technical manual kt8625 - texasinternational.com · kt8625 tong with clincher® backup technical...

• Specifications• Operation• Maintenance• Assembly

TECHNICAL MANUAL

Copyright © 2005 - 2012 McCoy Corporation. All rights reserved.Published by McCoy Corporation, Technical Publications Department14755 - 121A Avenue • Edmonton, AB, Canada, T5L 2T2

mccoyglobal.com

KT86258-5/8” (21.9cm) 25K Lbs.-Ft.Hydraulic Power Tong & 7-5/8” (19.3cm) / 8-5/8” (21.9 cm) CLINCHER® Backups

Model 80-0615-4Shown

Model 80-0615Shown

KT8625 Tong WiTh CLinChER® BaCKup

Section contentS iii technical Manual

This manual applies to the following models:

NOTE: Some illustrations used in this manual may not exactly match your model of tong.

PATENTED & PATENTS PENDING

oVeRall MoDel

tonG MoDel

BacKuP MoDel ReV DeScRiPtion

80-0615 80-0609-3 85-0604 0Tong isequippedwithRineermotor,motorvalve, liftcylindervalve,backupvalve,rigidsling,andsafetydoor.7-5/8”CLINCHER®com-pressionloadcell-stylebackup.

80-0615-4 80-0609-3 85-0606 0Tong isequippedwithRineermotor,motorvalve, liftcylindervalve,backupvalve,rigidsling,andsafetydoor.7-5/8”CLINCHER®tensionloadcell-stylebackup.

80-0615-6 80-0609-3 85-0607 0Tong isequippedwithRineermotor,motorvalve, liftcylindervalve,backupvalve,rigidsling,andsafetydoor.8-5/8”CLINCHER®com-pressionloadcell-stylebackup.

ORIGINAL INSTRUCTIONS

This technical manual applies to all CE-marked versions of the models listed in the table above.

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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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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

June2010 N/A N/A Re-badgedtongasKT8625

Jan.2011

All Addedimprovedwarningsymbologythroughout

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Intro

iii Addedmodel80-0615-6

v Addeddetailedwarningpage

viii Updatedtableofcontents

ix Addedlistofillustrations

2

2.1 AddedSling/LoadBearingDevicesafetysection

2.8 Consolidatedmultiplehydraulicschematicsintoone

2.9-2.11 Replacedallhydrauliccomponentidentificationimages

2.15 Addedlistofavailablejawsfor8-5/8”backup

2.17 Addedtongrig-upandlevelingsection

2.21-2.22 Replacedallvalveoperationimages

2.23 Addedinstructionsforproperlyshiftinggears

2.24 Addeddetailedinstructionsformakingandbreakingconnections

3

3.1 Addedsection“GeneralMaintenanceSafetyPractices”

3.1 Addedsection“PreventiveMaintenance”

3.9 Addedsection“ShifterDetentForceAdjustment”

3.10-3.12 Revisedandcorrected“OverhaulProcedures-Disassembly”

3.12-3.22 Revisedandcorrected“OverhaulProcedures-Assembly”

4 All Removedinapplicabletroubleshootinginstructions&addeddetailtorelevantinstructions

5

All Removedsection“StorageRecommendations”

All Re-numbered“Parts&Assemblies”-thisisnowSection5

5.2 Replacedgraphics

Continued on next page

Copyright©2007-2012McCoyCorporation,includingitswhollyownedsubsidiaries,(“McCoy”),allrightsreserved.ThisdocumentisthepropertyofMcCoyandissuppliedasreferenceinformationforusersofourproducts.Thisdocumentandthecontentswithinareconsid-eredconfidentialinformation,nottobedisclosed,copied,transmitted,transcribedinanyform,orstoredonanytypeofdatastoragemediawithouttheexpresswrittenconsentofMcCoy.

McCoyhasmadeeveryefforttoensuretheinformationcontainedinthisdocumentisaccurateandcurrent.Thismanualisintendedtoprovideequipmentoperationandsafetyinstructionsforyourequipment.However,McCoydoesnotwarrantorguaranteethattheinforma-tioniseithercompleteoraccurateineveryrespectandtheuserofthemanualshouldconsultwithitsMcCoysalesrepresentativeforanyclarificationsandupdates.

Theuserofthemanualshallprotect, indemnify,andholdharmlessMcCoyanditsdirectors,officers,employees,andagentsfromandagainstallliabilityforpersonalinjury,death,orpropertydamageresultingdirectlyorindirectlyfromtheuseoftheinformationcontainedinthismanual.

Observanceofalldescriptions, informationand instructionssetout in thismanual is the full responsibilityof theuser.Thismanual isintendedforguidanceandinformationalpurposesandmustbeusedinassociationwithadequatetrainingandon-the-jobsupervisiontoprovidesafeandeffectiveequipmentuse.

It istheresponsibilityoftheusertoconformtoallregulationsandrequirementsissuedbyanauthorityoragencywhichmayaffecttheoperation,safetyorequipmentintegrity,thatmayoverrulethecontentofthisdocumentation.

Theuserwillacknowledgeandobeyanygenerallegalorothermandatoryregulationinforcerelatingtoaccidentprevention,safety,andequipmentintegrity.


Section contentSviii technical Manual

Summary Of Revisions (Continued)Date Section Page Description Of Revision Approved

5

5.3 Replacedgraphics

SH

5.4-5.5 Replacedold-stylesupportrollerwithnewstyle

5.6-5.7 Replacedold-styledoorpivotsupportrollerwithnewstyle

5.22-5.23 Replacedbodygraphicwithcorrect“backup-ready”,correctedpartslist.

5.24-5.25 Addeddetailedgraphicsandpartslistforhydraulicsupports

5.34-5.35 Replaceddoorassemblygraphicstoreflectcurrentassembly,correctedpartslist.

5.40-5.41 Addedrearlegdrawingandpartslistformodel80-0615-6

5.46-5.47 Addedinformationformodel85-06078-5/8”CLINCHER®backup5.52-5.53 AddedinformationforBUC8623-018-5/8”CLINCHER®cylinder

6All Re-numbered“TorqueMeasurement”-thisisnowSection6

6.1 Correctedpartnumbersfortensionloadcellassembly

7All Re-numbered“HydraulicSection”-thisisnowSection7

7.27-7.37 AddedmaintenanceinstructionsforDVAvalves

Mar2011

2 2.15-2.16 Addedjawavailabilityfor8-5/8”backup

DB5 5.46-5.47 Corrected8-5/8”CLINCHER®backupdetails

5 5.52-5.53 Addeddrawing&BOMfor8-5/8”CLINCHER®Cylinders

MAY2012

Intro

iii Correctedlistofapplicabletongmodels

SH

vii Modifiedliability&copyrightinformation

xv AddedCEMarkedmodifierstatementandidentificationsymbol

1

1.2 Correcteddimensiondiagramforcompressionloadcell-stylebackups

1.3 Inserteddimensiondiagramfortensionloadcell-stylebackups

1.4 Insertedillustrationofadditionalhazardareas

1.5 Insertedillustration&identificationofFARRCENameplate

1.6 Correctedspecifications

2

2.1 Insertednewsection2.A,“InitialReceipt&InspectionofEquipment”

2.1 Renumberedsection2.B,“MajorComponentIdentification”

2.5 Renumberedsection2.C,“Sling&Load-BearingDeviceSafety”

2.8 Insertednewsection2.D,“LiftCylinderInstallation”

2.11 Renumberedsection2.E,“HydraulicSchematic&ComponentIdentification”

2.12 InsertedCE-applicablehydraulicschematic

2.15 Renumberedandrevisedsection2.F,“HydraulicConnections”

2.17Renumberedandrevisedsection2.G,“TongJawAvailability& Installation”.AddedCE-specific information&addedweights to listofavailable tong jawdiekits

2.21 Renumberedsection2.H,“TongRig-Up&Leveling”

2.24 Insertednewsubsection2.H.5,“AdjustingBackupHeight”

2.25 Insertednewsubsection2.H.6,“AdjustingBackupClampPressure”

2.26 Renumberedsection2.I,“TongOperation”

2.26 Insertednewsubsection2.I.1,“OperatorTraining”

2.26 Insertednewsubsection2.I.2,“OperatorSafety”

2.27 Renumberedandrevisedsubsection2.I.3,“ValveOperation”

2.28 AddedCE-specificinformationtoliftcylindervalveoperation

2.29 Renumberedsubsection2.I.4,“ShiftingGears”



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MAY2012

2

2.30 Insertednewsubsection2.I.5,“Pre-OperationalChecks”

SH

2.31 Renumberedsubsection2.I.6,“GeneralComments”

2.32 Renumberedsection2.J,“MakingandBreakingConnections”




2.40 Renumberedsection2.K,“ExtremeColdWeatherOperations”

3

3.1 Revisedsection3.A,“GeneralMaintenanceSafetyPractices”

3.1 Revisedsection3.C,“PreventiveMaintenancePractices”

3.2 Insertednewsection3.D,“HydraulicSystemDe-Pressurization”

3.2 Renumberedsection3.E,“LubricationInstructions”

3.2-3.8 ReplacedillustrationsSection3.E,“LubricationInstructions”

3.7 Insertedlubricationinstruction3.E.10,“DoorStopCylinder”

3.9 Renumberedsection3.F,“Adjustments”

3.9 Revisedsubsection3.F.1,“BrakeBandAdjustment”

3.10 Replacedillustration,subsection3.F.2,“DoorLatchCamAdjustment”

3.11 Replacedillustration,subsection3.F.3,“DoorLatchAdjustment”

3.11 Insertednewsubsection3.F.4,“SafetyDoorAdjustment”

3.12 Renumberedsection3.G,“RecommendedPeriodicChecks”

3.13Renumbered&revisedsection3.H,OverhaulProcedures-Disassembly.Cor-recteddisassemblyproceduresandaddedCE-specificinformationandwarn-ings.

3.15-3.27 Renumbered&revisedsection3.I,AssemblyProcedures.Correctedassem-blyproceduresandaddedCE-specificinformationandwarnings.

3.28 Moved“DailyInspection&MaintenanceChecklist(PowerTong)”fromappen-dicesandnumberedasnewsection3.J.AddedCE-Specificinformation.

3.30 Moved“DailyInspection&MaintenanceChecklist(Backups)”fromappendi-cesandnumberedasnewsection3.K.

3.31 Moved“MonthlyInspection&MaintenanceChecklist(PowerTong)”fromap-pendicesandnumberedasnewsection3.L.

3.32

Moved“TubularConnectionEquipmentDe-Commissioning”fromappendices.Revisedsectiontoaddpackagingandshippinginstructionsandretitled“Tu-bularConnectionEquipmentDe-Commissioning&Shipping”.Numberedasnewsection3.M.

3.39 Moved“TubularConnectionEquipmentRe-Commissioning”fromappendicesandnumberedasnewsection3.N.

4 4.1 Revisedsection4.A,Troubleshooting-TongWillNotDevelopSufficientTorque

4.2 Insertednewsection4.B,Troubleshooting-ReliefValve

4.4 Insertednewsection4.C,Troubleshooting-SafetyDoor

4.5 Renumberedsection4.D,Troubleshooting-TongRunningTooSlowly

4.6 Renumberedsection4.E,Troubleshooting-FailureofJawstoGripPipe

4.7 Renumberedsection4.F,Troubleshooting-Shifting

5

5.2 Insertedlistofcriticalspareparts

5.3 Insertedlistofrecommendedspareparts

5.4 Insertedlistofpartsneededforcompleteoverhaul



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MAY20125

5.10-5.11 Replacedillustration&correctedB.O.M.,SupportRoller-DoorPivot

SH

5.12-5.13 Replacedillustration,RotaryIdler

5.14-5.15 Replacedillustration&revisedB.O.M.,PinionIdler

5.16-5.17 Replacedillustration,Pinion

5.18-5.19 Replacedillustration&revisedB.O.M.,Clutch

5.20-5.21 Replacedillustration&revisedB.O.M.,Shifter

5.22-5.23 Replacedillustration&revisedB.O.M.toreflectchangestobackingpin,Ro-taryAssembly

Removedillustration&B.O.M.,TongJaws

5.26-5.27 Replacedillustration&revisedB.O.M.,HydraulicValveMounts.Addedil-lustrationforCE-specificguard.

5.28-5.29 Replacedillustration&revisedB.O.M.,BrakeBands

5.30-5.31 Replacedillustration&revisedB.O.M.,Motor&MotorMountAssembly

Removedillustration&B.O.M.,HydraulicAssembly

Removedillustration&B.O.M.,SafetyDoorHydraulics

5.32-5.33 Replacedillustration&revisedB.O.M.,TongDoor

5.34-5.35 Replacedillustration&revisedB.O.M.,SafetyDoorComponents.Addedaddi-tionB.O.M.forCE-specificcomponents.

5.52-5.53 Replacedillustration&revisedB.O.M.,RigidSling.AddedadditionillustrationandB.O.M.forCE-specificcomponents.

6 6.1-6.8 Completerevisionoftorquemeasurementsection


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TABLE OF CONTENTS

SECTION ONE: INTRODUCTIONIntroduction&ContactInformation....................................................................................................................................... 1.1EquipmentSpecifications..................................................................................................................................................... 1.2LubricantSpecifications....................................................................................................................................................... 1.7

SECTION TWO: SETUP & OPERATIONA. INITIALRECEIPTANDINSPECTIONOFEqUIPMENT.......................................................................................... 2.1B. MAJORCOMPONENTIDENTIFICATION................................................................................................................. 2.1C. SLING/LOADBEARINGDEVICESAFETY............................................................................................................. 2.5

1. InspectionOfSlings............................................................................................................................................ 2.62. ProperUseOfLoad-BearingDevices................................................................................................................ 2.73. StorageOfLoad-BearingDevices...................................................................................................................... 2.7

D. LIFTCYLINDERINSTALLATION1. InstallationProcedure.......................................................................................................................................... 2.82. LiftCylinderHydraulicConnection..................................................................................................................... 2.93. LiftCylinderSafety.............................................................................................................................................. 2.9

E. HYDRAULICSCHEMATIC/COMPONENTIDENTIFICATION................................................................................. 2.11F. HYDRAULICCONNECTIONS..................................................................................................................................... 2.15G. TONGJAWAVAILABILITY&INSTALLATION

1. JawAvailability.................................................................................................................................................... 2.172. Jaw/JawDieRemoval....................................................................................................................................... 2.183. BackupJaws........................................................................................................................................................ 2.194. CLINCHER®BackupJawRemoval/Installation................................................................................................ 2.20

H. TONGRIG-UP&LEVELING1. Suspension&Restraint....................................................................................................................................... 2.212. TongLeveling....................................................................................................................................................... 2.223. LoadCellConfiguration-Compression.............................................................................................................. 2.234. LoadCellConfiguration-Tension...................................................................................................................... 2.245. AdjustingBackupHeight..................................................................................................................................... 2.246. AdjustingBackupClampingPressure................................................................................................................ 2.25

I. TONGOPERATION1. OperatorTraining................................................................................................................................................. 2.262. OperatorSafety................................................................................................................................................... 2.263. ValveOperation................................................................................................................................................... 2.274. ShiftingGears...................................................................................................................................................... 2.295. Pre-OperationalChecks...................................................................................................................................... 2.306. GeneralComments............................................................................................................................................. 2.31

J. MAKINGANDBREAKINGCONNECTIONS1. MakingAConnection........................................................................................................................................... 2.322. BreakingOutAConnection................................................................................................................................ 2.38

K. EXTREMECOLDWEATHEROPERATIONPROCEDURES................................................................................... 2.40SECTION THREE: MAINTENANCEA. GENERALMAINTENANCESAFETYPRACTICES.................................................................................................. 3.1B. CLEANING................................................................................................................................................................... 3.1C. PREVENTIVEMAINTENANCEPRACTICES............................................................................................................ 3.1D. HYDRAULICSYSTEMDE-PRESSURIzATION........................................................................................................ 3.2E. LUBRICATIONINSTRUCTIONS................................................................................................................................ 3.2F. ADJUSTMENTS

1. BrakeBandAdjustment:...................................................................................................................................... 3.92. DoorLatchAdjustment........................................................................................................................................ 3.103. ShifterDetentForceAdjustment:........................................................................................................................ 3.114. SafetyDoorAdjustment:..................................................................................................................................... 3.11

G. RECOMMENDEDPERIODICCHECKS1. DoorStopSpring................................................................................................................................................. 3.122. ShiftingShaft....................................................................................................................................................... 3.123. BackingPin.......................................................................................................................................................... 3.124. TorqueGaugeAssembly..................................................................................................................................... 3.12

H. OVERHAULPROCEDURES-DISASSEMBLY......................................................................................................... 3.13I. ASSEMBLYPROCEDURES....................................................................................................................................... 3.15J. DAILYINSPECTION&MAINTENANCECHECKLIST(POWERTONG)................................................................. 3.28K. DAILYINSPECTION&MAINTENANCECHECKLIST(BACKUPS)......................................................................... 3.30L. MONTHLYMAINTENANCECHECKLIST-POWERTONG..................................................................................... 3.31M. TUBULARCONNECTIONEqUIPMENTDE-COMMISSIONING&SHIPPING...................................................... 3.34N. TUBULARCONNECTIONEqUIPMENTRE-COMMISSIONINGPROCEDURE.................................................... 3.39

Continued on next page...


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TABLE OF CONTENTS (Continued)

SECTION FOUR: TROUBLESHOOTINGA. TONGWILLNOTDEVELOPSUFFICIENTTORqUE.............................................................................................. 4.1B. RELIEFVALVEISINCORRECTLYSETORNOTFUNCTIONING.......................................................................... 4.2C. SAFETYDOORDOESNOTOPERATEORISMALFUNCTIONING....................................................................... 4.4D. TONGRUNNINGTOOSLOWLY................................................................................................................................ 4.5E. FAILUREOFJAWSTOGRIPPIPE........................................................................................................................... 4.6F. FAILUREORDIFFICULTYOFTONGTOSHIFT..................................................................................................... 4.7G. GENERALCOMMENTS.............................................................................................................................................. 4.8

SECTION FIVE: ASSEMBLIES & PARTSCriticalSparePartsList.................................................................................................................................................... 5.2RecommendedSparePartsList...................................................................................................................................... 5.3PartsList-CompleteOverhaul........................................................................................................................................ 5.4GearTrainLayout............................................................................................................................................................ 5.6SupportRoller.................................................................................................................................................................. 5.8SupportRoller-DoorPivot.............................................................................................................................................. 5.10RotaryIdler....................................................................................................................................................................... 5.12PinionIdler...................................................................................................................................................................... 5.14PinionAssembly............................................................................................................................................................... 5.16ClutchAssembly............................................................................................................................................................... 5.18ShifterAssembly.............................................................................................................................................................. 5.20Rotary(CagePlate)Assembly......................................................................................................................................... 5.22TongBodyAssembly....................................................................................................................................................... 5.24HydraulicValve&LineSupports..................................................................................................................................... 5.26BrakeBandAssembly...................................................................................................................................................... 5.28Motor&MotorMountAssembly....................................................................................................................................... 5.30TongDoorAssembly........................................................................................................................................................ 5.32SafetyDoorAssembly...................................................................................................................................................... 5.34TongLegAssemblies(Model80-0615)........................................................................................................................... 5.36TongLegAssemblies(Model80-0615-6)........................................................................................................................ 5.38TongLegAssemblies(Model80-0615-4)........................................................................................................................ 5.40BackupBodyAssembly-CompressionStyle(Model80-0615)...................................................................................... 5.42BackupBodyAssembly-CompressionStyle(Model80-0615-6)................................................................................... 5.44BackupBodyAssembly-TensionStyle(Model80-0615-4)........................................................................................... 5.467-5/8”CLINCHER®BackupCylinders............................................................................................................................ 5.488-5/8”CLINCHER®BackupCylinders............................................................................................................................ 5.50RigidSlingAssembly....................................................................................................................................................... 5.52

SECTION SIX: TORQUE MEASUREMENTA. BASICTORqUEMEASUREMENT........................................................................................................................... 6.1B. TROUBLESHOOTING................................................................................................................................................. 6.6C. PERIODICINSPECTIONANDMAINTENANCE......................................................................................................... 6.7

1. Inspection............................................................................................................................................................ 6.72. FluidRecharge.................................................................................................................................................... 6.73. ReferenceCheckingYourTorqueMeasurementSystem.................................................................................. 6.74. RepairAndCalibration........................................................................................................................................ 6.8

SECTION SEVEN: HYDRAULIC COMPONENT INFORMATION

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LIST OF ILLUSTRATIONSIllustratIon 1.a.1: Model 80-0615-Ce Kt8625 Ce-MarKed tong & CoMpressIon-style ClInCHer® BaCKup ....................... 1.1IllustratIon 1.a.2: Kt8625 tong & ClInCHer® BaCKup dIMensIons (Model 80-0615 sHown) ............................................... 1.2IllustratIon 1.a.3: Kt8625 tong & ClInCHer® BaCKup dIMensIons (Model 80-0615-4 sHown) ............................................ 1.3IllustratIon 1.a.4: Kt8625 tong & ClInCHer® BaCKup Hazard areas (Ce-MarKed asseMBly) ............................................. 1.4IllustratIon 1.a.5: Farr® Ce naMeplate ................................................................................................................................ 1.5IllustratIon 2.B.1: CoMponent IdentIFICatIon 01 ........................................................................................................................ 2.1IllustratIon 2.B.2: CoMponent IdentIFICatIon 02 ........................................................................................................................ 2.2IllustratIon 2.B.3: CoMponent IdentIFICatIon 03 ........................................................................................................................ 2.3IllustratIon 2.B.4: CoMponent IdentIFICatIon 04 ........................................................................................................................ 2.3IllustratIon 2.B.5: CoMponent IdentIFICatIon 05 ........................................................................................................................ 2.4IllustratIon 2.B.6: CoMponent IdentIFICatIon 06 ........................................................................................................................ 2.4IllustratIon 2.C.1: slIng angle ................................................................................................................................................. 2.5IllustratIon 2.d.1: lIFt CylInder & sprIng Hanger InstallatIon ................................................................................................ 2.8IllustratIon 2.d.2: lIFt CylInder HydraulIC ConneCtIon ............................................................................................................ 2.9IllustratIon 2.e.1: HydraulIC sCHeMatIC .................................................................................................................................... 2.11IllustratIon 2.e.2: HydraulIC sCHeMatIC - Ce MarKed .............................................................................................................. 2.12IllustratIon 2.e.3: HydraulIC CoMponent Id 01 ........................................................................................................................ 2.13IllustratIon 2.e.4: HydraulIC CoMponent Id 02 ........................................................................................................................ 2.13IllustratIon 2.e.5: HydraulIC CoMponent Id 03 ........................................................................................................................ 2.14IllustratIon 2.e.6: HydraulIC CoMponent Id 04 ........................................................................................................................ 2.14IllustratIon 2.e.7: HydraulIC CoMponent Id 05 ........................................................................................................................ 2.15IllustratIon 2.F.1: HydraulIC ConneCtIons 01 ........................................................................................................................... 2.15IllustratIon 2.F.2: HydraulIC ConneCtIons 02 ........................................................................................................................... 2.16IllustratIon 2.g.1: Jaw reMoval ............................................................................................................................................... 2.18IllustratIon 2.g.2: BaCKup Jaw extensIon ................................................................................................................................. 2.20IllustratIon 2.g.3: BaCKup Jaw dIe reMoval ............................................................................................................................. 2.20IllustratIon 2.g.4: BaCKup rear Jaw reMoval .......................................................................................................................... 2.21IllustratIon 2.H.1: tong levelIng - lateral adJustMent ........................................................................................................... 2.22IllustratIon 2.H.2: tong levelIng - axIal adJustMent ............................................................................................................... 2.23IllustratIon 2.H.3: CoMpressIon load Cell ConFIguratIon - MaKe up ....................................................................................... 2.23IllustratIon 2.H.4: CoMpressIon load Cell ConFIguratIon - BreaK out .................................................................................... 2.24IllustratIon 2.H.5: tensIon load Cell ConFIguratIon - MaKe up ............................................................................................... 2.24IllustratIon 2.I.1: HydraulIC Control - rotatIon ...................................................................................................................... 2.27IllustratIon 2.I.2: HydraulIC Control - lIFt CylInder ................................................................................................................ 2.28IllustratIon 2.I.3: HydraulIC Control - BaCKup ......................................................................................................................... 2.29IllustratIon 2.I.4: tong Manual sHIFter .................................................................................................................................... 2.30IllustratIon 2.J.1: rIgId slIng Master lInK ............................................................................................................................... 2.32IllustratIon 2.J.2: settIng BaCKIng pIn to “MaKe-up” posItIon .................................................................................................. 2.33IllustratIon 2.J.3: openIng tong door ..................................................................................................................................... 2.33IllustratIon 2.J.4: lIFt CylInder Control - raIse ...................................................................................................................... 2.34IllustratIon 2.J.5: BaCKup Control - ClaMp .............................................................................................................................. 2.35IllustratIon 2.J.6: Motor Control - MaKe-up ............................................................................................................................ 2.35IllustratIon 2.J.7: usIng Motor Control to release Jaws In “MaKe up” Mode ........................................................................ 2.36IllustratIon 2.J.8: usIng BaCKup Control to release BaCKup Jaws ......................................................................................... 2.37IllustratIon 2.J.9: usIng lIFt CylInder Control to lower asseMBly ........................................................................................ 2.37IllustratIon 2.J.10: settIng BaCKIng pIn to BreaK-out posItIon ............................................................................................... 2.38IllustratIon 2.J.11: Motor Control - BreaK out ....................................................................................................................... 2.39IllustratIon 2.J.12: usIng Motor Control to release Jaws In “BreaK out” Mode ................................................................... 2.40IllustratIon 3.e.1: CaM Follower luBrICatIon ........................................................................................................................... 3.2IllustratIon 3.e.2: support roller luBrICatIon ........................................................................................................................ 3.3IllustratIon 3.e.3: rotary Idler luBrICatIon ............................................................................................................................. 3.3IllustratIon 3.e.4: pInIon Idler luBrICatIon poInt ..................................................................................................................... 3.4IllustratIon 3.e.5: pInIon luBrICatIon poInts (top plate) ......................................................................................................... 3.4IllustratIon 3.e.6: pInIon luBrICatIon poInts (BottoM plate) .................................................................................................... 3.5IllustratIon 3.e.7: ClutCH luBrICatIon poInts ........................................................................................................................... 3.5IllustratIon 3.e.8: Motor Mount luBrICatIon poInt .................................................................................................................. 3.6IllustratIon 3.e.9: sHIFter sHaFt luBrICatIon ........................................................................................................................... 3.6IllustratIon 3.e.10: tong door luBrICatIon poInts .................................................................................................................. 3.7IllustratIon 3.e.11: door CylInder ........................................................................................................................................... 3.7IllustratIon 3.e.12: BaCKup ClaMp CylInder luBrICatIon poInts ............................................................................................... 3.8IllustratIon 3.e.13: CoMpressIon load Cell luBrICatIon........................................................................................................... 3.8



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LIST OF ILLUSTRATIONS (Continued)

IllustratIon 3.F.1: BraKe Band adJustMent ............................................................................................................................... 3.9IllustratIon 3.F.2: door latCH CaM adJustMent ....................................................................................................................... 3.10IllustratIon 3.F.3: sHIFter detent ForCe adJustMent ............................................................................................................... 3.11IllustratIon 3.F.4: saFety door swItCH adJustMent 01 ............................................................................................................ 3.12IllustratIon 3.I.1: tong asseMBly - rotary gear InstallatIon ................................................................................................... 3.16IllustratIon 3.I.2: tong asseMBly - gear asseMBly posItIonIng................................................................................................. 3.17IllustratIon 3.I.3: tong asseMBly - top Fastener loCatIons ..................................................................................................... 3.18IllustratIon 3.I.4: tong asseMBly - support rollers (leg Mount loCatIons) ........................................................................... 3.19IllustratIon 3.I.5: tong asseMBly - support rollers (seCurIng leg Mounts)........................................................................... 3.19IllustratIon 3.I.6: tong asseMBly - support rollers (BraKe Band weldMents) ........................................................................ 3.20IllustratIon 3.I.7: tong asseMBly - top sHIFter BusHIng asseMBly ........................................................................................... 3.21IllustratIon 3.I.8: tong asseMBly - Front Cage plate spaCers ................................................................................................ 3.22IllustratIon 3.I.9: tong asseMBly - saFety door valve InstallatIon ......................................................................................... 3.23IllustratIon 3.I.10: tong asseMBly - rIgId slIng adJustMent Bolt InstallatIon ......................................................................... 3.24IllustratIon 3.I.11: tong asseMBly - valve Handle guard InstallatIon - Ce MarKed ............................................................ 3.27IllustratIon 3.M.1: sHIppIng InstruCtIons - pallet .................................................................................................................... 3.36IllustratIon 3.M.2: sHIppIng InstruCtIons - wrappIng CHaIn slIng ............................................................................................. 3.37IllustratIon 3.M.3: sHIppIng InstruCtIons - BaCKup support ..................................................................................................... 3.37IllustratIon 3.M.4: sHIppIng InstruCtIons - strappIng equIpMent to pallet .............................................................................. 3.38IllustratIon 4.B.1: relIeF valve trouBlesHootIng - teMporary gauge InstallatIon ................................................................... 4.2IllustratIon 6.a.1: torque gauge (For IllustratIon purposes only) ........................................................................................ 6.1IllustratIon 6.a.2: tensIon load Cell ....................................................................................................................................... 6.1IllustratIon 6.a.3: CoMpressIon load Cell ............................................................................................................................... 6.1IllustratIon 6.a.4: tensIon load Cell exploded ....................................................................................................................... 6.3IllustratIon 6.a.5: CoMpressIon load Cell exploded ................................................................................................................ 6.4IllustratIon 6.a.5: turn Counter enCoder Mount .................................................................................................................... 6.5


Section contentS xv technical Manual

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IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS INSTALLATION GUIDE

McCoyDrilling&Completionsusesthreeindicatorstodescribeitemsofthreedegreesofimportance.

AHAZARDtooperatorsorequipmentisrepresentedbyanexclamationpointwithinaredtriangle.identifiesitemsofthehighestimportance.FailuretoheedinformationidentifiedbyaHAZARDsymbolmayresult inbodilyinjury,death,cata-strophicequipmentdamage,oranycombinationofthese.AHAZARDmayalsoindicatethepotentialfordangerousenvi-ronmentalcontamination.

The informationpresented in thisdocumentwill providesetup,operating,andmaintenance instructions foryourKT8625tongandbackup.Duetothewidevarietyofoperatingconditions,theseinstructionsmustbecon-sideredguidelinesratherthanabsoluteoperatingprocedures.Itistheresponsibilityoftheusertousetheseguidelinestogetherwithanexperiencedmanagertodevelopoperatingproceduresthatconformtoallpoliciessetforthbytheoperatingauthority(ies).

AWARNINGisrepresentedbyanexclamationpointwithinanorangetriangle,andcontainsinformationthatwillalertper-sonneltoapotentialsafetyhazardthatisnotlife-threatening.AWARNINGmayalsoservetoalerttheusertoinformationcriticaltothecorrectassemblyoroperationoftheequipmentinuse.

This identifies a HAZARD to operators or equipment

This identifies a WARNING to users

ACAUTIONisrepresentedbyanexclamationpointwithinayellowtriangleandhighlightsinformationthatmayaidtheuserduringassemblyoroperationofyourequipment.CAUTIONsarealsousedtoensurecommonerrorsarenotmadeduringassemblyoroperationofyourequipment.

This identifies a CAUTION to users

Observance of the following is the full responsibility of the user:

● all descriptions, information and instructions set out in this manual● any regulation or requirement issued by an authority or agency which may influence operation,

safety or integrity of the equipment that overrules the content of this document.● any legal or other mandatory regulation in force governing accident prevention or environmental

protection.

Somesectionsofthistechnicalmanualapplyonlyto“CE Marked”equipment.Thesesectionswillbeclearlyidentifiedbytheuseofthephrase“appliestoCE-markedtongsonly”,orbyuseoftheCElogowithinanenclosedborder.

This identifies a section that only applies to CE-Marked equipment


Section contentS 1.1 technical Manual

intRoDuction

McCoy Drilling & Completions | FARR14755121AAvenueEdmonton,AlbertaCanadaT5L2T2

Phone:780.453.3277Fax:780.455.2432

EmailEngineering:[email protected]:[email protected]

Website:http://www.mccoyglobal.com/drilling-completions

ILLUSTRATION 1.A.1: MOdEL 80-0615-CE KT8625 CE-MARKEd TONg & COMpRESSION-STyLE CLINCHER® BACKUp

CongratulationsonthepurchaseofyourFARR®KT86258-5/8”tongandbackupassembly.Thisunitwillprovideyouwithyearsofoutstandingperformance.Simplemaintenanceandcarewillextenditslifeandensureyearsofexcellentperfor-manceandreliability.Thesetup,operating,andmaintenanceinstructionsinthismanualwillassistyouingivingyourequip-mentthecareitrequires.Pleasecarefullyreadthemanualbeforeinstallingandusingyourequipment.ReplacementpartsarereadilyavailablefromMcCoyDrilling&Completions|FARRinEdmontonAlberta.NotethatmanypartsaretransferablebetweenFARR®tongsandbackups.Shouldyouneedreplacementparts,orshouldyouexperienceanydifficultynotcov-eredinthismanual,pleasecontact:


Section contentS1.2 technical Manual

SPecificationS

ILLUSTRATION 1.A.2: KT8625 TONg & CLINCHER® BACKUp dIMENSIONS (MOdEL 80-0615 SHOwN)

Color Coding:Green=Handleorcontrol,safetograspormanipulateYellow=Activeorpotentialhazard.Usecautionnottocontactareaespeciallywhentongisrotating.

58”

30”

36-3/4”

75-1

/4”

This drawing applies to models 80-0615 & 80-0615-6.



SPecificationS

ILLUSTRATION 1.A.3: KT8625 TONg & CLINCHER® BACKUp dIMENSIONS (MOdEL 80-0615-4 SHOwN)

54”

30”

36-3/4”

75-1

/4”

This drawing applies to model 80-0615-4.



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



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.

CEcompliant.ConformswiththeessentialrequirementsoftheapplicableConformitéEuropéennedirectives.

EUExplosiveAtmospherecertified

II EquipmentGroup(surface,non-mining)

2 EquipmentCategory-highlevelofprotection

Gc GasGroup(Acetylene&Hydrogen)-Certifiedforuseinacetyleneandhydrogenenvironments

T6 Maximumsurfacetemperatureof85oC.

ILLUSTRATION 1.A.5: FARR® CE NAMEpLATE

II 2 G c T6



SPecificationS

Torque Table **Pressure High Gear Low GearPSI / MPa Lbs.-ft. Nm Lbs.-ft. Nm

1000/6.89 1800 2440 8900 120671500/10.34 3100 4203 15300 207442000/13.79 4400 5966 21600 292862300/15.17 5100 6915 25400 34438

MAXIMUM RATED TORQUE: 25000 LBS.-FT. (25354 Nm)MAXIMUM SYSTEM PRESSURE: 2285 PSI (15.7545 MPa)

Speed TableFlow (US GPM / LPM) Low Gear (RPM) High Gear (RPM)

10/37.9 2.0 10.020/75.71 4.0 19.040/151.4 8.0 39.060/227.1 12.0 58.0

** 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)



SPecificationS

Use an EP synthetic grease that meets or exceeds the following specifications:

Thickener LithiumComplex NLGIconsistencygrade 2 NLGIperformancegrade GC-LB Penetration-ASTMD217(25°C[77°F]0.1mm)worked60strokes) 265-295minimum Droppingpoint,°F[°C]-ASTMD2265 550[288]minimum Hightemperaturelife,hours-ASTMD3527 160minimum Oxidationstability,psi-ASTMD942 (100hr/300hr)0/3 Waterwashout,percent-ASTMD1264 1.8max Rustandcorrosion-ASTMD1743 pass Oilseparation,percentloss-ASTMD1742(24hours,25°C[77°F]) 1.1max Leakage,glost-ASTMD4290 1.0max Fourballweartest,mmscar-ASTMD2266 0.40max Frettingwear,mg-ASTMD4170 3.4max FourballEP,kgf-ASTMD2596 Weldpoint 400minimum Loadwearindex 50minimum TimkenOKloadtest,lbs-ASTMD2509 50 Lowtemperaturetorque,N*m-ASTMD4693(-40°C[-40°F]) 1.3max LT-37pumpability,g/min(60°F/0°F[16°C/-18°C]) 360/7 Coppercorrosion-ASTMD4048 1B Oilviscosity:40°C[104°F],cSt 151 100°C[212°F],cSt 19.2 Flashpoint,°F[°C]-ASTM92 450[232]

Use a premium quality hydraulic fluid that meets or exceeds the following specifications: TypicalDensity(kg/m3) 878 Viscosity-cSt@40°C 68.8 -cSt@100°C 8.7 ViscosityIndex 97 PourPoint°F[°C] -22[-30] FlashPoint°F[°C] 432[222] Colour,ASTM 1.5 NeutralizationNumber 0.40 RustProtection-DistilledWater NoRust -SeaWater NoRust HydrolyticStability-CuMassLoss,mg/cm2 0.04 CopperCorrosionTest 1A Filterability:Denison-Wet&Dry Pass Afnor-Wet&Dry Pass CincinattiMilacronSpecApproved P69 DenisonHF-0: Approved DenisonP-46PistonPump: Pass DenisonT6CVanePump: Pass Vickers35Vq25VanePumpTest: Pass 104/105CVanePumpTest: NoDataAvailable Vanepumptesttotalringandvanewear,mg. <10 OxidationStability TurbineOilStabilityTestLife,hours 2500+ RotaryBombOxidationTest,minutes 325 FzGSpurGearTest,FailureLoadStage(FLS) 12



SetuP & oPeRation

YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY. HOWEVER, MCCOY ADVISES INSPECTING YOUR EQUIPMENT FOR SHIPPING DAMAGE UPON RECEIPT AND TESTING YOUR TONG BEFORE RELEASING TO AN OPERATIONAL ENVIRONMENT.

Performavisual inspectionfollowingremovalofallpackagingmaterial. Immediately identifyanyshippingdamagetotheshippingcompany,andcorrectalldamagebeforeconnectingequipmenttoahydraulicpowersource.

B. MAJOR COMPONENT IDENTIFICATION

Adequatesetupandproperhydraulicconnectionsareessentialinensuringreliableoperationofyourtong.Forbestresultsandlongtermreliability,readandobeythestart-upinstructionsinthissection.

A. INITIAL RECEIPT AND INSPECTION OF EQUIPMENT

Item Description1 MasterLink

2 RigidSling

3 TorqueGaugeMountingPlate

4 RearLegAssembly(supportsmodel85-0604compressionloadcell-stylebackup)

5 Tong

6 RearSpringSupportAssembly(onlyonmodels80-0615&80-0615-4)

7 FrontLegAssembly

ILLUSTRATION 2.B.1: COMpONENT IdENTIFICATION 01

7

5

4

1

2

3

6



Item Description8 HydraulicValveBankAssembly

9 RigidSlingLevelingDevice

10 BackingPinAssembly

11 SafetyDoorGuardAssembly

12 SafetyDoorSwitchAssembly

13 TongDoorLatch

14 CagePlateAssembly

15 BrakeBand

16 TongJawswithDieInserts

17 TongDoorCylinder

18 TongDoor


SetuP & oPeRation

9

10

11

12

13

14

15

16

8

17

18



Item Description19 ManualShiftAssembly

20 AccessPanel

21 CLINCHER®CylinderWithWraparoundInsert

22 HydraulicMotor

23 MotorMount

24 CompressionLoadCell-StyleCLINCHER® Backup(Model85-0604)



SetuP & oPeRation

19

20

21

22

23

24



Item Description25 RearLeg(supportsmodel85-0606tensionloadcell-stylebackup)

26 TensionLoadCell

27 RearBackupSpringSupportAssembly(appliesonlytomodel80-0615-6)

28 Model85-0606CLINCHER®Backup(TensionLoadCellConfiguration)29 Model85-0607-1CLINCHER®Backup(CompressionLoadCellConfiguration)



SetuP & oPeRation

25

26

29

27

28



ILLUSTRATION 2.C.1: SLINg ANgLE

McCoyDrilling&Completionsrecommendsfollowinganindustry-acceptedstandardsuchasOSHA,ASMEB30.9-2006,ormanu-facturer’sguidelineswhenperforminganyriggingandoverhead lifting.Usebyuntrainedpersons ishazardous. Improperusewillresultinseriousinjuryordeath.Donotexceedratedcapacity.Slingswillfailifdamaged,abused,misused,overused,orimproperlymaintained.

● 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

C. SLING / LOAD BEARING DEVICE SAFETY

SetuP & oPeRation

Sling Angle



SetuP & oPeRation

• Stretched,bent,twisted,ordeformedchainlinksorcomponents.• Evidenceofheatdamage.• Excessivepittingorcorrosion.• Lackofabilityofchainorcomponentstohinge(articulate)freely.• Weldsplatter.• Forhooks,removalcriteriaasstatedinASMEB30.10• Otherconditions,includingvisibledamage,thatcausedoubtastothecontinueduseofthesling.

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.

Additionalinspectionsshallbeperformedduringslingusewhereserviceconditionswarrant.Periodicinspectionintervalsshallnotexceedoneyear.Thefrequencyofperiodicinspectionsshouldbebasedon:

• Frequencyofuseoftheload-bearingdevice.• Severityofserviceconditions• Natureofliftsbeingmade• Experiencegainedontheservicelifeofload-bearingdevicesusedinsimilarcircumstances.

Guidelinesfortheintervalare:

• NormalService-yearly• SevereService-monthlytoquarterly• SpecialService-asrecommendedbyaqualifiedperson

1. Inspection Of Slings

McCoy strongly recommends the following practices:Acompleteinspectionofnewload-bearingdevicesandattachmentsshallbeperformedbyaqualified,designatedpersonpriortoinitialuse.Eachlinkandcomponentshallbeexaminedindividually,takingcaretoexposeandexamineallsurfacesincludingtheinnerlinksurface.Theslingshallbeexaminedforconditionssuchasthoselistedintheremovalcriteriabelow.Inaddition,dailyinspectionofslings,fasteningsandattachmentsshallbeperformedbyadesignatedperson.Ifdamageordefectsarefoundateitherinspection,thedamagedordefectivecomponentshallbequarantinedfromserviceuntilitcanbeproperlyrepairedorreplaced.

RemovalCriteria:

Aload-bearingdeviceshallberemovedfromserviceifconditionssuchasthefollowingarepresent:

• Missingorillegibleslingidentification.• Cracksorbreaks• Evidenceoftamperingisseen-slingtaghasbeenmodifiedorobscured,ortamper-proofnutsaremissing.• Signsofimpactonload-bearingcomponents,includingspreaderbars,liftinglugs,rigidslings&rigidslingweldments,andlegs&legmounts.

• Brokenordamagedwelds.• Excessivewear,nicks,orgouges.Refertothechartbelowtoensureminimumthicknessonchainlinkssuppliedisnotbebelowthevalueslisted:

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



SetuP & oPeRation

IF MECHANICAL DAMAGE IS SEEN OR SUSPECTED ON A LOAD-BEARING DEVICE, OR IF THE LOAD-BEARING DEVICE HAS BEEN OVERLOADED, IT MUST BE REMOVED FROM SERVICE AND QUARANTINED UNTIL RECERTIFIED

UnitsdesignedandmanufacturedinaccordancewithEN12079andDNV2.7-1shouldbetestedandexaminedinaccordancewiththefollowingscheduleofexaminationandtest.Theuseroftheload-bearingdeviceshallplaceapermanentplacardorplateuponwhichthetypeanddateofthelasttestshallberecorded.Toavoidconfusion,theplateshallnotcarrythedateofthenexttestorexamination,onlythemostrecent.

Test / Examination

tIMe / Interval lIFtIng tests1

non-destruCtIve exaMInatIon (nde)

oF lIFtIng poInts

tHorougH vIsual

exaMInatIon

suFFIx to Be MarKed on plate attaCHed

to unIt

InitialCertificationByFarr/Superior YES YES YES T

IntervalNotExceeding12Months

Atthediscretionofinspectionbody

Atthediscretionofinspectionbody YES TorVN3

IntervalNotExceeding60Months

Atthediscretionofinspectionbody YES YES TorVN

FollowingSubstantialRepairorAlteration YES YES YES T

1.LiftingtestasperS7.3BSEN12079orDNV2.7-1May19952.T=ProofTest,non-destructiveexamination;VN=nondestructiveexaminationandvisualexamination;V=visualexamination.3.Dependantuponwhethernon-destructiveexaminationhasbeencarriedout.4.Forthepurposesofthisstandard,asubstantialrepairormodificationisdefinedasanyrepairand/ormodificationthathasbeencarriedoutwhichmay,intheopinionoftheinspectionbody,affecttheload-bearingelementsofthecontainerorliftingdevice,orelementsthatcontributedirectlytoitsstructuralintegrity.

Writtenrecordsofthemostrecentperiodicinspectionshallbemaintained,andshallincludetheconditionofthesling.

2. Proper Use Of Load-Bearing DevicesWheneveranyload-bearingdeviceisused,thefollowingpracticesshallbeobserved.

• Load-bearingdevicesthataredamagedordefectiveshallnotbeused.• Slingsshallnotbeshortenedwithknotsorboltsorothermakeshiftdevices.• Slinglegsshallnotbekinked.• Load-bearingdevicesshallnotbeloadedinexcessoftheirratedcapacities.• Slingsshallbesecurelyattachedtotheirload.• Load-bearingdevicesshallbeprotectedfromsnagging,andshallnotbefurtherobstructedbyanyobject.• Suspendedloadsshallbekeptclearofallobstruction.• Allemployeesshallbekeptclearofloadsabouttobeliftedandofsuspendedloads.• Handsorfingersshallnotbeplacedbetweentheslinganditsloadwhiletheslingisbeingtightenedaroundtheload.• Shockloadingisprohibited.• Donotstanddirectlyunderaloadduringlifting.

3. Storage Of Load-Bearing DevicesProperstorageofout-of-service loadbearingdevices is important toensure full integrityof thedeviceonce it is returned toservice.McCoyrecommendsobservingthefollowingpractices.

• Wipeoffallexcessgrease.Useasolvent-basedcleaneronragstowipeallexternalsurfacestoremoveresidualgreaseorhydraulicfluid.Oncetheoutsidesurfaceshavebeende-greased,wipeallexternalsurfaceswithcleanwatertoremoveresidualsolvent.

• McCoyrecommendsthatananti-corrosiveagentsuchasTectyl®506beappliedtoallexternalsurfaces.Refertomanu-facturerdatasheetsforproperapplicationandsafetyinformation.Allowtheanti-corrosivecoatingampletimetodry-refertomanufacturerdatasheetsfordryingtimesatroomtemperature.

• Storeinaclean,drylocation.Whenreturningtoservice,notethatafullinspectionofthedevicemustbeperformed.



SetuP & oPeRation

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.

1. Installation Procedurei. Useacranetohoisttheliftcylinderbytheshackle,ensuringthehydraulichoseconnectionisatthebottomofthecylinder

whenitishoisted.

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.



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

Oncethefittinghassnappedintoplacegivethehydrauliclinealighttugupwardstoensurethefittingissecurelyseated.

Ifnotalreadydone,connectthemainhydraulicsupplytothepowertong(seesection2.Fforproperhydraulicconnectionpro-cedure).Energizethehydraulicsupplytothepowertong.

Lift thepower tongapproximately three inchesoff theworksurface,andsuspend the tong forapproximately thirtyseconds.Followingthesuspensionalternatelyliftandlowerthetongslightlytoconfirmthatliftandlowerfunctionseachoperatecorrectly.

ILLUSTRATION 2.d.2: LIFT CyLINdER HydRAULIC CONNECTION

SetuP & oPeRation

3. Lift Cylinder Safety

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.

WorkingLoadLimit(WLL)isthemaximumallowableloadinpoundswhichmaybeappliedtotheload-bearingdevice,whenthedeviceisneworin“asnew”condition,andwhentheloadisuniformlyanddirectlyapplied.TheWLLmustneverbeexceeded.

TheWorkingLoadLimit orDesign factormaybeaffectedbywear,misuse, overloading, corrosion, deformation, intentionalalterations,sharpcornercuttingactionandotheruseconditions.

SeeOSHARegulation for Slings 1910.184,ANSI/ASMEB30.9-”SLINGS”,ANSI/ASMEB30.10-”HOOKS” and ANSI/AMSEB30.26“RIGGINGHARDWARE”foradditionalinformation.



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Lift Cylinder Safety (continued):Theflexiblelineprovidinghydraulicpowertotheliftcylinderhasbeenequippedwithabrasion-resistant,highvisibilityprotectivewrap.Thehighvisibilitywrapallowsoperatorstoeasilyseemonitorthepositionofthehydrauliclineatalltimes,andcaneasilyseeifthelineappearstobecomeentangledorsnagged.

IMMEDIATELY CEASE LIFT CYLINDER OPERATION IN THE EVENT OF ENTANGLEMENT OF THE HYDRAULIC LINE WITH FIXED RIG COMPONENTS OR TONG SUPERSTRUCTURE.

REPLACE LIFT CYLINDER HYDRAULIC LINE EVERY TWO YEARS

Theprotectivewrapalsopreventswearofthehydrauliclinethoughabrasion.Donotremovetheprotectivewrapfromtheliftcylinderline,andreplaceprotectivewrapifitismissing,torn,orsplit.Regardlessofuseorcondition,thehydrauliclinesupplyingtheliftcylindermustbereplacedeverytwoyears.

DO NOT REMOVE THE SPEED-LIMITING ORIFICE FROM THE LIFT CYLINDER BREATHER PORT

Thecontrolvalvesectiononthepowertongisequippedwithaninternalcheckvalve,preventingsuddendropofthetongintheeventofhydraulicpowerfailure.Aspeed-limitingorificeisinstalledinthebreatherportoftheliftcylinder.Theorificepreventssuddendropoftheliftcylinderintheeventofarupturedhydraulicline,limitingthespeedatwhichthecylinderextendsandthetongdropstoasaferate.Donotremovethespeed-limitingorifice,andonlyreplacewithanidenticalorificesuppliedbyMcCoy.

Theworkingloadlimit(WLL)isclearlystenciledontothesideoftheliftcylinder.DonotuseliftcylinderiftheWLLstencilhasbeenrubbedofforintentionallyremoved.Locatethetestcertificatethataccompaniedthecylindertothejobsiteor,ifnecessary,obtainacopyofthetestcertificatefromthelocationatwhichtheoriginalcertificatehasbeenstored.Theliftcylindermustbeclearlyre-markedwiththeWLLbeforeitisreleasedtoanoperatingenvironment.

DO NOT USE A LIFT CYLINDER WITH A MISSING OR DEFACED WLL.



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E. HYDRAULIC SCHEMATIC / COMPONENT IDENTIFICATION

Item Description Part Number1 InletValve 10-9016

2 ReliefValve 10-0010R

3 MotorSection,4WAYSAEPORTS 10-9014

4 BackupSection,4WAYSAEPORTS 10-9019

5 LiftSection,1”ORBPORT 10-9015

6 OutletSection,SAEPORT 10-0086

7 FlowControlValve 08-9062

8 Pilot-To-OpenSafetyDoorValve(SeePp.7.29-7.30) 08-1625

9 SafetyDoorBlock 101-0727

10 SafetyDoorSwitch 08-0337

11 HydraulicMotor 87-0112

12 CheckValve(Optional) 02-9022

13 ReliefValve(SeePp.7.31-7.32) 08-1180

14 ReliefValveManifold(Backup) 08-1839

15 CheckValve(SeePp.7.33-7.34) 08-0481

16 CheckValveBody(Backup) 08-1327

17 3000psiPressureGauge 02-0245

18 CLINCHER®BackupCylinder 1403-00-00B

ILLUSTRATION 2.E.1: HydRAULIC SCHEMATIC

P

T

MOTOR

LIFT

14 13

16 15

17

18 18

1 2 3 4 5 6

12

11

9 810 7

OPTIONAL



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ILLUSTRATION 2.E.2: HydRAULIC SCHEMATIC - CE MARKEd

Item Description Part Number1 InletValve 10-9016

2 ReliefValve 10-0010R

3 MotorSection,4WAYSAEPORTS 10-9014

4 BackupSection,4WAYSAEPORTS 10-9019

4 LiftSection,1”ORBPORT 10-9019

6 OutletSection,SAEPORT 10-0086

7 FlowControlValve 08-9062

8 Pilot-To-OpenSafetyDoorValve(SeePp.7.29-7.30) 08-1625

9 SafetyDoorBlock 101-0727

10 SafetyDoorSwitch 08-0337

11 HydraulicMotor 87-0112

12 CheckValve(Optional) 02-9022

13 ReliefValve(SeePp.7.31-7.32) 08-1180

14 ReliefValveManifold(Backup) 08-1839

15 CheckValve(SeePp.7.33-7.34) 08-0481

16 CheckValveBody(Backup) 08-1327

17 3000psiPressureGauge 02-0245

18 CLINCHER®BackupCylinder 1403-00-00B

19 LiftCylinderOrifice

P T

14 13

16 15

17

18 18

1 2 3 4 4 6

12

11

9 810 7

OPTIONAL

19

MOTOR

CLINCHER®BACKUP

LIFT17



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ILLUSTRATION 2.E.3: HydRAULIC COMpONENT Id 01


6

7

543

1

2

9

8

11



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10

18 13

17



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F. HYDRAULIC CONNECTIONSApairofhydrauliclines-a1”supplylineanda1-1/4”returnline-connectthetongtothepowerunit(seeillustrationbelow).Ancillarydevices(hydraulicmotors,hydrauliccylinders,etc.)areconnectedthroughthevalveblock.

Performanyhydraulicconnectionwhenthepowerunitisnotrunning,orwhenthehydraulicpumpisdisengaged.Thepossibilityoferrorininter-changingthehighpressuresupplyhoseandthelowpressurereturnhosehasbeeneliminated,becausethesupplysidecouplingissmallerthanthereturnside.

ILLUSTRATION 2.F.1: HydRAULIC CONNECTIONS 01

Thesehosecouplingsareself-sealing,andcareshouldbetakentoensurecompleteengagementtopreventpartialclosureofthecheckvalveinthecoupling.Ensurethatthenut(female)sideiscompletelymadeupontothemaleconnector-thereisalineonthemalefittingthatindicatescompletemake-up.Snugthefemalefittingrightuptotheline(Seeillustration2.F.2nextpage).Hand-tightenonly-donotusetoolstoassistintighteningtheseconnections.Hydraulicfluidleakagefromhand-tightenedconnectionsisasignofdamagetotheseals.

1615

14

Hydraulic Supply (1”)

Hydraulic Return (1-1/4”)



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ILLUSTRATION 2.F.2: HydRAULIC CONNECTIONS 02


Main Hydraulic Connections (Cont’d):

Inspecttheseconnectionsuponactivationofthepowerunit.Leakingcomponentsmustberepairedbeforereleasingthetongtotheoperationalenvironment.Deactivatethepowerunitandde-pressurizethehydraulicsystemaccordingtotheprocedureinSection3.D.Disconnectthemainhydraulicconnectionsandinspectallfourconnectors(twomale,twofemale)fordamageordebris.Iftheconnectorscannotbecleanedoreasilyrepaired,McCoyrecommendsreplacementoftheleakingconnector.Notethatdamagetooneoftheconnectorsmayhavecauseddamagetoitsmate.

Turnoffpowerunitanddepressurizehydraulicsystembeforedisconnectingthemainhydrauliclinesundernormalworkingconditions.SeeSection3.Dforhydraulicsystemdepressurization.McCoyrecommendsplacingprotectivecapsovertheexposedconnectorstoprotectthemfromwaterandimpactdamage.

ALWAYS TURN OFF HYDRAULIC POWER AND DEPRESSURIZE HYDRAULIC SYSTEM BEFORE DISCONNECTING MAIN HYDRAULIC LINES.

Make up female fitting to Marked point on male fitting



G. TONG JAW AVAILABILITY & INSTALLATION1. Jaw Availability

Thefollowingtable listsall jawdiekits thatareavailableasstandardstockedsizes for thismodelof tong.McCoyDrilling&Completions|Farroffersagoodselectionofstandardjawsizes.However,pleasenotethatMcCoycancustom-engineerandmanufactureanysizeof jawwithin therangeof the tong.Jawsystemsareavailable toallowuseofdie inserts intendedforspecializedapplications.Calloursalesofficeforinformationonjawanddiesystemsdesignedforhigherorlowergrip,ornon-markingapplications.

Thetablelistsstandardcontoured,flatandwraparounddieinsertsthatareavailableasspareparts.However,awidevarietyofdiamond-tooth,GRITFACE®,andwrap-aroundfine-toothdiesareavailableforspecializedapplications.Pleaserefertoourwebsiteforcompleteinformation:

http://www.mccoyglobal.com/dies-inserts

STANDARD JAW DIE KITSDescription Part Number Weight (Per Single Jaw)

2.062”JawDieKit 1050-JDK-100A 18lbs/8.2kg

2-3/8”JawDieKit 1050-JDK-105B 18lbs/8.2kg

2-7/8”JawDieKit 1050-JDK-110C 18lbs/8.2kg

3-1/8”JawDieKit 1050-JDK-112D 18lbs/8.2kg



4”JawDieKit 1050-JDK-120 18lbs/8.2kg

4-1/2”JawDieKit 1050-JDK-130 19lbs/8.6kg









7-5/8”JawDieKit 1050-JDK-155 13.5lbs/6.1kg

7-3/4”JawDieKit 1050-JDK-160 12.5lbs/5.7kg


A-UsescontouredinsertPN12-0002

B-UsescontouredinsertPN12-0004

C-UsescontouredinsertPN12-0007

D-UsescontouredinsertPN12-0011

AllotherjawdiekitsuseflatdiePN13-0008-314-0

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USE OF ALUMINUM DIES IS FORBIDDEN ON CE-MARKED EQUIPMENT



ILLUSTRATION 2.g.1: JAw REMOvAL

Oncethe jawhasbeenremoved,extract thediekeeperscrewsandremovethediesbytappingdies lightlywithahammer.Replacethedies,tappingthemintoplaceifnecessary,andreplacethekeeperscrews.

Tongjawsareclearlymarkedwiththesize.Ensurethejawtobeinstalledisthepropersizeforthepipetoberun.Over-sizedorunder-sizedjawsmayresultinjawslippage,orcausethejawstoleavetheendofthecamsurfaceontheinsideoftherotarygear.Additionally,incorrectlysizedjawswillcausethepipetobeoff-centrerelativetothebackup,resultingineccentricrotationandpotentialpipethreaddamage.

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.

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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.



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3. Backup JawsThefollowingtablelistsallinsertsthatareavailableasstandardsizesforthe7-5/8”CLINCHER®backups,usedonmodelnumbers80-0615and80-0615-4.Ifyourdesiredsizeisnotlisted,McCoycanengineercustomjawsizes-contactsalesforfurtherinformation.

Thefollowingtablelistsallinsertsthatareavailableasstandardsizesforthe8-5/8”CLINCHER®backupsusedonmodelnumber80-0615-6.Ifyourdesiredsizeisnotlisted,Farrcanengineercustomjawsizes-contactsalesforfurtherinformation.

Description Part Number Description Part Number2.375”CLINCHER®FineToothDieInsert BUC86252375 5”CLINCHER®FineToothDieInsert BUC86255000

2.707”CLINCHER®FineToothDieInsert BUC86252708 5.5”CLINCHER®FineToothDieInsert BUC86255500




3.5”CLINCHER®FineToothDieInsert BUC86253500 7”CLINCHER®FineToothDieInsert BUC86257000


4”CLINCHER®FineToothDieInsert BUC86254000 7.625”CLINCHER®FineToothDieInsert BUC86257625



4.862”CLINCHER®FineToothDieInsert BUC86254862

Description Part Number Description Part Number2.375”CLINCHER®BackupInsert 12-6004 4.50”CLINCHER®BackupInsert 12-6052

2.875”CLINCHER®BackupInsert 12-6008 4.75”CLINCHER®BackupInsert 12-6054

3”CLINCHER®BackupInsert 12-6010 5”CLINCHER®BackupInsert 12-6056


3.125”CLINCHER®BackupInsert 12-6015 6”CLINCHER®BackupInsert 12-6096













4”CLINCHER®BackupInsert 12-6044 7.625”CLINCHER®BackupInsert 12-6065






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4. CLINCHER® Backup Jaw Removal/Installation1. ExtendCLINCHER® cylinders enough so that the hex flat-head cap screws securing the die retainer tabs arewell

exposed.Turnoffhydraulicpower.

ILLUSTRATION 2.g.2: BACKUp JAw ExTENSION

2. Removethetwohexflat-headcapscrewssecuringthedieretainertabonthetopoftheCLINCHER®die.

3. Removethetopdieretainertab.

4. Slidethediestraightup,andremove.

ILLUSTRATION 2.g.3: BACKUp JAw dIE REMOvAL



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CLINCHER® Backup Jaw Removal/Installation (Continued):Toremovethediefromtherearjaw,ensurebothcylindersareretracted.Removethehexboltsecuringtherearjawassembly,thensliderearjawforwardenoughsothattheflat-headcapscrewssecuringthedieretainertabiswellexposedRemovethediefollowingthesameproceduresasfortheCLINCHER®cylinders.

ILLUSTRATION 2.g.4: BACKUp REAR JAw REMOvAL

Reverseprocedurestoinstallnewdie.IfthebottomdieretainertabonCLINCHER®cylindersorrearjawrequireservicing,theassembliesmustbecompletelyremoved.

Reversethisproceduretoinstallorreplacejaws.

H. TONG RIG-UP & LEVELING1. Suspension & Restraint

Suspendthetongandbackupfromalocationasneartothecentreofthedrillrotaryaspossible,andfromalocationhighenoughonthemasttoensureeasyhandlingThelowerthepointfromwhichthetongissuspended,themoreeffortwillberequiredtomovethetongtoandfromtheconnectionpoint.

Thesuspensionlinemaybeextendedoverapulleyandbalancedbyacounterweightequaltotheweightofthetongandbackup,orsimplytiedoffinthederricktoformadeadline.WhenusingadeadlinearrangementitisnecessarytouseaFARRspringhangerassembly(seespecificationpageforrecommendedspringhanger).Thisspringhangercompensatesforthedownwardmovementofthecasingasthethreadismade-up,andimpartsadditionalforcetothesuspensioncable:

● a“singlespring”hangertypicallyapplies420lbs.(191kg.)tothesuspensionlineforeveryinchofthreadmadeup● a“doublespring”hangertypicallyapplies840lbs.(382kg.)tothesuspensionlineforeveryinchofthreadmadeup

Ifyoudonotknowwhichspecificspringhangerisinuse,contacttheengineeringdepartmentatMcCoyDrilling&Completionsforassistanceandinformation.McCoyDrilling&CompletionswillnotguaranteeorspecifyspringhangersotherthanwhathasbeensuppliedbyMcCoy.

Manyapplicationsusealiftcylinderforadjustingtheheightofthetong.Ensuretheweightoftheliftcylinderisknownifithasnotbeenincludedinthetotalweightofthetong.

Allforcesuponthesuspensionlinemustbeconsideredwhencalculatingnecessarystrengthofthesuspensionline.Theweightof the tong, theweightof the liftcylinder, theweightof thespringhanger,andthe force impartedonthesuspension linebythespringhangermustallbeaddedtogetherinordertoarriveatthetotalforcesupportedbythesuspensionline.Selectyoursuspensionlinebaseduponthetotalforceandthemarginsofsafetydictatedbythepoliciesofyourcompanyandbyestab-lishedengineeringpractices.Ultimately,calculatingtheforceonthesuspensionlineandselectionofthesuspensionlineisthecompleteresponsibilityofthecustomer.



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Suspension & Restraint (continued):McCoyDrilling&Completionsrecommendsusingdualbackup(snub)linesofsufficientstrengthtowithstandtheforceimpartedbythemaximumratedtorqueofthetongandbackupassemblyinuse.Thesnublineswillarrestuncontrolledmovementofthetongandbackupintheeventslippingofthebackupjaws.Calculatetheforceonthesnublinesbydividingthemaximumtorqueofthetongbythetong’storquearm(expressedinfeet).Forexample,an25,000lbs.-ft.tongwitha36inch(3ft.)torquearmwillgenerate8333lbs.offorceagainstthesnubline.Selectyoursnublinesbaseduponthetotalforceandthemarginsofsafetydictatedbythepoliciesofyourcompanyandbyestablishedengineeringpractices.Ultimately,calculatingtheforceonthesnublineandselectionofthesnublineisthecompleteresponsibilityofthecustomer.

Snublinesmustbesecurelyconnectedtotherearofthetongandbackupassembly,andtiedofftoasuitablyratedanchor.Whenproperlyinstalledthesnublineshouldbetautenoughtoallowverylittlemovement,preventingthetongfromgeneratingexcessiveforceonthelinesby“snapping”tightwhenrotationisapplied.

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.

2. Tong LevelingThetongmustbeleveledside-to-sideandfront-to-rearbeforeplacingintoservice.Thefollowingguidelineswillassistyouwhenlevelingyourtong.

i. Placealevelaxially(sidetoside)acrossthetong,ensuringthatitisparallelwiththesurfaceofthetong.Useathinwrenchontheflatoftheadjustinghelixtorotatethehelix,forcingtheliftlinktomovetowardstheoutersupportsofthesling.The3/4”Nylocknutonthepinmayhavetobeslightlyloosenedtoallowthehelixtorotate.Adjustthehelixuntilthelevelshowsthatthetongislevelside-to-side(seeillustration2.H.1).

ILLUSTRATION 2.H.1: TONg LEvELINg - LATERAL AdJUSTMENT

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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Tong Leveling Cont’d:

ii. Placealevellengthwise(fronttoback)alongthetong,ensuringthatitisparallelwiththesurfaceofthetong.Loosenthe1/2”jamnutsontheadjustingboltsonrigidslingbrackets.Completelyloosentheadjustingbolts.Turneachadjustingboltequallyuntiltonghangslevelfront-to-back.Lockadjustingboltsinplacewiththejamnuts.

ILLUSTRATION 2.H.2: TONg LEvELINg - AxIAL AdJUSTMENT

3. Load Cell Configuration - CompressionThebackupisdirectlycoupledtothecompressionloadcellviathebackupbodypaddle.Theloadcellhangerissimplyhungonthepaddleandsecuredthroughthetopofthe“U”byaboltandwasherset,andinnormaloperationdoesnotneedtobeadjustedorremoved.Theassemblyinthefirstofthefollowingtwoillustrationshasbeenconfiguredinthe“make-up”configura-tion;toconverttheassemblytothe“break-out”configurationremovetheboltandwashersetsecuringtheloadcellholdertothepaddle,andmovetheentireassemblytotheothersideofthepaddle.Wheninstallingcompressionloadcellensurethehydrauliclineandhydraulicfittingarenotincontactwithanycomponentsofthepaddleorloadcellholder.

ILLUSTRATION 2.H.3: COMpRESSION LOAd CELL CONFIgURATION - MAKE Up

Loosen 1/2” hex jam nut be-fore rotating adjustment bolt



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ILLUSTRATION 2.H.4: COMpRESSION LOAd CELL CONFIgURATION - BREAK OUT

Load Cell Configuration - Compression (continued):

4. Load Cell Configuration - TensionThebackupiscoupledtotherearlegoftheassemblywithatensionloadcellononeside,andarestraintchainontheother.Tochange the torquemeasurementconfiguration (makeup tobreakoutorvisaversa)simply remove theheavydutyboltssecuringtheloadcellandrestraintchains,andswitchtotheoppositesides.Reinstalltheheavydutyboltstosecuretheloadcellandrestraintchainsinplace.Foryourreferencetheassemblyinthefollowingillustrationhasbeenconfiguredtomeasuremakeuptorque.Ifmeasurementofbreakouttorqueisdesiredtheloadcellwouldbeconnectedbetweentherighthandsideoftherearlegandthebackup.

ILLUSTRATION 2.H.5: TENSION LOAd CELL CONFIgURATION - MAKE Up

5. Adjusting Backup Height (Does not apply to tension load cell equipped backups)OccasionallytheheightoftheCLINCHER®requiresadjustment.Thisisasimpleprocedurethatisaccomplishedwithoutspecialtools.Notethattheheightofbackupmodelnumber85-0606,equippedwithatensionloadcell,isfixedandcannotbechanged.

a. Determinethedistancethebackuprequiresraisingorlowering.



Adjusting Backup Height (continued):b. Identify theholes (oneper leg) in the front leg towhich thesupportboltmustbemoved toaccommodate thedistance

determinedinStep5a.Ifyourassemblyisequippedwiththe8-5/8”CLINCHER®backup(modelnumber85-0507),newpositionholesintherearlegmustalsobeidentifiedatthistime

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.

• slidetherearspringsupportassemblyupordownuntiltheboltholesalignwiththeadjustmentholesidentifiedinStep5b.

• insertthebottomsupportboltsthroughthoseholesandthesupportassembly,andsecurewithnylocknuts.

• useacranetohoistthetongandbackupassemblystraightupandoffthesupport,andplaceontheworksurfacenexttothesupport.Installthebackupdieinserts.Ifthefrontandrearlegspringsupportboltshavebeenequallyadjustedthebackupwillremainlevel,andtheadjustmentprocedureiscomplete.

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.

• iftherearofthebackuprequiresloweringloosenthebottom1-1/4”nut.Useaboxendorcrescentwrenchtoturnthetop1-1/4”nutcounter-clockwise,allowingtherearofthebackuptolower.WhenthebackupislevelthreadthelowernutuptothebottomoftheV-bracketandtighteninplace.

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BACKUP MUST BE LEVEL BEFORE RUNNING PIPE

6. Adjusting Backup Clamping PressureTheclampingpressureofthebackuprequiresoccasionaladjustmenttocompensateforwearofthebackupjawdieinsertsandforre-settingthebackuppressuretofactoryspecificationwhennewdieinsertsareinstalled.Occasionalloweringofthebackupclampingpressuremayberequiredforthin-walledpipeortubing,orifyouareusingthebackupinnon-markingapplications.

AwidevarietyofoperatingconditionspreventsMcCoyfromrecommendinganidealbackuppressureforanyonetypeofpipeorjoint;rather,theidealpressureisonlyidentifiedthroughacombinationof“trialanderror”andtheoperatingmanager’sbestestimatebasedontheirownexperience.

Usethisproceduretocheckandadjustthebackuppressure:

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)



ALWAYS WEAR APPROVED PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN OPERATING HYDRAULICALLY-POWERED EQUIPMENT.

Ensurehydraulicpower isdeactivatedandtonghydraulicsarede-pressurizedbeforedisconnectingthemainhydraulic lines.McCoyrecommendsdepressurizingthetonghydraulicsystembeforeconnectingordisconnectingquick-connectfittings.

DEPRESSURIZE EQUIPMENT BEFORE DISCONNECTING MAIN HYDRAULIC LINES.

Theareasurroundingthetongoperatingareamustbeclutter-freeandfreefromtrippinghazards,orprotrudingobjectsthatmaysnaghydraulichosesonthetong,backup,liftcylinder,ortorquemeasurementsystem.Operatingsurfaceordrillfloormustbekeptfreeofslippinghazardslikegrease,oil,water,etc.

Adequatelightingoftheworkareaisrequired.Allwarnings,labels,gauges,andsignsmustbeclearlyvisible

Thecomponentsofthetongcommonlymanipulatedorrequiringcontrolinputarepaintedgreen,andaresafeforcontinuoushandling.Areas painted yellow are designated as hazardous areas, and contact with those areasmust be avoided duringoperation.Alwayswearallpersonalprotectiveequipment(PPE)specifiedbyyourcompany’sHSEpolicy,andfollowallofyourcompany’ssafetyguidelines.

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Inspectanti-tamperdevicesonsafetydoorcomponentsbeforebeginningjob.Equipmentshowingsignsoftamperingonanysafetysystemmustbeimmediatelyremovedfromserviceandtested.Anti-tamperdevicesmustberestoredbeforeallowingequipmenttobereleasedtoanoperatingenvironment.

Adjusting Backup Clamping Pressure (continued):d. Whenthedesiredpressurehasbeensetreleasethepressuretothebackupcylinders,andusethebackupclampingvalve

toretractthecylinders.

e. Performenoughtestconnectionstodeterminethatthebackuppressureisadequateformakingupandbreakingoutjointswithinthecurrentapplication.Ifpipeslippageorcrushingisobservedrepeatthebackuppressureadjustmentprocedure.

I. TONG OPERATION1. Operator Training

Manycompaniessetqualificationstandardsthatmustbemetbeforeequipmentmaybeoperatedwithoutsupervision.McCoyDrilling&Completionsrecommendsoperatortraining,whichtypicallyconsistsofoperationoftheequipmentunderthesupervi-sionofatrainedequipmentoperatoruntilasatisfactorylevelofcompetenceisachieved.Typicaloperatortrainingshouldinclude:

• Introductiontoandgeneraldescriptionofequipment• Technicalspecificationsandperformancedata• Operatinginstructions• Controlsystemsandinterlocks• Operatinghazards• Checksandinspections• Hoistingandliftingdevicetraining

2. Operator SafetyMcCoyrecommendsthatahazardassessmentof theworkareabeperformedbyadesignatedsafetyrepresentativebeforecommencingoperations.Adesignatedsafetyrepresentativeisresponsibleforverifyingthatalloperatorshaveadequateequip-mentandsafetytraining.

Thesafetydoorsystemistheprimarydeviceprotectingthetongoperatorandnearbypersonnelfromtherotarygear.Confirmthecorrectoperationofthesafetydoorbeforeeveryjob.Neverdisablethesafetydoordevice.



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ILLUSTRATION 2.I.1: HydRAULIC CONTROL - ROTATION

3. Valve OperationSpring-loadedproportionalvalvescontroloperationofhydraulicdevicesonthetongassemblysuchashydraulicmotorsandcylinders.Whenanyonevalve is “centered”or in thedetentposition, there isnohydraulicoutput fromthevalve.When thevalveispushedforwardthereisaneffect,andwhenthevalveispulledback,thereisanoppositeeffect.Thesevalvesfeatureproportionalcontrol,whichmeansthatfurtherextensionofthevalvehandle(therebyfurtheropeningthevalveorifice)resultsinproportionallyhigherhydraulicoutputtothecontrolleddevice.

Thefollowingillustrationsdemonstratethetypeandeffectofthehydraulicvalveswithwhichthistongismaybeequipped.

TONGMOTOR

Thisisaproportionalvalve.Pushingthevalvehandleforwardwillcausethetongmotortorotateinaclockwisedirection(asseenfromthetopofthetong).Thisisthedesireddirectionofrotationformakingupajoint.Pullingthevalvehandleintheoppositedirectionresultsincounter-clockwiserotation,whichisthedesireddirectionofrotationforbreakingoutajoint.Releasingthevalvehandlewillcausethetongtoimmediatelystoprotation.



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LIFTCYLINDERCONTROLVALVE

Thisisadirect-actingvalve.Pullingoutonthevalvehandlewillcausetheliftcylindertoliftthetongvertically.Pushinginonthevalvehandlewillcausetheliftcylindertolowerthetong.Releasingthevalvehandlewillimmediatelystoptheliftingorloweringaction.

Pushingontheliftcylindercontrolvalvehandle(towardthecenterofthetong)willcausetheequipmenttolift,whilepullingon the lift cylindercontrolvalvehandle (toward theoperator)will cause theequipment to lower.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.

LIFTCYLINDERNEEDLEVALVE(Seeillustration2.I.2)

Thisneedlevalveregulateshydraulic fluid flowtothe liftcylinder.Closingtheneedlevalve(rotatingtheknobclockwise)willincreasinglyrestricttheflowrateofthefluid,resultinginsloweractuationofthecylinderinbothdirections(lifting&lowering).

ILLUSTRATION 2.I.2: HydRAULIC CONTROL - LIFT CyLINdER

Lift Cylinder Needle Valve



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BACKUP

PushingthisvalveforwardwillextendtheCLINCHER®cylinderstowardpipecenter.Pullingbackward,towardstheoperator,willretractthecylinders.

ILLUSTRATION 2.I.3: HydRAULIC CONTROL - BACKUp

4. Shifting GearsTheshiftingshafthasthree“detent”positionsidentifyingthelowspeed/hightorqueposition,the“neutral”orfree-spinningposi-tion,andthehighspeed/lowtorqueposition.Thedetentstrengthmaybeadjustedbyreleasingthelocknutonthedetenttubeandincreasingorrelaxingpressureonthedetentspring.Ensurethelocknutistightenedoncethedesireddetentpressurehasbeenset.

Toshifttothehigh-speedgear,movetheshiftinghandleDOWNfromneutralposition.Toshifttothelow-speedgear,movetheshiftinghandleUPthroughtheneutraldetenttoitsHIGHESTposition.Notethatthehighclutchgearorthelowclutchgearmaynotbeexactlyalignedwhenshifting,sotheoperatormayneedto“bump”themotorcontrolhandleslightlytoturnthemainclutchgearshaftandshiftingcollarintoalignment.Themosteffectivewayofachievingthisistoapplyasmallamountofpressureontothegearshiftleverinthedirectionyouwanttoshiftthetong,ensuringtheshiftingcollarwill“catch”whenthemainclutchgearalignswitheitherthehighorlowclutchgear(seeIllustration2.I.4nextpage)

DO NOT SHIFT TONG WHILE ROTATING THE MOTOR AND CAGE PLATE. CATASTROPHIC GEAR TRAIN FAILURE MAY RESULT.



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ILLUSTRATION 2.I.4: TONg MANUAL SHIFTER

5. Pre-Operational ChecksMcCoyrecommendsthatthefollowingpre-operatingtestsbeperformedpriortoreleasingthetongassemblytoaoperationalenvironment:

a. Connectthetongtoahydraulicpowersourceinacontrolledenvironment.Ensurethepowerunit’soperatingparametersarewithinthespecificationsasidentifiedonPg.1.3.Ensurethehydraulicconnectionsfromthepowerunitareproperlyandsecurelymadeup(seeSection2.E).Donotneglecttoconnectthemotordrainline.

b. Startthepowerunitasspecifiedbythepowerunitoperator’smanual.OpentheBypassValveonthehydraulicsystem,andinspectallpressureandreturnlinehoseconnectionstoensurecorrectandsecureinstallation.Arestrictioninthepressuresupplyhosewillresultinhighpressurewithinthepowerunithydraulicsystem,whichwillactivatethehydraulicgovernorandincreasetheenginespeedtoashighasmaximumRPM.Arestrictioninthereturnlinewillresultinhighpressurewithinthepowerunitandthetonghydraulicsystem,causingenginespeedsashighasmaximumRPM,andpossiblefailureofthemotorseal.


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.

Shifting Gears (continued):



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Pre-Operational Checks (continued):i. Shiftthetongtolowgear(seeSection2.I.3)androtatethetongslowlyforwardforapproximatelyaminute.Stopthetong

andthenreversetherotationdirectionforapproximatelyanotherminute.Stopthetong,shifttohighgear,andoperateinhighgearforapproximatelyanotherminute.Stopthetongandrotateintheoppositedirectioninhighgearforapproximatelyanotherminute.Ifatanytimeabnormaloperationissuspected(surging,grinding,squealing,orothernoisesdeemedtobeunusual,orfailuretooperate)discontinueoperationofthetongandcontactMcCoyDrilling&Completionsimmediately.

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.

Ifthesafetydoordoesnotoperateasdesigned,thesafetydoorswitchmayrequireadjustment,orfurthertroubleshootingofthesafetydoorsystemmayberequired.SeeSection3.F.4forsafetydoorswitchadjustmentprocedures,andSection4.Dforsafetydoortroubleshootinginstructions.

Thesafetydoorswitch isprotectedfromimpactbyasturdymetalguard,paintedyellow.Thisguardmustbe inspectedbeforeeachuseofthetong.Allcomponentsoftheguardmustbeinplace,andallfastenerssecuringtheguardmustbeintactandtight.Ensurewireties(whereapplicable)onsafetydoorcomponentsarepresentandsecure,anddonotshowsignsoftampering.

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.



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J. MAKING AND BREAKING CONNECTIONS

SetupandprepareyourequipmentforoperationasperSection2ofthismanualRefertothefollowingsections:

● 2.D-LiftCylinderInstallation● 2.F-HydraulicConnections● 2.G-TongJawInstallation● 2.H.1-TongRig-upandLeveling(Suspension)● 2.H.2-TongRig-upandLeveling(Leveling)

Yourtongandbackupassemblyshouldbeproperlysuspended,connectedtoahydraulicpowersource,andreadytomakeorbreakconnectionsatthispoint.

1. Making A Connectiona) Ensurehydraulicpowersupplytothetongisenergized.Themasterlinkontherigidslingmustbeusedtosuspendthe

tong.Donotsuspendthetongdirectlyfromtherigidsling.

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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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.

d) Graspthetongdoorhandleandpullthedoortoreleasethelatchandopenthedoor.(SeeIllustration2.J.3).Openingthetongdoorwillactivatethesafetydoorsystemandpreventrotationofthecageplate.

ILLUSTRATION 2.J.3: OpENINg TONg dOOR



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RIG PERSONNEL MUST STABILIZE THE TONG AS IT IS LIFTED FROM THE DRILL FLOOR

ILLUSTRATION 2.J.4: LIFT CyLINdER CONTROL - RAISE

Making A Connection (Continued) e) Actuatetheliftcylindercontrolvalvetolifttheassemblyfromthedrillfloor.Pullingonthevalvehandletowardtheoperator

willretracttheliftcylindertolifttheassembly(seeIllustration2.J.4below).Notethatrigpersonnelarerequiredtostabilizethetongandbackupasitisbeingliftedsoitdoesnotswingandcollidewithotherrigequipment.

f) Manuallyengagethethreadsofthetubingconnectionbeingmadeup.Ensurethreadsarenotcross-threaded.

g) Movethetongandbackupassemblyontothetubingjoint.Usetheliftcylindertoensuretheassemblyisatthecorrectheightsothatthebackupjawsarelocatedbelowtheconnectionpoint,andthetongjawsarelocatedabovetheconnectionjoint.

h) Firmlyclosethetongdoor.Ensurethedoorissecurelylatched(tugonthedoorhandletoensureitremainslatched).

i) Ensuretubingisroughlycenteredwithinthetongandbackupjaws-rigpersonnelarerequiredtostabilizethetongandbackuparoundtheconnectionuntilthejawshavebeenclampedshut.Actuatethebackupclampingvalve(pushittowardthecentreofthetong)toclampthebackupjawsontothetubingbelowtheconnectionpoint.Notethatthebackupcontrolis“clampandrelease”,meaningthatoncethebackupjawsareclamped,thejawsremainunderclampingpressureuntiltheoperatormanipulatesthebackupcontrolhandletoreleasepressure(seeIllustration2.J.5nextpage).

Pushingontheliftcylindercontrolvalvehandle(towardthecenterofthetong)willcausetheequipmenttolift.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.



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j) Beginrotationwiththetonginhighgearandthetongmotorsettohighspeed(highspeed/lowtorque).SeeSection2.I.3toproperlysetthetongtohighgear.Donotshiftgearswhilethetongisrotating.

SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE

k) Pushthemotorcontrolvalvetowardthetongtorotatethecageplateinthemake-updirection.Gentlypushtherotationcontrolvalvetowardthecentreofthetongtoslowlyrotatethecageplateuntil thetongjawscamontothetubing(seeIllustration2.J.6).

ILLUSTRATION 2.J.6: MOTOR CONTROL - MAKE-Up

Making A Connection (Continued)

ILLUSTRATION 2.J.5: BACKUp CONTROL - CLAMp



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Making Up A Connection (Continued)l) Whenthetongjawscamontothetubingpushtherotationcontrolhandleallthewayintothreadtheconnectiontogether

athighspeed.Asthejointbecomesfullymadeuptheincreasingtorquedemandwillstallthemotor,anddisplayedtorquewillincrease.

m) Stoprotation,andsetmotortolowspeedandshifttolowgear(lowspeed/hightorque-SeeSection2.I.3forshiftingtolowgear).Thiswillenablethetongtoproduceadequatetorquetomakeupthejointtospecification.

n) Pushtherotationcontrolhandleallthewayintocompletetheconnectionatlowspeed/hightorque.Observethetorquegauge-whenthespecifiedmake-uptorqueisreachedstoprotation.Ifyoursystemisequippedwithanautomaticdumpvalvethesystempressurewill“dump”totankwhenthepresettorquehasbeenreached,andallrotationwillstop.Reversetherotationcontrolvalvetoreleasethetongjawsfromthetubing(seeIllustration2.J.7).

ILLUSTRATION 2.J.7: USINg MOTOR CONTROL TO RELEASE JAwS IN “MAKE Up” MOdE

o) Whentongjawsarefreereleasethebackupjawsbypullingthebackupclampcontrolhandleawayfromthetongtowardtheoperator(seeIllustration2.J.8)nextpage.

COMPRESSION ENERGY STORED IN THE BACKUP SUPPORT SPRINGS MAY CAUSE THE TONG TO “JUMP” SLIGHTLY WHEN TONG JAWS ARE RELEASED.



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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.

Making Up A Connection (Continued)

p) Unlatchandopenthetongdoortofreetheassemblyfromthetubing.Notethatrigpersonnelmayberequiredtostabilizetheequipmentasitcompletelyreleasesfromthetubing.Guidetheassemblyawayfromthestring.Pushtheliftcylindercontrolvalvetowardthecentreofthetongtolowertheequipmenttothedrillfloor.

ILLUSTRATION 2.J.9: USINg LIFT CyLINdER CONTROL TO LOwER ASSEMBLy

q) Repeatsteps“e”through“p”untilthedesirednumberofconnectionsaremadeup.



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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.

e) Unlatchandopenthetongdoor(seeIllustration2.J.3).

f) Actuatetheliftcylindercontrolvalvetolifttheassemblyfromthedrillfloor.Pullingthevalvetowardtheoperatortoretractthe liftcylinder to lift theassembly(see illustration2.J.4).Note that rigpersonnelarerequired tostabilize the tongandbackupasitisbeingliftedsoitdoesnotswingandcollidewithotherrigequipment.


g) Movethetongandbackupassemblyontothetubingjoint.Usetheliftcylindertoensuretheassemblyisatthecorrectheightsothatthebackupjawsarelocatedbelowtheconnectionpoint,andthetongjawsarelocatedabovetheconnectionjoint.

h) Closethetongdoor.Ensurethedoorissecurelylatched(tugonthedoorhandletoensureitremainslatched).

Pushingontheliftcylindercontrolvalvehandle(towardthecenterofthetong)willcausetheequipmenttolift.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.



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Gentlypushtherotationcontrolvalvetowardthecentreofthetongtoslowlyrotatethecageplateuntilthetongjawscamontothetubing.


ILLUSTRATION 2.J.11: MOTOR CONTROL - BREAK OUT

Breaking Out A Connection (Continued)i) Ensuretubingisroughlycenteredwithinthetongandbackupjaws-rigpersonnelarerequiredtostabilizethetongand

backuparoundtheconnectionuntilthejawshavebeenclampedshut.Actuatethebackupclampingvalve(pushittowardthecentreofthetong-seeIllustration2.J.5)toclampthebackupjawsontothetubingbelowtheconnectionpoint.Notethatthebackupcontrolis“clampandrelease”,meaningthatoncethebackupjawsareclamped,thejawsremainunderclampingpressureuntiltheoperatormanipulatesthebackupcontrolhandletoreleasepressure.

j) Breakouttorqueisonlyavailableinlowgear.SeeSection2.I.3toproperlysetthetongtolowgear.Donotshiftgearswhilethetongisrotating.

k) Pushtherotationcontrolhandleallthewayintoensurefullbreakouttorqueisbeingdeliveredtothejoint.

l) Whenthejointreleases,stoprotationandshifttongtohighgear(seeSection2.I.3toproperlysetthetongtohighgear).Pressmotorcontrolvalvetowardthecentreofthetongtocompletelyun-threadtheconnection.Donotshiftgearswhilethetongisrotating.




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Breaking Out A Connection (Continued):m) Oncetheconnectionhasbeenun-threadedreversetherotationcontrolhandle(pulltowardoperator)toreleasethetong

jawsfromthetubing(seeIllustration2.J.12).

ILLUSTRATION 2.J.12: USINg MOTOR CONTROL TO RELEASE JAwS IN “BREAK OUT” MOdE

n) Whentongjawsarefreereleasethebackupjawsbypullingthebackupclampcontrolhandleawayfromthetongtowardtheoperator(seeIllustration2.J.8).

o) Unlatchandopenthetongdoortofreetheassemblyfromthetubing.Notethatrigpersonnelmayberequiredtostabilizetheequipmentasitcompletelyreleasesfromthetubing.Guidetheassemblyawayfromthestringandusetheliftcylindercontroltolowerittothedrillfloor.

p) Useyourrig’sstandardpipehandlingprocedurestoremoveandrackthefreedtubingsectionorstand.

q) Repeatsteps“f”through“p”asmanytimesasnecessarytobreakoutandun-threadthedesirednumberofconnections

K. EXTREME COLD WEATHER OPERATION PROCEDURES1) Consultthepowerunitengineoperator’smanualforallcoldweatheroperatingproceduresandprecautions.

2) Selectgearandbearinglubricantsthatarecompatiblewithexpectedclimaticconditions.

3) Selecthydraulicfluidthatiscompatiblewithexpectedclimaticconditions.

4) Allowhydraulicfluidtocirculateforapproximately20minutesafterstartingthepowerunit,priortoactivatingthebypassvalvetoallowfluidtocirculatetotong.Ifthepowerunitisequippedwithanoiltemperaturegauge,ensurethatthefluidhasreachedoperatingtemperatureasspecifiedbyhydraulicfluiddatasheet.

5) Allowforadequatedryingofmoisture(priortolubricating)whencleaningtongpartsincoldweather.




Maintenance

McCoyCompletions&Drillingrecognizesthatminoron-siterepairsandmodificationsarerequiredtomaintainpeakoperatingconditionofyourequipment,ortomatchyourequipmentwiththeoperatingenvironment.Examplesofminorrepairsare

● replacementofdamagedhydraulichosesandfittings.● replacementofmalfunctioningpressuregaugesandvalves.● replacementofdoorspringstopcylinders● replacementoffasteners

AnyreplacedcomponentmustbeanidenticalcomponentsuppliedbyMcCoyCompletions&Drilling.ReplacedfastenersmustbeGrade8orequivalent,orwhateverfastenerisspecifiedbyMcCoy.

A. GENERAL MAINTENANCE SAFETY PRACTICESThepracticesidentifiedhereareintendedasaguideline.Allpersonnelareresponsibleforperformingtheirtasksinamannerthatensuresworker,equipment,andenvironmentalsafety,andmayrequiretakingadditionalstepsthatarenotidentifiedinthissection.

Equipmentmaintenanceshallbeperformedonlybydesignatedqualifiedmaintenancepersonnel.Wearallpersonalprotectiveequip-ment(PPE)specifiedbyyourcompany’sHSEpolicy,andfollowallofyourcompany’ssafetyguidelines.Donotbeginamaintenancetaskwithoutthepropertoolsormaterialsonhand,ortheproperdrawingsanddocumentationnecessary.

Scheduleplannedmaintenancewithoperatorstoavoidconflicts,unnecessarydowntime,andthedangerofaccidentalequipmentactivation.Notifyoperationswhenmaintenanceproceduresarecompleteandequipmentfunctionalityisrestoredandtested.

Ifon-sitemaintenancemustbeperformed(inotherwords,ifequipmentcannotbetransportedtoacontrolledmaintenancefacility)isolatethelocationofthemaintenancetopreventunawarepersonnelfrominadvertentlyexposingthemselvestoahazard.Usetape,rope,orsignagetoclearlyindicate“off-limits”area.

Replacement of large, heavy individual parts and/or heavy structural componentsmust be performed using an approved liftingdeviceofsufficientliftingcapacity.Usecarewhenattachingtheliftingdevice,andsafeguardareatoavoidendangeringpersonnelorequipment.

AllsparepartsmustmeetorexceedOEMspecificationsinordertomaintainequipmentintegrity,especiallyprotectiveequipment.

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.

Manufacturersofpurchasedcomponentsincludedwithyourhydraulictubularconnectionequipment(forexample:motors,valves,etc.)mayspecifymaintenancetasksandintervalsoverandabovewhatMcCoyrecommendsaspartoftheirrecommendedproce-dures.Usersofthisequipmentmaychoosetoperformorignoretheseadditionaltasksattheirdiscretion.

Filtrationofthehydraulicfluidmustbe10micronsorbetter.Prematurefoulingofparticulatefilterswithinyourprimemoverorancil-laryhydraulicpowerunitrequiresimmediatehydraulicfluidlaboratoryanalysistopreventprematurewearofhydraulicsystemduetohighlevelsofwearmetalsinthefluid.

McCoyDrilling&Completionsrecommendstrackingallmaintenanceactivityincludingthelubricationscheduleandreplacementofhydraulichoses.Thismaybeasimpleaskeepingapaperlog,orusingasoftware-basedmaintenancetrackingutility.Amaintenancelogisavaluabletoolthatcanbeusedforeasilyretrievingmaintenancehistoryoridentifyingtrendsthatrequirecorrection.



Maintenance

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

1) Rotatethetongtothe“openthroat”position.Ensuretongandbackupdoors(ifequipped)areclosed.Fullyextendtheliftcylinder

2) De-energizethepowerunit.

3) RepeatedlyactuatethetongmotorcontrolvalveleverINBOTHDIRECTIONStodissipateanyresidualpressureinthevalveandmotor.

4) RemovethehydraulicSUPPLYlinefromtheequipment.

5) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressureintheremain-derofthehydrauliccontrolsystem.

7) DisconnectthehydraulicRETURNlinefromtheequipment.

8) Disconnectremaininghosessuchascasedrains,orlinesconnectedtotheturnscounter.

E. LUBRICATION INSTRUCTIONSUseaqualitymultipurposebearinglubricantthatwillremainwithinitsviscosityrangeatexpectedoperatingtemperatures.Inaddition,Farrrecommendsthefollowinglubricationprocedureatthecompletionofeachjobpriortostorage.

McCoyrecommendsthataliberalcoatingofgreasebeappliedtothecamsurfaceoftherotarydrivegearpriortojawinstallation.Also,theclutchinspectionplateshouldperiodicallyberemoved,andaliberalcoatingofgreaseappliedtotheclutch,drivegearsandshiftingshaft.

Coatthejawpinsandrollerswithaliberalamountofanti-seizecompoundwheninstallingnewjawdiekits.

1. Cage Plate Cam FollowersApplygreasetothecamfollowersthroughthegreasefittingsrecessedintothetopandbottomcageplates(thirteenlocationstop,thirteenlocationsbottom).

ILLUSTRATION 3.E.1: CAM FOLLOwER LUBRICATION



2. Support RollersApplygreasetothesupportrollerbearingsthroughthegreasefittingsrecessedintothetopandbottomofeachsupportrollershaft(12locationstotal).

ILLUSTRATION 3.E.2: SUppORT ROLLER LUBRICATION

ILLUSTRATION 3.E.3: ROTARy IdLER LUBRICATION

3. Rotary IdlersApplygreasetotherotaryidlerbearingsthroughthegreasefittingsrecessedintothetopofeachshaftonthetopofthetong(twolocationstotal).

Maintenance



Maintenance

ILLUSTRATION 3.E.4: pINION IdLER LUBRICATION pOINT

4. Pinion IdlerApplygreasetothepinionidlerbearingthroughthegreasefittinglocatedonthetopfaceofthetongunderthevalvebank(onelocationonly).

5. PinionApplygreasetothepinionbearingsthroughthegreasefittingslocatedonthebearingcapsonthetopandbottomfacesofthetong(twolocationstop,twolocationsbottom).

ILLUSTRATION 3.E.5: pINION LUBRICATION pOINTS (TOp pLATE)



Maintenance

ILLUSTRATION 3.E.6: pINION LUBRICATION pOINTS (BOTTOM pLATE)

Pinion Lubrication (Continued):

6. ClutchApplygreasetotheclutchbearingsthroughthetwogreasefittingslocatedontheclutchbearingcaponthebottomfaceofthetong,andthesinglegreasefittingrecessedintotheendoftheclutchshaft.(threelocationstotal).

ILLUSTRATION 3.E.7: CLUTCH LUBRICATION pOINTS



Maintenance

7. Motor MountApplygreasetothemotorgear/clutchdrivegearthroughthegreasefittinglocatedonthetopofthemotormount(onelocationonly).

ILLUSTRATION 3.E.8: MOTOR MOUNT LUBRICATION pOINT

ILLUSTRATION 3.E.9: SHIFTER SHAFT LUBRICATION

8. Shifting ShaftApplygreasetotheshiftingshaftandtopshiftingshaftbushing.Theshaftandshiftingyokecanbeaccessedthroughthecoverplateonthesideofthetong.

Access shifter components through this panel



Maintenance

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.

Lubricate door latch cam through grease fitting.



11. CLINCHER® Cylinders Applygreasetotheexternalsurfacesoftheclinchercylindersthroughthegreasefittingsinthetopandbottombodyplates(eightlocationstotal).

ILLUSTRATION 3.E.12: BACKUp CLAMp CyLINdER LUBRICATION pOINTS

12. Compression Load Cell Applygreasetotheflatsurfacesofthecompressionloadcellwherecontactismadewiththerearlegandthepaddleofthebackup.

ILLUSTRATION 3.E.13: COMpRESSION LOAd CELL LUBRICATION

Maintenance

AppLy A THIN LAyER OF gREASE TO THESE SURFACES



Maintenance

F. ADJUSTMENTS1. Brake Band Adjustment:

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



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



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.

Iftherotarygeardoesnotstopimmediatelyandcompletelystoprotatingwhenthedoorisopened,removethetongfromserviceandperformthefollowingadjustments:

a. Removethetopplatefromthesafetydoorguard.Wireties(ifapplicable)requireremovalbeforethefastenersonthetopplateofthedoorguidecanbereplaces.

b. Performaninitialalignmentofthesafetydoormechanism.Closethetongdoor.Ensurethetwosafetydoor“claws”areseatedfirmlytogether.Slightlyloosenthehexboltssecuringtheadjustmentplate-tapthebottomadjustmentplateonewayortheotheruntiltheshoulderboltsonthefloatingplateareinthecentreofthetravelingslots(seeIllustration3.F.4).



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.

G. RECOMMENDED PERIODIC CHECKS1. Door Stop Spring

Thespringinsidetheactuatorcylindermustbeofsufficientstrengthtoenablethedoorlatchmechanismtosnapclosedproperly.Doorstopspringfatiguewillresultinsluggishlatchoperation.Replacethelatchspringinsidethecylinderwhenthisoccurs.

2. Shifting ShaftTheshiftingyokeissecuredtotheshiftingshaftbyonehexjamnutandonelocknutonthebottomoftheyoke.Checkthesenutsaftereachjob.Dothisbyremovingtheclutchinspectionplateandensuringasnugfitpriortolubrication.

3. Backing PinPerformavisualinspectionofthebackingpinaftereachjob.Replacethepinifstresscracksorexcessivewearisfound,orifthepinappearsbent.

4. Torque Gauge AssemblyPeriodiccalibrationofthetorquegaugeisrecommendedtoassureaccuratetorquereadings.Whenhavingthetorquegaugeservicedandcalibrated,itiscriticaltonotethearmlengthofthetong,asindicatedonpage1.3.

Safety Door Adjustment (continued):

Maintenance

Correct position of shoulder bolts within the traveling slots.

Loosen 3/8” bolts on the adjustment plate.

Safety door “claws” aligned properly



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/

backupassemblyontotheconstructedsupportuntilallweightisremovedfromfrontlegsuspensionsprings.

2. Removethe7/16”nutandboltsetsfromthebottomofthefrontlegs,andslidethelowerspringcapsandfrontlegcoilspringsoffeachleg.Notethatthetopspringcapswillremainwithinthebackupbodyassembly.

3. Disconnectthetworearbackupsupportspringsconnectingthebackuptotherearleg.

4. Removetheloadcellassembly.

5. Lifttongandlegsupandawayfromthebackup,andsettongontoaflatworksurfacethatwillsupporttheweightofthetong,andallowaccesstothebottomplate-ensurethatthelegsdonothaveanyweightonthem.

REMOVAL OF LEG ASSEMBLIES.6. Removetherearlegassemblybyremovingtwo1-1/4”x9”hexboltandnutsetsandtwo1”x8”hexboltandnutsets.

7. Removethefrontlegassembliesbyremovingthe7/16”x3”boltsandnutsetoneachleg,andslidelegtubesoutoflegmountweldments.

REMOVAL OF TOP PLATE8. Removetherigidslingassemblybydisconnectingthelevelingdevicesfromthehangerbrackets.

9. Removethetworigidslinghangerbrackets.

10. Disconnectthethreehydraulicconnectionsfromthemotor.Undotherestraintssecuringtheinletandoutletlinesconnectionstotheirsupports.

11. Supportthehydraulicvalveassemblywithatemporary liftingslingandacrane.Removethe1/2”x4-1/2”boltssecuringthehydraulicvalveassemblytothevalvesupportposts.Liftthehydraulicvalvesectionupandawayfromthetopplateofthetong.Ifthehydraulicvalveassemblydoesnotrequireserviceensureitisstoredinaclean,securelocation.Coverallexposedcon-nections.DISASSEMBLY NOTE (CE MARKED TONGS ONLY):Thevalvehandleguarddoesnotneedtoberemovedfromthevalvebank.Donotliftthevalveassemblyusingtheprotectivehandle.

12. Removetheinletandoutletsupportpieces.

13. Removetopbrakebandassembly(leaveadjustmentlugweldmentsinplacefornow).

14. Removethetongdoorstopcylinder.Thedoorstopcylinderspringmayretainenergyfrombeingcompressed.Useaclamptocontaintheendsofthecylinderwhenitisremoved,andrelievethespringtensiongradually.

15. Removedoorassemblybyremovingthedoorrollershaft.Supportdoorassemblyastherollershaftisremoved.Removethenutfromthetopoftherollershaft,anduseasoftalloymaterial(e.g.brassrod,etc.)tolightlytaptheshaftdownthroughthesupportrollerassemblyuntilitcomesfreeatthebottom.Usecautionthatthethreadsontheendsofthesupportrollershaftsarenotdamaged.Donotlosethedoorshoulderbushings.

16. Removethehitchpinsecuringthetorquegaugeholdertothetorquegaugemountweldment,andremovethemount.

17. Removethefourhexsocketheadcapscrewssecuringthemotorandthetorquegaugemountweldment.Removethetorquegaugemountweldment,thenliftthemotorupandawayfromthemotormount.Inspectthemotorgear,locatedatthebottomofthemotorshaft,forgearclashingortoothdamage.Also,ensurethatthemotorgearissecurelyattachedtothemotorshaft.

18. Removethecotterpinandclevispinconnectingtheshifterhandletotheshiftershaft(itisnotnecessarytodisconnectthehandlefromthepivotlugweldment).

Theheadsofthefastenerssecuringtherigidslinghangerbracketsaredrilled,andareconstrainedtothebracketsusingwireties.Wiretiesmustberemovedbeforeextractingthefastenersandremovingtherigidslinghangerbracket.



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.

Maintenance

28. Removethetopnutsandpadsfortherotaryidlergears.

29. Removetheremainingtoprollershaftnuts.Notethatthetopbrakebandadjustmentlugweldmentsareremovedatthispoint.

30. Loosen,butdonotremovethedetentboltonthetopshifterlugweldment.Oncetheforcefromthedetentballhasbeenremovedfromtheshiftershaft,thetopshifterbushingcanbeun-threadedfromthetopplate.Takecarenottolosethedetentballwhenthebushingcomesfreeoftheshaft.

31. Removethehexheadboltsandhexflatheadcapscrewsaroundtheperimeterofthetongthatsecurethetopplate.

22. Withalltheabovestepstaken,thetoptongplatecanbeliftedoffprovidingaccesstotheinsideofthegearcase.

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

Removal of Top Plate (Continued):

19. Unboltthepivotlugweldmentfromthetopplate,andremovethepivotlugandhandleassembly.

20. Removethefourhexsocketheadcapscrewssecuringthemotormounttothetopplate.Usecarenottodislodgeandlosethetwopositioningdowels.

21. Removethesnapringsecuringthedrivegeartothetopoftheclutchshaft.Carefullyremovethedrivegearfromtheclutchshaft.

22. Removethetwo10-24x3/4”hexsocketheadcapscrewssecuringthetopclutchbearingretainertothetopplate.

23. Removethetopclutchbearingretainer,andbearingretainerspacer.Thetopclutchbearingandclutchbearingbushingmaycomeoffwiththebearingretainer.

24. Removethe1-1/4”nylocknutandthethree5/8”boltssecuringthepinionidlerhalf-moonpad.

25. Pullthetoppiniongearbearingcapbyremovingthefour1/2”boltswhichsecurethebearingcap.Threadtwooftheremovedboltsintotheextraholesontopofthebearingcap,andusethemasliftinglugstoliftthebearingcapoutofplace.



Maintenance

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.

TIGHTENING TORQUE GUIDESAE GRADE 8 - FINE THREAD

SIZE CLAMP LOAD PLAIN PLATED1/4-28(.250) 3,263 14ft.lbs. 10ft.lbs.

5/16-24(.3125) 5,113 27ft.lbs. 20ft.lbs.

3/8-24(.375) 7,875 49ft.lbs. 37ft.lbs.

7/16-20(.4375) 10,650 78ft.lbs. 58ft.lbs.

1/2-20(.500) 14,400 120ft.lbs. 90ft.lbs.

9/16-18(.5625) 18,300 172ft.lbs. 129ft.lbs.

5/8”-18(.625) 23,025 240ft.lbs. 180ft.lbs.

3/4-16(.750) 33,600 420ft.lbs. 315ft.lbs.

7/8”-14(.875) 45,825 668ft.lbs. 501ft.lbs.

1-12(1.000) 59,700 995ft.lbs. 746ft.lbs.

1-14(1.000) 61,125 1019ft.lbs. 764ft.lbs.

11/8-12(1.125) 77,025 1444ft.lbs. 1083ft.lbs.

11/4-12(1.125) 96,600 2012ft.lbs. 1509ft.lbs.

13/8-12(1.375) 118,350 2712ft.lbs. 2034ft.lbs.

11/2-12(1.500) 142,275 3557ft.lbs. 2668ft.lbs.

SAE GRADE 8 - COARSE THREADSIzE CLAMPLOAD PLAIN PLATED

1/4-20(.250) 2,850 12ft.lbs. 9ft.lbs.

5/16-18(.3125) 4,725 25ft.lbs. 18ft.lbs.

3/8-16(.375) 6,975 44ft.lbs. 33ft.lbs.

7/16-14(.4375) 9,600 70ft.lbs. 52ft.lbs.

1/2-13(.500) 12,750 106ft.lbs. 80ft.lbs.

9/16-12(.5625) 16,350 153ft.lbs. 115ft.lbs.

5/8”-11(.625) 20,325 212ft.lbs. 159ft.lbs.

3/4-10(.750) 30,075 376ft.lbs. 282ft.lbs.

7/8”-9(.875) 41,550 606ft.lbs. 454ft.lbs.

1-8(1.000) 54,525 909ft.lbs. 682ft.lbs.

11/8-7(1.125) 68,700 1288ft.lbs. 966ft.lbs.

11/4-7(1.125) 87,225 1817ft.lbs. 1363ft.lbs.

13/8-6(1.375) 103,950 2382ft.lbs. 1787ft.lbs.

11/2-6(1.500) 126,450 3161ft.lbs. 2371ft.lbs.

REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHER-WISE SPECIFIED.



Assembly Procedures1. Positionthetongbodygearcase(weight=400lbs/182kg)onastationarysupportcapableofsupportingatleast1500lbs

/682kg,ensuringthatthebottombodyplateremainsaccessible.

2. Slideasupportrollershaftspacer(PN1037-C-134)intoeachsupportroller(PN1037-135)(totalof12).

3. Presssupportrollerbearings(PN02-0094)intoeachsideofthesupportrollers.AssemblefivesupportrollerassembliesasshownonPp.5.4-5.5.

4. Installfivesupportrollerassembliesalongonesideofthebodycase.Insertshaftsthroughassemblies,butdonotinstallthebottomnylocknutsor,whereused,thetopwashers.

5. Threadtworated1/2”UNCeyeboltsintotherotarygear(weight=200lbs/91kg)toserveastemporaryliftingpoints.Installrotarygear,makingsurethebackingpinslotsareonthesidefacingup.Keepfingersclearofpinchpointsasrotarygearispositionedinthetongopening.EnsureonesideissupportedbythesupportrollersinstalledinStep4,andhavetheopeningintherotarygearorientedasshowninthefollowingillustration.

ILLUSTRATION 3.I.1: TONg ASSEMBLy - ROTARy gEAR INSTALLATION

Maintenance

6. Installsupportrollerassembliesinthelocationsexposedbytheopeningintherotarygear.Continuetorotatetherotarygear,supportingtherotarygearwiththesupportrollersandinstallingnewsupportrollerassembliesintherotarygearopeningasitisrotated.Finishwiththerotarygearalignedwiththeopeninginthebottomplateandcompletelysupportedbythesupportrollers.Donotinstallthedoorpivotsupportrollerassemblyatthistime.

7. Presspinionbearing(PN02-0007)intobottompinionbearingcap(PN1050-89),andinstallbearingcapintobottomplateoftongusingfour1/2”NCx1-1/2”hexboltsand1/2”lockwashers.

8. Presslowerclutchbearing(PN02-0004)intoclutchbearingcap(PN1050-C1-54),andinstallbearingcapintobottomplateoftongusingfour3/8”NCx1-1/2”hexboltsand3/8”lockwashers.

9. Installaretainerclip(PN02-0009)intobothrotaryidlergears(PN997-A2-119).Pressanidlerbearing(PN02-0011)intoeachgearandsecurewithasecondretainerclip.

10. Lightlygreasethelargercircumferenceofthetworotaryidlershafts(PN1050-D5-117)andslidethemthroughthebearingandgearsassemblies,centeringthegearontheshaft.

11. Slidetwobearingseals(PN02-0010)overeachendoftheidlershaftsandpressagainsttheretainerclips(seePp.5.6-5.7forcorrectorientation).

12. Slideabearingspacer(PN1050-D5-121)overeachendoftherotaryidlershafts.

13. Placeeachrotary idlerassembly throughthebottomplate,ensuring theendsof theshaftswith the threadedhole for thegreasefittingarepointedupwardandtherotaryidlergearsmeshwiththerotarygear.



Assembly Procedures (continued):14. Placeanidlerpad(PN997-D20-125)overthebottomsideofeachrotaryidlershaft,andsecureeachwitha1-1/2”UNFnylock

nut.

15. Thelowpiniongear(PN997-A5-88)ismachinedwithshouldersaroundthecentresplineonbothsidesofthegear.Placethesideofthelowpiniongearwiththesmallershoulderoverthelowerbearingandbearingcap,centeringasbestasable.

16. Installpiniongearshaft(PN997-A7-86)intothesplineofthebottompiniongearandthelowerpinionbearing.

17. Slide2needlebearings(02-02-0003)overeachendoftheclutchshaft(PN997-A8-50),andpressupagainstcentregear.Slidelowclutchgear(PN997-A1-52)overthebottomendoftheclutchshaft(thebottomendoftheclutchshaftcanbeidenti-fiedbythethreadsforthegreasefittingmachinedintotheend)ontothetwoneedlebearings.Ensurethesmallerdiameterofthelowclutchgearisdirectlyadjacenttothecentregearontheclutchshaft.Placelowerendofclutchshaftintothelowerclutchbearingthathasbeenpre-mountedinthelowerbodyplate.

18. Installshiftingcollar(PN997-A9-62)overthetopoftheclutchshaftandmeshwithlowclutchgearandthecentregearontheclutchshaft.

19. Slidetheshiftingforkweldment(PN1050-72)overthebottom(threaded)endoftheshiftingshaft(PN1116-71)andsecurewitha5/8”UNFhexnutand5/8”UNFhexjamnut.Placetheendoftheshiftingshaftinthelowershiftingbushing(weldedtothebottomplate)andmeshtheshiftingforkwiththeshiftingcollar.

20. Installaretainerclip(PN02-0009)intothepinionidlergear(PN997-A2-119).Pressanidlerbearing(PN02-0011)intothegear,andsecurewiththesecondretainerclip.

21. Slidethepinionidlerhalf-shaft(PN1050-D5-105)throughthepinionidlergearassembly.Slidethebearingseal(PN02-0010)overtheendofthehalf-shaft,andsecuretothehalf-shaftwithashaftretainerclip(PN02-0008).

22. Placepinionidlerassemblies,lesstheidlerpadsandtopfasteners,ontopofthelowerpiniongearandplacethemasbestaspossible-theirpositionmayhavetobeadjustedslightlyasthetopplateisattached(seeillustration3.I.2).

Maintenance

ILLUSTRATION 3.I.2: TONg ASSEMBLy - gEAR ASSEMBLy pOSITIONINg

23. Thehighpiniongear(PN997-A4-87)ismachinedwithshouldersaroundthecentresplineonbothsidesofthegear.Placethesideofthehighpiniongearwiththelargershoulderoverthetopofthesplinedpinionshaftandpressagainstthecentregearonthepinionshaft.

24. Installhighclutchgear(PN997-A1-51)ontotheclutchshaft,ensuringthesmallerdiameterisdirectlyadjacenttothecentregearontheclutchshaft.

25. Carefullyremoveallsupportrollershafts,usingcautionnottoshiftthepositionoftheinstalledsupportrollerassembliesortodamagethethreadsontheendoftheshafts.

26. Insertthree3/8”x1-1/2”dowelpins(PN09-0092)intothesidebodyofthetong-twointheun-threadedholesoneitherside,nearthefrontopening,andoneintheun-threadedholeintherearcentreofthebody.



Assembly Procedures (continued):27. Carefullypositionandinstallthetopplate(PN1050-7TP).Lowertheplateevenlyandleveled,andavoidbindingonthedowel

pins.Usecautionnottodamagethetopoftheclutchandpinionidlershafts.Securethetopplatewith143/8”NCx1-1/2”hexboltsand3/8”lockwashers,andten3/8”NCx1”hexsocketheadcapscrewsasshowninillustration3.H.3.Donotinstallfastenersattherigidslinghangerlocations,indicatedbytheredcircles,orthedoorcylindermountingluglocationindicatedbythegreencircle..

28. Installhalf-moonidlerpad(PN997-D17-109)overtheendofthepinionidlershaftandsecurewiththree5/8”NCx2-3/4”hexboltsand5/8”lockwashers,followedbya1-1/2”UNFnylocknut.

29. Slidetheremainingrotaryidlerpadsovertherotaryidlershaftsandsecurewith1-1/2”UNFnylocknuts.

30. Presstheremainingpinionbearing(PN02-0007)intothetoppinionbearingcapandinstalloverthetopofthepiniongearshaft-securewithfour1/2”NCx1-1/2”hexboltsand1/2”lockwashers.

31. Installtopclutchbearingretainer(PN997-D11-59)overtheclutchshaftintothecutoutinthetopplateandsecurewithtwo10-24x3/4”hexsocketheadcapscrews.

32. Inserttopclutchbearing(PN02-0002),followedbytheclutchbearingbushing(PN997-60).

33. Installclutchdrivegear(PN997-A3-61)andsecurewithretainingsnapring(PN1234-00-04).

34. Re-installsupportrollershafts:

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



ILLUSTRATION 3.I.4: TONg ASSEMBLy - SUppORT ROLLERS (LEg MOUNT LOCATIONS)

Maintenance

Assembly Procedures (continued):

34. Re-installsupportrollershaftscontinued:

ii) InstalltheRHfrontlegmountweldment(PN101-0879)andtheLHfrontlegmountweldment(PN101-0878)onthetothesupportrollershaftsusing1”narrowflatwashersand1”UNSthinnylocknuts.

ILLUSTRATION 3.I.5: TONg ASSEMBLy - SUppORT ROLLERS (SECURINg LEg MOUNTS)



Assembly Procedures (continued):34. Re-installsupportrollershaftscontinued:

iii) Installsupportrollershafts(PN101-3939)infourlocationswheretheyarecoincidentalwiththetopandbottombrakebandretainerweldmentsasshowninillustration3.H.6.Thesesupportrollersdonotusetoporbottomwashers.

ILLUSTRATION 3.I.6: TONg ASSEMBLy - SUppORT ROLLERS (BRAKEBANd wELdMENTS)

Maintenance

iv) Installsupportrollershafts(PN101-3939)intheremaininglocationsEXCEPTFORthedoorpivotroller.Ensurea1-1/8”narrowflatwasherisinstalledoneachsupportrollershaftbeforeinsertingthroughthebodyandsupportrollerassem-blies.Secureeachsupportrollershaftusing1”narrowflatwashersand1”UNSthinnylocknuts.

35. Threadthetopshifterbushing(PN101-0020)intothetopplate,overtheshiftershaft,untilsnug.Threadthedetenttube(PN101-0019)intothetopshifterbushingasshown.Threadthree5/8”NCx5/8”hexsocketsetscrewsintotheremainingthreeports inthebushing-thesesetscrewsareintendedtobeusedascontaminationbarriersonly.Donotbottomoutthesetscrewsontheshiftingshaft,ortheshaftwillnotmove.

36. Inserttheshifterdetentball(PN02-0018)intothedetenttube,followedbythedetentspring(PN01-0040).Threada7/16”NFhex jamnutontoa7/16”UNFx1-1/4”hexnut, thenthreadthe7/16”bolt intothedetent tube.This is thedetent forceadjustmentboltandlocknut(seeIllustration3.I.7nextpage):




37. Inserttwo5/16”x3/4”dowelpins(PN09-0170)intotheun-threadedholesintherearofthetong,behindtheclutchdrivegearoneithersideofthecutoutinthetopplate.

38. Placemotormount(PN1050-150)ontotopplateoverthedowelpinsinstalledinthepreviousstep,andsecurewithfour1/2”NCx1-1/2”hexsocketheadcapscrews.

39. Bolttheshifterlugweldment(PN101-0016)ontothetopplatewithfour3/8”NCx1-1/4”hexboltsand3/8”lockwashers.

40. Attachthemotorgear(PN997-A10-149)tothemotorshaft,securingwithtwo3/8”NCx3/8”flatpointhexsocketsetscrews.Donotneglecttoinstallthe5/16”squarex1-1/2”keybetweenthegearandthemotorshaft..

41. Installthemotor(PN87-0112)ontothemotormount.SecuretheRHsideofthemotortothemotormountwithtwo1/2”NCx1”hexsocketheadcapscrewsand1/2”lockwashers.

42. TheLHsideofthemotorissecuredwithtwo1/2”NCx1-1/4”hexsocketheadcapscrewsand1/2”lockwashers,whichalsosecuresthetorquegaugeholderweldment(PN1500-09-04A).

43. Installshiftinghandle(PN1037-D-20B).Securethehandletotheshiftershaftandshifterpivotlugweldmentwith5/16”x1-1/2clevispins.Useahitchpinoneachclevispintoensuretheydonotbecomedislodged.

44. Installthirteencamfollowers(PN02-0015)inthetopcageplate(PN1050-21),andsecureeachawith5/8”UNFhexjamnutand5/8”lockwasher.Onceinstalledthecamfollowerswillrideinthetopgrooveintherotarygear.

45. Installthirteencamfollowers(PN02-0015)inthebottomcageplate(PN1050-22),andsecureeachawith5/8”UNFhexjamnutand5/8”lockwasher.Onceinstalledthecamfollowerswillrideinthebottomgrooveintherotarygear.

46. Supportthebottomcageplateassembly(weight-80lbs/36.4kg)againstthebottomoftherotarygear,withthecamfollowersinthegrooveinthebottomoftherotarygearandtheopeningofthecageplatealignedwiththeopeninginthetongbody.

47. Placethetopcageplateassembly(weight-80lbs/36.4kg)onthetopoftherotarygear,withthecamfollowersinthegrooveinthetopoftherotarygearandtheopeningofthecageplatealignedwiththeopeninginthetongbody.

ILLUSTRATION 3.I.7: TONg ASSEMBLy - TOp SHIFTER BUSHINg ASSEMBLy

Maintenance



Assembly Procedures (continued):48. Inserttwocageplatespacers(PN1050-C3-38)betweenthecageplatesatthefrontofthecageplatesnexttotherotarygear.

Securethecageplatesthroughthespacersusing1/2”UNCx7-1/2”hexbolts,1/2”narrowflatwashers(onthebottom)and1/2”UNCnylocknuts.

49. Slidea1/2”flatwasherontoa1/2”UNCx9-1/2”hexbolt,followedbythebackingpinspacer(PN101-4186).Slidethelargerdiameterholeinthebackingpinretainerlink(PN101-4187)evertheendofthe9-1/2”hexboltontothebackingpinspacer.

50. Coathalfofthethreadedconnectingdowelpin(PN101-4097)withblueLoctiteandscrewintothebackingpin(PN101-4188).

51. Inserttheexposedhalfofthethreadeddowelpinthroughthesmallerdiameterholeofthebackingpinretainerlink.Slidethesmallbackingpinspacer(PN101-4096)overthethreadeddowelagainstthebackingpinretainerlin

52. Positiontheremainingcageplatespacer(PN1050-C3-38)betweenthecageplatesattherearoftheopening.Inserttheboltofthebackingpinassemblythroughthecageplatesandcageplatespacer,andthebackingpinintooneofthebackingpinholesattherearofthetopcageplate.Securetheboltwitha1/2”narrowwasheranda1/2”UNCnylocknut.

53. Threadthereardoorcylindermountinglug(PN1050-12-001)intothetopplatenexttotheLHtopbrakebandlugweldment(seeillustration3.H.3).

54. Installthedoorpivotshoulderbushings(PN101-0110)inthedoorweldmentassembly(PN1050-C4-10)(seePp.5.34-5.35forcorrectbushingorientation).

55. Ifnotalreadydone,installtheremainingsupportrollerassemblylesstheshaftandfastenersbetweenthebodyplatesinthedoorpivotlocation.

56. Alignthepivotholesinthedoorweldmentwiththepivotholesinthetopandbottomplates.Slidea1-1/8”narrowflatwasherontothedoorpivotrollershaft(PN101-3940)andinserttheshaftthroughthedoorbushings,supportrollercomponents,andbodyplates.Oncetheshaftisfullyinserted(itmayneedtobelightlytapped)securewitha1”narrowflatwasherand1”UNSthinnylocknut.

57. Threada1/2”UNChexnutontoa1/2”UNCx1-3/4”hexbolt.Threadthehexboltintothethreadedholeonthefrontofthedoorweldment.

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



Assembly Procedures (continued):60. Installthedoorstopcylinder(PN101-0069)usingtwo3/8”NCx1-1/4”hexbolts,two3/8”lockwashers,andtwo3/8”nar-

rowflatwashers.Donotneglecttoinstalldoorstopspacers(PN02-E0030)undertheflatwashersthrougheachendofthecylinder.

61. Installupperandlowerlinedbrakebandweldments(PN1050-D4-29).Secureeachbrakebandtothetoporbottomplatewithabrakebandretainer(PN101-0140),and3/8”NCx1”hexboltsand3/8”lockwashers.Attachthefrontsofeachbrakebandweldmenttothebrakebandlugweldmentswith3/8”UNCx1-1/2”hexbolts,3/8”narrowflatwashers,and3/8”UNChexnylocknuts.Thesenutandboltsetsareusedforadjustingthebrakebandtension.

62. Installthesafetydoorswitchassemblyusingthefollowingprocedure(seePp.5.36-5.37):

i. Attachsafetydoorlatchspacer(PN101-1411)tothetopofthedoorweldmentusingtwo3/8”NCx1”hexsocketheadcapscrewsand3/8”lockwashers.

ii. Attachsafetydoorlatchblock(PN101-1104)tothelatchspacerusingfour3/8”UNCx1/2”shoulderbolts.

ILLUSTRATION 3.I.9: TONg ASSEMBLy - SAFETy dOOR vALvE INSTALLATION

Maintenance

CE-markedtongsonly:attachsafetydoorlatchblock(PN101-1104)tothelatchspacerusingfour3/8”x1/2”UNCwire-drilledshoulderbolts

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.

CE-markedtongsonly:securesafetydoorlatchplate(PN101-1410)andguardweldment(PN101-1475)tothetopplateusingtwo3/8”UNCx3”wire-drilledhexboltsandlockwashers,andone3/8”UNCx1-1/4”wire-drilledhexboltandlockwasher.



ILLUSTRATION 3.I.10: TONg ASSEMBLy - RIgId SLINg AdJUSTMENT BOLT INSTALLATION

Maintenance

Assembly Procedures (continued):62. Installthesafetydoorswitchassembly(continued):

vii. Attachthetopplateoftheswitchguard(PN101-1474)totheswitchguardweldmentusingthree3/8”UNCx1”hexboltsand3/8”lockwashers.

CE-markedtongsonly:securetopplateoftheswitchguard(PN101-1474)totheswitchguardweldmentusingthree3/8”UNCx1”wire-drilledhexboltsandlockwashers.

64. Slidethemasterlifinglink(PN02-0516)overtheadjustmenthelix(PN1053-1-H),andinstalltheadjustmenthelixintherigidslingweldment(PN101-0112)usinga3/4”UNCx8”hexboltand3/4”UNCnylocknut.

63. InstalltheLH&RHrigidslingmountinglugs(LH=PN101-0113,RH=PN101-0115)usingtwo3/8”UNCx1-3/4”hexboltsand3/8”lockwashers,andtwo1/2”UNCx1-1/4”hexboltsandlockwashersperside.

CE-markedtongsonly:secureLH&RHrigidslingmountinglugstothetopplateusingtwo3/8”UNCx2”wire-drilledhexboltsand3/8”lockwashers,andtwo1/2”UNCx1-1/4”wire-drilledhexboltsandlockwashersperside.

65. Useacranetohoisttherigidslingweldment.Connecttherigidslingweldmenttotherigidslingmountinglugswithrigidslingpins(PN1053-C-1C).Secureeachpinwithtwo0.148”x2.938”hitchpins.

66. Threada3/4”UNChexnutontoeachoftworigidslinglevelingadjustmentweldments(PN1053-C-1L).Threadthelevelingadjustmentweldmentsintothefrontoftherigidslingweldmentmountingbrackets,roughlyadjustingthemsotherigidslingisapproximatelyperpendiculartothetopplateofthetong(seeillustration3.H.10nextpage).

67. Thread1/2”UNChexnutsontotwo1/2”UNCx1-3/4”hexbolts.Threadtheboltsintotherearoftherigidslingweldmentmountingbrackets.(seeillustration3.I.10).

CE-markedtongsonly:rigidslingweldmentforCE-markedtong=PN101-0112-CE



Assembly Procedures (continued):69. Useacraneandtemporaryslingtohoistthebackupassembly(weight=910lbs/414kg)ontoasuitablesupportstructure

nexttotheassemblylocationofthetong.Minimumheightforthebackupsupportsmustbe36”inordertoallowclearanceforinstallingthefrontlegs.

70. Attachtherearlegassemblytothetong:

a. Positionrearlegweldment(1302-908-00)onaflatsurfacenearthetongassemblylocation.

● Models80-0615,80-0615-2,&80-0615-6userearlegweldmentPN1302-908-00● Models80-0615-3&80-0615-4userearlegweldmentPN101-2031

b. Useacranetohoistthetongassemblyofftheassemblysurface.Bringthetongintocontactwiththerearleg,ensuringthecranecontinuestosupporttheentireweightofthetong.Attachtherearlegweldmenttothetongusingtwo1-1/4”UNCx9”hexboltsand1-1/4”UNCheavyhexnuts,andtwo1”UNCx8”hexboltsand1”UNCheavyhexnuts.

71. 80-0615-6 assembly (uses 85-0607 backup) only: installtherearbackupsupportspringassemblyintherearleg(seePp.5.40-5.41):

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

rodintotheheavyhexboltweldedtothetopplateofthebackupuntiltherodbottomsout.Lockthethreadedrodinplaceusingtheheavyhexnutthreadedontotherodinthepreviousstep.

c. Coatapproximately4”ofthreadatthetopofthethreadedrodwithblueLoctite®.Threadona1-1/4”UNCheavyhexnut,ensuringenoughthreadisexposedtoallowinstallationofthesuspensionspringv-bracketandanother1-1/4”UNCheavyhexnut.

d. Installthesuspensionspringv-bracket(PN1483-500-00-04)ontothethreadedrod,andsecurewithanother1-1/4”UNCheavyhexnut.

73. Removethesidepanelsfromthebackup.

74. Useacranetohoistthetongandrearlegassemblyandplaceinpositionoverthebackup.Ifusingthe85-0604or85-0607-1compressionloadcell-stylebackupstherearlegmustbeguidedsothatthe“paddle”onthebackupsitsbetweentheverticalplatesoftherearlegasthetongandrearlegassemblyareloweredoverthebackup.

Maintenance

CE-markedtongsonly:placearubberprotectivewasher(PN101-5733)onthetopplateofthebackupovereachfrontlegopening.Thefrontlegswillbeinsertedthroughtheseprotectivewashers.

75. Holdatopspringcap(PN1302-905-03B)underthetopplateofthebackup,andinsertafrontlegtube(PN1302-904-905C)fromthebottomofthebackup,throughthespringcap,andintothelegmountweldmentonthetong.Securethelegtubewitha7/16”UNCx4”hexbolt,7/16”narrowflatwasher,anda7/16”UNCnylocknut.Repeatfortheotherlegtube.

76. Slidealegspring(PN1391-905-02B)overthebottomofeachlegtube,followedbyabottomspringcap(PN1302-905-03C).Secureeachlegspringandbottomspringcaptothelegtubeusinga7/16”UNCx3”hexbolt,7/16”narrowflatwasher,anda7/16”UNCnylocknut.

CE-markedtongsonly:thefollowingfrontleginstallationstepssupersedesteps75&76below.

•slidealowerspringwasher(PN1302-905-03Aoverthetopofeach“CE-marked”frontlegweldment(PN101-5732).Temporarilypre-positionthelowerspringwashersonthefrontlegsbyinstalling7/16”UNCx3”bolts,flatwashersand7/16”UNCnylocknutsunderthefrontlegwashers.Thelowerfrontlegspringwashersmayneedtobeadjustedoncethefinalpositionofthebackupisdetermined.

•slideafrontlegspring(1391-905-03A)overthetopofeach“CE-marked”frontlegweldment.

•holdatopspringcap(PN1302-905-03B)underthetopplateofthebackup,andinsertthe“CE-marked”frontlegweldmentthroughthetopspringwasher,theprotectiverubberwasher,andsecureeachlegweldmenttothelegmountweldmentsonthetongusinga7/16”UNCx4”hexbolt,7/16”narrowflatwasher,anda7/16”UNCnylocknut.



Maintenance

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.

78. Hoisttongandbackupassemblyoffthebackupsupports,andlowerassemblysothatitsitsonitslegs.

79. Installgreasefittings:

a) Installone1/4”straightthreadgreasefitting(PN02-0097)intothetopsideofeachsupportrollershaft, includingthedoorpivotrollers(12locationstotal).

b) Installone1/4”straightthreadgreasefitting(PN02-0097)intothetopsideofthelatchadjustmentcam.c) Installone1/8”NPTgreasefitting(PN02-0005)intothetopofeachidlershaftorhalf-shaft(threelocationstotal).d) Installone1/8”NPTgreasefitting(PN02-0005)intotheendoftheclutchshaft,inthecentreoftheclutchbearingcap.e) Installtwo1/8”NPT90ogreasefittings(PN02-0093)ineachpinionbearingcap(fourlocationstotal).f) Installtwo1/8”NPT90ogreasefittings(PN02-0093)inclutchbearingcap(twolocationstotal).g) Installone1/8”NPT90ogreasefitting(PN02-0093)orone1/8”NPT45ogreasefitting(PN02-0006)inthetopofthe

motormount.h) Install two1/8”NPT90ogrease fittings (PN02-0093) into the topplateof thebackupdirectlyaboveeachclamping

cylinder,andtwointothebottombackupplatedirectlybeneatheachoftheclampingcylinders(eightlocationstotal).

i) Installdrive-ingreasefittings(PN02-0012)intotheendsofeachcageplatecamfollower(26locationstotal).

80. Installhydraulicinletsupportbase(PN101-1138)tothetopplatedirectlyadjacenttotheRHrotaryidler,usingtwo3/8”NCx1”hexboltsand3/8”lockwashers.Attachtheadjustmentplate(PN101-0022)tothesupportbaseusingtwo3/8”NCx1”hexbolts,3/8”narrowflatwashers,and3/8”UNChexnylocknuts.

81. Attachtheoutletcouplingsupportmountingbase(PN101-0021)tothetopplatetotheRHsideofthemotormountusingfour3/8”UNCx2”hexsocketheadcapscrews.

82. Attachtheoutletcouplingsupportweldment(PN101-0023)totheweldmentmountusingtwo3/8”NCx1”hexboltsand3/8”lockwashers.Attachtheadjustmentplate(PN101-0277)totheoutletsupportweldmentusingfour3/8”NCx1”hexbolts,3/8”narrowflatwashers,and3/8”UNChexnylocknuts.

83. Coatthethreadsofthehydraulicvalvemountingposts(PN101-0116)withLoctiteandthreadintothetopplatejustbehindthebrakebandoneithersideofthebrakebandretainer.

84. MounttheDVA35hydraulicvalveassemblyonthemountingpostsusingtwo1/2”UNCx4-1/2”hexboltsand1/2”narrowflatwashers.



Maintenance

CE-markedtongsonly:Installthevalvehandleguardweldment(PNCE-HANDLE-3)overthevalvehandleswhilesecuringthevalvebanktothevalvemountingposts.Usea1/2”UNCx4-1/4”hexbolt,1/2”narrowflatwasher,anda1/2”UNCthinnylocknuttosecuretherearofthevalvehandleguardweldmenttotherearoftheDVAvalveassembly

85. Attachtwo#20(1-1/4”)/1”JICflangeelbows(PN02-9216)tothemotorusing#20splitflangekits(PN02-9217).

86. Connectthesafetydoorvalveblock(PN101-0727)directlytotheflangeelbowsonthehydraulicmotor(theblockwillsitontopofthemotorfollowinginstallation).ConnecttherotationcontrolvalveontheDVA35valveassemblytothesafetydoorblock.

87. Connect thesafetydoorswitch to thesafetydoorblockandhydraulicvalveassembly.Refer tohydraulicschematic,orcallMcCoyDrilling&Completions-Farrengineeringdepartmentforassistance.

88. Installdesiredjawdiekitinthetongusingthejawpivotbolts(PN1050-C5-28).

89. Installmatchingjawdiekitsinthebackup.

90. Performacompletepre-operationalcheckbeforereleasingequipmenttoanoperatingenvironment.SeeSection2.Iforcom-pletetestingprocedures.


ILLUSTRATION 3.I.11: TONg ASSEMBLy - vALvE HANdLE gUARd INSTALLATION (CE MARKEd)



J. DAILY INSPECTION & MAINTENANCE CHECKLIST (POWER TONG)Farrrecommendsthatthefollowinginspectionandmaintenanceproceduresbeperformedbeforeeachuse,andatleastonceperdaywhenthetongisinsteadyuse,intheorderinwhichtheyarelisted.

1. Rotatecageplate/rotarygearuntiltheopeningintherotarygearfacestowardstherearofthetong.

3. Performaninitialwashofthetonginordertoremovethemajorityofdirtandgreasebuild-up.Ensureadequatecontain-mentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluidanddirtygrease.

4. Removetheaccesspanelonthesideofthetongdirectlyadjacenttotheshiftermechanism.

5.Useaflashlighttoperformavisualinspectionofthegeartrainthroughtheaccesspanelandtheopeningoftherotarygear.Ifgeardamageorchipsofmetalareseen,thetongshouldberemovedfromserviceandoverhauledtoavoidfurtherdamage.Replaceaccesspanelwheninspectioniscomplete.

6.Performavisualinspectionofallfastenersandprotrudingbodypieces(example:hydraulicvalvemounts,inlet&outletlinesupports,tonglegs,shifterhandlepivotlugs).Tightenorreplacelooseormissingfasteners.Farrrecommendsthatdamagedormissingbodypartsberepairedorreplaced.

7.Inspectthejawsanddies.Inspectthejawrollerpinsforsignsofdamage-replacepinsifnecessary.Ifthepinsareweldedinplace,replacetheentirejawassembly.Ensurediesaresecureinthejaw-replaceworndiesifnecessary.Ensurethatthejawrollersrotatefreely.Checktoensurethesizeoftheloadedjawsmatchthesizeofcasingorpipeyouarerunning.

8.Performavisualinspectionofallliftingpoints-ifvisibledamageisseen,includingcracks,brokenlugs,distortedmetal,etc.replacedamagedpart(s)beforeplacingtonginservice.Alsoinspectallchains,masterlinks,andturnbuckles-again,ifanydamageisnotedreplacethedamagedpart(s)beforeplacingthetonginservice.

9. Inspecttongforsignsofprematurewear,ormovingpartsthatarerubbing(baremetalwherethereusedtobepaintisagoodindicationofwear.

10. Inspectbackingpin(s).Ifcracked,broken,orbentit(they)mustbereplaced.

11.Inspecttopandbottombrakebandlinings-replaceifnecessary.Unequalwearofthebrakebandsindicatesthatthebrakebandtensionisnotevenlyadjusted.Refertothemaintenancesectionofthemanualforinstructionsonproperlyadjustingbrakebands.

12. Performavisualinspectionofallhydrauliclines.Replaceflexiblelinesiftheyappeartobecracked,fatigued,orhavevisiblesignsofwearfromcontactwitharigidobject.

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) Rotatethetongtothe“openthroat”position.Ensuretongandbackupdoors(ifequipped)areclosed.Fullyextendtheliftcylinder




5) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressureintheremainderofthehydrauliccontrolsystem.


8) Disconnectremaininghosessuchascasedrains.

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



21.Whilerotatingthecageplate,ensurethatthejawsproperlycam.If the jawsdonotcamproperly, thebrakebandsneedtobetightened.IncrementallyadjustboththetopandbottombrakebandsEqUALLYuntilpropercamactionisachieved.

13. Performacompletegreasingofthetong-refertoMaintenancesectionofthetechnicalmanual

14. Ensuremainsupplyandreturnconnectionstothetongarefullymadeup.Re-connecttheremainderofthehydrauliclines,and,ifapplicable,theelectricallinetotheturnscounter.

FAILURE TO ENSURE THAT THE SELF-SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE.

NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR

15.Performavisualinspectionoftheloadcell.Ifusingatensionloadcell,replaceanycracked,broken,ordistortedcom-ponentsincludinglinksandchains.Ifusingacompressionloadcell,replaceanycomponentthathasbeencrushedorotherwisedistortedthroughcompression.Inspecthydraulicline,fittings,anddiaphragmsealsforfluidleaks.

16. Ifapplicable,inspecttheloadcellanchorpins(tensionloadcellonly).Replacetheanchorpinsifcrackingormetaldistortionisseen.

Ifusingastand-alonepowerunit,startitnow-refertothepowerunittechnicalmanualforstartupprocedures.Listentopowerunitforamomenttoseeifthereareanyunusualmechanicalsounds(rubbing,grinding,excessivepumpnoise).Ifusingadieselunit,allowsufficienttimefortheenginetoreachoperatingtemperaturebeforeincreasingengineRPM.Onceengineiswarm,graduallyincreaseengineRPMuntiloperatingspeedisreached.

17. Ensurethatsupplypressureisatorabovethetong’sspecifiedoperatingpressure,andthatthereturnpressureislessthan350psi.

18. Performavisualinspectionofpressurizedhydrauliclines.Documentandcorrectanyhydraulicfluidleaks.

19. Performafullfunctionaltestofthetong(refertosection2.I.4).

20.Testsafetydoorfeature(ifequipped).Openthetongdoor(s),andattempttorotatethecageplateatlowspeed(lowgear)inbothdirections(makeupandbreakout).Ifcageplatebeginsrotating,thesafetydoormechanismisnotfunc-tional,andthetongmustberemovedfromserviceuntilthesafetydoormechanismcanberepaired.Ifthesafetydoorisoperatingcorrectly,cageplaterotationwillnotbeinhibitedoncethedoorisclosedandlatched.

Maintenance

CE-markedtongsonly:Inspectallwire-tiesondrilledboltsoncriticalsafetysystems.Allwiringmustbeintactandappeartamper-free.Checktheintegrityofallguards,includingtherubberprotectivewashersoverthebackuplegopenings.



Maintenance

K. DAILY INSPECTION & MAINTENANCE CHECKLIST (BACKUPS)FarrCanadarecommendsthat thefollowing inspectionandmaintenanceproceduresbeperformedbeforeeachuse,andat leastonceperdaywhenthebackupisinsteadyuse,intheorderinwhichtheyarelisted.

Donotperformanymaintenancewhile the tongandbackupassembly isconnected toanyhydraulicpowersupply.FarrCanadarecommendsthatallhydrauliclinesarefullydisconnected,andresidualhydraulicpressureisbledoff.Ensureadequatecontainmentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluid.

ALL UNITS

1. Performaninitialwashofthebackupinordertoremovethemajorityofdirtandgreasebuild-up.

2. Performanexternalinspection.Checktoensuretherearenolooseormissingfasteners-replaceifnecessary.

3. Checktoseeifbackupisparalleltothetong-ifthebackupisrestingatanangle,oneofthefrontlegspringsislikelybrokenorfatiguedtothepointitmustbereplaced.

wEdgE BACKUp ONLy

4.Removeaccesscoverfromtopplate.Performavisualinspectionottheinteriorofthebackup-useaflashlightifneces-sary.Prematurewearwheretherearemovingparts(baremetalwherethereusedtobepaint,andmetalshavingsinthegreasearegoodindicators)mayshowwhereacomponentneedstobeadjusted,orifnecessary,replaced.

5. Inspectlatchmechanismtoensurethedoorlatchplatecompletelyengagesthedoor.Adjustorreplaceifnecessary.

6. GreaseUC-300sliderpads,ramguides,doorcylinderpivots,anddoorpivots.

CLINCHER BACKUp ONLy

4.Useaflashlighttoperformavisualinspectionoftheinteriorofthebackup-removeonesidepanelifnecessary.Prema-turewearwheretherearemovingparts(baremetalwherethereusedtobepaint,andmetalshavingsinthegreasearegoodindicators)mayshowwhereacomponentneedstobeadjusted,orifnecessaryreplaced.Replaceanyremovedpanelswheninspectioniscomplete.

5. Greaseclinchercylinderguidesusingthegreasefittingsonthetopbodyplate.

6. Ensurethesplinesontheclinchercylinderfaces,andontherearofthediearecleanandfreeofdebrisbeforeinsert-ingclincherdie.Ifdiearealreadyinstalled,ensurefastenersinthedieretainersaretightlysecured.

7. Inspectrearspringhangerassembly.Ensurealleyebolts,shackles,andcotterpinsareinplaceandingoodcondi-tion.

8. Inspectclinchercylindersforhydraulicfluidleaksoncethesystempressurehasbeenrestored.

FARR-STyLE BACKUp ONLy

4. Inspectcamringgearforbrokenteeth.

5. Lubricatethecamfollowerarray.

6.Inspectthejawsanddies.Inspectthejawrollerpinsforsignsofdamage-replacepinsifnecessary.Ifthepinsareweldedinplace,replacetheentirejawassembly.Ensurediesaresecureinthejaw-replaceworndiesifnecessary.Ensurethatthejawrollersrotatefreely.Checktoensurethesizeoftheloadedjawsmatchthesizeofcasingorpipeyouarerunning.

7. Inspectfrontandrearcamcylindersupports.Repairorreplaceanypartsthatarebroken,cracked,orbent.

8. Inspectrearspringhangerassembly.Ensurealleyebolts,shackles,andcotterpinsareinplaceandingoodcondi-tion.

9. Openthebackupdoorandinspecttheconditionofthelatch.Repairorreplacedamagedlatchcomponents.Iflatchappearstobeingoodcondition,closethedoor,thentugfirmlyonittoensurethedoorremainslatched.

ALL UNITS (AFTER STARTINg pOwER UNIT)

10. Performavisualinspectionofpressurizedhydrauliclines-documentandcorrectanyhydraulicfluidleaks.

11. Performafullfunctionaltestofthebackup.Documentandcorrecthydraulicleaksfromthehydraulicvalvebank,orfromanyhydrauliccylindersthatareinuseonthebackup.



Maintenance

L. MONTHLY MAINTENANCE CHECKLIST - POWER TONGThefollowingmaintenancechecklistisintendedasaguidelineratherthanadefinitivemaintenanceschedule.Yourequipmentmayrequiremore,orless,maintenancedependinguponthefrequencyofuse,thepercentageofmaximumtorquethatyourequipmentisroutinelysubjectedto,andthefieldconditionsunderwhichyourequipmentoperates.Farrrecommendsthatthefollowinginspectionandmaintenanceproceduresbeperformedmonthly,orinconjunctionwithyourmaintenanceforeman’sexperienceandbestestimateofwhenyourequipmentisdueforthismaintenance.

1. Rotatecageplate/rotarygearuntiltheopeningintherotarygearfacestowardstherearofthetong.

3.Cleantheexteriorofthetoolthoroughly,usingeitherwater(ifusingapressurewasherensurealow-pressurewashwandisused),oranappropriatesolvent-basedgrease-cuttingcleanersuchasVarsol.Ensureadequatecontainmentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluid,dirtygrease,andcleaningagents.


5.Cleantheinteriorofthetongthoroughly,usingeitherwater(donotuseapressurewasher),oranappropriatesolvent-basedgrease-cuttingcleanersuchasVarsol.Ensureadequatecontainmentisinplacetopreventenvironmentalcon-taminationfromresidualhydraulicfluid,dirtygrease,andcleaningagents.Makeanoteifanymetalshavingsormetalpiecesareflushedoutofthegeartraincavity-ifshavingsormetalpiecesareseenthetongmustbeoverhauledbeforeitisreturnedtoservice.

6. Inspectallfastenersandfastenersafetywires(ifequipped).Replaceanymissingfasteners-useGrade8boltsonlyun-lessotherwisespecified.Re-torqueallexternalfastenerstoSAEspecifications.

7. Repairorreplaceanydamagedormissingexternalbodyparts,suchastorquegaugemounts,hydraulicsupports,safetydoorprotectors,etc.

8. Performavisualinspectionofallfastenersandprotrudingbodypieces(example:hydraulicvalvemounts,inlet&outletlinesupports,tonglegs,shifterhandlepivotlugs).Tightenorreplacelooseormissingfasteners.

9. Inspecttongforsignsofprematurewear,ormovingpartsthatarerubbing(baremetalwherethereusedtobepaintisagoodindicationofwear.

10.Inspectallpaint-locationsinwhichthepainthasbeendamagedmustberepairedpriortothetongbeingreturnedtoservice.Prepareareastobepaintedtoensuretheyarefreeofgrease,dirt,orsolvent.Touchupusingasolvent-basedacrylicpaint-“McCoyGrey”ispaintcolornumberRAL7015,“McCoyYellow”(hazardareas)isRAL1007,andMcCoyGreenisRAL6029(contactFarrsalesforpaintnumberforcustompaintapplications).Allowsufficienttimeforpainttodrybeforeproceeding.

11. Visuallyinspectallload-bearingwelds.Anyweldthatiscrackedorseparatingmustberepaired,re-tested,andrepaintedbeforereturningthetongtoservice.

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.



4) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressureintheremainderofthehydrauliccontrolsystem.



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

12.

Performavisualinspectionofallliftingpoints-ifvisibledamageisseen,includingcracks,brokenlugs,distortedmetal,etc.replacedamagedpart(s)beforeplacingtonginservice.Alsoinspectallchains,masterlinks,andturnbuckles-again,ifanydamageisnotedreplacethedamagedpart(s)beforeplacingthetonginservice.RefertoSection2Aofthetechnicalmanual(Sling/LoadBearingDeviceSafety)forinformationonrecommendedtestingandrecertification.Pleasenotethatturnbuckleswithpartnumber101-3086(shortturnbuckles)useahigh-strengthpinwhichmustbesuppliedbyFarr.

Ifusingastand-alonepowerunit,startitnow-refertothepowerunittechnicalmanualforstartupprocedures.Listentopowerunitforamomenttoseeifthereareanyunusualmechanicalsounds(rubbing,grinding,excessivepumpnoise).Ifusingadieselunit,allowsufficienttimefortheenginetoreachoperatingtemperaturebeforeincreasingengineRPM.Onceengineiswarm,graduallyincreaseengineRPMuntiloperatingspeedisreached.


24. Performavisualinspectionofpressurizedhydrauliclines.Ifanyhydraulicfittingsorhosesareleakingtheymustberepairedorreplacedbeforeproceeding.

25.Rotatetongforoneminuteinbothhighandlowgear.Stopthetongandreversethedirectionofrotationforanotherminuteinbothhighandlowgear,endingwiththeopeningoftherotarygearfacingthegeartrain.De-energizethepowerunit,andperformanothergenerouslubricationofthegeartrain,includingthegearhousing.


“SHORT” TURNBUCKLES HAVING PART NUMBER 101-3086 EMPLOY HIGH-STRENGTH PINS WHICH MUST BE SUPPLIED BY FARR.

13.Removehydraulicmotorandrotatethegeartrainbyhand,anduseaflashlighttoperformavisualinspectionofthegeartrainthroughtheaccesspanelandtheopeningoftherotarygearwhilethegeartrainisbeingrotated.Ifgeardamageorchipsofmetalareseen,thetongshouldberemovedfromserviceandoverhauledtoavoidfurtherdamage.Replaceaccesspanelwheninspectioniscomplete.

14.Inspectalljawsanddiesinuseforthemaintenanceinterval.Inspectjawcastingfordamageandcracking,particularlyalongthecornersofthedovetails.Removepin&roller,andinspectforsignsofdamage-replacepinsifnecessary.Ifthepinsareweldedinplace&theweldsarefoundtobedamaged,removeandquarantinethejawuntiltheweldisrepaired.Cleanthepinsandrollers,andreassembleusingaliberalcoatingofanti-seizecompound.Ensurediesaresecureinthejaw&dieretainersarepresent.Replaceworndiesifnecessary.Ensurethatthejawrollersrotatefreely.


16.Inspecttopandbottombrakebandlinings-replaceifliningisfoundtobeflakingorismissingpiecesofmaterial.Un-equalwearofthebrakebandsindicatesthatthebrakebandtensionisnotevenlyadjusted.Refertothemaintenancesectionofthemanualforinstructionsonproperlyadjustingbrakebands.

17. Inspectdoorsprings.Ensurethespringsretainsufficientstrengthtobeabletoassisttheopeningofthedoor,andtokeepthedooropen.Thespringsshouldalsohelpto“snap”thedoorshut.

18.Inspect backup springs (if applicable). The rear extension springs (where used) should be equally extended, andthefrontlegspringsshouldbeequallycompressed.Ensurethatneitheroftherearbackupspringshavebeenover-extendedandlacksufficienttensiontoadequatelysupportthebackup.Ensurethatneitherofthefrontlegsprings(or,wheninstalled,thesinglerearbackuplegspring)havebeenover-compressed,andstillretainenoughspringstrengthtosupportthefrontofthebackup.

19. Extendallhydrauliccylinders,andinspectcylinderrodsforsignsofmechanicaldamage,flaking,orrust.Farrrecom-mendsthatdamagedcylindersbereplacedpriortostorage.

20.Performavisualinspectionofallhydrauliclines.Replaceflexiblelinesiftheyappeartobecracked,fatigued,orhavevisiblesignsofwearfromcontactwitharigidobject.Ifyourtongisequippedwithrigidhydrauliclines,replaceanylinethatisdentedorappearstobestressedorcracked.

21. Generouslyfillthegeartrainhousingwithgreasethroughtheaccesspanel,andalsothroughtheopeningintherotarygear.Performafulllubrication-refertoMaintenancesectionofmanualtodeterminelubricationpoints.

22. Ensuremainsupplyandreturnconnectionstothetongarefullymadeup.Re-connecttheremainderofthehydrauliclines.



Maintenance

26. Energizepowerunit.Rotatetongforoneminuteinbothhighandlowgear.Stopthetongandreversethedirectionofrotationforanotherminuteinbothhighandlowgear,endingwiththeopeningoftherotarygearfacingthegeartrain.

27. De-energizethepowerunit,andperformathirdgenerouslubricationofthegeartrain,includingthegearhousing.

28. Rotatetonginlowgearfor5minuteswhilemonitoringpressurizedsealsandhydrauliclines.Ifaseal,line,orfittingbeginstoleakwhiletongisrotating,itmustbereplacedbeforetheequipmentisreturnedtoservice.

29.Rotatetonginhighgearfor5minuteswhilemonitoringtemperatureoftopandbottombearingcaps.Ifthebearingcapsarehottothetouch(higherthanapproximately50oC)replacetheapplicablebearings.Likewiseifthetongismakingunusualnoisescheckfordamagedbearings(seeMaintenanceManualforallbearinglocations).

30.Installloadcell.Ifusingatensionloadcell,performavisualinspectionandreplaceanycracked,broken,ordistortedcomponentsincludinglinksandchains.Ifusingacompressionloadcell,replaceanycomponentthathasbeencrushedorotherwisedistortedthroughcompression.Inspectloadcellfordamageorsignsofstress.Checkoillevelinloadcellandfillifnecessary(refertotechnicalmanualSection7orSection8).

31. Ifapplicable,inspecttheloadcellanchorpins(tensionloadcellonly).Replacetheanchorpinsifcrackingormetaldistortionisseen.

32.Ifapplicable,theweldsecuringthesingleloadcellanchortothebridgebarmainplatemustbeinspected(compressionloadcellonly).Iftheintegrityoftheweldhasbeencompromised,thetongmustberemovedfromserviceuntiltheweldisrepaired.Theloadcellbeamwillneedtobedisconnectedandremovedsotheweldisvisible.Beforere-installingthebeam,liberallygreasetheanchorpinbeforereinsertingintotheloadcellbeam.

33.Whilerotatingthecageplate,ensurethatthejawsproperlycam.If thejawsdonotcamproperly,thebrakebandsneedtobetightened.IncrementallyadjustboththetopandbottombrakebandsEqUALLYuntilpropercamactionisachieved.Refertothemaintenancesectionofthemanualforinstructionsonproperlyadjustingbrakebands.

34.Performa full functional test of the tong including, if applicable, backup components, lift cylinder, and float framecomponents(refertoSection2.I.4).Reportandcorrectanyhydraulicleaksfromthehydraulicvalvebank,orfromanyhydrauliccylindersthatareused.

35.Testsafetydoorfeature(ifequipped).Beginrotatingthetongatlowspeed,andopenthetongdoor(s).Ifrotationdoesnotimmediatelystop,thisisanindicationthatthesafetydoormechanismisnotoperatingcorrectlyandthetongmustberemovedfromserviceuntilthemechanismisrepaired.Repeatthetestwhileoperatingthetongintheoppositedirec-tion.Ifthesafetydoorisoperatingcorrectly,cageplaterotationwillnotbeinhibitedoncethedoorisclosedandlatched.


36.Farrrecommendsthatananti-corrosiveagentsuchasTectyl®506beappliedtoallexternalunpaintedsurfaces(andchainslings)EXCEPTcylinderrods,jawrollers,androtarygearcammingsurfaces.Refertomanufacturerdatasheetsforproperapplicationandsafetyinformation.

Once all of the above maintenance checklist items have been satisfactorily completed the tool may be returned to service.



Maintenance

M. TUBULAR CONNECTION EQUIPMENT DE-COMMISSIONING & SHIPPINGPerform the followingdecommissioningprocedureswhen removing tubularconnectionequipment fromservice,with the intentofshorttolong-termstorage.Theseproceduresareessentialforensuringproperprotectionoftheequipmentfromenvironmentalattack,andtoaidinthequickturnaroundwhenreturningtheequipmenttoservice.

Storeallo-rings,seals,packings,gaskets,etc.instrongmoistureproof,airtightcontainers.Ensurethattheseitemsarenotcrushed,nicked,orotherwisedamaged.

Donotperformany furtheractionsormaintenancewhile the tong isconnected toanyhydraulicpowersupply.Farr recommendsthatallhydrauliclinesarefullydisconnected,andresidualhydraulicpressureisbledoff.Ensureadequatecontainmentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluid.

1. Performaninitialwashofthetoolinordertoremovethemajorityofdirtandgreasebuild-up.Ensureadequatecontain-mentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluidanddirtygrease.


3.Cleantheinteriorofthetongthoroughly,usingeitherwater(donotuseapressurewasher),oranappropriatesolvent-basedgrease-cuttingcleanersuchasVarsol.Ensureadequatecontainmentisinplacetopreventenvironmentalcon-taminationfromresidualhydraulicfluid,dirtygrease,andcleaningagents.Makeanoteifanymetalshavingsormetalpiecesareflushedoutofthegeartraincavity-ifshavingsormetalpiecesareseenthetongmustbeoverhauledbeforeitisreturnedtoservice.

4.Cleantheexteriorofthetoolthoroughly,usingeitherwater(donotuseapressurewasher),oranappropriatesolvent-basedgrease-cuttingcleanersuchasVarsol.Ensureadequatecontainmentisinplacetopreventenvironmentalcontami-nationfromresidualhydraulicfluid,dirtygrease,andcleaningagents.

5. Inspectallfastenersandfastenersafetywires.Replaceanymissingfasteners-useGrade8boltsonly.Re-torqueallexternalfastenerstoSAEspecifications.


7. Repairorreplaceanydamagedormissingexternalbodyparts,suchastorquegaugemounts,hydraulicsupports,safetydoorprotectors,etc.

8.Inspectallpaint-locationsinwhichthepainthasbeendamagedmustberepairedpriortostorage.Prepareareastobepaintedtoensuretheyarefreeofgrease,dirt,orsolvent.Touchupusingasolvent-basedacrylicpaint-“McCoyGrey”ispaintnumberRAL7015.Allowsufficienttimeforpainttodrybeforeproceeding.

9.Performaliberallubricationoftheequipment-refertoMaintenancesectionofmanualtodeterminelubricationpoints.Generouslyfillthegeartrainhousingwithgreasethroughtheaccesspanel,andalsothroughtheopeningintherotarygear.

10. Connecttheequipmenttoahydraulicpowerunit.Ensurealllinesarefullymadeuptopreventequipmentdamagefromexcessivebackpressure.Donotneglecttoconnectthemotordrain.

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

backupdoors(ifequipped)areclosed.Fullyextendtheliftcylinder(ifequipped).Ifmountedinaframe,retractthefloatcylin-ders(ifequipped).




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.



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.

3) De-energizethepowerunit.4) RepeatedlyactuatethetongmotorcontrolvalveleverINBOTHDIRECTIONStodissipateanyresidualpressureinthe

valveandmotor.

5) RemovethehydraulicSUPPLYlinefromtheequipment.6) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressureinthe

remainderofthehydrauliccontrolsystem.7) Connecta low-pressureairsupply line(10PSIor less) to thehydraulicsupply line,andforceasmallamountof the

remaininghydraulicfluidfromthevalveassembly-thiswillallowforthermalexpansionofthehydraulicfluidiftheequip-mentisstoredortransportedinhighambienttemperatures.Failuretodothismayresultindamagedordestroyedsealsintheequipment.



11. Energizepowerunit.

12.Rotatetongforoneminute,stop,andreversethedirectionofrotationforanotherminute,endingwiththeopeningoftherotarygearfacingthegeartrain.De-energizethepowerunit,andperformanothergenerouslubricationofthegeartrain,includingthegearhousing.

13. Energizepowerunit.Rotatetongforoneminute,stop,andreversethedirectionofrotationforanotherminute,endingwiththeopeningoftherotarygearfacingthegeartrain.

14. De-energizethepowerunit,andperformathirdgenerouslubricationofthegeartrain,includingthegearhousing.

15. Energizepowerunit,androtatethetongforafinaltime,oneminuteinonedirection,stop,andreversethedirectionofrotationforanotherminute,thistimeendingwiththerotarygearinthe“openthroat”position.

16. Extendallhydrauliccylinders,andinspectcylinderrodsforsignsofmechanicaldamage,flaking,orrust.Farrrecom-mendsthatdamagedcylindersbereplacedpriortostorage.

17.

Ifyouareusingaframe-mountedtool,thetongmustbeloweredontothebackupinordertoremovetheriskofsuddenandcatastrophicmovementwhenpressureisremovedfromthefloatcylinders.Coverthetopofthebackupwithprotec-tiveclothtoprotectthepaintonthebackup.Placetwowoodenbeamsacrossthetopofthetong,ensuringthatthebeamshaveaminimumsizeof4”x4”xthewidthofthetong.Coverthetopsofthewoodenbeamswithmoreprotectiveclothtopreventpaintdamagetothetong.Whenloweringthetongontothebeams,ensurethatthebeamscomeintoflatcontactwiththebottomofthetong,awayfrombearingcaps,brakebands,orotherprotrusionsonthebottomofthetong.Ensurethatthetonghangerchainsareloose,butnotdanglingintocontactwiththehangersortopplateofthetong.

18. Ifanyhydraulicfittingsorhosesareleakingtheymustberepairedorreplacedbeforeproceeding.

19.Wipeallexcessgrease fromoutsideofequipment.Replace theaccessdoorpanel.Useasolvent-basedcleaneronragstowipeallexternalsurfacestoremoveresidualgreaseorhydraulicfluid.Oncetheoutsidesurfaceshavebeende-greased,wipeallexternalsurfaceswithcleanwatertoremoveresidualsolvent.

20. Farrrecommendsthatchainslingsberemovedandstoredseparately.Rigidslingsandotherrigidsuspensiondevicesmayremaininplace.

21. Applygreaseorheavyoiltoallexposedcylinderrods.

22. Farrrecommendsthatananti-corrosiveagentsuchasTectyl®506beappliedtoallexternalsurfacesEXCEPTcylinderrods(includingchainslings).Refertomanufacturerdatasheetsforproperapplicationandsafetyinformation.

DO NOT ALLOW ANTI-CORROSIVE AGENTS TO CONTACT CYLINDER RODS. CYLINDER ROD DAMAGE WILL OCCUR.



Ifpossible,storeinasealed,climatecontrolledenvironment.Ifisolatedstorageisnotavailable,Farrrecommendsstoringyourwrappedequipmentinasecure,out-of-the-waylocation,usingsilicageldesiccanttoreducethehumiditywithinthewrapping.Asaguideline,use125g.ofdesiccantforeachcubicmetreofspace,or3.5g.percubicfoot.

CALCULATION OF REqUIREd dESICCANT

1) Calculatethetrappedairvolumebymeasuringtheoutsidedimensionsofthetooltobestored,andtreatthatasthevolumetobestored.Forexample,theexternaldimensionsofaKT2000020”powertongare80.25”x50.5”x28”,whichcalculatestoanapproximatevolumeof113500in3,or66ft3(1.87m3).

2) Multiplythecalculatedairvolume,incubicfeet,bytherecommendedamountofdesiccantpercubicfoot.Carryingforththeexampleused in thepreviousstep, the requireddesiccantchargewouldbe3.5g.x66 ft3,equaling231g.Severalmanufacturersoffersilicageldesiccantinpackagedquantitiesof125gramsperbag,sotwopackagesofdesiccantwouldberequired.Pleasekeepinmindthatthisisaguidelineonly-moreorlessdesiccantmayberequiredinextremeenviron-mentalconditions.

Forbestcorrosionresistancetheequipmentshouldberemovedfromstorageandexercisedonaregularbasis,dependingonthestor-ageenvironment.Farrrecommendsthatforequipmentstoredinasalt-watermaritimeorexposeddustyenvironment,repeatsteps9through24monthly.Forequipmentstoredinisolatedstorageinanon-maritimeenvironment,repeatsteps9through24quarterly.Re-placedesiccantpacksatthistime-depleteddesiccantpacksmaybetreatedasregulardunnage.

SHIppINg INSTRUCTIONS

Thefollowingprocedureliststhestepstobefollowedtoprepareyourtongforshipping.

1. Ifnotalreadydoneremoveaccessories(tongjaws,loadcell,torquegauge,etc.)McCoyrecommendswrappingtheseitemsinprotectivewrapandplacinginaseparatewoodencrate.

2. Place theequipmentonasturdypalletconstructedof4”x4”cross-membersand2”x4” flooring.McCoyrecommendsplacinga2”x6”boardacrossthewidthofthetongunderthelegs(seeIllustration3.M.1).Ensurethepalletislargeenoughtoaccommodatethewoodencratecontainingthetongaccessories.

23. Allowtheanti-corrosivecoatingampletimetodry-refertomanufacturerdatasheetsfordryingtimesatroomtempera-ture.

24. Wrapentireassemblyin100gauge(1mil)corrosion-inhibitingwrap,atleast3layersthick.Attempttoensurethatthetooliswell-sealedwithinthewrapping,includingthebottom.

Maintenance

ILLUSTRATION 3.M.1: SHIppINg INSTRUCTIONS - pALLET



Maintenance

SHIppINg INSTRUCTIONS (CONTINUEd):3. Useacranetosupportthechainsling(ifequipped).Wrapthechainslingwithbubblewraporanothersimilarprotective

wrapping,andsecurethewrappingwithtape.Lowerthewrappedchainslingsoitsitsinsidetheopeningofthetong.

ILLUSTRATION 3.M.2: SHIppINg INSTRUCTIONS - wRAppINg CHAIN SLINg

4. Donotallowthebackup(ifequipped)to“float”onitssupportspringsduringshipping.Buildasturdywoodensupportstruc-tureunderthefrontandbackofthebackuptosupporttheweightofthebackupandreleasethecompressiononthesprings.Strapthebackuptothesupportblocksandpalletindependentofthetong,usingminimum3/4”x0.029”metalstrappinginatleasttwolocations.Placestrappingasclosetothebackupsupportsaspossible,andusecautionnottoentrapanyflexiblehydraulichosesbeneaththestrapping.Beforetighteningstrapping,placestrappingprotectorswhereverthemetalstrappingcomesintocontactwiththeequipment.

ILLUSTRATION 3.M.3: SHIppINg INSTRUCTIONS - BACKUp SUppORT



Maintenance

SHIppINg INSTRUCTIONS (CONTINUEd):5. Securelystrap theequipment inplaceusingmetalstrapping.Placestrappingasclose to thecross-membersunder the

equipmentlegsaspossible,andusecautionnottoentrapanyflexiblehydraulichosesbeneaththestrapping(guidestrap-pingthroughbeneaththehydraulichoses).Usethefollowingguidelinestodeterminethestrappingrequirements:

Assembliesweighing1000lbs.(454kg.)orless:

3/4”x0.029”metalstrapping,3320lbs.(1509kg.)tensilestrength Minimumtwostraps

Assembliesweighingmorethan1000lbs.(454kg.)orless:

1-1/4”x0.031”metalstrapping,5500lbs.(2500kg.)tensilestrength Minimumtwostrapsforassembliesweighinglessthan5000lbs.(2273kg.) Minimumthreestrapsforassembliesweighingmorethan5000lbs.(2273kg.)

Beforetighteningstrapping,placestrappingprotectorswhereverthemetalstrappingcomesintocontactwiththeequipment.

Placethewoodencratecontainingthetongaccessoriesonthecratenexttotheequipment.Strapthecratetothepalletusing3/4”x0.029”metalstrapping(seeIllustration3.M.4).

Ifitisnotpracticaltoplacelargerlooseitemsinawoodencrate,ensuretheyarealsosecurelystrappedtothepalletusing3/4”x0.029”metalstrapping.

6. Usealargepolyethyleneshippingbag(sometimescalledapalletcover)tocompletelyenclosetheequipment.Sealpoly-ethylenebagtothepalletusing1milpolyethylenewrap.Usethewraptoconformtheplasticcovertothegeneralshapeoftheequipment,butdonotwrapsotightthatsharpedgesontheequipmentperforatethecover.

7. McCoyrecommendsenclosingtheequipmentinasturdyshippingcratewhichissecurelyfastenedtothepallet.

ILLUSTRATION 3.M.4: SHIppINg INSTRUCTIONS - STRAppINg EqUIpMENT TO pALLET



N. TUBULAR CONNECTION EQUIPMENT RE-COMMISSIONING PROCEDUREPerform the following recommissioningprocedureswhenremoving tubularconnectionequipment fromshortor long-termstoragebackintoregularservice.Theseproceduresareessentialforensuringproperequipmentpreparationandoperation.ThefollowingproceduresalsoassumethatthedecommissioningandstorageproceduresrecommendedbyFarrhavebeenstrictlyobserved.

7. Energizepowerunit.


9. Performathoroughinspectionofpressurizedhydrauliclinesandfittings.Anyleakinghydraulicfluidlinesorfittingsmustbereplacedbeforetheequipmentisreturnedtoservice.

10. Performathoroughinspectionofallseals.Anysealthatisleakingor“weeping”mustbereplacedbeforetheequipmentisreturnedtoservice.

11.Rotatetonginlowgearfor5minuteswhilemonitoringpressurizedsealsandhydrauliclines.Ifaseal,line,orfittingbeginstoleakwhiletongisrotating,itmustbereplacedbeforetheequipmentisreturnedtoservice.Finishthisstepwiththerotarygearopeningfacingthegeartrain.De-energizethepowerunit.

12. Inspectallflexiblehydrauliclinesforsignsofwear,blistering,oranyothersignsofpotentialfailure-replaceifsignsofpotentialfailureareidentified.

13. Inspectthegeartrainhousing.Iftheamountofgreaseisinadequate,liberallygreasethegeartrainthroughtheaccesspanel,andthroughtheopeningintherotarygear.

14.Inspecttopandbottombrakebandlinings-replaceifnecessary.Unequalwearofthebrakebandsindicatesthatthebrakebandtensionisnotevenlyadjusted.Refertothemaintenancesectionofthemanualforinstructionsonproperlyadjustingbrakebands.Ensurethatallgreaseiswipedfrombrakebandliningsandthepartsofthecageplatesthatcomeintocontactwiththebrakebandlinings

15. Re-installaccesspanel.Installasetofpre-inspectedjawsthatarethecorrectsizeforthepipeorcasingbeingrun.

16.Install loadcell.Ifusingatensionloadcell,performavisual inspectionandreplaceanycracked,broken,ordistortedcomponentsincludinglinksandchains.Ifusingacompressionloadcell,replaceanycomponentthathasbeencrushedorotherwisedistortedthroughcompression.

17. Ifapplicable,inspecttheloadcellanchorpins(tensionloadcellonly).Replacetheanchorpinsifcrackingormetaldistor-tionisseen.

18.Ifapplicable,theweldsecuringthesingleloadcellanchortothebridgebarmainplatemustbeinspected(compressionloadcellonly).Iftheintegrityoftheweldhasbeencompromised,thetongmustberemovedfromserviceuntiltheweldisrepaired.Theloadcellbeamwillneedtobedisconnectedandremovedsotheweldisvisible.Beforere-installingthebeam,liberallygreasetheanchorpinbeforereinsertingintotheloadcellbeam.

19. Re-energizepowerunit.


1. Removeallprotectiveplasticwrapping.Iftherearedesiccantpackswiththeassembly,theymaybedisposedofwiththeregulargarbage.


3. Wipeexcessgreaseorheavyoilfromexposedcylinderrods.

4.Ifapplicable,re-connectchainslingtoliftinglugs.Performavisualinspectionofallliftingpoints-ifvisibledamageisseen,includingcracks,brokenlugs,distortedmetal,etc.replacedamagedpart(s)beforeplacingtonginservice.Alsoinspectallchains,masterlinks,andturnbuckles-again,ifanydamageisnotedreplacethedamagedpart(s)beforeplacingthetonginservice.Ifyourcompanyrequiresyearlycertificationofliftingequipment,ensurethatthemostrecenttestdatefallswithinthepastyear.Performrecertificationifnecessary.

5.Performaliberallubricationoftheequipment-refertoMaintenancesectionofmanualtodeterminelubricationpoints.Generouslyfillthegeartrainhousingwithgreasethroughtheaccesspanel,andalsothroughtheopeningintherotarygear.

6. Connecttheequipmenttoahydraulicpowerunit.Ensurealllinesarefullymadeuptopreventequipmentdamagefromexcessivebackpressure.Donotneglecttoconnectthemotordrain.

Maintenance



Maintenance

20. Performafullfunctionaltestoftheequipmentincluding,ifapplicable,backupcomponentsandfloatframecomponents.Reportandcorrectanyhydraulicleaksfromthehydraulicvalvebank,orfromanyhydrauliccylindersthatareused.

21.Ifusingaframe-mountedtongandbackupsystem,raisethetongoffthebeamsthatitisrestingupon.Removethebeamsandprotectivecloths-inspectthepaintontopofthebackupandthebottomofthetongtoensureithasnotbeendam-agedbythebeam.

22.Testsafetydoorfeature(ifequipped).Openthetongdoor(s),andattempttorotatethecageplateatlowspeed(lowgear)inbothdirections(makeupandbreakout).Ifcageplatebeginsrotating,thesafetydoormechanismisnotfunctional,andthetongmustberemovedfromserviceuntilthesafetydoormechanismcanberepaired.Ifthesafetydoorisoperatingcorrectly,cageplaterotationwillnotbeinhibitedoncethedoorisclosedandlatched.


23.Whilerotatingthecageplate,ensurethatthejawsproperlycam.Ifthejawsdonotcamproperly,thebrakebandsneedtobetightened.IncrementallyadjustboththetopandbottombrakebandsEqUALLYuntilpropercamactionisachieved.

24. Whenallofthepreviousstepsarecompleted,youmayreturnyourre-commissionedequipmenttoservice.



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Adequatemaintenanceandproperfluidselectionisessentialforminimizinghydraulic-relatedfailures.Alltroubleshootingmustbeper-formedbyatechniciantrainedinhydraulicsystems,andfamiliarwiththeequipmentdesign,assemblyandoperation.

Thefollowingtroubleshootinginstructionsareintendedtobeguidelinesonly.Anyfaultsnotsolvedthroughtheuseofthisguideshouldbereferredtoourengineeringdepartmentfortheirevaluationandrecommendations.

A. TONG WILL NOT DEVELOP SUFFICIENT TORQUE1. Malfunctioningreliefvalveontonghydrauliccircuit.

SeeSection4.B,ReliefValveTroubleshooting

2. POSSIBLEPROBLEM:Directionalvalveisleaking.

SOLUTION:Checkdirectionalvalve.Neutralpositionshouldreturnfluiddirectlytothereservoir.Replaceorrepairvalvetoensurecorrectoperation.

3. POSSIBLEPROBLEM:Powerunitisnotproducingadequatepressure.

SOLUTION:Troubleshootpowerunit(seeuser’smanualforyourparticularunit).

4. POSSIBLEPROBLEM:Poorhydraulicpressureatthetongdespiteadequatepressureatthepowerunit,orexcessivebackpressureinthereturnline.

SOLUTION:Restrictionsexistinlinebetweenpowerunitandtong.Inspectintegrityofself-sealingcouplingstoensuretheyareallowingfullfluidflow.Checktoensurenootherrestrictionsexist(contaminatedcatchscreensorfilters,forexample).

5. POSSIBLEPROBLEM:Fluidviscosityisnotappropriate(toohighortoolow).

SOLUTION:EnsurehydraulicfluidbeingusedistheviscosityrecommendedbyMcCoyDrilling&Completions.Powerunitpumpmaynotprimeiffluidistooheavy,andthehydraulicsystemwilloverheatiffluidistoolight.Replacewithproperviscosityfluid.

SOLUTION:Hydraulicfluidviscosityisaffectedbyenvironmentalconditions.Ensurethefluidbeingusedissuitableforhighorlowtemperatures.Replacewithproperviscosityfluidfortheoperatingconditionsifnecessary.

6. POSSIBLEPROBLEM:Wornordamagedtongmotorcausingslippage.

SOLUTION:Replaceorrepairwornordamagedmotor.

7. POSSIBLEPROBLEM:Damagedbearingsorgearscausingexcessivedrag.

SOLUTION:Replaceorrepairwornordamagedgearsorbearings.

8. POSSIBLEPROBLEM:Jawsslippingonpipe.

SOLUTION:Ensurejawdiesarenotworntothepointthattheycannotgrip.Ensurethecorrectsizedjawsareinuse.

9. POSSIBLEPROBLEM:Torquegaugeisindicatingincorrectly

SOLUTION:Incorrectgaugeisbeingused.Ensuregaugeistheproperrange,andhasbeenproperlycalibratedforthearmlengthoftheequipmentinuse.

SOLUTION:Gaugehasbeendamaged.Checkgaugeoperationandcalibrationonindependentsystem.

SOLUTION:Gaugehasmistakenlybeenmarriedtoanincorrectloadcell.

10. POSSIBLEPROBLEM:Loadcellismeasuringincorrectly.

SOLUTION:Incorrectloadcellisbeingused.

SOLUTION:Airistrappedintorquemeasuringcircuit(loadcell,hydraulicline,orgauge.Refertotorquemeasurementtrouble-shootinginSection6ofthismanual.

SOLUTION:Loadcellhasbeendamaged.Replaceloadcell,orreturntoMcCoyforrepairandre-calibration.

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.



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).


ILLUSTRATION 4.B.1: RELIEF vALvE TROUBLESHOOTINg - TEMpORARy gAUgE INSTALLATION

Connect a temporary 0 - 3000 PSI pressure indicator at this location



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RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING Cont’d:2. POSSIBLEPROBLEM:Reliefcannotbeadjustedtomaximumsystempressure(highfluidbypassresultsinlowsystempres-

sure).

SOLUTION:Debrisonvalveseat,springisbroken,springhaslostspringforceduetocontinuoustension

a. Isolateyourtongfromhydraulicpower,anddepressurizefollowingtheprocedureinsection3.D.

b. Loosenthelockingnutonthepressurereliefvalve.

c. Usealargeflat-headscrewdrivertocompletelyun-threadthepoppetandspringfromthereliefassembly.

d. Inspectthereliefvalvespring,poppet,andvalveseat.

e. Ifnodebrisisfoundinreliefvalveandifseatandpoppetareundamaged,replacereliefvalvespring.

f. Reassemblereliefvalve.

g. Reliefvalvemustbere-settoallowmaximumsystempressure.FollowtheprocedureinStep1ofthissectiontoproperlyadjustreliefvalve.

h. Ifmaximumsystempressurestillcannotbereached,replacetheentirereliefvalveassembly.



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C. SAFETY DOOR DOES NOT OPERATE OR IS MALFUNCTIONING

1. POSSIBLEPROBLEM:Safetydoorswitchrequiresadjustment.

SOLUTION:Adjustswitchaspersection3.F.4.

2. POSSIBLEPROBLEM:Safetydoorswitchhasfailed.

SOLUTION:Testsafetydoorswitchforproperfunctionandreplaceifnecessary.

3. POSSIBLEPROBLEM:Contaminationinhydrauliclines.

SOLUTION:Ensureallthreeflexiblehydrauliclinestosafetydoorswitcharefree-flowing.

4. POSSIBLEPROBLEM:Pilot-to-openvalveinsafetydoorvalveblockismalfunctioning.

SOLUTION: Removeeachvalve.Inspectseatsandsprings.Replacevalve(s)ifdamageisseenonvalveseats,orifspringappearstobedamagedorbroken.



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D. TONG RUNNING TOO SLOWLY

1. POSSIBLEPROBLEM:Obstructionintonghydrauliccircuitpreventingadequateflow.

SOLUTION:Inspectself-sealingcouplingstoensuretheyareproperlyengaged.

SOLUTION:Themainhydrauliclines(supplyanddischarge)tothetongareobstructed.Removeandcleanifrequired.

2. POSSIBLEPROBLEM:Powerunitisnotproducingadequatefloworpressure.

SOLUTION:Troubleshootpowerunit(seeuser’smanualforyourparticularunit).

3. POSSIBLEPROBLEM:Tongmotorisexcessivelywornandisleakinghydraulicfluidpastthevanes.

SOLUTION:Replacemotor,orrebuildasperSection7ofthismanual.

4. POSSIBLEPROBLEM:Bearingsingeartrainandrotarysectionareexcessivelyworn.

SOLUTION:Overhaultong.SeeSection3ofthismanualfortongoverhaulprocedures.

5. POSSIBLEPROBLEM:Shifterhasmalfunctionedandthetongisnotshiftingtohighgear.

SOLUTION:Inspectandrepairshiftmechanismasnecessary.

6. POSSIBLEPROBLEM:Two-speedhydraulicmotor(ifequipped)isnotsettocorrectspeed.

SOLUTION:Checkmotor,andsettothecorrectspeedifrequired.

7. POSSIBLEPROBLEM:Safetydoorsystemisnotproperlyadjusted-hydraulicfluidleakpastDeltrolvalve.

SOLUTION:Checkandadjustsafetydoorsystem.

8. POSSIBLEPROBLEM:Hydraulicfluidviscositytoohigh.

SOLUTION:EnsurehydraulicfluidmeetsMcCoyDrilling&Completionsspecifications.

SOLUTION:Ensurehydraulicfluidisappropriateforclimaticconditions,especiallyduringcold-weatheroperation..

9. POSSIBLEPROBLEM:By-passvalvenotfunctioning.

SOLUTION:Checkandrepair.



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E. FAILURE OF JAWS TO GRIP PIPE

1. POSSIBLEPROBLEM:Dieshavebecometoodulltoprovideadequategrip.

SOLUTION:Replacedies.

2. POSSIBLEPROBLEM:Incorrectjawsarebeingused.

SOLUTION:Double-checkjawsizetoensuretheyareratedforthediameterofpipeorcasingbeingrun.

3. POSSIBLEPROBLEM:Incorrectdiesarebeingused

SOLUTION:Ensurediesloadedinthejawsareappropriateforthetypeofpipeorcasingbeingrun.

4. POSSIBLEPROBLEM:Brakeband(s)is(are)insufficientlyadjusted,notallowingjawstocamproperly.

SOLUTION:Adjustbrakebandstogiveproperresistancetocageplates.

5. POSSIBLEPROBLEM:Jawrollerbrokenorworn.

SOLUTION:Removejawassemblyandinspect.Replacerollersthatarevisibly“flat-spotted”orotherwisedamaged.



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F. FAILURE OR DIFFICULTY OF TONG TO SHIFT

1. POSSIBLEPROBLEM:Bentorbrokenshifterhandle.

SOLUTION:Replaceshifterhandle.

2. POSSIBLEPROBLEM:Bentorbrokenshifteryoke.

SOLUTION:Inspectandreplaceshifteryoke.

3. POSSIBLEPROBLEM:“Frozen”orhard-to-moveshifterhandle.

SOLUTION:Greaseshiftershaft.

4. POSSIBLEPROBLEM:Bentorbrokenshiftershaft.

SOLUTION:Replace.

5. POSSIBLEPROBLEM:Lockingnutsonshiftingshafthaveloosenedandpositionofyokehaschanged.

SOLUTION:Repositionyokeandre-tightenlockingnuts.

6. POSSIBLEPROBLEM:Shiftingyokehascomeloosefromshiftingshaft

SOLUTION:Inspectyokeandinspectfordamage.Iffreeofdamage,replaceonshaftandtightenlockingnuts.

7. POSSIBLEPROBLEM:Tongpopsoutofgear

SOLUTION:Ensurethatdetentball&springassemblyhasbeencorrectlyset.



G. GENERAL COMMENTSThefollowingfactorsgenerallycontributetopoorhydraulicoperationandprematurewearofequipment:

1. Contaminatedhydraulicfluidduetooveruse,overheating,orinadequatefluidfiltration.

2. Unsuitablehydraulicfluid,especiallyinextremeclimaticconditions.

3. Defectivepackingorsealsincomponentsofthehydraulicsystem.

4. Poororincompletehydraulicsystemtraining.Usersmustbefullyqualifiedtooperatetheequipment,andhavecompleteunderstandingofthehydraulicsystem.

Ifyourhydraulictroubleshootingproceduresinvolveflowandpressuretestsatthepowerunit,McCoyCompletions&Drillingrecommendsconstructionofatestrigthatcaneasilybeconnectedtothemainsuctionanddischargeportsofthepowerunit.

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PARTS AND ASSEMBLIESMOdEL 80-0615 SHOwN (CE MARKEd)

MOdEL 80-0615-4 SHOwN



SPaRe PaRtS

MISC TONG & BACKUP PARTS

Description Part Number Qty. RequiredDumbbellRoller 1037-135 2

MotorGear 997-A10-149 1

DoorLatchSpring 997-16 2

JawPivotBolt 1050-C5-28 2

ShiftingCollar 997-A9-62 1

CagePlateSpacer 1050-C3-38 3

RigidSlingPins 1053-C-1C 2

BEARINGS & BUSHINGS

Description Part Number Qty. RequiredDumbbellRollerBearing 02-0094 10

RotaryIdlerBearing 02-0011 2

PinionBearing 02-0007 2

BallBearing(BottomClutchBearing) 02-0004 1

NeedleBearing(ClutchShaft) 02-0003 4

BallBearing(TopClutchBearing) 02-0002 1

CamFollower 02-0015 5

FASTENERS & FITTINGS

Description Part Number Qty. RequiredIdlerBearingSeal 02-0010 4

IdlerGearRetainer 02-0009 4

ExternalSnapRingClutch 02-0001 2

MotorGearSetScrew 09-0106 1

MotorGearKey 01-0317 1

HexBolt1/2"UNCX7"(CagePlateBolt) 09-1194 2

HexBolt1/2”UNCX9”(BackingPinBolt) 09-1202 1

5/8"LockWasher(CamFollowerFastener) 09-5114 5

5/8"UNFJamNut(CamFollowerFastener) 09-5514 5

HYDRAULIC COMPONENTS

Description Part Number Qty. RequiredReliefValve(Backup) 08-1180 1

CheckValve(Backup) 08-0481 1

ReliefCartridge(DVA35) 10-0010R 1

ReliefCartridge(SafetyDoor) 08-1625 1

SealKit-RineerGA15 87-7110 1

DVA35SealKit 07-0004 1

SafetyDoorSwitch 08-0337M 1

HydraulicHose-LiftCylinderSupply 02-0934H 1

High-VisibilityProtectiveWrap,LiftCylinderHydraulicHose 02-E0203 1

HydraulicHoseAssembly-Backup55”“A”Side 02-1011 1

HydraulicHoseAssembly-Backup52”“B”Side 02-1012 1

High-VisibilityProtectiveWrap,BackupHydraulicHose 02-E0204 1


ThefollowingtablelistspartsthatMcCoyDrilling&Completions|FARRhasidentifiedascriticalsparepartsforthismodeloftong.McCoyrecommendsthatthespecifiedquantityofeachpartbeonhandatalltimes.



SPaRe PaRtS

Inadditiontothecriticalsparepartsidentifiedintheprevioustable,McCoysuggestsstockingthefollowingspareparts.Eventhoughthesearenotcriticalspares,stockingthesecomponentsmaysignificantlydecreaserepairtimeintheeventoflongleadtimesfromthefactory.

MISC TONG PARTS

Description Part Number Qty. RecommendedBackingPin 101-4188 1

BackingPinSpacer 101-4096 1

BackingPinStud 101-4097 1

BackingPinKnob 02-0017 1

ShiftingYokeWeldment 1050-72-1 1

ShiftingShaft 1116-71 1

DoorSpringCylinder 101-0069 1

BrakeBandRetainer 101-0140 2

LinedBrakeBandWeldment 1050-D4-29 2

SafetyDoorLoadPlunger AE12-306 1

BEARINGS & BUSHINGS

Description Part Number Qty. RecommendedDoorBushing 101-0110 2


Description Part Number Qty. Recommended

ShifterDetentForceSpring 997-0-64 1

ShifterDetentForceBall 02-0018 1

1/8”NPTGreaseFitting 02-0005 2

1/8”NPT90oGreaseFitting 02-0093 2

1/8”NPT45oGreaseFittings 02-0006 2

1/4”StraightThreadGreaseFitting 02-0097 5

3/8UNCX.5"FlangeBolt(JawRetainer) 09-0229 10

5/16UNCX.5"Countersunk(JawRetainer) 09-1338 10


Description Part Number Qty. Required7-5/8”ClincherCylinderSealKit(ONLY IF USING 7-5/8” BACKUP) 1401-00-00-SK 1

8-5/8”ClincherCylinderSealKit(ONLY IF USING 8-5/8” BACKUP) ASAP2226 1

Critical Spare Parts List (Continued)JAW COMPONENTS

Description Part Number Qty. RequiredJawRoller 1050-JR-2125 2

JawPin 1050-JP 2

3.875"FlatDieInsert 13-0008-314-0 48

ContouredInsert(2-3/8”jawdiekitsonly) 12-0004 8

ContouredInsert(2-7/8”jawdiekitsonly) 12-0007 8

ContouredInsert(3-1/8”to3-1/2”jawdiekitsonly) 12-0011 16

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.



PaRtS liSt - coMPlete oVeRhaul

MISC TONG PARTS

Description Part Number Qty. RequiredJawPivotBolt 1050-C5-28 2

BackingPin 101-4188 1


BackingPinStud 101-4097 1

BackingPinKnob 02-0017 1

BackingPinRetainer 101-4186 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

IdlerBearing 02-0011 3

PinionBearing 02-0007 2

BallBearing(BottomClutchBearing) 02-0004 1

NeedleBearing(ClutchShaft) 02-0003 4

BallBearing(TopClutchBearing) 02-0002 1

CamFollower 02-0015 26

DoorBushing 101-0110 2

ThefollowingtableslistpartsMcCoyDrilling&Completionsrecommendsreplacingwhenperformingacompleteoverhaulofyourtongandbackupassembly.



PaRtS liSt - coMPlete oVeRhaul


Description Part Number Qty. Required

RotaryIdlerSeal 02-0010 5

RotaryIdlerRetainer 02-0009 6

1/4”StraightThreadGreaseFitting 02-0097 12

1/8”NPTGreaseFitting 02-0005 4

1/8”NPT90oGreaseFitting 02-0093 7

1/8”NPT45oGreaseFittings 02-0006 1

SnapRing(ClutchShaft) 02-0001 1

MotorGearSetScrew 09-0106 2

MotorKey 01-0317 1

1-1/8”NarrowFlatWasher(SupportRollerTopWasher) 02-0471 8

1”NarrowFlatWasher(SupportRollerBottomWasher) 09-5120 6

1"UNSThinNylockNut 09-9167 12

HexBolt1/2"UNCX7"(CagePlateBolt) 09-1194 2

HexBolt1/2”UNCX9”(BackingPinBolt) 09-1202 1

5/8"LockWasher(CamFollowerFastener) 09-5114 26

5/8"UNFJamNut(CamFollowerFastener) 09-5514 26

ShifterDetentForceSpring 997-0-64 1

ShifterDetentForceBall 02-0018 1


Description Part Number Qty. RequiredSafetyDoorSwitch 08-0337M 1

RineerGA15SealKit 87-7110 1

DVA35SealKit 07-0004 1

ReliefCartridge(DVA35) 10-0010R 1

ReliefCartridge(SafetyDoor) 08-1625 2

7-5/8”ClincherCylinderSealKit(ONLY IF USING 7-5/8” BACKUP) 1401-00-00-SK 1

8-5/8”ClincherCylinderSealKit(ONLY IF USING 8-5/8” BACKUP) ASAP2226 1

ReliefValve(Backup) 08-1180 1

CheckValve(Backup) 08-0481 1

HydraulicHose-LiftCylinderSupply 02-0934H 1

High-VisibilityProtectiveWrap,LiftCylinderHydraulicHose 02-E0203 1

HydraulicHoseAssembly-Backup55”“A”Side 1

HydraulicHoseAssembly-Backup52”“B”Side 1

High-VisibilityProtectiveWrap,BackupHydraulicHose 02-E0204 2

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.



GeaR tRain layout

B

C

D

H

J

A

K

E

FG



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



SuPPoRt RolleR

A

B

C

D

E

F

G

E

D

H

J



SuPPoRt RolleR

Item Type Description Qty Part NumberA Part 1/4”NFStraightGreaseFitting 1 02-0097

B Part SupportRollerShaft 1 101-3939

Part SupportRollerShaft(Long)(1) 101-3941

C Part 1-1/8”NarrowFlatWasher(2) 1 02-0471

D Part RollerBearingSpacer 2 101-3871

E Part Self-AligningBallBearing 2 02-0094

F Part SupportRollerShaftSpacer 1 1037-C-134

G Part SupportRoller 1 1037-135

H Part 1”NarrowFlatWasher(2) 1 09-5120

J Part 1”UNSThinNylockNut 1 09-9167

(1) Wherethesupportrolleriscoincidentalwiththefrontlegmountweldment,shaftnumber1050-131is used(4occurrences).(2) Wheresupportrollersarecoincidentalwithbrakebandlugweldmentsupper(1-1/8”)andlower(1”) washersarenotused.



SuPPoRt RolleR - DooR PiVot

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B

C

D

E

F

G

E

D

H

J



SuPPoRt RolleR - DooR PiVot

Item Type Description Qty Part NumberA Part 1/4”StraightThreadGreaseFitting 1 02-0097

B Part DoorPivotRollerShaft 1 101-3940

C Part 1-1/8”NarrowFlatWasher 1 02-0471

D Part SupportRollerSpacer 2 101-3871

E Part Bearing 2 02-0094

F Part SupportRollerInternalSpacer 1 1037-C-134

G Part SupportRoller 1 1037-135

H Part 1”NarrowWasher 1 09-5120

J Part 1”UNSThinNylockNut 1 09-9167



RotaRy iDleR aSSeMBly

AB

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E

F

G

H

J

G

F

D

C

B

D



RotaRy iDleR aSSeMBly

Item Type Description Qty Part NumberA Part 1/8”NPTGreaseFitting 1 02-0005

B Part 1-1/4”UNFHexNylockNut 2 09-5740

C Part IdlerPad 2 997-D20-125

D Part RotaryIdlerSpacer 2 1050-D5-121

E Part RotaryIdlerShaft 1 1050-D5-117

F Part BearingSeal 2 02-0010

G Part RetainingRing 2 02-0009

H Part Bearing 1 02-0011

J Part RotaryIdlerGear 1 997-A2-119



Pinion iDleR aSSeMBly

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E

L

M

D

F

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G

H



Pinion iDleR aSSeMBly

Item Type Description Qty Part NumberA Part 90o1/8”NPTGreaseFitting 1 02-0093

B Part 1-1/2”UNFHexNylockNut 1 09-5740

C Part 5/8”UNCx2-1/2”HexBolt 3 09-0081

D Part 5/8”LockWasher 3 09-5114

E Part IdlerPad 1 997-D17-109

F Part TopPlate(Shownforillustrationpurposesonly) 1

G Part PinionIdlerHalfShaft 1 1050-D5-105

H Part RetainingRing 2 02-0009

J Part Bearing 1 02-0011

K Part PinionIdlerGear 1 997-A2-119

L Part BearingSeal 1 02-0010

M Part BearingRetainer 1 02-0008



Pinion aSSeMBly

AB

C

E

F

G

H

E

D

C

B

A

D



Item Type Description Qty Part NumberA Part 1/8”NPT90oGreaseFitting 4 02-0093

B Part 1/2”UNCx1-1/2”HexBolts 8 09-1170

C Part 1/2”LockWashers 8 09-5110

D Part PinionBearingCap 2 1050-89

E Part PinionBearing 2 02-0007

F Part HighPinionGear 1 997-A4-87

G Part PinionGearShaft 1 997-A7-86

H Part LowPinionGear 1 997-A5-88

Pinion aSSeMBly



clutch aSSeMBly

AB

C

D

K

J

H

S

P

M

N

R

E

F

G

H

L

Q



clutch aSSeMBly

Item Type Description Qty Part NumberA Part OutsideSnapRing 1 1234-00-04

B Part DriveGear 1 997-A3-61

C Part TopClutchBearingSpacer 1 997-60

D Part #10-24x3/4”HexSHCS 2 09-0001

E Part TopClutchBearing 1 02-0002

F Part TopBearingRetainer 1 997-D11-59

G Part HighClutchGear 1 997-A1-51

H Part NeedleRollerBearing 4 02-0003

J Part SplinedClutchShaft 1 997-A8-50

K Part ShiftingCollar 1 997-A9-62

L Part LowClutchGear 1 997-A1-52

M Part BottomClutchBearing 1 02-0004

N Part ClutchBearingCap 1 1050-C1-54

P Part 3/8”LockWasher 4 09-5106

q Part 3/8”UNCx1-1/4”HexBolt 4 09-1048

R Part 1/8”NPTGreaseFitting 1 02-0005

S Part 1/8”NPT90Deg.GreaseFitting 2 02-0093



ShifteR aSSeMBly

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F

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RS



Item Type Description Qty Part NumberA Weldment ShiftingHandleWeldment 1 1037-D-20B

B Part HITCHPIN.0930X1.125 2 02-0274

C Part DetentBall 1 02-0018

D Part 7/16”UNFx1-1/4”HexBolt 1 09-1608

E Part 7/16”UNFHexJamNut 1 09-5508

F Part DetentSpring 1 997-0-64

G Part 5/8”UNCx5/8”HexSocketSetScrew 3

H Part ShiftingShaft 1 1116-71

J Weldment ShiftingForkWeldment 1 1050-72

K Part 5/8”UNFHexNut 1 09-5914

L Part 5/8”UNFHexJamNut 1 09-5915

M Part LowerShifterBushing(typicallyweldedtobottomplate) 1 1064-B1-95

N Part 3/8”UNCx1”HexBolt 4 09-1046

P Part 3/8”LockWasher 4 09-5106

q Part 5/16”x1-1/2”ClevisPin 2 09-0256

R Part ShifterLugWeldment(Bolted) 1 101-0016

S Part TopShifterBushing(threaded) 1 101-0020

ShifteR aSSeMBly



RotaRy aSSeMBly

A

B

C

D

K

J

L

T

U

Q

N

P

S

E

F

G

H

M

R



RotaRy aSSeMBly

Item Type Description Qty Part NumberA Part 1/2” UNC x 9” Hex Bolt 1 09-1202

B Part Backing Pin Knob 1 02-0017

C Part 3/8” UNF x 2” Threaded Stud 1 101-4097

D Part Backing Pin Spacer 1 101-4096

E Part Backing Pin Spacer 1 101-4186

F Part Backing Pin Retainer 1 101-4187

G Part Backing Pin 1 101-4188

H Part 5/8” UNF Hex Jam Nut 26 09-5514

J Part 5/8” Lock Washer 26 09-5114

K Part Cam Follower 26 02-0015

L Part Cage Plate - BOTTOM 1 1050-22

M Part 1/2” Regular Flat Washer 1 09-5010

N Part Jaw Pivot Bolt 2 1050-C5-28

P Part 1/2” UNC x 7” Hex Bolt 2 09-1194

Q Part 1/2” Narrow Flat Washer 1 09-5119

R Part Cage Plate - TOP 1 1050-21

S Assembly Jaw Die Kit (5-1/2” shown - see Pg. 2.17) 2

T Part Cage Plate Spacer 3 1050-C3-38

U Part Rotary Gear 1 1172-D1



tonG BoDy aSSeMBly

To lug ondoor weldment

Front leg mountsare secured usingsupport roller shaftsand nylock nuts

A

B

CD

N

Q

P

W XV

AA

X

FF

E

G

F

K

RS

T

U

Y Z

BB

CC

EE

L

M

HJ

DD



tonG BoDy aSSeMBly

Item Type Description Qty Part NumberA Assembly RigidSling(Pp.5.52-5.53) 1

B Part HydraulicValveMount 2 101-0116

C Assembly AdjustableHydraulicSupport-Inlet(Pp.5.26-5.27) 1

D Assembly DoorCylinderAssembly(Pp.5.32-5.33) 1 101-0069

E Part DoorPivotSupportRollerShaft 1 101-3940

F Assembly SafetyDoorSwitchAssembly(Pp.5.34-5.35) 1

G Part 11/8”NarrowWasher(DoorPivotRoller) 1 02-0471

H Part 3/8”UNCx1-1/2”HexBolt 22 09-1050

J Part 3/8”CarbonSteelLockWasher 22 09-5106

K Part BrakeBandAssembly(SeePp.5.28-5.29) 2

L Part DoorCylinderPost,Threaded 1 1050-12-001

M Part 3/8”UNCx1”HexSHCS 22 09-1738

N Assembly DoorAssembly(SeePp.5.32-5.33) 1

P Part ShoulderBushing(DoorPivotRoller 2 101-0110

q Part DoorStop(BottomMount) 1 101-1833

R Part 1”NarrowWasher(DoorPivotRoller) 1 09-5120

S Part 1”UNSThinNylockNut(DoorPivotRoller) 1 09-9167

T Part 3/8”NCx2”HexBolt 2 09-1054

U Weldment LHFrontLegMount 1 101-0878

Weldment RHFrontLegMount 1 101-0879

V Assembly HydraulicValveAssembly(Pp.2.11-2.13) 1

W Assembly AdjustableHydraulicSupport-Discharge(Pp.5.26-5.27) 1

X Part PinionBearingCapc/wfasteners(Pp.5.16-5.17) 2

Y Assembly Motor&MotorMount(Pp.5.30-5.31) 1

z Assembly ShifterAssembly(Pp.5.20-5.21) 1

AA Part PinionIdlerPadc/wfasteners(Pp.5.14-5.15) 1

BB Part TopPlate 1 1050-7T

CC Weldment SideBodyWeldment 1 101-0095

DD Part BottomPlate(Typicallyweldedtosidebodyweldment) 1 1050-7B

EE Part Geartrainaccesspanel 1 997-D13-161

FF Part ClutchBearingCapc/wfasteners(Pp.5.18-5.19) 1

See PaGe 3.15

ALL FASTENERS USED TO ASSEMBLE LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS) MUST BE TIGHTENED TO THE CORRECT TORQUE.



hyDRaulic ValVe MountS

A

C

D

E

B

G

L

K

J

F

B

CM

B

F G B H



hyDRaulic ValVe MountS

Item Type Description Qty Part NumberA Assembly DVAValveAssembly(SeePp.2.11-2.13) 1

B Part 3/8”UNCx1”HexBolt 10 09-1046

C Part 3/8”LockWasher 4 09-5106

D Part AdjustablePlate-DischargeLineSupport 1 101-0277

E Part DischargeLineSupportMountingPlate 1 101-0023

F Part 3/8”NarrowFlatWasher 6 09-5124

G Part 3/8”UNCNylockNut 6 09-5607

H Part AdjustablePlate-InletLineSupport 1 101-0022

J Part 1/2”UNCx4-1/2”HexBolt 3 09-1184

K Part 1/2”LockWasher 2 09-5110

L Part ValveBankMountingPost 2 101-0116

M Part InletLineSupportMountingBase 1 101-1138

N Weldment ValveHandleGuard 1 CE-HANDLE-3

P Part 1/2”FlatWasher 1 09-5010

q Part 1/2”UNCThinNylockNut 1 09-5610S

P

J

K

N

Q

The illustration on this page applies to CE-Marked versions only

J



BRaKe BanDS

A

C

G

H

J

D

F

E

B



BRaKe BanDS

Item Type Description qty PartNumber

A Weldment LinedBrakeBandWeldment 2 1050-D4-29

B Weldment BrakeBandLugWeldment(TopRight,BottomLeft) 2 101-0096

C Part 3/8”NarrowFlatWasher 4 09-5124

D Part 3/8”UNCThinNylockNut 4

E Part 3/8”x1”HexCapScrew 4 09-1046

F Part 3/8”LockWasher 4 09-5106

G Part BrakeBandRetainer 2 101-0140

H Part 3/8”UNCx1-1/4”HexBolt 4 09-1048

J Weldment BrakeBandLugWeldment(BottomRight,TopLeft) 2 101-0083



MotoR & MotoR Mount

A

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D

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E

H

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Q

B



MotoR & MotoR Mount

Item Type Description Qty Part NumberA Weldment TorqueGaugeMountWeldment 1 1500-09-03A

B Part 1/2”UNCx1-1/4”HexSocketHeadCapScrew 2 09-2168

C Part 1/2”UNCx1”HexSocketHeadCapScrew 2 09-2166

D Part 1/2”LockWasher 4 09-5110

E Part HydraulicMotor 1 87-0112

F Part MotorGear 1 997-A10-149

G Part 3/8”UNCx3/8”HexSocketSetScrew 2 09-0106

H Part 1/2”UNCx1-1/2”HexSocketHeadCapScrew 4 09-2170

J Part 1/8”NPT90oGreaseFitting 1 02-0093

K Part MotorMount 1 1050-150

L Part #20(1-1/4”)/JIC1”FlangeElbow 2 02-9216

M Part 0.148”x2.938”HitchPin 1

N Part #20(1-1/4”)SplitFlangeKit 2 02-9217

Part O-Ring 1

Part #20(1-1/4”)SplitFlange 2

Part 7/16”LockWasher 4

Part 7/16”UNCx1-1/2”HexBolt 4

P Weldment TorqueGaugeHolderWeldment 1 1500-09-04A

q Part 5/16”x5/16”x1-1/2”SquareGearKey 1



tonG DooR

A

C

A

B

D

E

F

M

GHJ

KU

QR

T

V

P

B

N

W

X

S

L



Item Type Description Qty Part NumberA Part 3/8”UNCx3/4”HexBolt 4 09-1044

Part CE-MARKED:3/8”UNCx3/4”HexBolt,SSD 3 09-1044SSD

B Part 3/8”CarbonSteelLockWasher 4 09-5106

C Part 1/8”NPTGreaseFitting 1 02-0005

D Part AdjustmentCam 1 1037-A-14

E Assembly SafetyDoorLatchBlockAssembly(Pp.5.30-5.31) 1

F Weldment DoorWeldment 1 1050-C4-10

G Part 1/2”LockWasher 1 09-5110

H Part 1/2”UNCHexNut 1 09-9124

J Part 1/2”x1-3/4”HexBolt 1 09-2172

K Weldment DoorLatchWeldment 1 1050-15

L Part LatchSpring 2 997-16

M Part SwitchGuardTopPlate 1 101-1474

N Part DoorPivotSupportRollerShaft 1 101-3940

P Part 1/2”x1/2”HexSocketShoulderBoltUNC 2 02-0973

q Assembly SafetyDoorLatchSwitchAssembly(Pp.5.30-5.31) 1

R Part 1/2”NarrowFlatWasher 2 09-5119

S Assembly DoorCylinder 1 101-0069

T Part 11/8”NarrowWasher(DoorPivotRoller) 1 02-0471

U Part ShoulderBushing 2 101-0110

V Part DoorCylinderMountingLug 1 1050-12-001

W Part 1”NarrowWasher(DoorPivotRoller) 1 09-5120

X Part 1”UNSThinNylockNut(DoorPivotRoller) 1 09-9167

tonG DooR



Safety DooR coMPonentS

A

B

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H

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P

S



Safety DooR coMPonentS

Item Type Description Qty Part NumberA Part 3/8”x1/2”ShoulderBolt,UNC 4 09-0125

B Part SafetyDoorLatchBlock 1 101-1104

C Part 15/16”ValveLockNut 1 09-0278

D Part SafetyDoorLatchBlock 1 101-1103

E Part 3/8”UNCx1”HexSocketHeadCapScrew 2 09-1738

F Part SafetyDoorLatchSpacer 1 101-1411

G Part 3/8”UNCx1-1/4”HexBolt 1 09-1048

H Part 3/8”CarbonSteelLockWasher 6 09-5106

J Part SafetyDoorLatchPlate 1 101-1410

K Part 3/8”UNCx1”HexSocketFlatCountersunkCapScrew 3 09-4046

L Part 3/8”UNCx3/4”HexBolt 4 09-1044

M Part SwitchGuardTopPlate 1 101-1474

N Part 1/4”NPT-JIC90degreeelbow2024-4-4 3 08-0284

P Part SafetyDoorSwitch 1 08-0337M

q Part LoadPlunger 1 AE12-306

R Part 3/8”UNCx3”HexBolt 2 09-1058

S Weldment SafetyDoorSwitchGuardWeldment 1 101-1475

CE-Marked tongs use the following parts in place of those in the previous table:Item Type Description Qty Part Number

A Part 3/8”x1/2”ShoulderBolt,UNC,SSDrilled 4 09-0125SSD

G Part 3/8”UNCx1-1/4”HexBolt,SSDrilled 1 09-1048SSD

L Part 3/8”UNCx3/4”HexBolt,SSDrilled 4 09-1044SSD

R Part 3/8”UNCx3”HexBolt,SSDrilled 2 09-1058SSD



leG aSSeMBlieS - coMPReSSion lc confiGuRation

THIS REAR LEg ASSEMBLy AppLIES TO MOdEL 80-0615 ONLy

A

B

C

D

E

H

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P

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P

G



Item Type Description Qty Part NumberA Part 1-1/4”NCx9”HeavyHexBolt 2 09-0288

B Part 3/8”NCShoulderPattern2-AEyeBolt 2 02-0262

C Weldment RearLegWeldment 2 1302-908-00

D Part 1-1/4”NCHeavyNylockNut 2 09-1484

E Part 1”NCHexNylockNut 2 09-5725

F Part RearLegSpring 2 1391-905-03

G Part TopLegSpringCap(Undertopbackupbodyplate) 2 1302-905-03B

H Part FrontLegTube 2 1302-904-905C

J Part 7/16”NCx3”HexBolt 2 09-0284

K Part FrontLegSpring 2 1302-905-08

L Part BottomLegSpringCap 2 1302-905-03A

J Part 3/8”CarbonSteelLockWasher 4 09-5106

K Part 3/8”NCx1-3/4”HexBolt 4 09-1557

M Part 1”NCx8”HeavyHexBolt 2 09-0286

N Part 7/16”NCx4”HexBolt 2 09-0285

P Part 7/16”NCHexNylockNut 4 09-5707

q Assembly ShackleAssembly 2 02-9063

R Weldment LHFrontLegMountWeldment 1 101-0878

Weldment RHFrontLegMountWeldment 1 101-0879

S Part 1”NFThinNylockNut(SupportRoller) 4 09-5627


R

S




A

B

C

D

E

F

G

H

J

K

L

J

THIS REAR LEg ASSEMBLy AppLIES

TO MOdEL 80-0615-6 ONLy



Item Type Description Qty Part NumberA Part 1-1/4”NCx9”HexBolt 2 09-0289

B Part RearBodySpacer 2 101-1378

C Weldment RearLegWeldment-CompressionLoadCellConfiguration 1 1302-908-00

D Part 1/2”NCx6”HexBolt 4 09-1190

E Part BackupSpringHolder-TopPlateWeldment 1 101-4496

F Part RearBackupSupportSpring 2 997-13

G Part 1/2”NCx9-1/2”HexBolt 2 09-1203

H Part BackupSpringHolder-BottomPlateWeldment 1 101-4495

J Part 1/2”NCHexNylockNut 6 09-5610

K Part 1”NCx8”HexBolt 2 09-0286

L Part TongBodyWeldment(Shownforillustrationpurposes) 1 1050-7




leG aSSeMBlieS - tenSion lc confiGuRation

A B

D

F

Q

R

P

K

J

P

E

L

G

H

C NM

THIS REAR LEg ASSEMBLy AppLIESTO MOdEL 80-0615-4 ONLy



leG aSSeMBlieS - tenSion lc confiGuRation

Item Type Description Qty Part NumberA Part 1-1/4”NCx9”HexBolt 2 09-0289

B Part 1”NCx8”HexBolt 2 09-0286

C Weldment RearLegWeldment-TensionLoadCellConfiguration 1 101-2031

D Part 1-1/4”NCHexNylockNut 2 09-1484

E Part 1”NCHexNylockNut 2 09-5725

F Part RearBackupSuspensionSpring 2 1391-905-03

G Part FrontLegTube 2 1302-904-905C

H Part TopSpringCap-FrontLeg 2 1302-905-03B


K Part FrontLegSpring 2 1391-905-02B

L Part BottomSpringCap-FrontLeg 2 1302-905-03C

M Part 3/8”NC-11/4”EyeBolt 2 02-0262

N Part Shackle 2 02-9063

P Part 7/16”NCNylockNut 4 09-5707

q Weldment RHFrontLegMountWeldment-TensionLoadCellConfiguration 1 101-0879

Weldment LHFrontLegMountWeldment-TensionLoadCellConfiguration 1 101-0878

R Part 7/16”NCx4”HexBolt 2 09-1122



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

L

JC D HG

RQ TM S

N

M

P

U V



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


W




THIS 8-5/8” BACKUp ASSEMBLy (85-0607) AppLIES TO MOdEL 80-0615-6 ONLy

AB

CD

G

E

F

D

HJ

HK

L

M

N

P

D




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



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

G

L

M

B

QN P

GF



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



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

H

CB

P Q

E F

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N R S T




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


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



THIS CyLINdER ASSEMBLy AppLIES TO 8-5/8” BACKUp MOdEL 85-0607 ONLy




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 SH959-41Wiper 1

Seal W47500625WearRing 1




RiGiD SlinG

A

B

C

D

E

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K

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QP

F

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H

N

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M



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



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.

Hydraulicforcegeneratedbyaloadcellistransmittedtothetorquegaugeviaareinforcedflexiblehydraulicline.ThehydraulicforceisdisplayedastorqueinunitsofFt.-Lbs.Thetorquegaugehasared“peaktorque”indicatorthattrackswiththetorquegaugeneedleto thepointofhighest torque,andremainsat thepointofhighest torqueuntilmanuallyreset.Note thateverymodelof tongandtongandbackupassemblyhasauniquearmlength,andthetorquegaugemustbecalibratedforthatarmlength.Torquegaugesthatarenotcalibratedforthearmlengthofthetoolinservicewillnotdisplaycorrecttorque.Toensurecorrecttorquemeasurement,ensurethearmlengthor“handle”asdisplayedonyourtorquegaugematchesthearmlengthofthetoolinserviceaslistedonthespecificationspageofthetechnicalmanual.

Theimagesonthispageareforillustrationpurposesonlyandmaynotaccuratelyrepresentthetorquegaugeandloadcellthathavebeensuppliedwithyourequipment.

ILLUSTRATION 6.A.1: TORqUE gAUgE (FOR ILLUSTRATION pURpOSES ONLy)

ILLUSTRATION 6.A.3: COMpRESSION LOAd CELL

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



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.

BASIC TORQUE MEASUREMENT (Continued:)Theimagesontheprecedingpageareforillustrationpurposesonlyandmaynotaccuratelyrepresentthetorquegaugeandloadcellthathavebeensuppliedwithyourequipment.Pleasenotethatthepartslistedinthefollowingtablesarecorrectforaccuratetorquemeasurementwhileusingtheequipmentforwhichthismanualissupplied.

toRque MeaSuReMent

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



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.

AB

C

D

E

F

G

HH

J

K

L

M

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



toRque MeaSuReMent

ILLUSTRATION 6.A.5: COMpRESSION LOAd CELL ExpLOdEd

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.

A

B

C

D

E

F

G

H

Compression Load Cell, 8 in2

Item Type Description Item Type Description

A Part 5/16” UNC x 1” Hex Socket Head Cap Screw E Part Diaphragm

B Part Load Plate F Part Diaphragm Casing

C Part 5/16” UNC x 3/4” Hex Socket Head Cap Screw G Part Street Elbow

D Part Retainer Ring H Part 1/4” NPT Brass Plug



ILLUSTRATION 6.A.5: TURN COUNTER ENCOdER MOUNT

toRque MeaSuReMent

2.74”2.75”

J

A

B

C

D

E

D

C

F

G

H

Item Type Description Qty Part Number

Assembly Standard Turn Counter Encoder Mount 1 60-0001

A Part 6-32 x 3/8” Hex Socket Head Set Screw 4

B 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



toRque MeaSuReMent

B. TROUBLESHOOTINGUndernormaloperatingconditions,andwithpropermaintenance,thetorquegaugeandloadcellsystemaredesignedtogivelastingtrouble-freeperformance.Faultyindicationonthegaugewillveryoftendefineafaultwithinthegauge.

1. Symptom: No indication on gauge.

PossibleProblem: Obstructioninhydraulichose.

Solutions: Checkhydraulichoseforkinks. Replacehydraulichose.

PossibleProblem: Lossofhydraulicfluid.

Solution: Rechargehydraulicfluid(seeSection6.C).NOTE:Ensureanybreachesinthehydraulicsystem betweentheloadcellandtorquegaugearerepairedtopreventfurtherfluidloss.

PossibleProblem: Internalmechanismoftorquegaugeisdamaged.

Solution: Replacegauge.

2. Symptom: Gauge indication unexpectedly high.

PossibleProblem: Excessivehydraulicfluid.

Solutions: Completelydrainhydraulicfluidfromtorquegauge/loadcellsystem.Rechargefollowingthe procedureinSection6.C.

PossibleProblem: Internalmechanismofgaugeisdamaged.


PossibleProblem: Incorrecttorquegaugeinuse(notpartoftheoriginaltorquegauge/loadcellpair).

Solution: Replacegaugewithgaugeproperlycalibratedfortheloadcellinservice.

3. Symptom: Gauge indication unexpectedly low

PossibleProblem: Insufficienthydraulicfluid.


PossibleProblem: Obstructioninhydraulichose.

Solutions: Checkhydraulichoseforkinks.

Replacehydraulichose.

PossibleProblem: Snublinenotatright-angletotonghandle.

Solution: Checkangleofsnublineandcorrectifnecessary.



PossibleProblem: Incorrecttorquegaugeinuse(notpartoftheoriginaltorquegauge/loadcellpair).

Solution: Replacegaugewithgaugeproperlycalibratedfortheloadcellinservice.

4. Symptom: Gauge indication is erratic or sluggish

PossibleProblem: Insufficienthydraulicfluidintorquemeasurementsection.


PossibleProblem: Lossofdampingfluidintorquegauge.

Solution: Topuporrefilldampingfluid(NOTE:Ensureleakagepointsingaugeareidentifiedandrepaired topreventfurtherlossofdampingfluid).

PossibleProblem: Airbubblesinhydraulicfluidinthetorquemeasurementsystem.

Solution: Bleedairfromloadcellandtorquegaugeandtopupfluid(ifnecessary)asperSection6.C.



IFTROUBLESHOOTINGREVEALSTHATTHEREISINSUFFICIENTFLUIDINTHESYSTEM,BEFORERECHARGING,CHECKTHATALLSYSTEMCOMPONENTSAREFREEFROMDAMAGE.THISWILLENSURETHATFLUIDLOSSWILLNOTCONTINUEAFTERRELOADING



toRque MeaSuReMent

C. PERIODIC INSPECTION AND MAINTENANCE

MAINTAIN GREATER-THAN HALF FULL FLUID LEVEL IN THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO THE SYSTEM. DO NOT ALLOW THE LEVEL TO FALL BELOW ONE-HALF FULL

UN-CONTAINED SPILLAGE OF THE HYDRAULIC FLUID IN THIS SYSTEM MAY CONTRAVENE GOVERNMENTAL ENVIRONMENTAL REGULATIONS, OR THE ENVIRONMENTAL 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.


1. InspectionThetorquemeasurementsystemsuppliedwithyourequipmentisdesignedandbuilttoprovideyearsoftrouble-freeservicewithminimummaintenance.Periodicinspectionsoftheloadcell,hydrauliclinesandfittingsarerecommendedinordertokeepthesystemintopoperatingcondition.Athoroughinspectionshouldbemadeateachrig-up.

2. Fluid RechargeRechargehydraulicsystemwithW15/16fluidthroughthecheckvalveonthetorqueindicatinggauge.Rechargingmustonlybeperformedwhenthereisnoloadontheloadcell.Refertotheillustrationsonpages6.3&6.4forguidanceifrequired.

a. Placethetorqueindicatinggaugehigherthantheloadcell.Removethebrass1/4”capfromthefittingonthecheckvalveonthetopofthegauge.

b. Connectthehandpumptothecheckvalvefitting.

c. Elevatetheloadcellsoitishigherthanthetorquegaugeandhandpump.

ONLY QUALIFIED, DESIGNATED PERSONNEL ARE PERMITTED TO PERFORM MAINTENANCE ON THE TORQUE MEASUREMENT SYSTEM.



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:

1000x(32/12)=2667

Therefore,theexpectedindicationonthetorquegaugeshouldbe2667lbs-ft.

CompressionLoadCell

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:

500x(36/12)=1500

Therefore,theexpectedindicationonthetorquegaugeshouldbe1500lbs-ft.

4. Repair And CalibrationReturntheloadcellandindicatorgaugetotheauthorizedrepairfacilityforrepairsandcalibration.



hyDRaulic infoRMation

Section 7: Hydraulic Component InformationThemanufacturerinformationcontainedinthissectionhasbeenobtainedfrompubliclyavailablewebsitesandhasbeenprovidedforinformationpurposesonly.McCoyDrilling&Completionsdoesnotguaranteetheaccuracyoftheinformationcontainedinthissection.Alloriginalcopyrightsclaimedbythemanufacturer(s)apply.




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.

R

MA

NU

FA

CT

URER OF HYDRAULIC

MO

TO

RS




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




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.




Performance Data - Selected Displacements

The above performance data was obtained at 140OF with ISO 46(DTE 25). These values must be maintained to obtain the performance indicated. Contact Rineer Hydraulics, Inc. for additional displacements.

6 C.I.D.ACTUAL TORQUE AND POWER 6-CID

0102030405060708090

100110120130140150160170180190200

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0

10

20

30

40

50

60

70

POW

ER(H

P)

2000 RPM

100 RPM

2000 RPM

1200 RPM

400 RPM

100 RPM

800 RPM

1600 RPM

ACTUAL FLOW - 6 CID

0

5

10

15

20

25

30

35

40

45

50

55

60

65

0 500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

RPM800

1000

1200

1400

1600

1800

2000

200

400

600

100

9.5 C.I.D.

ACTUAL FLOW - 9.5 CID

0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

15001400

1200

1000

800

600

400

200100

1700

ACTUAL TORQUE AND POWER 9.5-CID

020406080

100120140160180200220240260280300320340360

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0102030405060708090100

POW

ER(H

P)

1700 RPM100 RPM

1700 RPM

900 RPM

300 RPM100 RPM

500 RPM

1300 RPM

RPM

11.5 C.I.D. ACTUAL TORQUE AND POWER - 11.5 CID

0255075

100125150175200225250275300325350375400425450

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0102030405060708090100110120130

POW

ER(H

P)

1600 RPM

800 RPM

200 RPM100 RPM

400 RPM

1200 RPM

1600 RPM100 RPM

ACTUAL FLOW - 11.5 CID

0

10

20

30

40

50

60

70

80

90

100

0 500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

1600

400

600

800

1000

1200

1400

100

200

RPM

15 C.I.D. ACTUAL TORQUE AND POWER - 15 CID

0255075

100125150175200225250275300325350375400425450475500525550575600

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0

25

50

75

100

125

150

POW

ER(H

P)

1500 RPM

100 RPM

1500 RPM

700 RPM

300 RPM100 RPM

500 RPM

1100 RPM

ACTUAL FLOW - 15 CID

0

10

20

30

40

50

60

70

80

90

100

110

500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

1500

1100

1300

500

700

900

100

300

RPM




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

Open During Crossover67 = Two Speed Double Pilot

Closed During Crossover1S = Std.1H = High Speed

006 = 6 in3 (98cc)/rev.007 = 7 in3 (115cc)/rev.008 = 8 in3 (131cc)/rev.009 = 9.5 in3 (156cc)/rev.

010 = 10.5 in3 (172cc)/rev.011 = 11.5 in3 (189cc)/rev.013 = 13 in3 (213cc)/rev.015 = 15 in3 (246cc)/rev.

30 = Keyed Shaft31 = Splined Shaft32 = Wheel Motor34 = Double Key50 = Retractable53 = API Thread

Bearing Package Selection

Seal - Package Selection

Special Code Designator

331 Breesport San Antonio, Texas 78216

210-341-6333 Fax: 210-341-1231 e-mail: [email protected]

Applications

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.

Limited Warranty Policy




Standard Motor

Two Speed Motor

HYDRAULICS, INC.HYDRAULICS, INC.

R

MA

NU

FA

CT

U

RER OF HYDRAU

LIC

MO

TO

RS

15 Series

Repair Manual

331 BREESPORT * SAN ANTONIO, TX 78216 * (210) 341-6333 FAX (210) 341-1231




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





9

10

11

12

13

14

15

16

6

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) Replace plate on rotor/stator cartridge.2) Turn rotor/stator cartridge over.3) Repeat steps 14 & 15.

1) Remove o-ring and springs with a small screwdriver.2) Remove dowels pins.

1) Place cartridge on any object which will hold it off the table.2) Remove two each 10-32 place screws.3) Remove timing plate.

Lift up rotor/stator cartridge and remove from the rear housing.

DISASSEMBLY OF FRONTHOUSING AND SHAFT

DISASSEMBLY OF ROTOR/STATORCARTRIDGE





17 21

22

23

24

18

19

20

7

1) Remove the rotor.2) Remove both the rotor and stator vanes.3) Note: On motors manufactured prior to 1987, rotor vane slots and rotor vanes should be numbered so that vanes can be reassembled in the same vane slot.

Inspect all springs and seals. We recommend replacement of all seals and springs whenever the motor has been disassembled.

Inspect all parts and replace any parts which obviously show excessive wear or damage.

VANES: Normal wear results in slight flattening of vane tips which does not impair motor performance. Replace vane if radius is reduced by 50%.Clearance between the rotor vane and rotor vane slot varies with the vane selection. The design allows the vane to "lean" slightly in the slot, providing the required mechanical seal.

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





25

26

27

28

29

30

31

32

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





33

34

35

36

B

A

9

1) Install dowel pins into rotor/stator cartridge.2) Pour a small amount of clean oil into the cartridge.3) Install front housing onto rotor/stator cartridge.4) Make sure alignment marks are lined up.

1) Install 5/8-11 bolts.2) Torque bolts to 50 ft./lbs.

1) Rotate shaft in both directions to assure that the shaft turns smoothly.2) Torque motor to 190 ft./lbs.3) Rotate shaft again in both directions to assure that the shaft turns smoothly.

NOTE: Spool should be oriented as shown for two speed motors with model codes 62, 63, 68, & 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




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

331 Breesport San Antonio, Texas 78216

210-341-6333 Fax: 210-341-1231 e-mail: [email protected]

WHEEL MOTOR

STANDARD MOTOR

TWO SPEED MOTOR




Pilot-to-open, spring biased closed, unbalancedpoppet logic element

Capacity:15 gpm (60

L/min.)

Functional Group:Products : Cartridges : Logic Element : Unbalanced Poppet : Pilot-to-open,spring biased closed

Model:LKDC-XDN

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.

Technical DataU.S. Units Metric Units

Model Weight 0.28 lb. 0.13 kg.Cavity T-11ACapacity 15 gpm 60 L/min.

PN: 08-1625




Area Ratio, A3 to A1 1.8:1Area Ratio, A3 to A2 2.25:1Maximum Operating Pressure 5000 psi 350 bar

Maximum Valve Leakage at 110 SUS (24 cSt) 10 drops/min.@1000psi

10 drops/min.@70bar

Pilot Passage into Valve .031 in. 0,8 mmPilot Volume Displacement .02 in³ 0,33 ccSeries (from Cavity) Series 1U.S. Patent # 4,795,129Valve Hex Size 7/8 in. 22,2 mmValve Installation Torque 30 - 35 lbf ft 45 - 50 NmSeal Kits Buna: 990-011-007Seal Kits Viton: 990-011-006

LKDC-XDN

Control Minimum Pilot Pressure External Material/SealMaterial

X Not Adjustable +0.00 D 50 psi (3,5 bar) +0.00 N Buna-N +0.00

If the material/seal is P, the control must be XIf the material/seal is W, the control must be X

Explanation of Sun cartridge control options - US units.Explanation of Sun cartridge control options - metric units.

Copyright © 2007-2008 Sun Hydraulics Corporation. All rights reserved.Terms and Conditions - ISO Certification - Statement of Privacy

Pilot-to-open, spring biased closed, unbalancedpoppet logic element

Capacity:15 gpm (60

L/min.)

Functional Group:Products : Cartridges : Logic Element : Unbalanced Poppet : Pilot-to-open,spring biased closed

Model:LKDC-XDN

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).




Model Weight 0.28 lb. 0.13 kg.Cavity T-11ACapacity 15 gpm 60 L/min.




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).



PN: 08-1180





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




Pilot-to-open check valve with standard pilotCapacity:

30gpm (120 L/min.)

Functional Group:Products : Cartridges : Pilot-to-Open Check Valve : 3-Port, Non-Vented : StandardPilot, Steel Seat

Model:

CKEB

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




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.


Cavity T-2ACapacity 30 gpm 120 L/min.Pilot Ratio 3:1 3:1Maximum Operating Pressure 5000 psi 350 barMaximum Valve Leakage at 110 SUS (24 cSt) 1 drops/min. 0,07 cc/min.Series (from Cavity) 2Valve Hex Size 1 1/8 in. 28,6 mmValve Installation Torque 45 - 50 lbf ft 60 - 70 NmModel Weight .50 lb 0,25 kgSeal Kits Buna: 990-202-007Seal Kits Viton: 990-202-006

Option Selection

CKEB-X C N

Preferred Options

Control Cracking PressureExternalMaterial/SealMaterial

X Standard Pilot C 30 psi (2 bar) N Buna-N

Pilot-to-open check valve with standard pilotCapacity:

30gpm (120 L/min.)

Functional Group:Products : Cartridges : Pilot-to-Open Check Valve : 3-Port, Non-Vented : StandardPilot, Steel Seat

Model:

CKEB

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

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