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This technical manual applies to all CE-marked versions of the models listed in the table above.
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS v technical Manual
WARNINGS
ANY REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED.
WHEN RE-ASSEMBLING LOAD-BEARING DEVICES (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS, ETC.) NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE OF FASTENER (SEE SECTION 3 - OVERHAUL). ANY THREADED FASTENER IN A LOAD-BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE™.
A “LOAD-BEARING DEVICE” IS A CHAIN SLING, RIGID SLING, SPREADER BAR ASSEMBLY, FRAME, OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH THIS MANUAL HAS BEEN PRODUCED
THE LOAD-BEARING DEVICE SUPPLIED BY MCCOY DRILLING & COMPLETIONS IS DESIGNED TO SUP-PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL. MCCOY DRILLING & COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, ASSEM-BLY OR COMBINATION OF PARTS AND ASSEMBLIES. MCCOY DRILLING & COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD-BEARING DEVICE, OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT, UNLESS SUPPLIED BY MCCOY DRILLING & COMPLETIONS.
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS vii technical Manual
Summary Of RevisionsDate Section Page Description Of Revision Approved
Sep2007 N/A N/A InitialRelease
July2008 All Addedinformationfor7585tension-styleCLINCHER®backupAug2008 1 1.3 Correctedarmlengthforsystemwithcompressionbackup
May2010 All Correctedincorrectpagereferencesthroughout,addedproperCLINCHER®trademarks,revisedlogos/design,correctedTOC
Observanceofalldescriptions, informationand instructionssetout in thismanual is the full responsibilityof theuser.Thismanual isintendedforguidanceandinformationalpurposesandmustbeusedinassociationwithadequatetrainingandon-the-jobsupervisiontoprovidesafeandeffectiveequipmentuse.
It istheresponsibilityoftheusertoconformtoallregulationsandrequirementsissuedbyanauthorityoragencywhichmayaffecttheoperation,safetyorequipmentintegrity,thatmayoverrulethecontentofthisdocumentation.
The informationpresented in thisdocumentwill providesetup,operating,andmaintenance instructions foryourKT8625tongandbackup.Duetothewidevarietyofoperatingconditions,theseinstructionsmustbecon-sideredguidelinesratherthanabsoluteoperatingprocedures.Itistheresponsibilityoftheusertousetheseguidelinestogetherwithanexperiencedmanagertodevelopoperatingproceduresthatconformtoallpoliciessetforthbytheoperatingauthority(ies).
Observance of the following is the full responsibility of the user:
● all descriptions, information and instructions set out in this manual● any regulation or requirement issued by an authority or agency which may influence operation,
safety or integrity of the equipment that overrules the content of this document.● any legal or other mandatory regulation in force governing accident prevention or environmental
ILLUSTRATION 1.A.4: KT8625 TONg & CLINCHER® BACKUp HAzARd AREAS (CE-MARKEd MOdEL SHOwN)
SPecificationS
THIS PAGE ILLUSTRATES THE “SAFE TO HANDLE” AND “HAZARD” AREAS OF THIS EQUIPMENT
In addition to the HAZARD areas of this equipment that are coated YELLOW, a rotating cage plate assembly and backup clamp cylinders pose significant hazards when the equipment is active. Keep hands clear of the cage plate and backup clamp cylinders when equipment is energized. SAFE areas to handle while the equip-ment is energized are indicated by GREEN coating
Keep hands clear of cage plate when equipment is energized
Keep hands clear of backup opening when equipment is energized
TORQUE GAUGEMOUNTS IN THIS
LOCATION
SYSTEMPRESSURE
GAUGE
BACKUPPRESSURE
GAUGE
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 1.5 technical Manual
SPecificationS
ALL REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER-WISE SPECIFIED.
** These are ideal values. Actual achieved torque is highly dependant upon tong efficiency, final position of rotary gear when full torque load is reached, and the motor with which the tong is equipped.
Jaws available (inches): Allstandardsizesfrom2.062”to8-5/8”(SeePg.2.14)
ONLY USE SPRING HANGER SUPPLIED BY MCCOY. IF USING SPRING HANGER REFER TO SEC-TION 2.H FOR PROPER RIGGING INSTRUCTIONS.
Maximum Hydraulic Requirements60GPM(227.1LPM)
2500PSI(17.237MPa)
Maximum Dimensions (80-0615 & 80-0615-6)Length(DoorsClosed) 58”/147.3cm
Height 75-1/4”/191.1cm
Width 36-3/4”/93.3cm
Maximum Dimensions (80-0615-4)Length(DoorsClosed) 54”/137.2cm
Height 75-1/4”/191.1cm
Width 6-3/4”/93.3cm
Maximum Elevator Diameter Unlimited(tongcomesoffpipe)
Torque Arm Length (Pipe center to anchor center)32“/81.3cm(TensionLoadCell)
36”/91.4cm(CompressionLoadCell)
Dead Weights (Approximate)Model80-0615 2440lbs/1109kg(Model80-0615)
Model80-0615-4 2485lbs/1130kg(Model80-0615-4)
Model80-0615-6 2430lbs/1105kg(Model80-0615-6)
Sound Levels (dBa)Model80-0615 97dBA@1m/96dBC@1m
Model80-0615-4 97dBA@1m/96dBC@1m
Model80-0615-6 97dBA@1m/96dBC@1m
Recommended Spring Hanger 85-0106XXH(Capacity=3500lbs/1591kg)
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Section contentS 1.7 technical Manual
SPecificationS
Use an EP synthetic grease that meets or exceeds the following specifications:
YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY. HOWEVER, MCCOY ADVISES INSPECTING YOUR EQUIPMENT FOR SHIPPING DAMAGE UPON RECEIPT AND TESTING YOUR TONG BEFORE RELEASING TO AN OPERATIONAL ENVIRONMENT.
● Onlygrade80orgrade100alloychainshouldbeusedforoverheadliftingapplications.● WorkingLoadLimit(WLL)isthemaximumallowableloadinpoundswhichmaybeappliedtotheload-bearingdevice,whenthedeviceisneworin“asnew”condition,andwhentheloadisuniformlyanddirectlyapplied.TheWLLmustneverbeexceeded.● WorkingLoadLimit(WLL)isthemaximumworkingloadforaspecificminimumslingangle,measuredfromthehorizontalplane.TheWorkingLoadLimitisidentifiedonthesling.● TheWorkingLoadLimitorDesignfactormaybeaffectedbywear,misuse,overloading,corrosion,deformation,intentionalal-terations,sharpcornercuttingactionandotheruseconditions.● Shockloadingandextraordinaryconditionsmustbetakenintoaccountwhenselectingalloychainslings.● SeeOSHARegulation for Slings 1910.184,ANSI/ASMEB30.9-”SLINGS”,ANSI/ASMEB30.10-”HOOKS” and ANSI/AMSEB30.26“RIGGINGHARDWARE”foradditionalinformation.
THE SUPPLIED LOAD-BEARING DEVICE (CHAIN SLING, RIGID SLING, SPREADER BAR ASSEM-BLY, FRAME, OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT DESCRIBED IN THIS MANUAL) HAS BEEN SPECIFIED OR DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS DOCUMENT. FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, ASSEMBLY OR COMBINA-TION OF PARTS AND ASSEMBLIES, OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT, UNLESS SUPPLIED BY MCCOY DRILLING & COMPLETIONS.
MCCOY DRILLING & COMPLETIONS DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD-BEARING DEVICES, UNLESS THOSE MODIFICATIONS ARE PERFORMED BY MCCOY DRILLING & COMPLETIONS.
THE MINIMUM SLING ANGLE (THE ANGLE OF THE LEG OF THE SLING MEASURED FROM THE HORIZONTAL) MUST NEVER FALL LOWER THAN THE ANGLE SPECIFIED FOR THE SLING IN USE
Inspectall lugsand fixingpoints for signsof elongationand/orbending, or formaterial build-uparound thehole.Repair orreplacecomponents that appeardistorted.Ensureall hardware is tight and ingoodcondition.Replacemissinghardware ifnecessary.Allhardwaremustbefreeofrustandcorrosion.
McCoy strongly recommends the following practices:Acompleteinspectionofnewload-bearingdevicesandattachmentsshallbeperformedbyaqualified,designatedpersonpriortoinitialuse.Eachlinkandcomponentshallbeexaminedindividually,takingcaretoexposeandexamineallsurfacesincludingtheinnerlinksurface.Theslingshallbeexaminedforconditionssuchasthoselistedintheremovalcriteriabelow.Inaddition,dailyinspectionofslings,fasteningsandattachmentsshallbeperformedbyadesignatedperson.Ifdamageordefectsarefoundateitherinspection,thedamagedordefectivecomponentshallbequarantinedfromserviceuntilitcanbeproperlyrepairedorreplaced.
Minimum Allowable Chain Link Thickness at Any PointNominal Chain Size Minimum ThicknessInches MM Inches MM
7/32 5.5 0.189 4.80
9/32 7 0.239 6.07
5/16 8 0.273 6.93
3/8 10 0.342 8.69
1/2 13 0.443 11.26
5/8 16 0.546 13.87
3/4 20 0.687 17.45
7/8 22 0.750 19.05
1 26 0.887 22.53
1-1/4 32 1.091 27.71
Refer To ASME B30.9
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Section contentS 2.7 technical Manual
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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
3. Storage Of Load-Bearing DevicesProperstorageofout-of-service loadbearingdevices is important toensure full integrityof thedeviceonce it is returned toservice.McCoyrecommendsobservingthefollowingpractices.
D. LIFT CYLINDER INSTALLATIONTheliftcylinderisnotorientation-specific;thatis,theliftcylinderwillfunctionthesamewayindependentofwhichendisconnectedtothecraneandwhichendisconnectedtothemainliftinglugofthetong(orthespringhanger,ifused).However,McCoyrecom-mendsorientingtheliftcylinderwiththehydraulichoseconnectionatthebottomofthecylindertoensurethehoseisnotstressedwhencylinderisatfullextension.
ILLUSTRATION 2.d.1: LIFT CyLINdER & SpRINg HANgER INSTALLATION
TEST LIFT CYLINDER BEFORE INSTALLATION. REFER TO THE LIFT CYLINDER TECHNICAL MANUAL FOR DETAILED TESTING AND OPERATING PROCEDURES, AND DETAILED SAFETY GUIDELINES.
ii. RemovethetwoR-clipssecuringtheclevispin,andremovetheclevispin.
iii. Orientthespringhangersothepistonwillextenddownduringthreadmake-up,preventingwateranddebrisfromgatheringaroundtheseal.
iv. PlacetheweldedU-connectioninsidetheclevis.Replacetheclevispin,andsecuretheclevispinwiththetwoR-clips.
v. Hoisttheliftcylinderandspringhanger.
vi. Placea1”shacklearoundthemasterliftinglinkonthetongsling.Securetheshackletotheextendingendofthespringhangerusingthe1-1/8”UNCx4-3/4”modifiedhexboltand1-1/8”UNChexjamnut.Securethejamnuttotheboltusinga3/16”x1-1/4”cotterpin.
IF USING A SPRING HANGER ITS WEIGHT MUST BE ACCOUNTED FOR WHEN CALCULATING TOTAL SUSPENDED WEIGHT.
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Section contentS 2.9 technical Manual
2. Lift Cylinder ConnectionInspectthehydraulichosebeforeconnection,ensuringthelineisfreeofruptures,cracks,cuts,orotherdamage.Inspectthefemalequick-connect fittingtoensure it is freefromdamage.Connect thefemalequick-connectonthe liftcylinderhydraulichosetothemalequick-connectfittingattachedtotheneedlevalveonthetongvalvebank.
Installation Note:Pressurecontainedwithintheliftcylinderhydrauliclinemaypreventeasyconnectionofthequick-connectfittings.Bleedpressure from the liftcylinder linebypressingor “tapping” thecentralspring-loadedseal in the femalequick-connectagainstasolidprotrudingobject
Lift thepower tongapproximately three inchesoff theworksurface,andsuspend the tong forapproximately thirtyseconds.Followingthesuspensionalternatelyliftandlowerthetongslightlytoconfirmthatliftandlowerfunctionseachoperatecorrectly.
A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR.
McCoyDrilling&Completions recommends following an industry-accepted standard suchasOSHA,ASMEB30.9-2006, ormanufacturer’sguidelineswhenperforminganyriggingandoverheadlifting.Usebyuntrainedpersonsishazardous.Improperusewillresultinseriousinjuryordeath.Donotexceedratedcapacity.
F. HYDRAULIC CONNECTIONSApairofhydrauliclines-a1”supplylineanda1-1/4”returnline-connectthetongtothepowerunit(seeillustrationbelow).Ancillarydevices(hydraulicmotors,hydrauliccylinders,etc.)areconnectedthroughthevalveblock.
Useof jawsnotmanufacturedbyMcCoy isnot recommended,andmayresult in jawslippage jawfailure,ordamageto thecammingsurfacesoftherotarygear.
ENSURE JAWS TO BE INSTALLED ARE THE CORRECT SIZE. USE OF JAWS NOT SUPPLIED BY MCCOY MAY CAUSE JAW SLIPPAGE OR FAILURE, AND MAY RESULT IN DAMAGE TO THE TONG.THE USE OF REDUCER DIES IS NOT RECOMMENDED.
SetuP & oPeRation
DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED.
2. Jaw / Jaw Die Removal
JAWS MAY PRODUCE METAL SLIVERS. WEAR STURDY GLOVES WHEN REMOVING AND INSTALLING JAW DIE KITS.
Thetongjawswilloftenrequireremovaltochangejawsizeorreplacewornjawdieinserts.Openthetongdoortodisabletongrotation(rotation is inhibitedbysafetydoorsystems).Support the jawbeingremovedfromthebottom,anduseawrenchtoloosenandremovethejawpivotbolt.Slidethejawawayfromtherotarygeartowardsthecentreofthecageplateassembly,andliftclearofthetong(seeIllustration2.G.1nextpage).Repeatfortheotherjaw.
4. CLINCHER® Backup Jaw Removal/Installation1. ExtendCLINCHER® cylinders enough so that the hex flat-head cap screws securing the die retainer tabs arewell
Allforcesuponthesuspensionlinemustbeconsideredwhencalculatingnecessarystrengthofthesuspensionline.Theweightof the tong, theweightof the liftcylinder, theweightof thespringhanger,andthe force impartedonthesuspension linebythespringhangermustallbeaddedtogetherinordertoarriveatthetotalforcesupportedbythesuspensionline.Selectyoursuspensionlinebaseduponthetotalforceandthemarginsofsafetydictatedbythepoliciesofyourcompanyandbyestab-lishedengineeringpractices.Ultimately,calculatingtheforceonthesuspensionlineandselectionofthesuspensionlineisthecompleteresponsibilityofthecustomer.
MCCOY DRILLING & 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 SUS-PENSION AND SNUB LINES MUST BE RATED FOR THE CALCULATED FORCES.
i. Placealevelaxially(sidetoside)acrossthetong,ensuringthatitisparallelwiththesurfaceofthetong.Useathinwrenchontheflatoftheadjustinghelixtorotatethehelix,forcingtheliftlinktomovetowardstheoutersupportsofthesling.The3/4”Nylocknutonthepinmayhavetobeslightlyloosenedtoallowthehelixtorotate.Adjustthehelixuntilthelevelshowsthatthetongislevelside-to-side(seeillustration2.H.1).
ONLY USE THE MASTER LINK TO SUSPEND THE TONG ASSEMBLY. THE RIGID SLING IS DESIGNED TO BE USED FOR VERTICAL LIFTING ONLY.
3/4” Nylock nut may have to be loosened
Rotate helix using flat
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Section contentS 2.23 technical Manual
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Tong Leveling Cont’d:
ii. Placealevellengthwise(fronttoback)alongthetong,ensuringthatitisparallelwiththesurfaceofthetong.Loosenthe1/2”jamnutsontheadjustingboltsonrigidslingbrackets.Completelyloosentheadjustingbolts.Turneachadjustingboltequallyuntiltonghangslevelfront-to-back.Lockadjustingboltsinplacewiththejamnuts.
c. Constructasturdystructurethatwillsupporttheentireweightofthebackup(weight=875lbs/398kg).Theheightofthestructuremustbehighenoughtoremoveallcompressionfromthefrontlegsprings,butnottoohighthatthestructureontopofthebackupwillimpactthebottomofthetong.
d. Useacranetohoistthetongandbackup.LowerontothesupportstructureconstructedinStep5cuntilthelegsofthetongareontheworksurfaceandthebackupisfullysupported.
e. Supportthefrontlegsprings(weight=7.5lbs/3.4kg)andremovethebottomsupportboltandnutsetfromeachfrontleg.
f. SlidethebottomspringsupportwashersandthelegspringssotheyarejustabovetheholeidentifiedinStep5b,andinsertthesupportboltsthroughthenewholes.Securewiththenylocknuts.
g. Adjusttherearheightofthebackup:
Applies to 8-5/8” backup only (model number 85-0607):• supporttherearspringassembly(weight=8.5lbs/3.9kg)andremovethebottomsupportnutandboltsetssecuringtheassemblywithintherearleg.
Applies to 7-5/8” backups only (model number 85-0604):• useacranetohoistthetongandbackupassemblystraightupandoffthesupport,andplaceontheworksurfacenexttothesupport.Installthebackupdieinserts.
• iftherearofthebackuprequiresraisingloosenthebottom1-1/4”nutontherearbackupspringsupportassembly(seePp5.45-5.46)andthreaditapproximatelyoneinchdownthethreadedsupportrod.Useaboxendorcrescentwrenchtoturnthetop1-1/4”nutclockwise,forcingtheV-bracketdownandliftingtherearofthebackup.Keepthreadingthelowernutdown the threaded rodasneeded.When thebackup is level thread the lowernutup to thebottomof theV-bracketandtighteninplace.
a. Theassemblymustbeconnectedtoanactivehydraulicfluidpowersourcetoperformthisprocedure.
b. Usethebackupcontrolvalvetofullyextendthebackupclampcylinders(seesection3.Iforvalveoperatingprocedures).Whenthecylindersarefullyextendeddo notreleasethevalvehandle-maintainhydraulicpressureonthecylinders.
c. Backupclampingpressureisdisplayedonthebackuppressureindicator(seePp.5.42-5.47).Rotatingthereliefvalveclockwisewillincreasethebackuppressure,androtatingthereliefvalvecounter-clockwisewilldecreasethebackuppres-sure.Maximumbackuppressureisthesystempressure(asdisplayedonthesystempressureindicatoronthetong),or2500PSI(17.232MPa),whicheverislower.Neverexceedaclampingpressureof2500PSI(17.232MPa).
BACKUP CLAMPING PRESSURE MUST NEVER EXCEED 2500 PSI (17.237 MPA)
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Section contentS2.26 technical Manual
ALWAYS WEAR APPROVED PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN OPERATING HYDRAULICALLY-POWERED EQUIPMENT.
Thecomponentsofthetongcommonlymanipulatedorrequiringcontrolinputarepaintedgreen,andaresafeforcontinuoushandling.Areas painted yellow are designated as hazardous areas, and contact with those areasmust be avoided duringoperation.Alwayswearallpersonalprotectiveequipment(PPE)specifiedbyyourcompany’sHSEpolicy,andfollowallofyourcompany’ssafetyguidelines.
e. Performenoughtestconnectionstodeterminethatthebackuppressureisadequateformakingupandbreakingoutjointswithinthecurrentapplication.Ifpipeslippageorcrushingisobservedrepeatthebackuppressureadjustmentprocedure.
3. Valve OperationSpring-loadedproportionalvalvescontroloperationofhydraulicdevicesonthetongassemblysuchashydraulicmotorsandcylinders.Whenanyonevalve is “centered”or in thedetentposition, there isnohydraulicoutput fromthevalve.When thevalveispushedforwardthereisaneffect,andwhenthevalveispulledback,thereisanoppositeeffect.Thesevalvesfeatureproportionalcontrol,whichmeansthatfurtherextensionofthevalvehandle(therebyfurtheropeningthevalveorifice)resultsinproportionallyhigherhydraulicoutputtothecontrolleddevice.
Pushingontheliftcylindercontrolvalvehandle(towardthecenterofthetong)willcausetheequipmenttolift,whilepullingon the lift cylindercontrolvalvehandle (toward theoperator)will cause theequipment to lower.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.
a. Connectthetongtoahydraulicpowersourceinacontrolledenvironment.Ensurethepowerunit’soperatingparametersarewithinthespecificationsasidentifiedonPg.1.3.Ensurethehydraulicconnectionsfromthepowerunitareproperlyandsecurelymadeup(seeSection2.E).Donotneglecttoconnectthemotordrainline.
b. Startthepowerunitasspecifiedbythepowerunitoperator’smanual.OpentheBypassValveonthehydraulicsystem,andinspectallpressureandreturnlinehoseconnectionstoensurecorrectandsecureinstallation.Arestrictioninthepressuresupplyhosewillresultinhighpressurewithinthepowerunithydraulicsystem,whichwillactivatethehydraulicgovernorandincreasetheenginespeedtoashighasmaximumRPM.Arestrictioninthereturnlinewillresultinhighpressurewithinthepowerunitandthetonghydraulicsystem,causingenginespeedsashighasmaximumRPM,andpossiblefailureofthemotorseal.
A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR.
c. Allowhydraulicsystemtowarmbycirculatingfluidforabout10minutes,thenslowlyclosethebypassvalvetoallowhydrau-licfluidtocirculatethroughthehosesandtong.Ensurecirculatingpressuredoesnotexceed200psi.
d. Inspectallhydraulichosesandconnectionsonthetong.Immediatelycorrectanyhydraulicfluidleaks.
e. Inspectallgauges.Replaceleakingorcrackedgauges,oranygaugenotregisteringareading.
f. Confirmthatallload-bearingpinsandR-clipretainersareinstalledandingoodcondition(rigidslingpins,liftcylinderpins).
g. Confirmallhydraulichoses(withtheexceptionofthesupply&returntothebackup)aresecurelyfastenedtothetong,andarenotincontactwiththecageplateorcreatingasnagginghazard.
h. Ensurethetongdoorissecurelyclosedbeforerotatingtong.
DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE TONG ROTATION IN ORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL.
j. Re-inspectallhydrauliclinesandconnectionsonthetong,andcorrectallleaks.
k. Thesafetydoorsystemistheprimeprotectivemeasureseparatingtheoperatorfromtherotarygear,andmustbeinwork-ingconditionwhenoperatingtong.Carefullyinspectthesafetydoorcomponents,andtesttheoperationofthesafetydoorusingthefollowingprocedure:
i. Keepnon-essentialpersonnelclearoftheunitundertest.Thistestprocedurewillonlyincludetwopeople:onetorunthecontrolvalveandonetooperatethedoor.
ii. Ensurethetongdoorissecurelyclosed.
iii. ShifttoLOWgear.
iv. Beginrotatingthetong(directionofrotationisnotimportant).
v. Openthetongdoorwhiletherotatingthetong.Thetongmustimmediatelyandcompletelystoprotatingassoonasthedoorisopened.
vi. Continuetoapplyrotationcontrol,andopen&closethedoorthroughoutitscompleterange.Slowlyclosethedooruntilitlatches.Rotationmustnotbeginuntilthedooriscompletelyclosedandsecurelylatched.
6. General Commentsa) Positionrotarygearincontactwithbothidlergearswhenmakinguporbreakingoutjointsorcollarswhentorqueinexcess
of50%oftheratedtorqueisrequired.
b) Whenmaking-upintegral(shouldered)joints,itisessentialtomakeupthelastturnofthethreadsinlowgear.Thisreducesthetendencyofaninstantstoporasuddenincreaseintorque,whichinducesextremelyhighstressuponthegeartrain.
c) DONOTemploy the “snap break”method of breaking-out jointswhen pulling a string.By definition, the “snap break”methodisaprocedureusedbysomeoperatorstobreakoutconnections,accomplishedbyleavingslackinthe“jaw-pipe”engagement,andthenquicklypullingthethrottlevalvecontrolleverallowingthetongtosnapintoitsloadedorhightorquecondition.Theextremelyhighstressplacedonthegeartrainfrequentlycausesgearbreakage.
DO NOT USE THE “SNAP BREAK” METHOD TO BREAK OUT JOINTS
DO NOT OPERATE TONG WITH A MALFUNCTIONING OR NON-OPERATING SAFETY DOOR SYS-TEM.
THESE OPERATING PROCEDURES ASSUME THE USER HAS PROPERLY SET UP AND PREPARED THE EQUIPMENT FOR OPERATION AS PER SECTIONS 2D, 2E, AND 2F OF THIS MANUAL.
THE MASTER LINK MUST BE USED TO SUSPEND THE TONG ASSEMBLY
b) Ensure thebackingpin is in the “makeup”position.From the frontof the tong, thebackingpincorrectlyconfigured formakeupwillbeinthe10o’clockposition(seeIllustration2.H.2nextpage).Ifitisnot,simplyliftupandplaceinthecorrectposition.Thecageplateopeningmustbealignedwiththedooropeningwhensettingthebackingpinposition.
ILLUSTRATION 2.J.1: RIgId SLINg MASTER LINK
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Section contentS 2.33 technical Manual
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Making A Connection (Continued)
ILLUSTRATION 2.J.2: SETTINg BACKINg pIN TO “MAKE-Up” pOSITION
c) Properlyconfiguretheloadcellformakingupconnections(seeSection2.H.3&2.H.4).Connectsnublinestotherearofthetongtoarrestuncontrolledrotationoftheassemblyintheeventofbackupjawslippage.Thesnublinesmustberatedfortheappliedtorquepluswhateversafetymarginsstatedbyyourownoperatingpolicies.Thesnublineconnectionpointsonthedrillfloormustbesturdyenoughtoabsorballappliedforces.
m) Stoprotation,andsetmotortolowspeedandshifttolowgear(lowspeed/hightorque-SeeSection2.I.3forshiftingtolowgear).Thiswillenablethetongtoproduceadequatetorquetomakeupthejointtospecification.
COMPRESSION ENERGY STORED IN THE BACKUP SUPPORT SPRINGS MAY CAUSE THE TONG TO “JUMP” SLIGHTLY WHEN TONG JAWS ARE RELEASED.
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Section contentS 2.37 technical Manual
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ILLUSTRATION 2.J.8: USINg BACKUp CONTROL TO RELEASE BACKUp JAwS
Pullingon the liftcylindercontrolvalvehandle (toward theoperator)willcause theequipment to lower.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.
2. Breaking Out A ConnectionYourtongandbackupassemblyshouldbeproperlysuspended,connectedtoahydraulicpowersource,andreadytomakeorbreakconnectionsatthispoint.
a) Ensurehydraulicpowersupplytothetongandbackupisenergized.Themaster linkontherigidslingmustbeusedtosuspendthetong.Donotsuspendthetongdirectlyfromtherigidsling.SeeIllustration2.J.1.
b) Setthebackingpinfor“breakout”operation.Liftuponthebackingpinandrotateittothe“breakout”position,whichis2o’clockasseenfromthefrontofthetong.Theopeningintherotarygearmustbealignedwiththetongdooropeninginordertoproperlysetthebackingpin.
ILLUSTRATION 2.J.10: SETTINg BACKINg pIN TO BREAK-OUT pOSITION
c) Ensuretheloadcellisconfiguredforbreak-outoperation(seeSectionseeSection2.H.3&2.H.4fordetailedinstructionsforconfiguringtheloadcellonyourequipment).
d) Connectsnublinestotherearofthetongtoarrestuncontrolledrotationoftheassemblyintheeventofbackupjawslip-page.Thesnub linesmustbe rated for theapplied torquepluswhateversafetymarginsstatedbyyourownoperatingpolicies.Thesnublineconnectionpointsonthedrillfloormustbesturdyenoughtoabsorballappliedforces.
f) Actuatetheliftcylindercontrolvalvetolifttheassemblyfromthedrillfloor.Pullingthevalvetowardtheoperatortoretractthe liftcylinder to lift theassembly(see illustration2.J.4).Note that rigpersonnelarerequired tostabilize the tongandbackupasitisbeingliftedsoitdoesnotswingandcollidewithotherrigequipment.
RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR
A. GENERAL MAINTENANCE SAFETY PRACTICESThepracticesidentifiedhereareintendedasaguideline.Allpersonnelareresponsibleforperformingtheirtasksinamannerthatensuresworker,equipment,andenvironmentalsafety,andmayrequiretakingadditionalstepsthatarenotidentifiedinthissection.
Replacement of large, heavy individual parts and/or heavy structural componentsmust be performed using an approved liftingdeviceofsufficientliftingcapacity.Usecarewhenattachingtheliftingdevice,andsafeguardareatoavoidendangeringpersonnelorequipment.
DO NOT PERFORM MAINTENANCE UNTIL TUBULAR CONNECTION EQUIPMENT HAS BEEN COM-PLETELY ISOLATED FROM HYDRAULIC POWER
Your equipment usesmaterials thatmay be harmful to the environment if improperly disposed of (hydraulic fluid, grease, etc.).Disposeofallmaterialsaccordingtoyourcompany’sproscribedenvironmentalprotectionregulations.
B. CLEANINGClean tong thoroughlycleanedwithagoodpetroleum-basedcleaningagentaftereach job,prior tostorage.Farr® recommendsthatthemotorandvalveassemblybeperiodicallyremoved,alongwiththetoptongplate,sothatguides,rollersandgearscanbeproperlycleaned(seeSection3.H,Overhaul).Ensurethatcleaningsolventsandchemicalsarecapturedtopreventenvironmentalcontamination,anddisposeofallmaterialsaccordingtoyourcompany’sproscribedenvironmentalprotectionregulations.
C. PREVENTIVE MAINTENANCE PRACTICESRegularmaintenanceprogramsarenecessary,andmustbeestablished toassuresafe,dependableoperationofyourHydraulicTubularConnectionSystemandtoavoidcostlybreakdownmaintenance.Thefollowingmaintenanceproceduresprovidesinforma-tion required toproperlymaintainyourequipment.Yourequipmentmay requiremore,or lessmaintenancedependingupon thefrequencyofuseandthefieldconditionsunderwhichyourequipmentoperates.Thesemaintenanceproceduresaredesignedforequipmentoperatingat10°Cto35°Cambienttemperaturefor10hoursperday.McCoyrecommendsthattheinspectionandmain-tenanceproceduresinthissectionbeperformedasrecommendedinthemaintenancechecklists(seeAppendices),orinconjunctionwithyourmaintenanceforeman’sexperienceandbestestimateofwhenyourequipmentisdueforthismaintenance.
D. HYDRAULIC SYSTEM DE-PRESSURIZATIONMcCoyDrilling&Completionsrecommendsthatthehydraulicsystembede-pressurizedpriortomaintenanceonanyhydrauliccom-ponent.Performthefollowingstepstoensurethedangersposedbyhydraulicfluidunderpressureareminimized.
HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INJURIES
ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINA-TION FROM RESIDUAL HYDRAULIC FLUID
E. LUBRICATION INSTRUCTIONSUseaqualitymultipurposebearinglubricantthatwillremainwithinitsviscosityrangeatexpectedoperatingtemperatures.Inaddition,Farrrecommendsthefollowinglubricationprocedureatthecompletionofeachjobpriortostorage.
9. Door LubricationApplygreasetothedoorlatchadjustmentcamthroughthegreasefittinglocatedinthetopoftheadjustmentcamshaft.Applygreasetothecontactsurfacesofthesafetydoorswitchplunger.
ILLUSTRATION 3.E.10: TONg dOOR LUBRICATION pOINTS
10. DOOR STOP CYLINDER Periodicallydisassemblethedoorstopcylindersandcoatthespringandcylinderwithageneralpurposelubricatingoil.
ILLUSTRATION 3.E.11: dOOR CyLINdER
THE DOOR STOP CYLINDER SPRING MAY RETAIN ENERGY FROM BEING COMPRESSED. USE A CLAMP TO CONTAIN THE ENDS OF THE CYLINDER BEFORE IT IS REMOVED, AND RELIEVE THE SPRING TENSION GRADUALLY.
Lubricate safety door switch plunger contact area.
Thetopandbottombrakebandsmustbeperiodicallyadjustedtocontinuetoprovidesmoothandefficientjawcamaction.Ifthecageplateturnswiththerotarygear, the jawswillnotcamproperlyand, therefore,willnotbiteonthetubingorcasing.Tighteningthebrakebandagainstthecageplateswillincreasefrictionalresistance,allowingjawstocamproperlyandgripthecasing.Adjustthebrakebandusingtheadjustmentnutandboltsetasshownintheillustrationbelow.Usecaution,asover-tighteningwillcauseexcessiveweartothebrakebands.
ILLUSTRATION 3.F.1: BRAKE BANd AdJUSTMENT
TOP AND BOTTOM BRAKE BANDS MUST BE ADJUSTED SIMULTANEOUSLY AND EQUALLY
BRAKE BAND
BRAKE BAND ADJUSTMENT BOLT AND NYLOCK NUT
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Section contentS3.10 technical Manual
Maintenance
2. Door Latch AdjustmentNormaloperationofthetongmaycausewearofthedoorlatch,whichwillcausethedoortodevelopaloosefitatthelatch.Alatchcamplateislocatedatthetopfaceofthedoor.Thecamplatehaseightpositioningholeslocatedona360degreeboltcircle.Thelatchcamshaftextendsdownthroughthedoorandissecuredatthetopbya3/8”hexheadbolt.Tomakeadjust-mentsindooralignment,removethe3/8”boltandturnthecamwithawrench.Whenthedoorhasbeenadequatelyaligned,replacethe3/8”bolt.
THE DOOR IS AN IMPORTANT PART OF THE STRUCTURAL INTEGRITY OF THE TONG. IT IS IMPERATIVE TO KEEP A SECURE FIT AT THE DOOR IN ORDER TO MAINTAIN PROPER GEAR ALIGNMENT, AND TO MINIMIZE THE POSSIBILITY OF DAMAGE TO THE GEAR TRAIN WHEN OPERATING THE TONG AT SPECIFIED TORQUE. A CLOSED DOOR ALSO ENSURES SAFETY OF OPERATING PERSONNEL.
ILLUSTRATION 3.F.2: dOOR LATCH CAM AdJUSTMENT
DOOR LATCHADJUSTMENT CAM
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Section contentS 3.11 technical Manual
Maintenance
3. Shifter Detent Force Adjustment:Overtimeweartotheshiftingshaft,weartothedetentball,andlossofspringtensioninthedetentspringmayresultinalooseor“sloppy”fitwithinthetopshifterbushing.Thedetentpressuremaybeincreasedorotherwiseadjustedbylooseningthe7/16”UNFlockingjamnut,andturningthe7/16”UNFdetentbolt.Shouldadequatedetentactionnotbeachieved,theshiftingshaft,detentball,ordetentspring(orpossiblyallthree)mayneedtobereplaced(seePp.5.16-5.17).
ILLUSTRATION 3.F.3: SHIFTER dETENT FORCE AdJUSTMENT
4. Safety Door Adjustment:Thesafetydoorsystemistheprimeprotectivemeasureseparatingtheoperatorfromtherotarygear,andmustbeinworkingconditionwhenoperatingtong.Thesafetydoorswitchisdesignedtointerrupthydraulicpowertothemotorwhenthetongdoorisopened,orevenslightlyajar.Thisisacriticalsafetysystem,andproperadjustmentisnecessarytomaintaintheintendedfunction.
KEEP HANDS CLEAR OF SAFETY DOOR LATCH CLAWS (PAINTED YELLOW) WHEN CLOSING DOOR.
a. Removethetopplatefromthesafetydoorguard.Wireties(ifapplicable)requireremovalbeforethefastenersonthetopplateofthedoorguidecanbereplaces.
b. Performaninitialalignmentofthesafetydoormechanism.Closethetongdoor.Ensurethetwosafetydoor“claws”areseatedfirmlytogether.Slightlyloosenthehexboltssecuringtheadjustmentplate-tapthebottomadjustmentplateonewayortheotheruntiltheshoulderboltsonthefloatingplateareinthecentreofthetravelingslots(seeIllustration3.F.4).
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Section contentS3.12 technical Manual
ILLUSTRATION 3.F.4: SAFETy dOOR SwITCH AdJUSTMENT 01
c. Oncetheadjustmentplatehasbeensatisfactorilyadjusted,tightenthe3/8”boltsontheadjustmentplate.
d. Testthesafetydoorsystem.Connecthydraulicpowertothetong.Ensurethedoorisclosedandallpersonnelareclear.Beginrotatingthecageplate.Openthetongdoor-thecageplateshouldimmediatelyandcompletelystop.
e. Ifthecageplatedoesnotstoprotating,furtheradjustmentofthesafetydoorswitchisrequired.Stoprotationandremovehydraulicpowerfromthetong.
f. Slightlyloosenthehexboltssecuringtheadjustmentplate-tapthebottomadjustmentplatetowardthecentreofthetonginsmall increments(i.e.about1mmatatime).Aftereachadjustmentthesafetydoormechanismmustbere-testedtodetermineifsafetydoorfunctionhasbeenrestored.Repeatstepsd,e,&funtilsatisfactorysafetydoorfunctionhasbeenestablished.
g. Ifadjustment limitshavebeen reachedbeforesafetydoor functionhasbeenestablished further troubleshootingof thesafetydoorsystemisrequiredbeforethetongisplacedintoservice.
Correct position of shoulder bolts within the traveling slots.
Loosen 3/8” bolts on the adjustment plate.
Safety door “claws” aligned properly
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Section contentS 3.13 technical Manual
Maintenance
ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP. THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED.
REPLACEMENT FASTENERS (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT.FASTENERS USED FOR MAINTENANCE OR OVERHAUL OF LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, LEGS) MUST BE TIGHTENED TO THE PROPER TORQUE
H. OVERHAUL PROCEDURES - DISASSEMBLYSeparatethetongandbackupusingthedisassemblyinstructionsspecifiedinthefollowingprocedure.Followingseparationofthetongandbackupthegeartrainisaccessedbyremovingthetopplateofthetong.
SEPARATION OF TONG FROM BACKUP1. Suspendtongassemblywithcrane.Constructasupportstructurethatwillsupporttheweightofthebackup.Lowerthetong/
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.
26. Removethejawpivotboltsandthejawassemblies.
27. Ensure thebottomcageplate is supportedbeforebeginning this step.Remove the two front cageplatebolt andnut sets.Removethebackingpinassemblyandtherearcageplatebolt,andthecageplatespacers.Thetopandbottomcageplatesmaynowberemoved-Notethatthecamfollowersarefastenedtothetopandbottomcageplates,sousecautionnottodam-agethem.
THE CAGE PLATE BOLTS ARE THE ONLY ITEMS FASTENING THE BOTTOM CAGE PLATE TO THE TONG. SUPPORT THE BOTTOM CAGE PLATE FROM BELOW PRIOR TO REMOVING CAGE PLATE BOLTS IN ORDER TO PREVENT DAMAGE TO THE BOTTOM CAGE PLATE OR PERSONAL INJURY TO THE MECHANIC
ALL FASTENERS USED DURING REASSEMBLY OF LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS) MUST BE TIGHTENED TO THE CORRECT TORQUE. THREADED FASTENERS USED IN LOAD-BEARING DEVICES MUST BE SECURED WITH RED LOC-TITE™.
I. ASSEMBLY PROCEDURESAssemblyofFarrHydraulicPowerTongsissimple,andcanbeaccomplishedwithouttheuseofspecialtools.Theinstructionsonthispagearepresentedasaguideonly,andaresimilartotheassemblysequenceourtechnicianwouldusewhileassemblingthetonginourplant.
NOTE ON INSTALLATION PRACTICES: Ensure all bearings are liberally greased before installing over a shaft or into gears or bearing caps. When inserting a shaft through a support roller assembly ensure shaft is greased. Also ensure all metal-to-metal contact in the gear train is adequately greased. When graphics are not used in the assembly process, please refer to the relevant exploded diagrams in Section 5.
REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER-WISE SPECIFIED.
13. Placeeachrotary idlerassembly throughthebottomplate,ensuring theendsof theshaftswith the threadedhole for thegreasefittingarepointedupwardandtherotaryidlergearsmeshwiththerotarygear.
i) Install longersupport rollershafts (PN101-3941) in four locationswhere theyarecoincidentalwith the two front legmountweldmentsasshowninillustration3.H.4.Ensurea1-1/8”narrowflatwasherisinstalledonthesupportrollershaftbeforeinsertingthroughthebodyandsupportrollerassemblies(seeIllustration3.I.4nextpage).
ILLUSTRATION 3.I.3: TONg ASSEMBLy - TOp FASTENER LOCATIONS
Maintenance
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ILLUSTRATION 3.I.4: TONg ASSEMBLy - SUppORT ROLLERS (LEg MOUNT LOCATIONS)
58. Refer to Pp. 5.34 - 5.35 for a door assembly illustration. Lightly grease the door latch adjustment cam (PN 1037-A-14).Positionthedoorlatchweldment(PN1050-15)atthefrontofthedoorweldment,andinsertthetwolatchsprings(PN997-16)betweenthelatchweldmentandthedoorweldment.Pressthelatchweldmentagainstthedoorweldmentuntilthelatchpivotholesalign,andinsertthedoorlatchcamshaft.Securethelatchadjustmentcamtothetopplateofthedoorweldmentwitha3/8”UNCx3/4”hexboltand3/8”lockwasher.
59. Installmechanicaldoorstop (PN101-1833) to thebottomplateof the tongnext to theLHbrakebandretainerweldment.Securewithtwo3/8”NCx2”boltsand3/8”lockwashers.
ILLUSTRATION 3.I.8: TONg ASSEMBLy - FRONT CAgE pLATE SpACERS
Maintenance
Cage plate spacers & 1/2” NC x 7-1/2” bolt and nut sets
iii. Attachsafetydoorlatchblock(PN101-1103)tosafetydoorlatchplate(PN101-1410)usingthree3/8”NFx1”flatheadcountersunkcapscrews.
iv. Placethesafetydoorlatchplate(PN101-1410)ontothebottomplateofthesafetyswitchbaseandguardweldment(PN101-1475)andaligntheboltholes.Securetothetopplateusingtwo3/8”UNCx3”hexboltsandlockwashers,andone3/8”UNCx1-1/4”hexboltandlockwasher.Notethatthetwolongercapscrewsinthisstepreplacetwoofthetong’sperimeterfasteners.
v. Insertloadplunger(PNAE12-306)intoLHsafetydoorlatchblock(PN101-1103).
vi. Attachthree1/4”NPTx1/4”JICelbows(PN08-0284)totheDeltrolsafetydoorvalve(PN08-0337M).Positiona15/16”valvelocknut(PN09-0278)asshowninillustration3.H.9,andsecurethesafetydoorvalvetothesafetydoorlatchblockusingthevalvelocknut.
b. Useacranetohoistthetongassemblyofftheassemblysurface.Bringthetongintocontactwiththerearleg,ensuringthecranecontinuestosupporttheentireweightofthetong.Attachtherearlegweldmenttothetongusingtwo1-1/4”UNCx9”hexboltsand1-1/4”UNCheavyhexnuts,andtwo1”UNCx8”hexboltsand1”UNCheavyhexnuts.
a. Placetwosprings(PN991-13)inthebottomsupportweldment(PN101-4495).Placethetopsupportweldment(PN101-4496)overthespringsandusefour1/2”UNCx6”hexbolts,1/2”narrowflatwashers,and1/2”UNChexnylocknutstofastentheassemblytogether.
b. Installthespringsupportweldmentintherearlegusingtwo1/2”UNCx9-1/2”hexbolts,1/2”narrowflatwashers,and1/2”UNChexnylocknuts.Thelocationofthesupportcanbechangedasrequiredwhenlevelingthebackup.
72. 85-0604 and 85-0606 backup assemblies only:ifusingeitherofthesebackupsensuretheyareproperlypreparedformatingwiththetongandrearlegassembly.RefertoPp.5.40-5.41.
a. Threada1-1/4”UNCheavyhexnutontothe1-1/4”UNCx8”threadedrod(PN101-1993).b. Coatapproximately2”ofthreadonthebottomofthethreadedrodwithblueLoctite®.Screwthecoatedpartofthethreaded
c. Coatapproximately4”ofthreadatthetopofthethreadedrodwithblueLoctite®.Threadona1-1/4”UNCheavyhexnut,ensuringenoughthreadisexposedtoallowinstallationofthesuspensionspringv-bracketandanother1-1/4”UNCheavyhexnut.
d. Installthesuspensionspringv-bracket(PN1483-500-00-04)ontothethreadedrod,andsecurewithanother1-1/4”UNCheavyhexnut.
Assembly Procedures (continued):77. 85-0604 and 85-0606 backup assemblies only:
a. Threada3/8”NCshoulderpattern2-Aeyeboltintothetongbodyfromthebottomofthetopplateoftherearlegweld-ment,nearthefrontoftherearleg(seePp.5.42-5.43).
b. Connectoneendofarearbackupsupportspring(PN1391-905-03)tooneoftheeyeboltsinstalledinthepreviousstep,andtheotherendofthespringtothev-bracketinstalledinstep71d.Securetheendofthespringtothev-bracketusingaspringretainer(PN1480-500-00-04B)andacotterpin.Repeatforthesecondspring.
DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON-NECTED TO ANY HYDRAULIC POWER SUPPLY. FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED, AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF. ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMI-NATION FROM RESIDUAL HYDRAULIC FLUID.
2.
dEpRESSURIzE HydRAULIC SySTEM IN pREpARATION FOR MAINTENANCE:
HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP-MENT IS USED TO GUARD AGAINST PRESSURE INJURIES
Maintenance
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Section contentS 3.29 technical Manual
21.Whilerotatingthecageplate,ensurethatthejawsproperlycam.If the jawsdonotcamproperly, thebrakebandsneedtobetightened.IncrementallyadjustboththetopandbottombrakebandsEqUALLYuntilpropercamactionisachieved.
K. DAILY INSPECTION & MAINTENANCE CHECKLIST (BACKUPS)FarrCanadarecommendsthat thefollowing inspectionandmaintenanceproceduresbeperformedbeforeeachuse,andat leastonceperdaywhenthebackupisinsteadyuse,intheorderinwhichtheyarelisted.
Donotperformanymaintenancewhile the tongandbackupassembly isconnected toanyhydraulicpowersupply.FarrCanadarecommendsthatallhydrauliclinesarefullydisconnected,andresidualhydraulicpressureisbledoff.Ensureadequatecontainmentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluid.
L. MONTHLY MAINTENANCE CHECKLIST - POWER TONGThefollowingmaintenancechecklistisintendedasaguidelineratherthanadefinitivemaintenanceschedule.Yourequipmentmayrequiremore,orless,maintenancedependinguponthefrequencyofuse,thepercentageofmaximumtorquethatyourequipmentisroutinelysubjectedto,andthefieldconditionsunderwhichyourequipmentoperates.Farrrecommendsthatthefollowinginspectionandmaintenanceproceduresbeperformedmonthly,orinconjunctionwithyourmaintenanceforeman’sexperienceandbestestimateofwhenyourequipmentisdueforthismaintenance.
DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON-NECTED TO ANY HYDRAULIC POWER SUPPLY. FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED, AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF. ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMI-NATION FROM RESIDUAL HYDRAULIC FLUID.
2.
dEpRESSURIzE HydRAULIC SySTEM IN pREpARATION FOR MAINTENANCE:1) De-energizethepowerunit.
HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP-MENT IS USED TO GUARD AGAINST PRESSURE INJURIES
34.Performa full functional test of the tong including, if applicable, backup components, lift cylinder, and float framecomponents(refertoSection2.I.4).Reportandcorrectanyhydraulicleaksfromthehydraulicvalvebank,orfromanyhydrauliccylindersthatareused.
Once all of the above maintenance checklist items have been satisfactorily completed the tool may be returned to service.
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Section contentS3.34 technical Manual
Maintenance
M. TUBULAR CONNECTION EQUIPMENT DE-COMMISSIONING & SHIPPINGPerform the followingdecommissioningprocedureswhen removing tubularconnectionequipment fromservice,with the intentofshorttolong-termstorage.Theseproceduresareessentialforensuringproperprotectionoftheequipmentfromenvironmentalattack,andtoaidinthequickturnaroundwhenreturningtheequipmenttoservice.
HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP-MENT IS USED TO GUARD AGAINST PRESSURE-INDUCED INJURIES
dEpRESSURIzATION pROCEdURE IN pREpARATION FOR STORAgE:1) Rotatethetongsothat theopening in therotarygear facesthegeartrain(towardstherearof thetong).Ensuretongand
5) Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in theremainderofthehydrauliccontrolsystem.
IN ORDER TO MAINTAIN THE INTEGRITY OF INSTALLED SEALS, MCCOY RECOMMENDS THAT THE MAXIMUM STORAGE INTERVAL NOT EXCEED ONE YEAR. AT LEAST ONCE PER YEAR ALL TUBULAR CONNECTION EQUIPMENT IN LONG-TERM STORAGE SHOULD BE RECOMMISSIONED AS PER SECTION 3.M. IF FURTHER STORAGE IS REQUIRED, THE EQUIPMENT SHOULD THEN BE PUT THROUGH ANOTHER DE-COMMISSIONING PROCEDURE.
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Section contentS 3.35 technical Manual
Maintenance
dEpRESSURIzATION pROCEdURE FOR STORAgE:1) Rotatethetongtothe“openthroat”position.2) Exerciseeachhydrauliccylinderseveraltimes-openthetongandbackupdoors(ifequipped),retractandextendthe
remotebackingpin ramp(ifequipped), retractandextend the floatcylinders.Leaveallcylindersexcept for thedoorcylinders in their fullyretractedposition.Thegeneral idea is tohaveas littleof thechromecylinderrodsexposedaspossible.
2) Multiplythecalculatedairvolume,incubicfeet,bytherecommendedamountofdesiccantpercubicfoot.Carryingforththeexampleused in thepreviousstep, the requireddesiccantchargewouldbe3.5g.x66 ft3,equaling231g.Severalmanufacturersoffersilicageldesiccantinpackagedquantitiesof125gramsperbag,sotwopackagesofdesiccantwouldberequired.Pleasekeepinmindthatthisisaguidelineonly-moreorlessdesiccantmayberequiredinextremeenviron-mentalconditions.
2. Place theequipmentonasturdypalletconstructedof4”x4”cross-membersand2”x4” flooring.McCoyrecommendsplacinga2”x6”boardacrossthewidthofthetongunderthelegs(seeIllustration3.M.1).Ensurethepalletislargeenoughtoaccommodatethewoodencratecontainingthetongaccessories.
ILLUSTRATION 3.M.4: SHIppINg INSTRUCTIONS - STRAppINg EqUIpMENT TO pALLET
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Section contentS 3.39 technical Manual
N. TUBULAR CONNECTION EQUIPMENT RE-COMMISSIONING PROCEDUREPerform the following recommissioningprocedureswhenremoving tubularconnectionequipment fromshortor long-termstoragebackintoregularservice.Theseproceduresareessentialforensuringproperequipmentpreparationandoperation.ThefollowingproceduresalsoassumethatthedecommissioningandstorageproceduresrecommendedbyFarrhavebeenstrictlyobserved.
MCCOY DRILLING & COMPLETIONS GUARANTEES CALIBRATION OF A LOAD CELL/TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR. MCCOY SUGGESTS THAT THE LOAD CELL/TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE-CALIBRATION ON A YEARLY BASIS.
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Section contentS4.2 technical Manual
tRouBleShootinG
B. RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING1. POSSIBLEPROBLEM:Reliefpressuresettoo low,resultingininsufficient tong torque.
POSSIBLEPROBLEM:Reliefpressuresettoo high,resultingincrushed pipe or gear train failure.
SOLUTION:Adjustsetting:
a. Ifyourtongisequippedwithasystempressureindicatorproceedtostep“f”.Ifyourtongdoesnothaveasystempressureindicator,atemporary0-3000PSIindicatormustbeinstalledonthehydraulicinlet.
b. Isolateyourtongfromhydraulicpower,anddepressurizefollowingtheprocedureinsection3.D.
c. Teeinatemporaryindicatoratthesafetydoorsupplypressureport.Ensureallhydraulicconnectionsareper-formedbyaqualifiedhydraulictechnician.
d. Re-establishhydraulicpowertoyourtong.Ensurethatnoequipmentfunctionsareactive.
e. Loosenthelockingnutonthepressurereliefvalve.
f. Openthetongdoortoactivatethesafetydoorsystemandinhibittongrotation.
g. Activatemotorcontrolvalve.Observethepressuredisplayedonthepressureindicator.Adjustthereliefvalveuntilthepressureindicatedisatthemaximumsystempressurespecifiedonthespecificationspage(maximumsystempressureisthepressureatwhichyourtongachievesitsspecifiedtorque).
DO NOT ADJUST PRESSURE RELIEF TO A SETTING THAT ALLOWS HIGHER THAN MAXIMUM SYSTEM PRESSURE. DOING SO CREATES A POTENTIAL FOR SERIOUS INJURY OR DEATH, AND MAY CAUSE CATASTROPHIC EQUIPMENT FAILURE.
h. Releasethemotorcontrolvalveandtightenthelockingnutonthepressurereliefvalve.
i. Isolateyourtongfromhydraulicpower,anddepressurizefollowingtheprocedureinsection3.D.
j. Closethetongdoor,andremovethetemporarypressureindicator.Restorethesafetydoorpressuresupplylinetofactoryspecifications.Verifythatsafetydoorisoperatingcorrectly(seesection2.I.5.k).
Connect a temporary 0 - 3000 PSI pressure indicator at this location
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Section contentS 4.3 technical Manual
tRouBleShootinG
RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING Cont’d:2. POSSIBLEPROBLEM:Reliefcannotbeadjustedtomaximumsystempressure(highfluidbypassresultsinlowsystempres-
ITEMS ON THE CRITICAL SPARE PARTS LIST MARKED IN RED INDICATE ESSENTIAL HEALTH & SAFETY ITEMS. FAILURE TO REPLACE DAMAGED ESSENTIAL HEALTH & SAFETY ITEMS WILL PRESENT IMMEDIATE DANGER TO PERSONNEL OR EQUIPMENT. HAVE THESE ITEMS ON HAND AT ALL TIMES. STOP WORK AND QUARANTINE TONG UPON DISCOVERY OF DAMAGED OR DEFECTIVE HEALTH AND SAFETY COMPONENTS UNTIL PARTS CAN BE REPLACED.
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.4 technical Manual
PaRtS liSt - coMPlete oVeRhaul
MISC TONG PARTS
Description Part Number Qty. RequiredJawPivotBolt 1050-C5-28 2
BackingPin 101-4188 1
BackingPinSpacer 101-4096 1
BackingPinStud 101-4097 1
BackingPinKnob 02-0017 1
BackingPinRetainer 101-4186 1
BackingPinSpacer 101-4187 1
CagePlateSpacer 1050-C3-38 3
LinedBrakeBandWeldment 1050-D4-29 2
BrakeBandRetainers 101-0140 2
DoorCylinder 101-0069 1
DoorCylinderPost 1050-12-001 1
LatchSprings 997-16 2
SafetyDoorInterlock 101-1103 1
SafetyDoorInterlock 101-1104 1
SafetyDoorLoadPlunger AE12-306 1
ShiftingShaft 1116-71 1
ShiftingYoke 1050-72-1 1
TopShifterBushing 101-0020 1
DumbbellRoller 1037-135 12
RollerSpacer 101-3871 24
RollerSpacer 1037-C-134 12
DoorPivotRollerShaft 101-3940 1
RollerShaft 101-3939 11
DriveGear(Clutch) 997-A3-61 1
ShiftingCollar 997-A9-62 1
HighClutchGear 997-A1-51 1
SplinedClutchShaft 997-A8-50 1
LowClutchGear 997-A1-52 1
MotorGear 997-A10-149 1
BEARINGS & BUSHINGS
Description Part Number Qty. RequiredDumbbellRollerBearings 02-0094 24
ITEMS ON THE CRITICAL SPARE PARTS LIST MARKED IN RED INDICATE ESSENTIAL HEALTH & SAFETY ITEMS. FAILURE TO REPLACE DAMAGED ESSENTIAL HEALTH & SAFETY ITEMS WILL PRESENT IMMEDIATE DANGER TO PERSONNEL OR EQUIPMENT. HAVE THESE ITEMS ON HAND AT ALL TIMES. STOP WORK AND QUARANTINE TONG UPON DISCOVERY OF DAMAGED OR DEFECTIVE HEALTH AND SAFETY COMPONENTS UNTIL PARTS CAN BE REPLACED.
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.6 technical Manual
GeaR tRain layout
B
C
D
H
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FG
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.7 technical Manual
GeaR tRain layout
ITEM TYPE DESCRIPTION QTY PART NUMBERA Part HydraulicMotor 1 87-0112
B Assembly ClutchAssembly(SeePp.5.14-5.15) 1
C Assembly PinionAssembly(SeePp.5.12-5.13) 1
D Assembly RotaryIdlerAssembly(SeePp.5.8-5.9) 2
E Assembly SupportRollerAssembly(SeePp.5.4-5.5) 11
F Part RotaryGear 1 1172-D1
G Assembly CamFollowerAssembly(SeePp.5.18-5.19) 24
H Assembly DoorPivotRollerAssembly(SeePp.5.6-5.7) 1
J Assembly ShifterAssembly(SeePp.5.16-5.17) 1
K Assembly PinionIdlerAssembly(SeePp.5.10-5.11) 1
L Part MotorGear 1 997-A10-149
L
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.8 technical Manual
SuPPoRt RolleR
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.9 technical Manual
SuPPoRt RolleR
Item Type Description Qty Part NumberA Part 1/4”NFStraightGreaseFitting 1 02-0097
BacKuP BoDy aSSeMBly - coMPReSSion lc confiGuRation
THIS 7-5/8” BACKUp ASSEMBLy (85-0604) AppLIES TO MOdEL 80-0615 ONLy
A B E F K
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JC D HG
RQ TM S
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.43 technical Manual
TItem Type Description Qty Part NumberA Weldment LoadCellHolderWeldment 1 01-9116B
B Part 3/8”RegularFlatWasher 1 09-5006
C Part 3/8”NCx1-1/4”HexBolt 1 09-1048
D Part 1-1/4”NCHexNut 3 09-5832
E Part SuspensionSpringV-Bracket 1 1483-500-00-04
F Part SuspensionSpringRetainer 2 1483-500-00-4B
G Part 1-1/4”NCx8”ThreadedRod 1 101-1993
H Part 1/4”NCx3/4”HexBolt 2 09-1005
J Part 2-1/2”Face0-3000PSI1/4”NPTGauge 1 02-0246
K Weldment GaugeProtectorWeldment 1 1483-500-18
L Part 3/8”NCx1-1/2”HexBolt 1 09-1050
M Part 3/8”CarbonSteelLockWasher 17 09-5106
N Part 1”NCx8-1/2”HexBolt 4 09-0287
P Part RearJaw 1 1401-08
q Part Rear-SideCoverPlate 2 1389-801-12
R Part 3/8”NCx3/4”HexBolt 16 09-1044
S Part SideCoverPlate 2 1391-7-1
T Assembly CLINCHER®CylinderAssembly 2 1401-00-00B
U Part 1”NCNylockNut 4 09-5725
V Weldment BackupBodyWeldment 1 1389-801
W Part ReliefValve 1 08-1180
X Part ReliefValveManifold(NotShown) 1 08-1839
Y Part CheckValve(NotShown) 1 08-0481
z Part CheckValveBody(NotShown) 1 08-1327
BacKuP BoDy aSSeMBly - coMPReSSion lc confiGuRation
W
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.44 technical Manual
BacKuP BoDy aSSeMBly - coMPReSSion lc confiGuRation
THIS 8-5/8” BACKUp ASSEMBLy (85-0607) AppLIES TO MOdEL 80-0615-6 ONLy
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.45 technical Manual
BacKuP BoDy aSSeMBly - coMPReSSion lc confiGuRation
Item Type Description Qty Part NumberA Part 3/8”NCx1-1/2”HexBolt 1 09-1050
B Part 1”NCx8”HexBolt 4 09-0288
C Part RearJaw 1 BUC8620-01
D Part 3/8”NCx3/4”HexBolt 16 09-1044
E Part BackupSidePlate 2 101-5079
F Assembly CLINCHER®8-5/8”CylinderAssembly 2 BUC8623-01
G Part 1”NCNylockNut 4 09-5725
H Part 3/8”NCx1-1/4”HexBolt 3 09-1048
J Part 2-1/2”Face0-3000PSI1/4”NPTGauge 1 02-0246
K Part 3/8”CarbonSteelLockWasher 17 09-5106
L Weldment LoadCellHolderWeldment 1 01-9116D
M Weldment GaugeProtectorWeldment 1 1483-500-18
N Weldment BackupBodyWeldment 1 101-5076
P Part BackupSidePlate 2 1389-801-12
q Part ReliefValve 1 08-1180
R Part ReliefValveManifold(NotShown) 1 08-1839
S Part CheckValve(NotShown) 1 08-0481
T Part CheckValveBody(NotShown) 1 08-1327
Q
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.46 technical Manual
BacKuP BoDy aSSeMBly - tenSion lc confiGuRation
THIS 7-5/8” BACKUp ASSEMBLy (85-0606) AppLIES TO MOdEL 80-0615-4 ONLy
A B D E J KHC
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M
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GF
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.47 technical Manual
BacKuP BoDy aSSeMBly - tenSion lc confiGuRation
Item Type Description Qty Part NumberA Part RearBodyPlate 1 1391-7-3
B Part 1-1/4”NCHexNut 3 09-5832
C Part 1-1/4”NCx8”ThreadedRod 1 101-1993
D Part SuspensionSpringV-Bracket 1 1483-500-00-04
E Part SuspensionSpringRetainer 2 1483-500-00-4B
F Part 3/8”NCx1-1/2”HexBolt 1 09-1050
G Part 3/8”CarbonSteelLockWasher 21 09-5106
H Part 1”NCx9”HexBolt 4 09-0288
J Weldment BackupBodyWeldment 1 1391B-500-00
K Part RearJaw 1 1401-08
L Part Rear-SideCoverPlate 2 101-2433
M Part 3/8”NCx3/4”HexBolt 20 09-1044
N Part SideCoverPlate 2 1391-7-1
P Assembly CLINCHER®CylinderAssembly 2 1401-00-00B
q Part 1”NCNylockNut 4 09-5725
r Part ReliefValve 1 08-1180
s Part ReliefValveManifold(NotShown) 1 08-1839
t Part CheckValve(NotShown) 1 08-0481
u Part CheckValveBody(NotShown) 1 08-1327
R
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.48 technical Manual
7-5/8” clincheR® cylinDeRS
THIS CyLINdER ASSEMBLy AppLIES TO 7-5/8” BACKUp MOdELS 85-0604 ANd 85-0606 ONLy
A
K
D
G
J L
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P Q
E F
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.49 technical Manual
7-5/8” clincheR® cylinDeRS
TItem Type Description Qty Part NumberA Part 3/8”NFx1”HexSocketHeadCapScrew 4 09-2044
B Part DieRetainer 4 101-2291
C Part WraparoundInsert(7-3/4”Shown)(SeePg.2.13) 1
D Part CylinderHousing 1 1401-01B
E Part CylinderRod 1 1401-04B
G Part CylinderPiston 1 1401-05B
J Part 3/8”NCx1”HexBolt 4 09-1170
K Part 3/8”CarbonSteelLockwasher 4 09-5106
L Part 3/8”PlainNarrowWasher 4 09-5124
M Part BackingPlate 1 1401-03B
N Part 5/8”NCx1-1/4”HexSocketHeadCapScrew 4 09-0240
P Part CylinderGland 1 1401-06B
Kit CLINCHER® Cylinder Seal Kit 1401-00-00-SKF Seal 2-231O-Ring 1
H Seal 37504750POLYPAK 1
q Seal SH940-41Wiper 1
R Seal STD25004500Polypak 1
S Seal W2-4750-625WearRing 1
T Seal SEALPARKERPOLYPAK25005000 1
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.50 technical Manual
THIS CyLINdER ASSEMBLy AppLIES TO 8-5/8” BACKUp MOdEL 85-0607 ONLy
8-5/8” clincheR® cylinDeRS
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.51 technical Manual
TItem Type Description Qty Part Number1 Weldment Rod/BackingPlateWeldment 1 BUC8626A
2 Part 8-5/8”BackupCylinderHousing 1 BUC8631A
3 Part Gland 1 BUC5528
4 Part Piston 1 BUC5525
5 Part SplineJawClip 4 73064
6 Part 3/8”UNCx3/4”HexSocketHeadCapScrew 4 09-2044
7 Part 3/16”x1/2”RollPin 4 1005-A
8 Part 5/8”UNCx1-1/4”HexSocketHeadCapScrew 4 09-0240
Kit CLINCHER® Cylinder Seal Kit ASAP2226Seal 8-231BackupRing 1
Seal POLYPAK37504750 1
Seal POLYPAK25005000 1
Seal POLYPAK25004500 1
Seal POLYPAK12502625 1
Seal SH959-41Wiper 1
Seal W47500625WearRing 1
8-5/8” clincheR® cylinDeRS
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS5.52 technical Manual
RiGiD SlinG
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 5.53 technical Manual
ALL FASTENERS USED TO ASSEMBLE LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS) MUST BE TIGHTENED TO THE CORRECT TORQUE.
Item Type Description Qty Part NumberA Part LiftingLink 1 02-0516
B Part RigidSlingAdjustmentHelix 1 1053-1-H
C Part 3/4”NCx9”HexBolt 1 09-1322
D Weldment RigidSlingWeldment 1 101-0112
E Part 1/2”NCHexJamNut 2 09-5810
F Part 1/2”NCx1-3/4”HexBolt 2 09-1172
G Part 3/8”NCx2”HexBolt 4 09-1046
H Part 3/8”HelicalLockWasher 4 09-5106
J Weldment LHRigidSlingBracket 1 101-0113
Weldment RHRigidSlingBracket 1 101-0115
K Weldment LevelAdjustmentBolt 2 1053-C-1L
L Part 3/4”UNCHexNut 2 09-5818
M Part RigidSlingPin 2 1053-C-1C
N Part 3/4”NCNylockNut 1 1429-39-02
P Part 3/16”HitchPin 4 02-0028
q Part 1/2”UNCx1-1/2”HexBolt 4 09-1170
R Part 1/2”LockWasher 4 09-5110
RiGiD SlinG
See PaGe 3.15
CE-Marked tongs use the following parts in place of those in the previous table:Item Type Description Qty Part NumberD Weldment RigidSlingWeldment 1 101-0112-CE
G Part 3/8”UNCx2”HexBolt,SSDrilled 4 09-1054SSD
q Part 1/2”UNCx1-1/4”HexBolt,SSDrilled 4 09-1168SSD
Rigid Sling Weldment - Standard Tong Rigid Sling Weldment
- CE Marked Tong
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 6.1 technical Manual
toRque MeaSuReMent
A. BASIC TORQUE MEASUREMENT Basictorquemeasurementsareperformedusingasimplehydraulicmeasurementsystem.Ahydraulicloadcellconnectstoacali-bratedtorquegaugethroughareinforcedflexiblehydraulichose.Thetorquegaugeisfactory-calibratedtodisplayaccuratetorquemeasurementsforatongortongandbackupassemblywithaparticulararmlength.Thearmlengthisameasurementfromthecentreofthepipeorcasingtothecentreoftheforcebeingappliedtotheloadcell.
Twoloadcelloptionsareavailable.Atensionloadcellistypicallyusedwithasuspendedstand-alonetong.Thisapplicationrequiresthat the loadcellbeattachedto therearof the tongaspartof therestraint line thatopposesthe forcegeneratedwhenthe tongmakesuporbreaksoutajoint.Acompressionloadcellisusedinatongandbackupassembly,andistypicallylocatedontherearofthebackupbetweenthebackupandastationaryframe.Theloadcellmustbelocatedinthecentreofthecompressionforcevectorgeneratedbetweenthebackupandtheframe.
THE IMAGES DISPLAYED ARE SUPPLIED FOR ILLUSTRATION PURPOSES ONLY
TORQUE GAUGES AND LOAD CELLS ARE FACTORY-SUPPLIED AS MATCHED CALIBRATED PAIRS. IF REPLACING EITHER COMPONENT THE LOAD CELL AND TORQUE GAUGE MUST BE RETURNED TO THE FACTORY FOR RE-CALIBRATION BEFORE PLACED INTO SERVICE.
Torquegaugesand loadcellsaresuppliedasamatchedcalibratedpair.Substitutingoneor theotherwill render thecalibrationinaccurateeven if theactualmodelnumbersappear tobe identical.Theserialnumbersofmatching loadcellandtorquegaugesareclearlyidentifiedonthecalibrationcertificate.Shouldyoususpecttheaccuracyofyourtorquemeasurements,orwishtoreplaceeithercomponentthepairshouldbereturnedtothefactoryforre-calibrationbeforeplacingintoservice.
ILLUSTRATION 6.A.2: TENSION LOAd CELL
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS6.2 technical Manual
Type Description Qty Part #Assembly 36”Arm-30KCompressionLoadCellandGauge 1 10-0017C
Part 8in2CompressionLoadCell(c/w5’hose&quick-disconnect) 1 10-0008C
Part TorqueGauge,30,000Lbs-Ft.36”Arm 1 10-0017CG
Part 5Ft.HydraulicHoseAssembly 1 02-0069
Type Description Qty Part NumberAssembly 32”Arm30KTensionLoadCellandTorqueGaugeAssembly 1 10-0022T
Assembly TensionLoadCell 1 10-0008T
Part TorqueGauge,30000Lbs-Ft.32”Arm 1 10-0022G
Part 5Ft.HydraulicHoseAssembly 1 02-0069
THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE. THE PART NUMBERS LISTED IN THE FOLLOWING TABLE ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED.
LOAD CELLS ARE NOT USER SERVICEABLE. ILLUSTRATIONS 6.A.4 & 6.A.5 ARE PROVIDED FOR INFORMATION PURPOSES ONLY. DAMAGED LOAD CELLS MUST BE RETURNED TO THE FAC-TORY FOR REPAIR AND RE-CALIBRATION.
ELECTRONIC LOAD CELLS ARE NOT PERMITTED FOR USE WITH CE MARKED EQUIPMENT
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 6.3 technical Manual
ILLUSTRATION 6.A.4: TENSION LOAd CELL
toRque MeaSuReMent
This is the standard tension load cell supplied by McCoy Drilling & Completions | Farr. Contact our sales depart-ment for information about optional application-specific tension load cells.
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Item Type Description
Assembly Tension Load Cell, 4.08 in2
A Part 1/4” NC x 1/2” Binding Head Machine Screw
B Part Stat-O-Seal
C Part O-Ring
D Part O-Ring
E Part Load Cell Piston
F Part Flange Gasket
G Part Load Cell End
H Part Load Cell Rod
J Part Wiper
K Part O-Ring
L Part Load Cell Body
M Part 3/8” NC x 3/8” Cup Point Hex Set Screw
Seal Kit Replacement Seal Kit 4.08 in2 Tension Load Cell
This is the standard hydraulic compression load cell supplied by McCoy Drilling & Completions | Farr. Contact our sales department for information about optional application-specific compression load cells.
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Compression Load Cell, 8 in2
Item Type Description Item Type Description
A Part 5/16” UNC x 1” Hex Socket Head Cap Screw E Part Diaphragm
B Part Load Plate F Part Diaphragm Casing
C Part 5/16” UNC x 3/4” Hex Socket Head Cap Screw G Part Street Elbow
D Part Retainer Ring H Part 1/4” NPT Brass Plug
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 6.5 technical Manual
ILLUSTRATION 6.A.5: TURN COUNTER ENCOdER MOUNT
toRque MeaSuReMent
2.74”2.75”
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Item Type Description Qty Part Number
Assembly Standard Turn Counter Encoder Mount 1 60-0001
A Part 6-32 x 3/8” Hex Socket Head Set Screw 4
B Part Helical Flexible Encoder Shaft Coupling 1 60-0130N
C Part Internal Retainer Ring 2 1376-13
D Part Bearing 2 1376-05
E Part Encoder Housing 1 1392-104A
F Part Internal Retainer Ring 1 02-0436
G Part Encoder Shaft 1 1392-103A-01
H Part Encoder Gear 1 01-0320A-M
J Part 10-24 x 1-1/4” Hex Socket Head Set Screw 1
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS6.6 technical Manual
toRque MeaSuReMent
B. TROUBLESHOOTINGUndernormaloperatingconditions,andwithpropermaintenance,thetorquegaugeandloadcellsystemaredesignedtogivelastingtrouble-freeperformance.Faultyindicationonthegaugewillveryoftendefineafaultwithinthegauge.
MAINTAIN GREATER-THAN HALF FULL FLUID LEVEL IN THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO THE SYSTEM. DO NOT ALLOW THE LEVEL TO FALL BELOW ONE-HALF FULL
UN-CONTAINED SPILLAGE OF THE HYDRAULIC FLUID IN THIS SYSTEM MAY CONTRAVENE GOVERNMENTAL ENVIRONMENTAL REGULATIONS, OR THE ENVIRONMENTAL REGULATIONS AND POLICIES OF YOUR COMPANY. FARR CANADA CORP. HIGHLY RECOMMENDS PLACING YOUR LOAD CELL IN A CONTAINMENT BASIN BEFORE PROCEEDING WITH THE BLEEDING & REFILLING PROCESS.
d. FillhandpumpbowlwithW15/16hydraulicfluid.
e. RemovetheventplugscrewandStat-O-Seal(ItemsCandDonIllustration6.A.4,oritemHonIllustration6.A.5)toallowtrappedairtoescape.
f. Pumpfluidintothesystemuntilnomoreairisseenescapingfromtheventport.
g. ReplacetheventplugscrewandStat-O-Sealandtightensecurely.
h. Removeloadcellfromcontainmentvesselandwipeclean.Reclaimthehydraulicfluid(ifitisclean)ordisposeofallwastematerialsaccordingtogovernmentaloryourcompany’sproscribedenvironmentalprotectionregulations.
i. Disconnectthehandpumpfromthetorquegauge.
j. Replacethebrasscaponthetorquegaugecheckvalvefitting.
3. Reference Checking Your Torque Measurement SystemThefollowingstepsdefineaprocessfordeterminingifyourtorquemeasurementsystemiscorrectlymeasuringandindicatingwithinanexpectedrange.Thisprocedureisbestsuitedforperforminginashoporlocationremovedfromthedrillfloor,withinrangeofacrane.Thisisareferencecheckandnotacalibration.Calibrationsmustbeperformedatanauthorizedcalibrationfacility.
TensionLoadCell
a. Locateaknownweightintherangeofapproximately500to1000lbs(227to455kg),andmovetheweightnexttothetongandbackupassembly.
b. Removethetensionloadcellfromthetong,butdonotdisconnectfromthetorquegauge.
c. Suspendtheloadcell,pistonsideup,fromacranecapableofsupportingtheknownweightinStep3a.
d. Connecttherodsideoftheloadcelltotheknownweight,andusethecranetohoisttheweightfromthesurfacetobesuspendedfreely.
a. Placethetorqueindicatinggaugehigherthantheloadcell.Removethebrass1/4”capfromthefittingonthecheckvalveonthetopofthegauge.
b. Connectthehandpumptothecheckvalvefitting.
c. Elevatetheloadcellsoitishigherthanthetorquegaugeandhandpump.
ONLY QUALIFIED, DESIGNATED PERSONNEL ARE PERMITTED TO PERFORM MAINTENANCE ON THE TORQUE MEASUREMENT SYSTEM.
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS6.8 technical Manual
Reference Checking Your Torque Measurement System (continued):TensionLoadCell(continued):
e. Performasimplecalculationtodeterminetheexpectedindicationonthetorquegaugebasedontheknownhoistedweight.This is a calculation thatmust be performedusing imperial units (eg., poundsand feet). The calculation is: [KNOWNWEIGHT]x[ARMLENGTH(infeet)].Forexample,ifthearmlengthis32inchesandthehoistedweightis1000lbsthecalculationis:
a. Locateaknownweight,andmovetheweightnexttothetongandbackupassembly.
b. Removethecompressionloadcellfromthetong,butdonotdisconnectfromthetorquegauge.
c. Placethecompressionloadcell,pistonsidedown,onasturdysurfacesuchasaconcreteshopfloor.
d. Useacranetohoisttheknownweightontotherodendofthecompressionloadcell.Thisisasmallarea,soanidealknownweightshouldberelativelysmallanddense.Ablockofsolidmetalorconcreteispreferred.Theweightmustbecenteredexactlyontherodendoftheloadcelltoensureevenandaccuratecompression.Donotuseatallunrestrainedknownweight that could topple.Donot disconnect the knownweight from the crane, but ensure the craneexerts noupwardforceontheweight.Theattachedcranepreventsanun-centeredweightfromtoppling.
e. Performasimplecalculation todetermine theexpected indicationon the torquegaugebasedon theknownweightontheloadcell.Thisisacalculationthatmustbeperformedusingimperialunits(eg.,poundsandfeet).Thecalculationis:[KNOWNWEIGHT]x[ARMLENGTH(infeet)].Forexample,ifthearmlengthis36inchesandtheknownweightis500lbsthecalculationis:
Eight fixed displacement motorsranging from 6 in3 to 15 in3.Starting and stall torques equalto 90-94% of theoretical torque.Speed to 2,000 RPM continuous.Up to 75 HP continuous.Conforms to SAE 'C' mountingspecification.Weighs 43 lbs.
Features of the 15 Series Standard Motor:Standard Motor - 3000 PSI (Code 61)
MOTOR SELECTION GUIDE
POWER to be the Best!
CROSS SECTION
Made in USA PUBLICATION DS151005 8/03
HYDRAULICS, INC.HYDRAULICS, INC.
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MA
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FA
CT
URER OF HYDRAULIC
MO
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KT8625 Tong WiTh CLinChER® BaCKup
Section contentS 7.3 technical Manual
hyDRaulic infoRMation
1.38
SAE 14T 12/24 PITCHFLAT ROOT SIDE FITINVOLUTE SPLINE
OPTIONAL SHAFT
6.81
3.41
4.51
5.70
9/16" DIA., 4 HOLES
17°
17°
CENTERLINECASEDRAIN
CENTERLINE
CASEDRAIN
5.91
5.69
7.17 2.18
5.87.24
.51 1.62EFF.KEY
1.0
5.0004.998
1.2501.248
.314
.3161/2-
13UNC
3/8" O-RING BOSSCASE DRAIN(2) PLACESSAE STD. 1.25
4-BOLT FLANGENEAR AND FAR
15 Series Standard Motor Envelope
A
B
6.82
3.41
4.50SQR.
5.70
17°
CENTERLINECASEDRAIN
17°
CENTER LINECASE DRAIN
PORT"B"
PORT"A"
5.91
9.0 2.18
5.80.24
.50 1.62EFF.KEY
1.0
5.0004.998
1.2501.248
.313
.315
7.80
PORT 'A'
5.40
1.3
OPTIONAL SHAFT
1.8 2.2
REAR VIEW
SAE 14T 12/24 PITCHFLAT ROOT SIDE FITINVOLUTE SPLINE
ALTERNATEPORT "A"1-1/4 O-RING BOSS
ALTERNATEPORT "B"
1-1/4 O-RING BOSS
1/2-13UNCx 1/2 DP.
3/8" O-RING BOSSCASE DRAIN(2) PLACES
SAE STD. 1.254-BOLT FLANGENEAR AND FAR
SAE 1/4 O-RING BOSS
1/4 O-RING BOSS
9/16" DIA., 4 HOLES
15 Series Two Speed Envelope
KT8625 Tong WiTh CLinChER® BaCKup
Section contentS7.4 technical Manual
hyDRaulic infoRMation
Technical Information - All Styles
VANE CROSSING VANEThe Rineer patented vane crossing vane design producesmuch higher volumetric and mechanical efficiencies than ispossible with a standard vane type design. This designprovides a sealing vane between cavities to improvemechanical and volumetric efficiencies.
STARTING AND STALL TORQUEThe Rineer motor produces torque curves which are virtuallyflat, with starting and stall torque equal to approximately 90-94% of theoretical torque.
MORE POWER STROKES PER REVOLUTIONThe 15 Series has four stator cavities and 10 rotor vanes.Each rotor vane works in each stator cavity once perrevolution, which results in 40 power strokes per revolution.This helps produce higher mechanical efficiency and flattertorque curves.
BEARING LOADINGThe bearings in the 15 Series can accept radial load per theradial capacity chart. Thrust load is not recommended undermost conditions. Consult with a Rineer Application Engineerfor optional bearing configurations to match your application.
SEALSBuna N seals are supplied as standard on the Rineer 15series motors. Viton seals may be ordered as an option.
ROTATING GROUP - 1S or 1HUnder most operating conditions, 1S (standard rotatinggroup parts) should be used. Under some high speedconditons 1H can be specified.
ROTATIONThe 15 Series Motor rotates equally well in either directionand smoothly throughout its entire pressure and speedrange. Looking into the end of the shaft, rotation is clockwisewhen oil is supplied to port "A".
HORSEPOWER LIMITATIONMaximum horsepower limitations may vary with differentapplications. When using the 15 Series Motor above 75HP, consult a Rineer Application Engineer.
FILTRATION25 micron minimum.
FLUIDWe suggest premium grade fluids containing high quality rust,oxidation and foam inhibitors, along with anti-wear additives.For best performance, minimum viscosity should bemaintained at 100 SSU or higher. Fluid temperature should notexceed 180O F. Elevated fluid temperature will adversely affectseal life while accelerating oxidation and fluid breakdown. Fireresistant fluids may be used with certain limitations. ContactRineer for additional information.
CASE DRAINThe 15 Series Motor is designed for either internal or externalcase drain. Two case drain ports are supplied. When usinginternal case drain, simply plug the two ports. When usingexternal case drain, use the port at the highest elevation. Werecommend case drain pressure of 35 PSI or less when usingthe standard seals.
CASE DRAIN CIRCULATIONFluid should be circulated through the case when atemperature differential exists between the motor and thesystem in excess of 50O F. Should this occur, contact aRineer Application Engineer.
MOUNTINGThe mounting position is unrestricted. The shafts, pilots, andmounting faces should be within .002 TIR.
INTERMITTENT CONDITIONSIntermittent conditions are to be less than 10% of every minute.
OTHER AVAILABLE MOTORSFor information on additional Rineer Motors, request one of thefollowing publications:
37 Series ..............................................Publication DS37100357 Series ..............................................Publication DS571003125 Series ............................................Publication DS1251003
Technical Information - Retractable Shaft Motor
RETRACTING THE SHAFTThe shaft is spring loaded into the engaged position. Pullingon the knob attached to the shaft at the rear of the motor willmove the shaft 1.25 inches into the motor.CAUTION: Retracting the shaft must be done when themotor and driven mechanism are not in operation andare unloaded.
RETAINING SHAFT IN RETRACTED POSITIONThe shaft is retained in the retracted position by inserting a2.0 inch wide spacer between the rear housing and the knobattached to the shaft. Depending on the application andmounting position of the motor, the spacer design may vary.Spacers are not supplied with the motor.
RE-ENGAGING THE SHAFTThis is accomplished by releasing the shaft, then rotating itclockwise until the splines of the shaft line up and engage thesplines of the driven mechanism.CAUTION: Re-engaging the shaft must be done when themotor and driven mechanism are not in operation and areunloaded.
BEARING LOADINGThe 15 series Retractable is not suitable for applications whichrequire radial or axial loading of the shaft.
MOUNTINGThe mounting position is unrestricted. CAUTION: The shaftextension and knob at the rear of the motor rotates whenthe motor is in operation.
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Performance Data - Selected Displacements
The above performance data was obtained at 140OF with ISO 46(DTE 25). These values must be maintained to obtain the performance indicated. Contact Rineer Hydraulics, Inc. for additional displacements.
For durable hydraulic motors that meet your demands, specify Rineer.For over 35 years, we have specialized in only one thing - engineering the right motor for your needs.Rineer delivers the performance you can count on.
Model CodeM015 - 61/62 -1S -015 -31 -B1 -TV -000
M015 - 61 = 015 Single SpeedM015 - 62 = 015 Two Speed
Options:62 = Two Speed Single Pilot
Open During Crossover63 = Two Speed Single Pilot
Closed During Crossover65 = Two Speed Double Pilot
Rineer Hydraulics, Inc. warrants that, at the time of shipment toPurchaser, our product will be free of defects in the material andworkmanship. The above warranty is LIMITED to defectiveproducts returned by Purchaser to Rineer Hydraulics, Inc., freightprepaid within four hundred and fifty-five (455) days from date ofshipment, or one (1) year from date of first use, whichever expiresfirst. We will repair or replace any product or part thereof which isproved to be defective in workmanship or material. There is noother warranty, expressed or implied, and in no event shall RineerHydraulics, Inc. be liable for consequential or special damages.Dismantling the product, operation of the product beyond thepublished capabilities or for purposes other than that for which theproduct was designed, shall void this warranty.
WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
1
2
3
4
5
6
7
8
5
1) Remove snap ring
WARNING: Use caution when removing snap ring. If released accidentally it can become an airborne hazard.
1) Pry out shaft seal plate with two screw drivers.2) Remove seal plate o-ring from groove in bearing bore.
1) Loosen and remove 8 each 10-32 bolts.2) Pry off seal plate with screw driver.
Loosen and remove 8 each 3/8" bolts with 5/16" socket head wrench.
1) Press shaft out of bearing box.2) Proceed to step 9, disregarding steps 11 & 12
1) Loosen clamp screw in lock nut.2) Unscrew lock nut and remove.
Lift up on the bearing box to remove from motor.
1) Two of the 3/8" bolt holes are provided with jack screw threads.2) Insert a piece of 1/4" round stock by 2-1/2" long into each jack screw hole3) Screw two 7/16-14 bolts into the jack screw threads until the bearing box is free of the motor.
REMOVAL OF SHAFT SEAL
REMOVAL OF WHEEL MOTOR SEALPLATE AND BEARING BOX
DISASSEMBLY OF WHEEL MOTORBEARING BOX
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WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
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1) Remove front housing2) Note: Two 5/16" ball checks and one main body o-ring may be dislodged and fall free.
1) Mark one side of the motor for proper assembly, paying careful attention that the cartridge will not be installed upside down.2) Secure the motor prior to loosening the 5/8-11 bolts.
With the seal plate removed, press shaft and ball bearing out of front housing.
1) Remove snap ring from shaft.2) Press shaft out of bearing.
1) Remove o-ring and springs with a small screwdriver.2) Remove dowels pins.
1) Place cartridge on any object which will hold it off the table.2) Remove two each 10-32 place screws.3) Remove timing plate.
Lift up rotor/stator cartridge and remove from the rear housing.
DISASSEMBLY OF FRONTHOUSING AND SHAFT
DISASSEMBLY OF ROTOR/STATORCARTRIDGE
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WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
17 21
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23
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7
1) Remove the rotor.2) Remove both the rotor and stator vanes.3) Note: On motors manufactured prior to 1987, rotor vane slots and rotor vanes should be numbered so that vanes can be reassembled in the same vane slot.
Inspect all springs and seals. We recommend replacement of all seals and springs whenever the motor has been disassembled.
Inspect all parts and replace any parts which obviously show excessive wear or damage.
VANES: Normal wear results in slight flattening of vane tips which does not impair motor performance. Replace vane if radius is reduced by 50%.Clearance between the rotor vane and rotor vane slot varies with the vane selection. The design allows the vane to "lean" slightly in the slot, providing the required mechanical seal.
Note: Measure the rotor and stator length to the fourth decimal point and supply measurement when ordering rotor, stator, or vanes.
STATOR: Normal wear results in polishing of cam form which does not impair motor performances.Noticeable wear may be apparent along the corner of one side of the staor vane slot. This does not necessarily require replacement of the stator, but may slightly affect volumetric efficiency.
ROTOR: Normal wear results in polishing of rotor faces which does not impair motor performance.Examine the rotor vane slots closely. Polishing down in the slots is normal, but if there is any indication of a "pocket" forming in the wall of the slot, the rotor should be replaced.
PLATES: Normal wear results in marking of timing plates which does not impair motor performance.Replacement of the timing plate is required if any smearing, galling, or heat cracks are present.
INSPECTION AND REPLACEMENTOF PARTS
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WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
25
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8
1) Reverse the procedures in steps 17, 16, 15, and 142) NOTE: Make sure that the radiused edge of each stator vane points to the rotor and the radiused edge of each rotor vane points to the stator.3) NOTE: Make sure springs are seated in the bottom of the spring pocket in both the rotor and stator.
1) Press bearing onto shaft.2) Install snap ring.
Press shaft and bearing assembly into front housing by pressing on the outer race of bearing.
1) Place seal in seal plate.2) Place seal plate o-ring into groove in the front housing.3) Press seal plate into front housing.4) Install snap ring.5) Proceed to step 30.
1) Install main body o-ring into front housing.2) Install ball checks into front housing.3) Place a small amount of grease over ball checks and o-ring.4) Wipe off excess grease.
1) Place rotor/stator cartridge onto rear housing.2) NOTE: Make sure assembly marks from step 3 are lined up.
1) Install dowel pins into rear housing.2) Install ballchecks into rear housings.3) Install main body o-ring.
1) Reverse the procedures in steps 8 thru 3.2) Screw lock nut onto shaft until all threads are engaged.3) Tighten clamp screw until lock nut turns with a slight drag.4) Tighten lock nut until desired rolling drag of bearing is obtained - see procedure Page 9.5) Tighten clamp screw6) Tighten all seal plate bolts.
ASSEMBLY OF ROTOR/STATORCARTRIDGE
ASSEMBLY OF FRONT HOUSING
ASSEMBLY OF WHEEL MOTORFRONT HOUSING
ASSEMBLY OF MOTOR
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WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
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B
A
9
1) Install dowel pins into rotor/stator cartridge.2) Pour a small amount of clean oil into the cartridge.3) Install front housing onto rotor/stator cartridge.4) Make sure alignment marks are lined up.
1) Install 5/8-11 bolts.2) Torque bolts to 50 ft./lbs.
1) Rotate shaft in both directions to assure that the shaft turns smoothly.2) Torque motor to 190 ft./lbs.3) Rotate shaft again in both directions to assure that the shaft turns smoothly.
NOTE: Spool should be oriented as shown for two speed motors with model codes 62, 63, 68, & 69.
NOTE: Slight design variations may exist in motors manufactured either before or after the printing of this manual.
SPOOL ASSEMBLY FOR THETWO SPEED MOTOR
1)� Clean ALL assembly parts w/ lacquer thinner.2)� Dip clampnut and clamping bolt separately in lacquer thinner. � (Steps 3 thru 10 must be conducted to completion ONE assembly at a time.)3)� Press bearing cups into bearing housing. Make sure they are pressed completely against bearing shoulders.4)� Coat inner race of large cone with #609 (green) Loctite and press cone onto the shaft. Make sure the cone is completely against the shoulder of the shaft.5)� Insert shaft and large cone into bearing housing.6)� Coat inner race of small cone with #609 (green) Loctite and press small cone onto shaft.7)� Apply #272 (red) Loctite to the clampnut threads of the shaft. Apply #242 (blue) Loctite to the threads of the clamping bolt and install in the clampnut.8)� Spin clampnut onto shaft with the "B" face towards bearings. After the nut threads are fully engaged, but prior to the nut contacting the bearings, �� tighten the clamping bolt until there is drag on the clamping nut (see note Fig. 1). Tighten the nut until a 20 to 30 inch pound rolling torque is achieved.9)� Tighten clamping bolt on clampnut to 70 inch pounds and recheck rolling torque. Apply inspectors lacquer to head of the bolt.10)� Allow a minimum of 24 hrs. to dry.
Figure 1
CUTAWAY
Note:The slit in the clampnut allows for loose assembly on the shaft. Once in position, the clampnut clamping bolt MUST be tightened to a slight drag in order to correctly engage the threads on the shaft to achieve the clamp force required.
FACE"A"
CLAMPING BOLT
FACE"A"
FACE"B"
WHEEL MOTOR SHAFT AND BEARING ASSEMBLY PROCEDURE
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Information:Bolt Torque -� Main Bolts (5/8-11): 190 ft. lbs.� Seal Plate (3/8-16)� (Wheel Motor only): 45 ft. lbs.Grease used for bolt threadsand o-ring retention:� Pennzoil 707L REDShaft seal assembly lube:� Mobilgrease special� with Moly
Seal Kits:� Standard 15 series seal kit� � #0150940� Standard 15 two speed seal kit� � #0150940� Standard 15 wheel motor seal kit� � #0150936
Product DescriptionThese unbalanced poppet, logic valves are 2-way switching elements that arespring-biased closed. Pressure at either work port 1 or 2 will further bias thevalve to the closed position while pressure at port 3 will tend to open it. Theforce generated at port 3 must be greater than the sum of the forces actingat port 1 and port 2 plus the spring force for the valve to open. NOTE: Thepilot area (port 3) is 1.8 times the area at port 1 and 2.25 times the area atport 2.
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Technical FeaturesBecause these valves are unbalanced, operation ispressure dependent. Opening and closing of thepoppet are functions of the force balances onthree areas: Port 1 = 100%, Port 2 = 80%, andPort 3 = 180%.
These valves are pressure responsive at all threeports, therefore it is essential to consider allaspects of system operation through a completecycle. Pressure changes at any one port maycause a valve to switch from a closed to an openposition, or vice versa. All possible pressurechanges in the complete circuit must beconsidered to assure a safe, functional systemdesign.
These valves have positive seals between port 3and port 2.
All ports will accept 5000 psi (350 bar).
Stainless steel cartridge options P or W areintended for use within corrosive environmentswith all external components manufactured instainless steel or titanium. Internal workingcomponents remain the same as the standardvalves.
Incorporates the Sun floating style construction tominimize the possibility of internal parts bindingdue to excessive installation torque and/orcavity/cartridge machining variations.
Product DescriptionThese unbalanced poppet, logic valves are 2-way switching elements that arespring-biased closed. Pressure at either work port 1 or 2 will further bias thevalve to the closed position while pressure at port 3 will tend to open it. Theforce generated at port 3 must be greater than the sum of the forces actingat port 1 and port 2 plus the spring force for the valve to open. NOTE: Thepilot area (port 3) is 1.8 times the area at port 1 and 2.25 times the area atport 2.
Download
Technical FeaturesBecause these valves are unbalanced, operation ispressure dependent. Opening and closing of thepoppet are functions of the force balances onthree areas: Port 1 = 100%, Port 2 = 80%, andPort 3 = 180%.
These valves are pressure responsive at all threeports, therefore it is essential to consider allaspects of system operation through a completecycle. Pressure changes at any one port maycause a valve to switch from a closed to an openposition, or vice versa. All possible pressurechanges in the complete circuit must beconsidered to assure a safe, functional systemdesign.
These valves have positive seals between port 3and port 2.
All ports will accept 5000 psi (350 bar).
Stainless steel cartridge options P or W areintended for use within corrosive environmentswith all external components manufactured instainless steel or titanium. Internal workingcomponents remain the same as the standardvalves.
Incorporates the Sun floating style construction tominimize the possibility of internal parts bindingdue to excessive installation torque and/orcavity/cartridge machining variations.
Pilot operated, balanced piston relief valveCapacity:
50 gpm (200 L/min.)
Functional Group:: Cartridges : Relief : 2 Port : Pilot Operated, Balanced Piston
Model:
RPGC
Product DescriptionPilot-operated, balanced-piston relief cartridges are normally closedpressure regulating valves. When the pressure at the inlet (port 1)reaches the valve setting, the valve starts to open to tank (port 2),throttling flow to regulate the pressure. These valves are accurate,have low pressure rise vs. flow, they are smooth and quiet, and aremoderately fast.
Technical Features Will accept maximum pressure at port 2; suitable
for use in cross port relief circuits. If used in crossport relief circuits, consider spool leakage.
Main stage orifice is protected by a 150 micronstainless steel screen.
Not suitable for use in load holding applicationsdue to spool leakage.
Back pressure on the tank port (port 2) is directlyadditive to the valve setting at a 1:1 ratio.
All 2-port relief cartridges (except pilot reliefs) arephysically and functionally interchangeable (sameflow path, same cavity for a given frame size).
Stainless steel cartridge options P or W areintended for use within corrosive environmentswith all external components manufactured instainless steel or titanium. Internal workingcomponents remain the same as the standardvalves.
Incorporates the Sun floating style construction tominimize the possibility of internal parts bindingdue to excessive installation torque and/orcavity/cartridge machining variations.
PN: 08-1180
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Technical DataU.S. Units Metric Units
Cavity T-3ACapacity 50 gpm 200 L/min.Adjustment - Number of Clockwise Turns toIncrease Setting 5 5
Factory Pressure Settings Established at 4 gpm 15 L/min.Maximum Operating Pressure 5000 psi 350 barMaximum Valve Leakage at 110 SUS (24 cSt) 3 in³/min.@1000 psi 50 cc/min.@70 barResponse Time - Typical 10 ms 10 msSeries (from Cavity) 2Valve Hex Size 1 1/8 in. 28,6 mmValve Installation Torque 45 - 50 lbf ft 60 - 70 NmAdjustment Screw Hex Socket Size 5/32 in. 4 mmAdjustment Nut Hex Size 9/16 in. 15 mmAdjustment Nut Torque 108 lbf in. 12 NmModel Weight .50 lb 0,25 kgSeal Kits Viton: 990-203-006Seal Kits Buna: 990-203-007
Option Selection
RPGC-L A N
Preferred Options
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Pilot-to-open check valve with standard pilotCapacity:
Product DescriptionThis valve is a pilot to open check valve. It has a non-sealed pilot, a steel seat, and is non-vented. It allows free flow from the valve (port 2) to the load (port 1) and blocks flow in theopposite direction. Pressure at the pilot (port 3) will open the valve from port 1 to port 2. Pilotpressure needed at port 3 to open the valve is directly proportional to the load pressure at port1. Pressure at port 2 directly opposes pilot pressure.
Technical Features Provides hose break protection,
prevents loads from drifting andpositively locks pressurized loads.
Standard unsealed pilot allows airtrapped in the pilot line to be purgedfrom the circuit.
Extremely low leakage. The seat andpoppet are heat treated for long life. Ifthe load drifts due to the valve, the seathas probably been damaged bycontamination and the valve should bereplaced.
Optional external porting out of the hexend of the cartridge is available forexternal piloting. In this configuration,port 3 is blocked. See Control optionsE, and P.
Pilot-to-open check cartridges arelocking valves, not motion controlvalves. For motion control applications,
This 3 port pilot-to-open check valveand 3 port counterbalance valves arephysically interchangeable (i.e. same
PN: 08-0481
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use counterbalance valves. cavities, same flow path for a givenframe size). However, cartridgeextension dimensions from themounting surface may vary.
Stainless steel cartridge options P or Ware intended for use within corrosiveenvironments with all externalcomponents manufactured in stainlesssteel or titanium. Internal workingcomponents remain the same as thestandard valves.
Incorporates the Sun floating styleconstruction to eliminate the effects ofinternal parts binding due to excessiveinstallation torque and/orcavity/cartridge machining variations.
Product DescriptionThis valve is a pilot to open check valve. It has a non-sealed pilot, a steel seat, and is non-vented. It allows free flow from the valve (port 2) to the load (port 1) and blocks flow in theopposite direction. Pressure at the pilot (port 3) will open the valve from port 1 to port 2. Pilotpressure needed at port 3 to open the valve is directly proportional to the load pressure at port1. Pressure at port 2 directly opposes pilot pressure.
Technical Features Provides hose break protection,
prevents loads from drifting andpositively locks pressurized loads.
Standard unsealed pilot allows airtrapped in the pilot line to be purgedfrom the circuit.
Extremely low leakage. The seat andpoppet are heat treated for long life. Ifthe load drifts due to the valve, the seathas probably been damaged bycontamination and the valve should bereplaced.
Optional external porting out of the hexend of the cartridge is available forexternal piloting. In this configuration,port 3 is blocked. See Control optionsE, and P.
Pilot-to-open check cartridges arelocking valves, not motion controlvalves. For motion control applications,
This 3 port pilot-to-open check valveand 3 port counterbalance valves arephysically interchangeable (i.e. same