAULIC SCHEMATIC HYDRAULIC COMPONENT IDENTIFICATION D E 514 15 12 E fa EY i 4 ILLUSTRATION 2 C 1 HyDRAULIC SCHEMATIC ITEM DESCRIPTION PART NUMBER DVA35 A880 Inlet Valve 10 9016 DVA35 MRV 2 Relief Valve 10 0062 3 1 DVA35 MA8 Motor Section Valve 10 9014 DVA35 DA8 Motor Section Valve 10 9019 DVA35 TR99 Outlet Valve 10 0086 6 CBCA LHN Counterbalance Valve 08 1848 ECJ Valve Body 08 1807 8 1 LKHC XDN Pilot To Open Check Valve 08 1625 9 1 HCM Valve Body 08 1829 VM503RC Safety Door Switch 08 0121 1 4 FNDT Ball Valve SS 434F Unloader Valve W01321 Dump Valve R4V 10 5A3 10 11G 3000 psi Pressure Gauge 02 0245 600 psi Pressure Gauge 10 0130 Check Valve SH 4600 Staffa HMB 080 Hydraulic Motor 87 0210B Technical Manual Section Contents 27 KT20000 50K Tong C9 A 11 2 8 Setup amp Operation ILLUSTRATION 2 C 3 HYDRAULIC COMPONENT IDENTIFICATION 02 Technical Manual Section Contents AACCOY MOVING CLOBAL ENERGY FORWARD FARR
71. TORAGE 1 2 3 4 5 7 8 9 Rotate the tong to the open throat position Exercise each hydraulic cylinder several times open the tong and backup doors if equipped retract and extend the remote backing pin ramp if equipped retract and extend the float cylinders Leave all cylinders except for the door cylin ders in their fully retracted position The general idea is to have as little of the chrome cylinder rods exposed as possible De energize the power unit Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor Remove the hydraulic SUPPLY line from the equipment Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system Connect a low pressure air supply line 10 PSI or less to the hydraulic supply line and force a small amount of the remain ing 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 Disconnect the hydraulic RETURN line from the equipment Disconnect remaining hoses such as case drains or lines connected to the turns counter 1 8 B If any hydraulic fittings or hoses are leaking they must be repaired or replaced bef
72. TR99 DONNE 20 Orb Plug With Machined 48 Orb Port Bushing n item EN EXT ung EN EN ng uti ERN E ng Ii Technical Manual Section Contents 5 29 MOVING GLOBAL ENERGY FORWARD 20000 50 Tong 5 30 Tong Door Assembly Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR FARR AACCOY MOVING CLOBAL ENERGY FORWARD Tong Door Assembly 20000 50K Tong tye dy _ fat Door Prot Roller Srat Support Rone 2 _ p Fan Door Gyiinder Mounting mros Fat Flat Point T a Regular Carbon SteeiLockwasher boorweamen Technical Manual Section Contents 5 31 Safety Door Assembly 20000 50K Tong dev SNOILAId NOD ONIT1NAC ADAANA ONIAOW ACDDVN Technical Manual Section Contents 5 32 FARR AACCOY MOVING CLOBAL ENERGY FORWARD Safety Door Assembly 20000 50K Tong Tye Besrpto PatNumbe Ce en emorsa osa _ p fm rome 0504 Pan 30 Regular Carbon Steel Lockwasher osme H Wenen fa vave Mount Base Pate M fa Door vane 2 oe
73. UE THREADED FASTENERS USED IN LOAD BEARING DEVICES MUST BE SECURED WITH RED LOCTITETV 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 assem bling the tong in our plant However much emphasis has been placed on disassembly and reassembly in the maintenance and overhaul section of this manual It is therefore recommended that this assembly section be used only to aid in familiarization of parts and their locations and the overhaul and maintenance section be used as a specific guide to assembly NOTE INITIAL ASSEMBLY STEPS SHOWN WITHOUT TONG SIDE BODY FOR CLARITY APPLY A THIN LAYER OF GREASE TO THE SURFACE OF EACH MOVING PART DURING ASSEMBLY TO AID IN THE ASSEMBLY PROCESS 1 Position the tong body gear case on a suitable stationary support such that the bottom body plate is accessible 2 Install 25 cam followers PN 02 0107 into the bottom plate as shown in the illustration Secure each with 7 8 lockwasher and 7 8 UNF jam nut ILLUSTRATION 3 H 1 Cam FOLLOWER INSTALLATION PLATE 3 14 Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Maintenance KT20000 50K Tong Assembly Procedures Cont d d Insert
74. UTLET rmi Technical Features Counterbalance valves should seiat e Turn adgustment clockwise decrease least 1 3 times the maximum load setting and release Induced pressure Full clockwise Setting is less than 200 Backpressure port 2 adds 10 the psi 14 bar effective relief setting at rabo of 1 plus tha pilot ratio times the backpressure Reseat exceeds 65 of set pressure Sun counterbalance cartridges can be when the valve is standard set Setbngs installed deecthy into a cavity machined lower than the standard set pressure In an actuator housing for added may result in lower reseat percentages protection and improved stiffness in the 7 26 Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Hydraulic Components amp Two check valve cracking pressures ane avadable Use the 25 psi 1 7 check unless actuator cCavstation is pon counterbalance load control and pilot to open check cartridges physically interchangeable i e same flow path cavity for given frame circuit This valve does not have positive seals on the pilot section and will pass up to 2 1201000 psi 32 comin 70 bar between port 2 and port 3 This is considerabo n in master slave circuits and in the leak testing of valve cylinder assemblies steel options P or W a
75. VEL IN THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO THE SYSTEM DO NOT ALLOW THE LEVEL TO FALL BELOW ONE HALF FULL d Retighten load cell vent screw when the system has been adequately recharged 3 Repair And Calibration Load cell and indicator gauge should be returned to authorized repair facility for any repairs or calibration required Technical Manual Section Contents 6 5 20000 50 KT20000 50K Tong This page intentionally left blank Hydraulic Components KT20000 50K Tong Kawasaki Motors Corp U S A Precision Machinory Diviasn Staffa Fixed Displacement Hydraulic Motor FARR AACCOY MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 7 1 20000 50K Tong CONTENTS Page 1 General Description 3 Model Code 4 Performance Motor data Fl definitions _ Bearing lile Circuit and Application Motes Starting tongues Cooling Mow Motor casing pressure Hydraulic Fluids 7 Temperature Limits 8 Filtration 9 Nossa Levels 10 Moment of inertia 11 Mass 12 installation Generi 7 Crankcarse drain 7 T 1 Ge EF qe qm ode de yu cb cg cup cp Cn Start up 13 Installation Dimensions 8 t 1 7 2 Hydraulic Components 1 GENERAL DESCRIPTION The HIMBOSO fixed displacement motor B one of 12 frame sizes in Kawasaki Saia range of high terque Kw spem radial piston motors which extends tram 94 68
76. ach top brakeband lug weldment using two 3 8 UNC x 4 hex bolts and 3 8 lockwashers Attach the safety door valves PN 08 0121 to the valve mount plates and the valve mount baseplates using one 5 16 UNC x 2 1 4 hex bolt one 5 16 UNC x 3 1 4 hex bolt and two 5 16 lockwashers per valve Further secure the valve mount plate to the baseplate with a 5 16 UNC x 2 hex bolt and 5 16 lockwasher ILLUSTRATION 3 H 11 SArETY Door VALVE INSTALLATION Thread a 1 4 straight thread grease fitting PN 02 0097 into the top of each door pivot roller shaft Mount the safety door cam weldments PN 101 1705 to each door weldment using two 3 8 UNC x 1 hex bolts and 3 8 lockwashers per weldment Technical Manual Section Contents 3 21 KT20000 50K Tong Maintenance Assembly Procedures Cont d 52 53 54 92 56 cd Install the safety door valve guards PN 101 0839 Mount the guards to the safety door valve mount baseplates using two 3 8 UNC x 1 hex bolts and 3 8 lockwashers Attach four leg weldments PN 997 D8 160A to the bottom plate of tong using 7 8 UNC x 1 1 2 hex bolts and 7 8 plain narrow flatwashers Attach the hyaraulic supports to the top plate Attach hydraulic valve mount weldments PN 101 1442 to the top plate near the LH rotary idler using one 3 8 UNC x 1 hex bolt and 3 8 lockwasher per mount ii Attach the hydraulic line support baseplate weldment PN 101 1943 to
77. ach door assembly Thread far enough through door weldments that a 1 2 jam nut can be threaded on to each set screw from the inside of the door assemblies Slide a 1 1 8 plain washer on to each door pivot roller shaft PN 101 3940 Position the RH door assembly in its proper location and insert a door pivot shaft from the top through the door assembly and the support roller components Secure the door pivot shaft on the bottom using a 1 flatwasher and 1 UNS thin nylock nut Repeat the installation procedure for the LH door assembly Install the door stop cylinders PN 1037 A4 144 using 1 2 UNC x 1 1 4 hex bolts 1 2 narrow flatwashers and 1 2 lockwashers Do not neglect to install a door stop spacer PN 1037 A4 145 through the end of each cylinder Install top and bottom lined brakeband weldments Fasten each brakeband weldment to the top and bottom body plates with two brakeband retainers PN 101 1631 securing each retainer with two 3 8 NC x 1 hex bolts and 3 8 lockwashers Fasten the ends of the brakebands to the brakeband lug weldments using two 3 8 NC x 4 1 2 adjustment bolts and 3 8 NC hex nylock nuts per brakeband one per side Ensure that the adjustment spring PN 08 9264 is installed between the head of the adjustment bolt and the tab on the brakeband weldment four locations see Pp 5 22 5 23 Install the two safety door valve mounting base plates PN 101 1707 on the top plate of the tong directly adjacent to e
78. ad bearing device when the device is new or in as new condition and when the load is uniformly and directly applied The WLL must never be exceeded Working Load Limit WLL is the maximum working load for a specific minimum sling angle measured from the horizontal plane The Working Load Limit is identified on the sling The Working Load Limit or Design factor may be affected by wear misuse overloading corrosion deformation intentional alterations sharp corner cutting action and other use conditions Shock loading and extraordinary conditions must be taken into account when selecting alloy chain slings See OSHA Regulation for Slings 1910 184 ANSI ASME B30 9 SLINGS ANSI ASME B30 10 HOOKS and ANSI AMSE B30 26 RIGGING HARDWARE for additional information THE 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 FARR AACCQOY MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 2 A 1 SLING ANGLE Technical Manual Section Contents 2 1 KT20000 50K Tong 1 2 2 Setup amp Operation Inspection Of Slings McCoy Completions amp Drilling 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
79. alve mounts inlet amp 8 outlet line supports tong legs shifter handle pivot lugs Tighten or replace loose or missing fasteners Farr recom mends that damaged or missing body parts be repaired or replaced as soon as possible 9 Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be is a good indication of wear Inspect all paint locations in which the paint has been damaged must be repaired prior to the tong being returned 1 0 to service Prepare areas to be painted to ensure they are free of grease dirt or solvent Touch up using a solvent j based acrylic paint Farr Blue is paint number RAL5005 contact Farr sales for paint number for custom paint applications Allow sufficient time for paint to dry before proceeding 1 1 C Inspect all external welds Any weld that is cracked or separating must be repaired and repainted before returning tong to service Technical Manual Section Contents 3 25 KT20000 50K Tong Maintenance 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 1 D C turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service Refer to Section 2A of technical manual Sling Load Bearing Devi
80. and examine all surfaces including the inner link surface The sling shall be examined for conditions such as those listed in the removal criteria below In addition daily inspection of slings fastenings and attachments shall be performed by a designated person If damage or defects are found at either inspection the damaged or defective component shall be quarantined from service until it can be properly repaired or replaced Hemoval 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 Excessive wear nicks or gouges to the chart below to ensure minimum thickness on chain links supplied 15 not be below the values listed Minimum Allowable Chain Link Thickness at Any Point Nominal Chain Size Minimum Thickness 0 189 4 80 0 239 6 07 0 273 6 93 0 342 8 69 32 27 71 0 443 11 26 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
81. ank his step es che most crinical the disassembly procedure It should be followed closely 10 ensure thal the valve bank ts properly reassembled after repairs have been made With a waterproof quick drying marker mark each easing with a sequential number Stan by making the inlet casting wiih ihe 1 and finesh by marking the outlet wilh the highest Next mark the port boss closest 15 the back cap on each work section with a B for back cap end Then mark the port boss closest t the spool clev on each work section with a C for clevis end Finally if relief valves are removed from the valve bank they must be marked with the corresponding number of the casting and port location oc C from which thes uere removed Inlei and relsef valves are marked with a casting namber only Step 2 Tie Bolts Remove the four ne bolts thai hold the bank together amd separate ther sections valve the bolts thread into the outlet casting VG valve tie bolts pass through the entire hank requiring washers and hex nuts to be fastened at beth ends of the FARR Step 3 Section Seals The inlet mad inlet and each parallel work sectson have four section seals Fig nems amp 2 on the downstream maling face Senes work sections and rhe VANGIS split mad lave three secti n scalis on the downstream mating face Fig 1 items amp 1 These
82. ank Introduction KT20000 50K Tong Congratulations on the purchase of your new Farr Canada 20 tong assembly This unit will provide you with years of outstanding performance Simple maintenance and care will extend its life and insure a continuing level of excellent performance and reliability This manual will assist you in giving your equipment the care it requires Please read the manual and follow the enclosed maintenance instructions Replacement parts are readily available from FARR Canada Ltd in Edmonton Alberta However most of the parts that are subject to wear or damage are standard items likely to be found in supply stores or parts depots Many parts are transferable between FARR tongs and backups Should you need replacement parts or should you experience any difficulty not covered in this manual please contact McCoy Drilling amp Completions FARR 14755 121A Avenue Edmonton Alberta Canada T5L 212 Phone 780 453 3277 Fax 780 455 2432 Sales Fax 780 481 9246 Email Engineering engFarr mccoyglobal com Email Sales salesFarr mccoyglobal com Customer Care customerCareFarr mccoyglobal com Website htto www mccoyglobal com index php drilling completions FARR AACCOY MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 1 1 20000 Technical Manual Section Contents 1 1 KT20000 50K Tong B 4 i i E m 80 25 IL
83. asis a Up to 50 15 duty for periods up 0 5 minutes Cer 50 pimin 2 duty Tor up 30 188275 58 746 937 mimm output torque and power 741 100125 BE of a fully run in motor dor range operating with zero pressure on petroleum of 50 232 505 viscosity High rebum line pressures will reduce torque for given PEE ES 7 4 b le Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components BEARING LIFE The nomograph allows the median bearing be determined for 1 exse and axial Side load and no axial A ane L10 by o2 Example 1 follow chain dotted linet System pressure Speed N Median bearing life L10 bearing rating median x 0 2 Example 2 ifollow chain dotted lina Load oftan A from molor mounting facie Speed Median L10 bearing rating median x 0 2 ai 0 bi 207 bar 3000 psi c 300 r min di 23 000 hrs 4600 hrs e 40 KM 9000 fi 50 mm 2 0 in gi 207 bar 3000 psi hi 25 b 62 000 hrs 12 400 hrs Tec
84. bar 5 psi check vale lubrication af the upper bearing see above diagram line should be run aboye the level Of Ie uppermost bearing mere risk of siphoning then a siphon should be fitted START UP Fill the crankcase with system Where practical a short period 130 minutes of running in should be 7 7 KT20000 50K Tong Hydraulic Components 13 INSTALLATION DIMENSIONS IN INCHES FRONT MOUNTING MODELS HMBOBD MOTORS WITH TYPE 1 PORT CONNECTION Gee separabe drawing for dual rmoant model VS See additional views for shaft bypes and for types 7503 and 504 part connection draaiing of dual mount model Tor d tails of types amd port connection EFLD aj i hy 30 3 dae porta peri more Fun 52405 FE 2 TT robilior uio ponies apes polio 2 heilen 7000 ELI VLA nn append ioe 02809 ped and h hom lio
85. ce Safety for information on recommended test ing 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 geartrain by hand and use a flashlight to perform a visual inspection of the geartrain through the ac 1 3 C cess panel and the opening of the rotary gear while the geartrain is being rotated If gear damage or chips of metal are seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is complete Inspect all jaws and dies in use for the maintenance interval Inspect the jaw roller pins for signs of damage re 14 place pins if necessary If the pins are welded in 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 brakeband linings replace if necessary Unequal wear of the brakebands indicates that 7 6 the brakeband tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brakebands 1 7 Inspect door springs Ensure springs retain sufficient str
86. d for makeup will be in the 10 o clock position see Illustration 2 H 2 next page If it is not simply lift up and place in the correct position see Illustration 2 next page The cageplate opening must be aligned with the door opening when setting the backing pin position 2 18 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation _ 20000 50K Tong Making A Connection Continued ILLUSTRATION 2 H 2 SETTING BAckiNG To Make up PosiTION c Ensure the load cell and snub line s are properly configured making up connections The snub line is a length of wire rope that connects the rear of the tong body to a sturdy anchor on the drill floor see Section 2 F 1 The snub line prevents the tong body from spinning in the opposite direction of the cageplate when torque begins to build in the joint The snub line must be rated for the applied torque plus whatever safety margins stated by your own operating policies The snub line connection point on the drill floor must be sturdy enough to absorb all applied forces when making up the joints When making up joints the snub line is attached to the ariller s side of the tong which is the left side of the tong as seen from the rear For accurate torque measurement the snub line must be perpendicular to the vertical and perpendicular to the centre line of the tong d Actuate the lift cylinder control
87. damage due to improper use comosion or normal wear 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 equipment disconnecting all hoses fittings control handles and linkage connectors that might be attached to the valve Plug all ports and thoroughly clean the exterior of the valve bank then the port plugs can be removed 7 15 KT20000 50K Tong 4 Parts List For Work Section Item Description Qty VAIVG20 Part No Parallel Section Seals See Figure 1 1 Square Seals 3 391 2881 208 2 Square Seal 1 3981 2BB1 2D0 Series Section Seals 1 Square Salis 2 391 2881 206 Square meal 1 491 2 1 627 Parallel and Series Section Component Parts See Figure 1 4 Back Cap Screws 2 381 1433 020 Lock washers B i 5 Back 1 34 1 6000 100 6 Retainer Plates x 301 2183 001 Back up Rings 381 2681 378 Spool Saas 2 391 1985 014 8 Retamer Plate Screws 2 291 143 015 10 Check Valve 1 491 581 044 Or Valve Cap 1 391 2281 015 11 Ring Seal 1 391 2881 204 12 Check Spring 1 391 3581 713 13 Check Valve Poppel 1 391 248 1 069 Exploded View of Work Section Parallel Sealing Face includes inlets and mid inlets Nat required in Float in neutral Sections 7 16 VA VG35 Part Mo 391 2881 200 301 2B881 403 391 2881 200 391 2881 628 391
88. drawings and documentation necessary Schedule planned maintenance with operators to avoid conflicts unnecessary downtime and the danger of accidental equip ment 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 person nel or equipment spare parts must meet or exceed OEM specifications in order to maintain equipment integrity especially protective equip ment McCoy recommends that disconnection of hydraulic connectors be performed with the power unit off and the hydraulic circuit depressurized Your equipment uses materials that may be harmful to the environment if improperly disposed of hydraulic fluid grease etc Dispose of all materials according to your company s proscribed environmental protection regulations B CLEANING Clean tong thoroughly cleaned with a good petroleum based cleaning agent after each job prior to storage Farr recommends that the motor and valve assembly be periodically removed along with the top tong
89. e Run the backup through several clamp unclamp sequences to ensure functionality e Inspect all components and hydraulic fittings for possible defects following completion of the tests All FARR Tongs have been throughly 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 15 operating cor rectly 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 oo AND COULD RESULT IN THE FOLLOWING FAILURES A restriction in the pressure supply hose will result in high pressure within the power unit hydraulic system which will activate the hydraulic governor and increase the engine speed to as high as maximum RPM e Arestriction in the return line will result in high pressure within the power unit and the tong hydraulic system caus ing engine speeds as high as maximum R
90. e 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 VISUAL On PLATE ATTACHED TIME INTERVAL LIFTING TESTS LIFTING POINTS EXAMINATION To UNIT Initial Certification By YES YES YES T Farr Superior Interval Not Exceeding At the discretion of At the discretion of YES T or VN 12 Months inspection body inspection body Interval Not Exceeding At the discretion of GO Months inspection body Following Substantial YES YES YES Repair or Alteration 1 2 2 4 Lifting test as per S 7 3 BS 12079 or DNV 2 7 1 1995 T Proof Test non destructive examination VN 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 Writte
91. e hydraulic system will overheat if fluid is too light Replace with proper viscosity fluid SOLUTION Hydraulic fluid viscosity is affected by environmental conditions Ensure the fluid being used is suitable for high or low temperatures Replace with proper viscosity fluid for the operating conditions if necessary 6 POSSIBLE PROBLEM Worn or damaged tong motor causing slippage SOLUTION Replace or repair worn or damaged motor 7 POSSIBLE PROBLEM Damaged bearings or gears causing excessive drag SOLUTION Replace or repair worn or damaged gears or bearings 8 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 9 POSSIBLE PROBLEM Torque gauge 15 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 independant system Technical Manual Section Contents 4 1 KT20000 50K Tong Troubleshooting TONG WILL NOT DEVELOP SUFFICIENT TORQUE Cont d 10 4 2 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 troubleshooting in Section 6 of this manual SOLUTION Load
92. e the bottom of the shifting shaft into the lower shifting bushing Attach the toe of the shifting handle weldment PN 1037 D 20B to the shift pivot lug weldment using a 3 8 x 1 1 2 hex socket head shoulder bolt and 7 16 UNC thin nylock nut Connect the shifting handle weldment to the shifting shaft using two shifting links PN 101 5116 two 3 8 x 1 hex socket head shoulder bolts and two 7 16 UNC thin nylock nuts Insert the shifter detent ball PN 02 0018 into the detent tube on the top shifter bushing Insert the shifter detent spring PN 997 0 64 into the detent tube Thread a 7 16 UNF jam nut on to the 7 16 UNF x 1 1 4 hex bolt and then thread the bolt into the end of the detent tube Lock the bolt to the detent tube with the hex nut See Pg 3 7 for information about adjusting the shifter detent tension Position the bottom cageplate PN 1037 D 51 against the bottom plate of the tong over the previously installed cam fol lowers and support until it is attached to the top cageplate Technical Manual Section Contents 3 19 20000 50K Tong Maintenance Assembly Procedures Cont d 39 Position the top cageplate PN 101 1580 on the top plate of the tong over the previously installed cam followers Secure the bottom cageplate to the top cageplate using two 1 NC x 8 hex bolts and the rear cageplate bolt PN 1037 36 Do not neglect to install the three cageplate spacers PN 1037 C 38 between the t
93. ect changes to current tong model 5 0 5 16 5 17 Revised Shifter assembly images and part numbers to reflect changes to current tong model 5 0 5 18 5 21 Revised Tong Body assembly images and part numbers to reflect changes to current tong model S D O20 2 27 Revised Motor amp Motor Mount assembly images and part numbers to reflect changes to current tong model and include omitted parts 5 0 5 20 5 29 Revised Hydraulic assembly images and part numbers to reflect changes to current tong model 5 30 5 31 Revised Tong Door assembly images and part numbers to reflect changes to current tong model 60 AL Renumbered Torque Measurement as Section 6 z0 ALL Renumbered Hydraulic Components as Section 7 viii Technical Manual Section Contents FARR AACCODY MOVING CLOBAL ENERGY FORWARD MOVING GLOBAL ENERGY FORWARD FARR KT20000 50K Tong The information presented in this document will provide setup operating and maintenance instructions for your 20000 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 guide lines together with an experienced manager to develop operating procedures that conform to all policies set forth by the operating authority ies IDENTIFICATION OF OF WARNINGS AND OTH
94. ecuring the single load cell anchor to the bridge bar main plate must be inspected compres 1 8 sion load cell only If the integrity of the weld has been compromised the tong must removed from service until weld is repaired The load cell beam will need to be disconnected and removed so weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam 1 9 Re energize power unit 3 32 Technical Manual Section Contents FARR AACCODY MOVING CLOBAL ENERGY FORWARD FARR AACCQOY MOVING GLOBAL ENERGY FORWARD Maintenance KT20000 50K Tong Perform a full functional test of the equipment including if applicable backup components and float frame compo 20 nents 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 cageplate at low speed low 2 2 gear both directions makeup and breakout If cageplate begins rotating the safety door mechanism is not func tional and the tong must be removed from service unt
95. eed 2 2 low gear in both directions makeup and If cageplate begins rotating the safety door mechanism is g not functional and the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cageplate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR While rotating the cageplate ensure that the jaws properly If the jaws do not cam properly the brakebands 23 need to be tightened Incremently adjust both the top and bottom brakebands EQUALLY until proper cam action is achieved 3 24 Technical Manual Section Contents AACCODY MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Maintenance ___ 20000 50K Tong 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 conjuction with your maintenance foreman s experience and best estimate of when your
96. el lengthwise front to back along the tong ensuring that it is parallel with the surface of the tong If the tong needs to be leveled front to rear adjust both chains equally either both rear chains or both front chains The leveling process may have to be repeated in order to optimize the adjustment of the hanger chains and ensure the tong is level 2 14 ILLUSTRATION 2 F 3 LEVELING USING TURNBUCKLES Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation 20000 50K Tong G TONG OPERATION 1 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 POSESSION IN ORDER TO ELIMINATE THE POSSIBILITY OF SHIPPING DAMAGE McCoy Completions amp Drilling recommends that the following pre operating tests be performed after receipt from the fac tory 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 e Connect the tong to the power unit and apply full hydraulic pressure Inspect and correct any leaks Operate the tong at full speed and in high gear for a duration of one half hour Hot bearing caps may indicate impend ing bearing failure e Switch to low gear and operate for an additional one half hour at full speed
97. ength 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 hyaraulic cylinders and inspect cylinder rods for signs of mechanical damage or rust Farr recommends that damaged cylinders be replaced prior to storage Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued 20 or have visible signs of wear from contact with a rigid object If your tong is equipped with rigid hydraulic lines replace any line that is dented or appears to be stressed or cracked 21 Generously fill the geartrain housing with grease through the access panel and also through the opening the rotary gear Perform full lubrication refer to Maintenance section of manual to determine lubrication points gt 2 Ensure main supply and return connections to the tong are fully made up Re connect remainder of draulic lines and if applicable
98. ent repeat steps 9 through 24 quarterly Replace desiccant packs at this time depleted desiccant packs may be treated as regular dunnage AACCQOY MOVING GLOBAL ENERGY FORWARD FARR Technical Manual Section Contents 3 31 KT20000 50K Tong Maintenance M TUBULAR CONNECTION EQUIPMENT RE COMMISSIONING PROCEDURE Perform the following re commisioning procedures when removing tubular connection equipment from short or long term stor age 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 all protective plastic wrapping If there desiccant packs with the assembly they may be disposed of with the regular garbage 2 Remove the access panel on side of 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 lifing 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 4 Also inspect 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 ce
99. equipment is due for this maintenance 7 Rotate cageplate 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 HYDRAU LIC LINES ARE FULLY DISCONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINATION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HyDRAULIC SvsrEM 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 pres 2 sure the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pres sure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETUHN 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 A QUALIFIED SERVICE TECHNICICAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS
100. es Fig 2 item 16 will release from the spou Detent Spool The detent assembly should not be removed from the spool unless these parts meed to be replaced Wrap the detent sleeve Fig 2 nem 17 with clean lint free cloth Grip the cloih covered sleeve and pull firmly As the sieeve moves backwards the detent halls Fig 2 18 amd the detent spring Fag 2 19 will release abrapily The cloth should capture these paris and prevent teu boss Next clamp the spool in a soft jawed vise and remove the detent poppei retamer Fig 2 20 Place undersized bar throggh the detent ball bore serve as wrench Leghtly tap the detent poppet retainer with hammer ded pusch to help break ihe adhesive application of heal may be requened since xn anaerehbic adhesive was also used m the deteni assembly CAUTION Too much heat may distort the spool CLEANING INSPECTION AND REPAIR l Inspect ihe spool transition check scat and spool from each secton for deep scratches gouges or excessive wear If any of these condition exist replace Ihe section Manor surface damage on the spool and check poppei can be carefully polished away wiih a very fine crocus cloth 2 Examine the machined surfaces of the valve housing for nicks and burrs that could cause leakage between sections Lightly stone these surfaces to remove any rough spots C
101. eteni spring the through bole an the detent ball retainer Place the steel balls on the ends of the spring Compress the balls and spring then slap on ihe detent sleeve Note The detent sleeve noi symmetrical one end of the sleeve has a lead in Chanter Thus hamfer mad lace the cl esss when assembled Move ihe deteni sleeve io the neutral middle positon io preveni the subassembly from separating subsequent icp MOVING CLOBAL ENERGY FORWARD 7 22 Technical Manual Section Contents FARR Hydraulic Components 20000 50K Tong Valve Assembly Instructions Step 1 Spool Subassembly Apply 2 3 drops of Loctite 26279 of equivalent to the fallister crew holes on both ends of the housing Apply a light coating of hydraulic eil the valve spon Carefully insert the spool assembly into the housing Use caution to avoid burrs Be careful to pench roll oc damage the seals Make sure that the spool amd biousing are in the proper orentabion see Step 1 page 6 disassenvbly Step 2 Spool Seal and Back up Apply Parker Super O Lube the spool seal Fig 1 iem 8 amd slide it onto the spool Side on the back up ring Fig item 7 Push hems into the coanter until bey better ul Assemble the from retainer plates Fig item 6 using the two short Fillister screws Fig 1 nem 9 Check retziner plates for proper aligmment Tighten to a fi
102. ex nut Slide clutch bearing PN 02 0104 over the bottom end of the splined clutch shaft PN 1037 D 38 Install two upper clutch bearings PN 02 0103 over the top side of the clutch shaft Press bearings tight to the center gear on the splined clutch shaft Slide the low clutch gear PN 1037 D 40 over the lower bearing so that the larger diameter gear on the low clutch gear is tight to the center gear on the clutch shaft and place end of clutch shaft into bottom clutch bearing installed in Step 7 Mesh the low clutch gear with the low pinion gear as it is installed Place the shifting collar PN 1037 D 34 over the middle section of the clutch shaft Slide the high clutch gear PN 1037 D 41 over the two top clutch bearings If not already done insert the two remaining gear keys in the pinion gear shaft Install the high pinion gear PN 1037 D 12 over the top of the pinion gear shaft meshing with the high clutch gear as it is installed Fasten the lower shifter bushing PN 1037 C 21B to the bottom plate with four 3 8 NC x 1 1 4 hex bolts and 3 8 lock washers Place the shifting fork weldment PN 1037 D 27 up against the shifting collar roughly in its final position 3 16 Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Maintenance _ 20000 50K Tong Assembly Procedures Cont d 22 Install 25 cam followers PN 02 0107 in the top plate PN 101 1723 as shown in the illustrat
103. fety door system POSSIBLE PROBLEM Hyaraulic fluid viscosity too high SOLUTION Ensure hyaraulic fluid meets McCoy Drilling amp Completions specifications SOLUTION Ensure hyaraulic fluid is appropriate for climatic conditions especially during cold weather operation POSSIBLE PROBLEM By pass valve not functioning SOLUTION Check and repair Technical Manual Section Contents FARR AACCQOY MOVING CLOBAL ENERGY FORWARD MOVING GLOBAL ENERGY FORWARD FARR Troubleshooting KT20000 50K Tong D FAILURE OR DIFFICULTY OF TONG TO SHIFT POSSIBLE PROBLEM Bent broken shifter handle SOLUTION Replace shifter handle POSSIBLE PROBLEM Bent or broken shifter yoke SOLUTION Inspect and replace shifter yoke POSSIBLE PROBLEM Frozen or hard to move shifter handle SOLUTION Grease shifter shaft POSSIBLE PROBLEM Bent or broken shifter shaft SOLUTION Heplace POSSIBLE PROBLEM Locking nuts on shifting shaft have loosened and position of yoke has changed SOLUTION yoke and re tighten locking nuts POSSIBLE PROBLEM Shifting yoke has come loose from shifting shaft SOLUTION Inspect yoke and inspect for damage If free of damage replace on shaft and tighten locking nuts POSSIBLE PROBLEM Tong pops out of gear SOLUTION Ensure that detent ball amp spring assembly has been correctly set Technical Manual Section Contents 4 5 20000
104. fting handle down through the neutral detent to its lowest position Note that the high clutch gear or the low clutch gear may not be exactly aligned when shifting so the operator may need to bump the motor control handle slightly to turn the main clutch gear shaft and shifting collar into alignment This is most effective when applying a small amount of pressure on the gear shift lever in the direction you want to shift the tong ensuring the shifting collar will catch when the main clutch gear aligns with either the high or low clutch gear see Illustration 2 G 4 next page SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGEPLATE MAY RESULT IN CATASTROPHIC GEARTRAIN FAILURE FARR 4 GENERAL COMMENTS a Position rotary gear in contact with both idler gears when breaking out joints or collars where high torques 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 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 h
105. g Setup amp Operation 2 Tong Leveling The tong must be leveled side to side and front to rear before placing into service The following guidelines wil assist you when leveling your tong L lii Support tong by the chain sling Preset the positions of all four chains by rotating the turnbuckles on each chain hanger until the eye bolts are about half way engaged in the turnbuckle The turnbuckles can often be turned by hand if this is not the case use an adjustable wrench across the flats on the turnbuckle to turn it Rotating the turn buckles in one direction will cause the two eye bolts to extend away from the centre of the turnbuckle while rotating them in the other direction will cause the eye bolts to retract toward the centre of the turnbuckle Place a level axially side to side across the tong ensuring that it is parallel with the surface of the tong Equally rotate the two turnbuckles on one or the other side of the tong until the level indicates the tong is parallel for instance if you decide to adjust the left side hangers to adjust the axial leveling adjust the left side front and rear chains the same amount If there seems to be a large adjustment to make split the adjustment between the two sides make half the adjustment using the two chains on one side and the remaining adjustment using the two chains on the other side If all four chains were pre set there should not be a large adjustment to make Place a lev
106. generous lubrication of the geartrain including the gear hous 3 26 Technical Manual Section Contents AACCODY MOVING CLOBAL ENERGY FORWARD FARR Maintenance 20000 50K Tong 2 8 Re energize power unit and extend all hydraulic cylinders Inspect cylinder rods for signs of mechanical damage flaking or rust recommends that damaged cylinders be replaced 29 tong low gear for 5 minutes while monitoring pressurized seals and hyaraulic 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 3 0 caps are hot to the touch higher than approximately 50 replace the applicable bearings Likewise if the tong is making unusual noises check for damaged bearings see Maintenance Manual for all bearing locations Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or dis 3 1 B torted components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 3 2 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 s
107. h current model Amedmsmuchonfrprepenyalgnngdoors Addedinstuctonforadustmgshiterdetenore Added instruction tor adjusting safety doorswitch __ Revised and improved Assembly Procedures to reflect changes to tong model Added section Daily Inspection amp Maintenance Checklist Power Tong 80 8325 Added section Monthly Maintenance Checklist Power Tong Added section Daily Inspection amp Maintenance Checklist Power Unit Added section Tubular Connection Equipment De commissioning 3 0 3 29 Added section Tubular Connection Equipment He commissioning 3 0 3 32 Troubleshooting as Section 4 4 0 ALL Removed irrelevant troubleshooting procedures and revised remaining procedures Continued on next page Technical Manual Section Contents vii KT20000 50K Tong Summary Of Revisions Continued Section Page Description Of Revision OLD Section 6 Storage Recommendations has been removed See FEB2011 6 0 OLD ALL Section 3 L for preservation and storage instructions 0 50 AL Renumbered Parts amp Assemblies as Section 5 5 0 5 4 5 5 Revised Support Roller assembly images and part numbers to reflect changes to current tong model 5 U 9 0 20 7 Revised Door Pivot Roller assembly images and part numbers to refl
108. he rotary idler shafts total of four locations located on each side of the tong ILLUSTRATION 3 D 5 Rotary IDLER LUBRICATION 4 Pinion Idler Bearings Apply grease to these bearings through the grease fittings in the ends of the idler half shafts located on the bottom face of the tong MOVING CLOBAL ENERGY FORWARD ILLUSTRATION 3 D 5 Pinion IDLER LUBRICATION 3 4 Technical Manual Section Contents FARR AACCQOY MOVING GLOBAL ENERGY FORWARD FARR Maintenance 20000 50K Tong 5 Pinion Bearings Apply grease to these bearings through the grease fittings in the pinion bearing caps which are located on the top and bottom face of the tong four locations total ILLUSTRATION 3 0 6 LUBRICATION 6 Clutch Shaft Apply grease to these bearings through the grease fittings in the clutch bearing cap which 15 located at the bottom face of the tong Do not neglect to apply grease to the middle fitting which 15 inset in the bearing cap ILLUSTRATION 3 D 7 CLUTCH LUBRICATION Technical Manual Section Contents 3 5 20000 50K Tong Maintenance 7 Shifting Shaft Apply grease to the shifting shaft and shifting shaft bushings which may be accessed through the cover plate on the side of the tong Access shifter shaft and bushings through this panel ILLUsTRATION 3 D 8 SHIFTER COMPONENT LUBRICATION AccEss 8 Jaw Rollers App
109. heck 30 105 wi bar Check 1000 70 Standard Setting External Material Seal Material P Saina Buna V Viton ioe Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Hydraulic Components KT20000 50K Tong Capacity Pilot to open spring biased closed unbalanced 60 gpm 240 L min poppet logic element Functional Group Products Cartridges Corrosion Resistant Logic Element Unbalanced Poppet Moga Pilot to open Switching Element Spring biased closed External Pilot Port 3 LKHC pilot toured 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 farce generated at port 3 must be greater than the sum of the forces acting at port 1 and 2 plus the spring force for the valve to open NOTE The pilot area part 3 is 1 8 times the area at port 1 and 2 25 times the area at port 2 LOCATING SHOULDER 1 81 46 0 1 81 46 0 X CONTROL SHOWN IHSTALLED TATA CAVITY 1 T gt DE gt gt HEX DIMEMSION gt ACROSS FLATS 1 1 4 31 8 9 lt PILOT PORT in mr Technical Features o Because these
110. hnical Manual Section Contents KT20000 50K Tong For mone precise prediction or where axis thrusts are computer analysis can be provided by on receipt of machine duty SHAFT STRESS LIMIT The shaft stress limit in thi nomograph is based on the fatigue rating of shalt types and Infrequent loading abowe these limits ma be permitied consult 7 5 20000 50K Tong This nomograph enables the average volumetric efficiency crankcase rain leakage and winch slip sham creep speed be estimated v en 1 Pressure 3 Viscosity 4 Volumetric efficiens bar 3000 psi 25 r min 50 cSt 232 SUS 91 8 1 9 115 0 intimin 1 9 r min attempts fo rotate the molor against dosed ports may occur for example in winch applications 5 CIRCUIT AND APPLICATION NOTES STARTING TORQUES The starting shown on fhe graph on page 4 ane average nnd Minimum operating speeds are determined by bad conditions kad 7 6 Hydraulic Components drive elasticity ete For operation speeds below 3 nmin HIGH BACK PRESSURE When both inlet and outlet ports are pressure in one port must nol exceed 70 bar 1000 Consult Kawasaki on nBpplicatiore beyond this limit Note that high back pressures
111. hor Capacity 1000 2045 Ib 273 500 kg McCoy P N 85 0106XXXH Double Spring Hanger 3450 Ib 1570 kg 8 5 8 to 20 See Pg 3 6 REPLACEMENT FASTENERS BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC MUST BE GRADE 8 OR EQUIVALENT 1 3 20000 50 Tong Specifications Use an EP synthetic grease that meets or exceeds the following specifications Thickener NLGI consistency grade NLGI performance grade Penetration ASTM D 217 25 77 F 0 1 mm worked 60 strokes Dropping point FC 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 24 hours 25 77 F Leakage g lost ASTM D 4290 Four ball wear test mm scar ASTM D 2266 Fretting wear mg ASTM D 4170 Four ball EP kgf ASTM D 2596 Weld point Load wear index Timken OK load test lbs ASTM D 2509 Low temperature torque ASTM D 4693 40 40 F LT 37 pumpability g min 60 F 0 F 16 C 18 Copper corrosion ASTM D 4048 Disc brake wheel bearing specifications Ford ESA M1C 198A Chrysler MS 3701 Oil viscosity 40 104 F cSt 100 C 212 F cSt Flash point F C ASTM 92 Lithium Complex 2 GC LB 265 295 minimum 550 288 minimum 160 minimum 100 hr 300 hr 0 3 1 8 max pass 1 1 max 1 0 max 0 40 max 3 4 max 400 minimum 50 minimum 5
112. igh 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 MOVING GLOBAL ENERGY FORWARD THE SNAP BREAK METHOD IS HAZARDOUS TO RIG PERSONNEL AND EQUIPMENT Technical Manual Section Contents 2 17 KT20000 50K Tong Setup amp Operation H MAKING AND BREAKING CONNECTIONS THESE OPERATING PROCEDURES ASSUME THE USER HAS PROPERLY SET UP AND PRE PARED THE EQUIPMENT FOR OPERATION AS PER SECTIONS 2D 2E AND 2F OF THIS MANUAL Set up and prepare your equipment for operation as per Section 2 of this manual Refer to the following sections e 2 D Hydraulic Connections e 2 E Tong Jaw Installation e 2 F 1 Tong Rig up and Leveling Suspension e 2 F 2 Tong Rig up and Leveling Leveling Your tong and backup assembly should be properly suspended connected to a hydraulic power source and ready to make or break connections at this point 1 Making A Connection a Ensure hydraulic power supply to the tong is energized The master link on the rigid sling must be used to suspend the tong Do not suspend the tong from any other point M m Hs ns n A q ILLUSTRATION 2 H 1 Master LIFTING 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 configure
113. il the safety door mechanism can be repaired If the safety door is operating correctly cageplate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH BYPASSED OR MALFUNCTIONING SAFETY DOOR While rotating the cageplate ensure that the jaws properly cam If the jaws do not cam properly the brakebands 23 B need to be tightened Incremently adjust both the top and bottom brakebands 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 Technical Manual Section Contents 3 33 20000 50 KT20000 50K Tong Maintenance This page intentionally left blank AACCOY MOVING GLOBAL ENERGY FORWARD FARR Troubleshooting 20000 50K Tong Adequate maintenance and proper fluid selection is essential for minimizing hydraulic related failures All troubleshooting must be performed by a technician trained in hydraulic systems and familiar with the equipment design assembly and operation The following troubleshooting instructions are intended to be guidelines only Any faults not solved through the use of this guide should be referred to our engineering department for their evaluation and recommendations A TONG WILL NOT DEVELOP SUFFICIENT TORQUE 1 Malfunctioning relief valve on tong hydraulic circuit a POSSIBLE PROBLEM Relief pressure set too low SOLUTION Increase
114. ingle load cell anchor to the bridge bar main plate must be inspected com 3 3 pression load cell only If the integrity of the weld has been compromised tong must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam 3 4 Inspect load cell for damage signs of stress Check oil level in load cell and fill if necessary refer to technical d manual Section 7 or Section 8 While rotating the cageplate ensure that the jaws properly cam If the jaws do not cam properly the brakebands 35 need to be tightened Incremently adjust both the top and bottom brakebands EQUALLY until proper cam action 15 achieved Refer to the maintenance section of the manual for instructions on properly adjusting brakebands Perform a full functional test of the tong including if applicable backup components lift cylinder and float frame 3 6 m components Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used Test safety door feature if equipped Begin rotating the tong at low speed and open the tong door s If rotation does not immediately stop this is an indication that the safety door mechanism is not operaing correctly and the 3 tong must be removed from service until the mechani
115. ion below Secure with 7 8 UNF jam nuts and 7 8 lockwashers ILLUSTRATION 3 H 4 Cam FOLLOWER INSTALLATION TOP PLATE 23 Carefully remove all the support roller shafts ensuring the support roller assemblies do not shift position as you are doing 50 24 Insert three 3 8 x 1 1 2 hardened ground production dowel pins into the side body one at exact rear centre and one on either side of the front opening Position the top plate in its proper location use caution not to damage threads when align ing the top plate with the idler and support roller shafts Ensure the plate is aligned exactly horizontal to prevent binding on the dowel pins Use caution when aligning the previously installed cam followers with the rotary gear Tap plate securely into place with a rubber mallet 25 Secure the top plate with twenty seven 3 8 NC x 1 1 2 hex bolts two 3 8 NC x 1 1 4 hex bolts install these two above the removeable access panel and eight 3 8 NC x 1 hex socket cap screws Note that fasteners are NOT to be installed at the chain sling hanger locations circled in red in illustration 3 H 5 fal 2 qe us e FARR MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 3 H 5 PLATE FASTENER EXCLUSIONS Technical Manual Section Contents 3 17 KT20000 50K Tong Maintenance Assembly Procedures Cont d 26 Install ten horizontal cam follower guides PN 1037 A 49 to the top side of the top plate and secure
116. ir 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 Technical Manual Section Contents 3 1 KT20000 50K Tong Maintenance D 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 Cam Followers The cageplate cam followers are sealed units and do not require lubrication However the cageplate and rotary gear grooves in which the cam followers ride should be lightly greased When the cageplate is rotated as a unit the cam follow ers are exposed and can be greased Continue rotating the cageplate assembly until all cam followers top and bottom are greased see first illustration below Rotate cageplate assembly until all cam followers are greased IL
117. jaw using a hammer Replace the die tapping it into place if necessary and replace the keeper screws TONG RIG UP amp LEVELING 1 Suspension amp Restraint Suspend the tong 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 handing 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 or simply tied off in the derrick to form a dead line When using a dead line arrangement it is necessary to use a spring hanger assembly see specification page for recommended spring hanger This spring hanger compensates for the down ward movement of the casing as the thread is made up and imparts additional force to the suspension cable e single spring hanger typically applies 420 Ibs 191 kg to the suspension line for every inch of thread made up e 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 what has been supplied by McCoy
118. kout 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 see Illustration 2 H 8 ILLUSTRATION 2 H 8 SETTING BAckiNG Pin To BREAK OuT PosITION c Ensure the load cell and snub line are configured for break out operation The load cell must be transferred to the off driller s side the right hand side as seen from the rear of the tong and the snub line must be transferred to the ariller s side to perform break out operations d Open the tong doors see Illustration 2 H 4 FARR e Actuate the lift cylinder control valve to lift the assembly from the drill floor if necessary Pushing the valve toward the center of the tong will retract the lift cylinder to lift the assembly see illustration 2 H 3 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 equip ment RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR f Move the tong on to the tubing joint Use the lift cylinder to ensure the tong jaws are at the correct location above the connection joint g Firmly close the tong door against the latch post h Ensure tubing is roughly centered within the tong jaws rig personnel are required to stabilize the tong above the connection until the jaws have been cammed on to the pipe or
119. l 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 i is less than 350 psi 1 f Perform a visual inspection of pressurized hydraulic lines Document and correct any hydraulic fluid leaks 1 8 C Perform a full functional test of the tong Report and correct any hydraulic leaks from the hydraulic valve bank or from any hyaraulic cylinders that are used Perform a visual inspection of the load cell If using a tension load cell replace any cracked broken or distorted 19 components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 2 0 If applicable inspect load 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 com 2 1 pression load cell only If the integrity of the weld has been compromised tong must be removed from service 5 until the weld is repaired The load cell beam will need to be disconnected and removed so 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 equipped Open the tong door s and attempt to rotate the cageplate at low sp
120. ll the bear ing cap in the top plate of the tong using four 5 8 lockwashers and four 5 8 NC x 1 1 2 hex cap screws Note that the flat on the bearing cap faces toward the rear of the tong Place the motor thrust washer PN 101 3289 over the top of the splined clutch shaft followed by the motor spacer PN 1037 0 385 Install the motor mount 1037 0 7 ensuring that flat on the motor mount is oriented toward the pinion bearing cap and the notch in the motor mount is oriented to accomodate the top shifter bushing Secure with five 3 4 NC x 1 1 4 hex socket head cap screws and 3 4 lockwashers Install hydraulic motor PN 87 0210B Do not neglect to install the upper motor spacer PN 1037 0 385 between the top of the clutch shaft and the motor as per the previous step Use caution to make sure the splines on the motor shaft are properly aligned with the grooves in the clutch shaft Secure the motor to the motor mount using four 3 4 NC x 2 1 2 hex bolts and S 4 lockwashers plus the shifter handle pivot lug weldment PN 101 5114 and one 3 4 UNC x 2 3 4 hex socket head cap screw and 3 4 lockwasher at the hole location directly adjacent to the top shifter lug weldment ILLUSTRATION 3 H 8 SHIFTER Pivot Luc WELDMENT INSTALLATION Guide the shifting shaft PN 1037 C 20A through the top shifter bushing and secure to shifting fork weldment using two 7 8 UNF hex jam nuts Once the shifting fork has been secured plac
121. ly Spring Centered Clamp the of the comtrol spool in a sof jawed vise Apply Parker ube M tbe spei seal Fig 1 item 8 and slide it onto tbe of the away from clevia Slide on the back up ring Fig 1 item 7 and retamer plate Firg 1 item 6 Position these onto the spool so that they do mol interior with the spool operator mechanasm dunng assemhlsy Do not allow the O rimg 1 corse sn contact with the sharp edge of the spool notches Step 2 Attach Spring Guides and Spring Apply 2 3 drops af Loctite 2627 or equivalent anaerobic adhesive mear the middle of the female threads in the spool Assemble the spring guides Fig 2 16 spring Fre 2 15 and stripper bolt Fig 2 item 14 onto the spool Reverse od Siep 7 Torque the stripper bolt 173 m 74 in CAUTION Care must be taken to ensure that the spring retainer is not pinched under the shoulder bolt during assembly This cam result in burrs that may cause spool binding Check binding by corpressimg the and guides or by rotating the spring guide nearest the bowsing Lightly coat sprimg with high sempesarure grease rustimg Set the spool assembly asede and bet cure for of 1 hear Aficr curing test the stripper bolt io make certam it can withsiand 125 in Ibs of
122. ly grease to the jaw rollers through the grease fitting at the end of the jaw roller pin r 4 A 112 gm A i x d 4 o ha x d od i 1 Se 1 f f a KD 4 E AACCODY MOVING CLOBAL ENERGY FORWARD ILLUSTRATION 3 0 9 Jaw ROLLER LUBRICATION Farr recommends that a liberal coating of grease be applied to the cam surface of the rotary drive gear prior to jaw installation Also the clutch inspection plate should periodically be removed and a liberal coating of grease applied to the clutch drive gears and shifting shaft 3 6 Technical Manual Section Contents FARR Maintenance 20000 50K Tong 9 DOOR STOP CYLINDER Periodically disassemble the door stop cylinders and coat the spring and cylinder with a general purpose lubricating oil ILLUSTRATION 3 D 10 Door CYLINDER E ADJUSTMENTS 1 Brakeband Adjustments 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
123. mal torque of 34 im lbs 2 in lbs FARR Step 3 Back cap Install the back cap wing the rwo long screws Fig 1 4 Tighten to a Final torque of 14 Ibs He a in Ibs Caution Excessive torque will damage the hack cap ears MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 7 23 KT20000 50K Tong Valve Assembly Instructions Step 4 Install Transition Check pect transition check components for cleanlimess Install chock poppet Fig 1 iem 13 imo the transition check cavity Align the check spring Fig item 12 bo the poppet then carefully place the check cap Fig 1 dem over the poppet and spring Taming by hand engage several threads Tighten to a final of 75 The Step 5 Relief Valves Reta all relief valves to their proper possiions and torque 10 75 1 new section seals Place section seals Fig ibems l amp 2 or items amp 1 in the proper grooves Make seals stay an their grooves dunng asseris Step 6 Install Tie Bolts Slade the the bolts through the inlet casting If eap screws are used piace a washer on the cap screw prior to lation Place salve sections on the bols in their proper sequence see Siep page 4 Teaming by hard engxge several threads im seres assembly assemble nut and washer to either end ofthe stud aed follow above i
124. mation contained in this technical documenta tion is subject to change without notice If you feel this document does not meet your needs please contact our sales office for the most current available documentation for your product Section Page 7 Description Of Revision __ mproved story symboiogy throughout ee Moved Section 2 Tong Assembly to the Maintenance section Renum bered Setup amp Operation as Section 2 Added Sling Load Bearing Safety section o Renamed Jaw Removal Installation to Jaw Removal amp Die Replace ment Revised procedure TC 29 ea Added section TonpRipUb amp levin O P 26 Replaced valve operation images reflect current tong modol o 727 20 218 Added section Making and Breaking Connections 90 AL Renumbered Maintenance as Section 3 T 7 Added section General Maintenance Safety Practices ________ or Acted section Preventive Mantenan 52 Replaced support roler lubrication images reflect current tong model P Replaced shiting shaft ubrication image reflect current tong model TdT Added Jaw Roller lubrication Td 87 Added Door Cylinder lubrication instruction 80 370 Replaced Brakeband Adjustment image to match current model Replaced Door Latch Adjustment image to matc
125. mp Maintenance 3 23 Monthly Tong Inspection amp Maintenance Checklist 3 25 Daily Power Unit Inspection amp Maintenance 3 28 De commissioning amp Storage PrODCeQures i e as ba a RO edo CR RR ao e iod io o ba 3 29 COMMMUSSIONING 3 194 3 32 TIOUDICSNOGUNG gt Gace Section 4 Tong Will Not Develop Sufficient 4 1 TO GIO FDE Tc m 4 3 Tono RO TOO ai in a 4 4 Faure Or Difliculiy OF Tong TO SUN s a asics dii e p rue caedi iil accio d dc 4 5 MT _ _ _ 4 6 ASSCIMDICS Ang Pans Section 5 Gaaran n 5 2 Support Roller 2a deo eerte ire rice sc VS Dc a SR nic 5 4 Door Fivot Roller Assembly PEE 5 6 qos A EE 5 8 5 10 FONAS I 5 12 CIMICR ASSEM a pde X4 dr Roa pde a 5 14 SMO _ Gumi ips 5 16 Tono Bouy ASSOIDIV
126. n of parallel tandem and series circuitry in single bank The internal conng of each valve section determines its circuitry and the number of gasket seals required All sections with optional features such as port relief valves crossover relief valves and anti cavitation checks are dimensionally larger when measured from the top of the port to the bottom of the housing These are referred to as hi boy sections Those without work port options can use the low profile castings which are called lo boy sections Technical Manual Section Contents REPLACEMENT PARTS The illustrations and instructions in this manual apply only to the V A VG series assemblies subassemblies and components valve components except for spools and housings are available as replacement parts or subassemblies Spools hone fitted to their individual housings so damage to either of these components means the entire section must be replaced We recommend that you use only genuine VANG series replacement parts in your service program Manufactured to the same exacting tolerances and quality controls as the original equipment genuine replacement pans may help preven premature component failure and costly downtime Service parts and assemblies are available through vour original equipment dealer any authorized distributor MAINTENANCE Valves are often used in hazardous environments Inspect them frequently for
127. n records of the most recent periodic inspection shall be maintained and shall include the condition of the sling 2 Proper Use Of Load Bearing Devices Whenever any load bearing device is used the following practices shall be observed Load bearing devices that are damaged or defective shall not be used Slings shall not be shortened with knots or bolts or other makeshift devices Sling legs shall not be kinked Load bearing devices shall not be loaded in excess of their rated capacities Slings shall be securely attached to their load Load bearing devices shall be protected from snagging and shall not be further obstructed by any object Suspended loads shall be kept clear of all obstruction employees shall be kept clear of loads about to be lifted and of suspended loads Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load Shock loading is prohibited Do not stand directly under a load during lifting 3 Storage Of Load Bearing Devices Proper storage of out of service load bearing devices is important to ensure full integrity of the device once it is returned to service Farr recommends observing the following practices Wipe off all excess grease Use a solvent based cleaner on rags to wipe all external surfaces to remove residual grease or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove
128. nd remove the two 1 2 hex bolts securing the valve assembly to the support post weldments Lift the hydraulic section away from the tong Remove the four tong hangers Remove the torque gauge mount assembly from the rear top plate of the tong Remove the top and bottom brakeband assemblies DO Remove tong doors Remove the door cylinders i Remove the thin nylock nuts and large flatwashers from the top of the two door pivot roller shafts ili Ensure each door assembly is well supported when performing this next step Use a soft alloy material e g brass rod etc to lightly tap the shaft down through the support roller assembly until it drops out Use caution that the threads on the ends of the support roller shafts are not damaged 9 Disconnect the shifting handle from the shifting shaft and shifting lug 10 Remove the motor from the motor mount Staffa motors are secured with five 3 4 bolts while Rineer motors are secured with six 5 8 bolts Inspect the splined motor shaft for clashing or spline damage 11 Hemove the motor mount by removing the five socket head cap screws The motor mount can be lifted out of place Take care not to lose the two position dowels one or both may come off with the mount 12 Remove the access panel on the body side adjacent to shifter assembly Back off the detent adjustment bolt on the top shifter bushing Remove the 7 8 jam nut from the shifting shaft to loosen the shifting fork
129. nder 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pres 2 sure 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 pres sure 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 TECHNICICAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INJURIES 3 Perform an initial wash of tong order to remove the majority of dirt and grease build up Ensure adequate con tainment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease 4 Remove the access panel on side of tong directly adjacent to the shifter mechanism Use a flashlight to perform a visual inspection of the geartrain 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 overhauled to avoid further damage Replace access panel when inspection is complete
130. ng with the opening of the rotary gear facing the geartrain 14 De energize the power unit and perform a third generous lubrication of the geartrain including the gear housing 1 5 Energize power unit and rotate tong for a final time one minute one direction stop and reverse the direction of rotation for another minute this time ending with the rotary gear in the open throat position 1 6 Extend 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 If you are using a frame mounted tool the tong must be lowered onto the backup in order to remove the risk of sud den and catastrophic movement when pressure is removed from the float cylinders Cover the top of the backup with protective cloth to protect the paint on the backup Place two wooden beams across the top of the tong ensuring that 1 7 the beams have a minimum size of 4 x 4 x the width of the tong Cover the tops of wooden beams with more protective cloth to prevent paint damage to the tong When lowering the tong onto the beams ensure that the beams come into flat contact with the bottom of the tong away from bearing caps brakebands 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 S
131. nstructions Torque the tie bolts im a cnossscorner pattern Tie Bolt Torque Values 20 29 ft Ibs 348 in Ibs VG20 42 ft Ibs 504 in Ibs VA35 34 ft ibs 408 in Iba VG35 75 ft ibs 900 in Ibs 150 ft lbs 1800 in Ibs Hydraulic Components 7 24 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components 20000 50K Tong Troubleshooting TROUBLE PROBABLE CAUSE REMEDY Pinched blown or missing Replace section seal section seal Chl leaks between sections Stud fasteners nol t comedy Replace section seals and re torque torqued Mounting plate not level Loosen mounting bolts and shim as required Contamination burrs on seal Clean seal groove replace section Qil leaks at either end Over pressurized tank core Correct high back pressure of spool comdihon LLL Broken centering spring Replace centering spring Spring centered spools Misalignment of operating Check linkage for retum to neutral linkage mechanical binding Foreign particles in system Clean valve and system _ Cylinder leaking or wor Check cylinder repair n Load will not hold Port relief valve not holding Remove and clean or replace Spool or housing scored or Replace section worn excessively Load drops when spool Dirt or foreign particles Disassemble clean moved fr
132. ntainers Ensure that these items are not crushed nicked or otherwise damaged Do not perform any further actions or maintenance while tong is connected to any hydraulic power supply Farr recommends that all hydraulic lines are fully disconnected and residual hydraulic pressure is bled off Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid DEPRESSURIZATION PROCEDURE IN PREPARATION FoR STORAGE 1 Rotate the tong so that the opening in the rotary gear faces the geartrain towards the rear of the tong Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder if equipped If mounted in a frame retract the float cylinders if equipped 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter 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 TECHNICICAN AND THAT
133. om neutral lodged between check valve amp reassemble poppet and seat Scored or sticking check Replace poppet valve popp Defective cylinder or molor Repair or replace Low reservoir oil level Add oil to specifications Nomoto sow Cran rl system Check Te operation Relief valve not properly set Check pressure setting 3 Relief valve poppet or Replace relief seat scored amp sticking open valve Valve spool not shifted Check spool linkage to full stroke travel Technical Manual Section Contents 7 25 KT20000 50K Tong Hydraulic Components i Capacity 3 1 pilot ratio standard capacity counterbalance 15 gpm 60 L min valve Functional Group Mody Products Cartridges Counterbalance J Port Nen vented Standard 3 1 Pilt CBCA Ratio Product Description Counterbalance valves with pilot assisi ane meant to control overrunnimng load check valve allows free flow from direcional valve port 2 to the _ load port 1 while dired acbng pilol assisled rebef valve controls flow from port 1 to port 2 Pilot assist at port 3 lowers the effective setting of the relief vale at determined by the pilot ratio i Other names for this valve include motion control valve and over center valve LOCATING SHOULDER L 1 97 50 0 1 38 35 1 C 229158 2 INSTALLED L CONTROL SHOWN T 11A CAVITY HEX DIMENSION ACROSS FLATS 7 6 22 2 2 PILOT O
134. op and bottom cageplates ILLUSTRATION 3 H 9 Top amp Bottom CAGEPLATE INSTALLATION 40 Press the four door pivot shoulder bushings PN 101 0110 into the RH door weldment PN 101 1703 and the LH door weldment PN 101 1697 The bushings are installed so that the shoulders are towards the inside of the weldments 41 Install latch weldment PN 101 1570 onto RH door assembly see Pp 5 32 5 33 Install two latch springs between the latch weldment and the door weldment and secure latch to RH door using the door latch shaft PN 1037 C 200 and two latch cam plates PN 1037 C 151 Secure each latch cam plate to the top and bottom door plates with one 3 8 UNC x 1 1 4 hex bolt and 3 8 lockwasher 42 If not already done install the door pivot roller components that fit between the two body plates i e everything except the roller shafts nuts washers and door stop spacers 43 Install the threaded door cylinder posts 101 0446 one on each side of the bottom plate adjacent to the brakeband lug weldments on the bottom plate ILLUSTRATION 3 H 10 Door CYLINDER Post INSTALLATION 3 20 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR Maintenance 20000 50K Tong Assembly Procedures Cont d 44 45 46 47 48 49 FARR AACCOY MOVING GLOBAL ENERGY FORWARD 50 51 Thread two 1 2 UNC x 1 1 4 hex socket head set screws into e
135. or to lubricating when cleaning tong parts in cold weather Technical Manual Section Contents 2 25 20000 50 KT20000 50K Tong This page intentionally left blank FARR AACCOY MOVING GLOBAL ENERGY FORWARD Maintenance 20000 50K Tong McCoy Completions amp Drilling recognizes that minor on site repairs and modifications are required to maintain peak operating condi tion 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 replacement of door cylinders replacement of fasteners Any replaced component must be an identical component supplied by McCoy Completions amp Drilling Replaced fasteners must be Grade 8 or equivalent or whatever fastener is specified by McCoy A GENERAL MAINTENANCE SAFETY PRACTICES The practices identified here are intended as a guideline All personnel are responsible for performing their tasks in a manner that ensures worker equipment and environmental safety and may require taking additional steps that are not identified in this section Equipment maintenance shall be performed only by designated qualified maintenance personnel Wear approved eyewear 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
136. ore proceeding Wipe all excess grease from outside of equipment Replace the access door panel Use a solvent based cleaner on 1 9 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 2 0 Farr recommends that chain slings be removed and stored separately Rigid slings and other rigid suspension de vices may remain in place 2 1 B Apply grease or heavy oil to all exposed cylinder rods 2 2 C Farr recommends that an anti corrosive agent such as 506 be applied to all external surfaces EXCEPT inder 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 perature 2 4 Wrap entire assembly in 100 gauge 1 mil corrosion inhibiting wrap at least 3 layers thick Attempt to ensure that 3 30 the tool is well sealed within the wrapping including the bottom Maintenance Technical Manual Section Contents AACCODY MOVING CLOBAL ENERGY FORWARD FARR Maintenance KT20000 50K Tong If possible store in a sealed climate controlled environment If isolated storage
137. orrect if necessary 8 Check that the supply and return lines on the hydraulic fluid reservoir are both fully open 9 Apply grease to any grease fittings that your power unit may have Apply grease to each fitting until grease is vis ibly displaced from bearing or as recommended by your power unit manual 1 0 Ensure supply and return connections at power unit and at equipment use are fully made FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE 1 1 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 3 28 Technical Manual Section Contents AACCODY MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Maintenance KT20000 50K Tong L TUBULAR CONNECTION EQUIPMENT DE COMMISSIONING PROCEDURE Perform the following decommisioning 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 co
138. r See Step 1 scala Fig 1 8 and back up rings Fig nem 7 should be Step 6 Transition Check The trareition check is located an the bottom censer ot the work section housing Carefully clamp the work secibon im a vise with ports down Do mot clamp on the machimed surface Remove ihe check valve cap Fig amd its O nng seal Fag 1 item 11 Discard the seal Remove the check spring Fig 1 12 1 and check valve poppe Fig 1 nen 131 NOTE Only cylinder work sections ports blocked in newtrali have a transition check Motor sections have only cap plug 7 19 KT20000 50K Tong Hydraulic Components Valve Disassembly Instructions Spool Disassembly Spring Centered Spool The spring should net be removed from the spool unless these parts need to be replaced Once the spool ia free of tbe work sectson housing 1t must be handled carefully to avoid damage Place the spool vertically in seft 4awed vise clamping on the flat spool clevis and remove the stripper bolt Fig inem 14 with wrench Lighily tap ithe stripper boh with a hammer and a punch help break the adhesive Cautious application of heat may be required to free the stripper bolt since an araerobuc thread as used daring its assembly CAUTION Too much heat may distort the spool As the stripper bolt threads disengage the spring Fig 2 15 and spring guid
139. re intended for use corrosme environments with all axtemal components manufactured in stainless steel or intemal working 20000 50K Tong FARR AACCOY MOVING GLOBAL ENERGY FORWARD components remain the same as the Standard valves s Incorporates the Sun floating style construction to eliminate the effects of imenal parts binding due excessive installation torque andor cavity cartridge machining variations Technical Data U S Units Units EE valve Hex SiL ou Technical Manual Section Contents 7 27 KT20000 50K Tong Free Flow and Piloted Open Pressure Drop Hydraulic Components Typical Relief Characteristics Free Flow and Piloted Open Pressure Drop Option Selection Preferred Options Control L Standard Screw Adjustment Standard Options C Tamper Resistant Factory cet 7 28 CBCA L H N R Functional Setting Range H 1000 4000 psi wi 25 Check 70 280 bar wil bar Check SEI psi 210 Standard Setting 1000 4000 wd pi Check 70 280 wi 3 Check 3000 210 5randand B 300 1500 wd ps Check 30 105 Bar bar Check 1000 70 bar 5iandand Setting 1 400 1500 C
140. reduce the effective torque output of thi molor BOOST PRESSURE When operating a molor the outlet pressure should equal or exceed fe crankcase pressure If pumping occurs ovenrunning Keds then a posite pressure P is required at the motor intel ports Calculaie P according to 1 C bear Pips 145 psi Technical Manual Section Contents Port D value F2 Dear 1500 Desi 103 Dear 10 000 690 503 504 FM3 few rate of needed for the make up system can be estimated from the crankcase leakage figure see Volumetic Efficiency graph Allowance should be made for other system losses and also dor fair wear nnd tear during the lite of the motor pump and other system components COOLING FLOW Operation within the continuous ratings does not require any additional cooling continuous up the intermmitient ratings additional cooling may be required This be introduced through the spare crankcase drain hole of iri speci cases through the AACCQOY MOVING CLOBAL ENERGY FORWARD FARR AACCOY MOVING GLOBAL ENERGY FORWARD FARR Hydraulic Components ixcesd 3 5 bar S0 On installations with long drain lines a relel valve is recommended b prevent ger pressurizing the seal d s L __ cr ute
141. residual solvent Farr recommends that an anti corrosive agent such as Tectyl 506 be applied to all external surfaces Refer to manu facturer 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 Store in a clean dry location When returning to service note that a full inspection of the device must be performed Technical Manual Section Contents 2 3 KT20000 50K Tong Setup amp Operation 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 B MAJOR COMPONENT IDENTIFICATION 24 ILLUSTRATION 2 B 1 COMPONENT IDENTIFICATION 01 Mem i O Chain Sling Assembly Cageplate Assembly Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR FARR AACCOY MOVING GLOBAL ENERGY FORWARD Setup amp Operation 20000 50K Tong MAJOR COMPONENT IDENTIFICATION Cont d ILLUSTRATION 2 B 3 COMPONENT IDENTIFICATION 03 Mem Description _ 6 Manual shift Assembly 8 StaffaHMB 80 or Rineer GA125 Hydraulic Motor Torque Gauge Mounting Plate Motor Mount Technical Manual Section Contents 2 5 KT20000 50K Tong Setup amp Operation MAJOR COMPONENT IDENTIFICA
142. riginating tom liquid borne noise can be further attenuated by providing nitur line back pressune of 2 to 5 bar to 70 10 POLAR MOMENT OF INERTIA Typical 0 06 kg 210 Ib in 11 MASS Approx models 144 317 11 INSTALLATION DATA GENERAL Spigot motor should be located by the mounting spigot on a flat robust using comecthy bolts The diametal clearance between te mosor amp pigot and He mounting must not paced 0 15 mm 0 0006 im the application incurs shock loading be used one fitted bolt Bolt torque recommended torque wrench settings for the mounting bolts are 20 bots 407514 Nm 30010 Ibi Wa bolts 393214 Mm 290 10 Ib Shaf coupling Where the motor is coupled qo shaft hving independent bearings the shafts must be abgaed to within 0 13 mm 0 005 in Technical Manual Section Contents KT20000 50K Tong from a position above the horizontal centre line af the motor Axis vertical shan up Mkia dean port Gua rain pori 547 186 0 45 bor 45 pai An Ga ESPF drain port i amp provided when the ghan vertically upwards designeador given after the shot type letter in position El of the model code This additonal drain should connechbed imo the maln motor casing drain line downstream ol 0 35
143. rnal mechanism of gauge is damaged Gauge indication too low Insufficient hydraulic fluid enub line not at right angle to tong handle Gauge internal mechanism damaged Erratic or sluggish gauge indication Pointer rubbing glass or dial Insufficient hydraulic fluid Dirty gauge movement Improper pointer damper adjustment Gauge internal mechanism damaged Technical Manual Section Contents FARR AACCQOY MOVING CLOBAL ENERGY FORWARD MOVING GLOBAL ENERGY FORWARD FARR Torque Measurement KT20000 50K Tong B PERIODIC INSPECTION AND MAINTENANCE 1 Inspection Tong Torque Systems are built to give years of trouble free service with minimum maintenance Periodic inspections of the load cell and 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 via the filling connection at the top of the indicating gauge Recharging must only be performed when there is no load on the load cell a Connect hand pump to filling connection on gauge b Fill hand pump bowl with W15 16 hydraulic fluid and pump fluid into the system until the piston rod on the load cell extends no more than 1 2 from the body Loosen vent screw on load cell body to permit trapped air to escape during loading MAINTAIN GREATER THAN HALF FULL FLUID LE
144. rtification of lifting equipment ensure that the most recent test date falls within the past year Perform recertification if necessary Perform a liberal lubrication of the equipment refer to Maintenance section of manual to determine lubrication 5 points Generously fill the geartrain housing with grease through the access panel and also through the opening in the rotary gear 6 Connect equipment a hydraulic power unit Ensure lines are fully made to prevent equipment damage from excessive back pressure Do not neglect to connect motor FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE f B Energize power unit 8 Ensure that supply pressure is at or above the tong s specified operating pressure and that the return pressure is x less than 350 psi 9 Perform a thorough inspection of pressurized hydraulic lines and fittings Any leaking hydraulic fluid lines or fittings must replaced before the equipment is returned to service 1 0 Perform a thorough inspection of all seals Any seal that is leaking or weeping must replaced before equip ment 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 1 1 begins to leak while tong is rotating it must be replaced before the equipment is returned
145. s 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 P TONG LIFT ILLUSTRATION 2 6 1 Moron CONTROL LIFT CYLINDER This is a proportional 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 TONG LIFT Hit LO SHIFT ILLUSTRATION 2 6 2 CYLINDER CONTROL 2 16 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation _ 20000 50K Tong 3 SHIFTING GEARS The shifting shaft has three detent positions identifying the low speed high torque position the neutral or free spinning position and the high speed low torque position The detent strength may be adjusted by releasing the locknut on the detent tube and increasing or relaxing pressure on the detent spring Ensure the locknut is tightened once the desired detent pressure has been set To shift to the high speed gear move the shifting handle upward from neutral position To shift to the low speed gear move the shi
146. sm is repaired Repeat test while operating the tong the opposite direction If the safety door is operating correctly cageplate 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 38 and chain slings EXCEPT cylinder rods jaw rollers and rotary gear camming surfaces Refer to manufacturer data sheets for proper application and safety information FARR Once all of the above maintenance checklist items have been satisfactorily completed the tool may be returned to service AACCOY MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 3 27 20000 50K Tong Maintenance K 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 mainentance especially lubrication is essential in order to ensure that your equipment always meets specifications and to prevent cata strophic 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
147. sure Drop Full Open Pressure Drop Option Selection LKHC X DWN Preferred Options External Material Seal Control Cracking Pressure Material Standard Options X Mot Adjustable M Buna N V Viton 7 30 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR
148. switch by adjusting the mounting plate Remove the safety door switch guard Slightly loosen the 3 8 mounting bolts on the mounting block and use a hammer to lightly tap the block toward the cam weld ment Perform each adjustment in very small increments before re tightening the mounting bolts and testing switch function see Illustration 3 E 6 Technical Manual Section Contents Maintenance MOVING CLOBAL ENERGY FORWARD FARR Maintenance 20000 50K Tong Safety Door Switch Adjustment Continued I bli ILLUSTRATION 3 E 6 SHIFTER DETENT ADJUSTMENT 10 Repeat steps 5 through 9 as many times as necessary to properly adjust the safety door switch Once the switch has been satisfactorally adjusted the tong my be returned to service 11 If the adjustment limit is reached without proper safety door function being reestablished further maintenance is required inspect safety door switch plunger and cam weldments If either has been worn to the extent that adjustment of the switch position cannot compensate for the wear and tear replacement of the cam weldment or switch or both is necessary if mechanical parts of the safety door switch appear to be in satisfactory condition and safety door function still cannot be reestablished troubleshooting of the hydraulic system is required Perform necessary repairs before returning the tong to service FARR DO NOT PLACE A TONG
149. tation Reverse the rotation control valve to release the tong jaws from the tubing see lllustration 2 H 6 FARR MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 2 H 6 Motor ConTRoL RELEASING JAWS Technical Manual Section Contents 2 21 KT20000 50K Tong Setup amp Operation Making A Connection Continued o When tong jaws are free align the opening in the rotary gear with the mouth of the tong and open the tong doors to free the tong from the arill string Note that rig personnel may be required to stabilize the tong as it completely releases from the drill string Guide the tong away from the string and use the lift cylinder control to lower it to the drill floor if desired ILLUSTRATION 2 H 7 Lirr CYLINDER CONTROL LOWER p Repeat steps through until the desired number of connections are made up 2 22 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation KT20000 50K Tong 2 Breaking A Connection YOUR TONG SHOULD BE PROPERLY SUSPENDED CONNECTED TO A HYDRAULIC POWER SOURCE AND READY TO BREAK CONNECTIONS 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 from any other point See Illustration 2 H 1 b Set the backing for breakout operation Lift up on the backing pin and rotate it to the brea
150. thin the tong jaws rig personnel are required to stabilize the tong above the connection until the jaws have been cammed on to the pipe or casing Begin rotation with the tong in high gear high speed low torque See Section G 3 to properly set the tong to high gear Do not shift gears while the tong is rotating SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGEPLATE MAY RESULT IN CATASTROPHIC GEARTRAIN FAILURE Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation 20000 50K Tong Making A Connection Continued Push the motor control valve toward the tong to rotate the cageplate in the make up direction TONG LIFT LO SHIFT ILLUSTRATION 2 H 5 Motor ContTRoL MAKE UP I When the tong jaws cam on to the tubing push the rotation control handle all the way in to thread the connection together at high speed As the joint becomes fully made up the increasing torque demand will stall the motor and displayed torque will increase m Stop rotation and set motor to low speed and shift to low gear low speed high torque See Section 2 G 3 for instruc tions for shifting to low gear This will enable the tong to produce adequate torque for making up the joint to specifica tion n Push the rotation control handle all the way in to complete the connection at low speed high torque Observe the torque gauge when the specified make up torque is reached stop ro
151. tomer Technical Manual Section Contents KT20000 50K Tong 20000 50 4 PERFORMANCE DATA data is valid Tor Statia HMIBOSO motors fully rum in and operating with petroleum See separate table dor possum and speed limits when using fluids Leakage values art ad fluid viscosity of 50 232 SUS Geometric dispbacemer nr 1344 82 ben bi i n 1 01 Max continuous speed 300 150 Max continuus e pressure pesi 250 3525 250 3525 Max pressuri bar 293 A2 500 293 42505 A nes beer dialects ae rte sped Ger e See Hang inpor fae page LIMITS FOR FIRE RESISTANT FLUIDS Continuous Iriermitient r min 103 15000 138 2000 for petroleum HFB 60 40 water in oll 20 _ 1720500 Aa for oil PE water glycol 103 1500 138 2000 pelokum oil phosphate ester 250 x25 2934250 As for petrolirum oil Hydraulic Components CONTINUOUS RATING For continuous dut the motor must be operating within each of the maximum INTERMITTENT RATING Operation within the intermitlent power rating up te the maximum continuous permitted on a 15 duty basis for periods up to 5 minutes maximam INTERMITTENT PRE 293 bar 42540 psi 5 allowable on the following b
152. ulating the force on the snub line and selection of the snub line is the complete responsibility of the customer 2 12 Technical Manual Section Contents AACCQOY MOVING CLOBAL ENERGY FORWARD FARR Setup amp Operation 20000 50K Tong Suspension amp Restraint Cont d Snub lines must be securely connected to the rear of the tong and tied off to a suitable anchor One snub line must be secured to the load cell which 15 then secured to the rear of the tong The side of the tong the load cell connects to 15 dependant upon whether make up or break out activities are underway To ensure accurate torque measurement the torque measurement line must be connected perpendicular to the lengthwise axis of the tong and perpendicular to the hang line see illustrations 2 F 1 and 2 F 2 Connect the second snub line on the opposite side of the load cell perpendicu lar to the lengthwise axis of the tong and perpendicular to the vertical MCCOY DRILLING amp COMPLETIONS ACCEPTS NO RESPONSIBILITY FOR DESIGNING AND SELECTING AN ADEQUATE SUSPENSION AND RESTRAINT SYSTEM FOR YOUR DRILLING EQUIPMENT ALL SELECTED FASTENERS SHACKLES CLAMPS ETC USED FOR CONSTRUCTING THE SUSPENSION AND SNUB LINES MUST BE RATED FOR THE CALCULATED FORCES 90 FARR MOVING GLOBAL ENERGY FORWARD ILLUSTRATION 2 F 2 TONG SUSPENSION RELATIVE To VERTICAL CENTRE Technical Manual Section Contents 2 13 KT20000 50K Ton
153. urn Counter Encoder Pp 5 8 5 9 Assembly Support Roller Assembly Pp 5 4 5 5 Technical Manual Section Contents E o _ 2 Eu 1037 D 46 5 3 Support Roller KT20000 50K Tong dev SNOILA IdINOO ONITIIeC AO 3N3 ONIAOW NODWN Technical Manual Section Contents AACCOY MOVING CLOBAL ENERGY FORWARD FARR Support Roller A Part Part C Part Part Part Part Part art Support Roller Spacer Support Roller Part Roller Bearing Spacer Support Roller Bearing 20000 50K Tong 1 UNS Thin Nylock Nut 09 5627 Technical Manual Section Contents 5 5 Door Pivot Roller KT20000 50 Tong dev SNOILA IdINOO ONITIIeC AO 3N3 ONIAOW NODWN Technical Manual Section Contents 5 6 Door Pivot Roller KT20000 50K Tong FARR 1 UNS Thin Nylock Nut 09 5627 Roller Bearing Spacer MOVING GLOBAL ENERGY FORWARD Technical Manual Section Contents 5 7 KT20000 50K Tong Rotary Idler Assembly Technical Manual Section Contents FORWARD MOVING GLOBAL ENERGY FARR FARR AACCOY MOVING CLOBAL ENERGY FORWARD Rotary Idler Assembly KT20000 50K Tong Counter Encoder Turn Counter Encoder Spacer 02 0009 Technical Manual Section Contents 5 9 KT20000 50K
154. valves are unbalanced e These valves are pressure responsive operation i amp pressure dependant at all three ports therefore is z Opening and closing of the poppet are essential to consider all aspects of functions of the force balances on three system operation through completa areas 1 Port 1 100 Port 2 80 cycle Pressure changes at any one and 3 180 pori may cause a valve to switch from a T clased 1o open position or vice versa All possible pressure changes in lt tha complate circuit must be considered 5 to assure safe functional system 5 design 9 9 Z gt O gt Technical Manual Section Contents 7 29 KT20000 50K Tong Hydraulic Components These valves have positive seals s steel cartridge options or between port 3 and port 2 are Intended for use within corrosive environments with all extemal components manufactured in stainless steel or titanium Internal working components remain the same as the standard valvas Incorporates the Sun floating style construction to eliminate the effects of internal parts binding due to excessive installation torque and or cavitylcartridga machining variabons Technical Data Metric Units Area Ratio to 2 oeratinc Seres from Gavi 5 Patent amp Valve Hex Size m 990 1 017006 Full Open Pres
155. ve Therslom ho gum of the pressures in the circula can Ine circuit main relief valve Parallel Circuits Parallel circuits are the mast common or mobile equipment because more than one function can be operated and al random two functions are fully operated al the same te one with the lightest load will asser priority because the fluid will take the path of least resistance However the can divide the flaw between lunctiong by rmetering Ihe Movement of the spool meters or shuts off the flow of os thru the open center pas amd pressurizes ihe pas m then available operator s descrelion t work ports eannected ihe parallel passage Hydraulic Components Tandem Circuits available in tha program Tandem circuits are sometimes called priordy or standard circus by olhar manufacturers Tandem irom ihe open contor passage like aariaa Becbons bul rahan ow is directed bo thee tank retum passage and is nol awai able downslneam I a tandem section is followed by series or landem aaection operating the bnndem section nearest the inlet will assert priority and downstream sections will not functor Typical Work Section Schematics 7 14 Ce oe Seer ERREUR Standard Cylinder
156. with 1 4 NC x 1 1 4 hex socket head cap screws and 1 4 high collar lockwashers Install ten horizontal cam followers PN 02 0108 in the horizontal cam follower guides and secure each with a 7 16 UNF jam nut and 7 16 lockwasher ILLUSTRATION 3 H 6 INSTALLATION or HonizoNTAL CAM FOLLOWERS AND GUIDES 27 He install the support roller shafts Note that the two top and bottom brakeband lug weldments top RH and bottom LH weldments are PN 101 1636 and the top LH and bottom weldments are PN 101 1637 are retained by four support roller shafts as shown in illustration below Secure the support roller shafts with 1 UNF SS wire drilled jam nuts PN 101 3922 and 1 narrow SS flatwashers except where noted Note that 1 narrrow flatwashers are not used where the support roller shafts are coincidental with the brakeband lug weld ments E 7 E ILLUSTRATION 3 H 7 SuPPoRT ROLLER BRAKEBAND WELDMENT INSTALLATION 3 18 Technical Manual Section Contents MOVING CLOBAL ENERGY FORWARD FARR MOVING GLOBAL ENERGY FORWARD FARR Maintenance KT20000 50K Tong Assembly Procedures Cont d 28 29 30 31 32 33 34 35 36 37 38 Install the remaining 1 1 2 UNF nylock nuts and idler pads over tops of the four idler assemblies Press the remaining bearing in the pinion assembly into the top pinion bearing cap PN 1037 C 10 and insta
157. y or agency which may influence opera tion safety or integrity of the equipment that overrules the content of this document any legal or other mandatory regulation in force governing accident prevention or environ mental protection Technical Manual Section Contents ix KT20000 50K Tong Table Of Contents introduction amp SPCCHICAHONS enews Section 1 amp Company o e C dr rcu bo __________ 1 1 DENS E TEE EEE E E E E E E E E E E E E 1 2 PC ra a id etie rad ene xd we tees ee eb a A esse oes _ 1 4 Setup amp Section 2 Sling Load Bearing DEVICE md rab dd dar Se dica 2 1 Maior Component Ideni UL au ad auta t e ee e E dei a d E on ace e o a Dh ae eda o Re E 2 4 Hydraulic Schematic Component Identification 2 7 FIVOIAUICCONNCCHONS MP 2 10 Tong Jaw Availability amp Installation nnn nnn 2 11 Tong Rig Up amp Leveling Ped 2 12 2 a sae ated gt 2 14 Tong Operation 1 Initial Start up amp

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