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KT5500 - Texas International Oilfield Tools LTD

1. SS 1 7 7 TL 7 16 TECHNICAL MANUAL SECTION CONTENTS GY SSF wet 77 tly Motor INFORMATION Seal Kits Standard 15 series seal kit 0150940 Standard 15 two speed seal kit 0150940 Standard 15 wheel motor seal kit 0150936 DRILLING amp COMPLETIONS AACCCY MOVING GLOBAL ENERGY FORWARD HYDRAULIC VALVE INFORMATION 5500 5 1 18 7K Inlets 2500 psi End inlet ven rwr Mig Fem cet dh nasa finian palgi NON PORTED HOUSING NOTE iniata ane for a man Ry or Th pre lug and wilh piante closures Del inlet section Saction 32 for inlet port Outlets Tank Return Type Adjustable Relief Valve Cartridges For Inlets and Mid section Inlets Coda Description DVA35 MRV 1 pressure 800 2000 pi Factory set 1500 psi S0 gpm DVASE MAV 2 FUN presaure ange 01 2500 psi Factory bol 2500 ps S0 gore OVASS MAVP valve plug DRILLING amp AACCCY COMPLETIONS TECHNICAL MANUAL 7 17 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7
2. nnns ss nana 3 25 Decommissioning TE TOT 3 26 HOCOmimis TOC BOUE 3 29 o MeL Section Four Tong Will Not Develop Sufficient 20 000000000000 4 1 Failure Of Jaws To Grip PIDC iiiter esee ba Eiri E 4 3 Tong RUNNING TOO SONY 4 4 OF DI cU OF Tong To SIU m 4 5 e NERONE 4 6 PANS Section Five 5 2 AOO _ 5 4 HOM F Y 5 6 emo _______ ________ 5 8 POR FASS 5 10 5 12 TA SII m E 5 14 dec 5 16 Ern 5 18 TOO FAS SEONG 5 20 X 5 22 MOr MOUN A 5 24 EE 5 26 Door ASSEDI ss e 5 28 AIC Bold rej M 5 30
3. nar he pec foem wiles pans need io be replaces Wrap the geient Pig 2 1 71 with a clean lis rec eai Gap the zlah eavered sleeve amd pull rfe moves me delent balla Fig 2 18 and ike pru Fio 2 191 niil release Vee cll beste capiant lese paris teur Loss ext Clamp fhe p m a aed rome the detent poppe retainer Fig 2 iem 20 Place un tendered through ibe bete were 25 2 wrewh rip the pop rebimerwi hammer and a push in help break ibe aleve agplieanan af tay be required ago alee s len unl im minang be ie placed Chor rhe CAUTION Too much heal may distort the spool CLEANING INSPECTION AND REPAIR che spans bere check sent ami senol imm section fnr pougey of eyoeerve wear If Of hee due nm the port speed amd cheek poppe om be Adil pal ied away witha very nme ene 2 1 Examine machined surfaccs cl the valve nicks ard hurre could leakage bere ern Lighily stone these surfaces ju remove uny miigh pour CAUTION shallew milled relief aren extends across the O ring face of va
4. TECHNICAL MANUAL KT 5500 5 1 3 14 cm 18 7K Lbs Ft Hydraulic Power Tong Specifications Operation Maintenance Assembly Copyright 2007 2012 McCoy Corporation All rights reserved OY MOVING GLOBAL ENERGY FORWARD Published by McCoy Corporation Technical Publications Department CCOYQ 14755 121A Avenue Edmonton AB Canada T5L 272 5500 5 17 18 7K This manual covers the following models TONG MODEL DESCRIPTION 80 0420 3 1 Backup ready tong with Rineer motor motor valve backup valve lift cylinder valve rigid sling and safety door 80 0420 5 Tong with Rineer motor motor valve rigid sling and safety door 80 0420 6 Tong with Rineer motor motor valve lift cylinder valve rigid sling and safety door Backup ready tong with Rineer motor motor valve backup valve lift cylinder 80 0420 9 valve rigid sling amp safety door CLOSED CENTRE SYSTEM 80 0420 12 Tong with two speed Rineer motor motor valve rigid sling and safety door 80 0420 13 Tong with Rineer motor motor valve lift valve rigid sling and safety door 80 0420 14 2 Backup ready tong with two speed Rineer motor motor valve backup valve lift cylinder valve rigid sling safety door and Wincatt dump valve 80 0420 15 Backup ready tong with two speed Rineer motor motor valve backup valve lift cylinder valve rigid s
5. HYDRAULICS ING lt Standard Motor Two Speed Motor 331 BREESPORT SAN ANTONIO TX 78216 210 341 6333 FAX 210 341 1231 DRILLING amp 7 8 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Motor INFORMATION 79 SERIES 15 STD MOTOR EXP VIEW ITEM PART NO DESCRIPTION 0150111 SEAL PLATE SNAP RING 0150135 SEAL PLATE 0150161 SEAL SHAFT TCN NOT USED 150114 SEAL PLATE O RING 150730 SNAP RING BEARING 150710 BALL BEARING 150701 SHAFT KEYED 150702 SHAFT SPLINED 150901 BOLT 150102 FRONT HOUSING INTERNAL 150428 DOWEL PINS FRONT 150610 O RING 150902 BALL CHECKS 150620 E SCREW 150608 150400 150401 150402 150403 150404 150406 150407 STATO 150409 STATO 150300 ROTOR 150313 VANE 10 150320 ROTOR VANE SPRING OUTER 20 150321 ROTOR VANE SPRING INNER 20 150410 STATOR VANE 4 150420 STATOR VANE SPRING 8 2 1 1 ers Oo O COC AJUAN O o gt gt 11 5 15 15 9 5 8 0 7 0 6 5 0 2222222 20 17 18 19 20 21 22 23 24 25
6. KT 5500 5 1 2 tong This unit will provide you with years of outstanding performance Simple maintenance and care will extend its life and ensure years of excellent performance and reliability The setup operating and maintenance instructions in this manual will assist you in giving your equipment the care it requires Please carefully read the manual before installing and using your equipment Replacement parts are readily available from McCoy Drilling amp Completions FARR in Edmonton Alberta Note that many parts are transferable between FARR tongs and backups Should you need replacement parts or should you experience any difficulty not covered in this manual please contact McCoy Drilling amp Completions FARR 14755 121A Avenue Edmonton Alberta Canada T5L 212 Phone 780 453 3277 Fax 780 455 2432 Sales Fax 780 481 9246 Email Engineering engFarr mccoyglobal com Email Sales salesFarr mccoyglobal com Customer Care customerCareFarr mccoyglobal com Website http www mccoyglobal com index php arilling completions Model 80 0420 3 Shown DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 1 1 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K SPECIFICATIONS 25 1 2 _____ gt ALL REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED DRILLING amp 1 2 SECT
7. SPECIFICATIONS Use an EP synthetic grease that meets or exceeds the following specifications Thickener NLGI consistency grade NLGI performance grade Penetration ASTM D 217 25 77 F Dropping point ASTM 02265 High temperature life hours ASTM D 3527 Oxidation stability psi ASTM D 942 Water washout percent ASTM D 1264 Rust and corrosion ASTM D 1743 Oil separation percent loss ASTM D 1742 Leakage g lost ASTM D 4290 Four ball wear test mm scar ASTM D 2266 Fretting wear mg ASTM D 4170 Four ball EP kgf ASTM D 2596 Weld point Load wear index Timken OK load test lbs ASTM D 2509 Low temperature torque N m ASTM D 4693 LT 37 pumpability g min Copper corrosion ASTM D 4048 Oil viscosity 40 C 104 F cSt 100 212 F cSt Flash point F C ASTM 92 Lithium Complex 2 GC LB 265 295 minimum 0 1 mm worked 60 strokes 550 288 minimum 160 minimum 100 hr 800 hr 0 3 1 8 max pass 1 1 max 24 hours 25 77 F 1 0 max 0 40 max 3 4 max 400 minimum 50 minimum 50 1 3 max 40 40 F 360 7 60 F 0 F 16 C 18 1B 151 19 2 450 232 Use a premium quality hydraulic fluid that meets or exceeds the following specifications Typical Density kg m3 Viscosity cSt 40 cSt 100 Viscosity Index Pour Point F lt Flash Point F lt Colour ASTM Neutralization Number Rust Protection Distilled Water Sea Wate
8. TECHNICAL MANUAL 523 MOVING GLOBAL ENERGY FORWARD KT5500 5 17 18 7K Motor Mount AssEMBLY DRILLING amp 5 24 BSEC USES TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor Mount AssEMBLY KT5500 5 1 18 7K item Fat 12 Hon Socket Head Cap 2 24 _ D Fa 9 7 7 Rineer GA15 1965 Two Speed Motor Optional 1 87007 G Fat 2 09086 2 LX Weldment Torque Gauge Holder Weldment 1 1500 09 04 ES e Pant Fa ooo 4 1 1 L Pat 420 1 4 Split Flange Kt 2 1 2 DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 525 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K HYDRAULIC ASSEMBLY DRILLING amp 526 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC ASSEMBLY KT5500 5 1 18 7K tem ______ Por Number 8 fa WMWS _ D hyras ovaa E at Waer wxCoperh ng 3 fam romo G Awemby 1 Connection Hose Assomby 2 lora Awemby MORBUIC LONG cudes sea
9. TROUBLE Chi leaks herween sections Chl beaks at enlier of spool Spring centered spooks not renim ro neutr l Load will riot haki E cal drops when moved from motion ie operation 734 SECTION CONTENTS Troubleshooting PROBABLE CAUSE Punched blown ur mint Stud fasteners nor correctly Mounting plate mot Level Centinimalion burrs en seal erin ef operating linkage Foreign particles in system Cylinder leaking or worn relief valve holding Spool or housing scored or Wom excessively Did or foreign partecles lodged between check valve Scored or sticking check popper Defective zyl inder or motor Luw neserypir wil level Clovped Sirine line Relief valve not properly act Relief valve pappet or seat scored amp sticking open Valve spool mot shrfied to full stroke TECHNICAL MANUAL Cheek cylinder repair MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION REMEDY Replace section seal Replace section seals and Loosen mounting bolts and shim as required Clean seal groove replace Correct high back pressure m Replace seals ind seal retainers Replace centering spring Check linkage for mechanical binding Clean valve and system
10. DRILLING amp 520 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD LEG ASSEMBLIES Pet 8 Pet p Ra 5500 5 1 18 7K Backup Leg Mount Weldments Backup ready tongs only Part Number Load Cell Tie Off Bolt 1 1 4 NC x 8 101 0148 Load Cell Tie Off Bolt Backup Ready Tong 0 148 x 2 938 Hitch Pin 2 09 0090 09 5832 1 1 4 NC Heavy Nylock Nut Backup Ready Tong 09 1484 Rear Leg Weldment 3 8 Carbon Steel Lock Washer 3 8 NC x 1 3 4 Hex Bolt LH Front Leg Weldment s msu s ms Front Backup Leg Mount Pan Narrow Washer Suppor Roe osa MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS TECHNICAL MANUAL SECTION CONTENTS 521 KT5500 5 1 18 7K Brake ASSEMBLY DRILLING amp 5 22 CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Brake ASSEMBLY 5500 5 1 18 7K mem ay Pa tr emn _ 4 mios _ Fat Carbon Steel Lock Waster 4 T4450 _ D at Brake Band 2 1068 RH Top amp LH Bottom Brake Band Lug Welzment 2 DRILLING amp
11. Inspect all paint locations in which the paint has been damaged must be repaired prior to the tong being returned to 1 0 service Prepare areas to be painted to ensure they are free of grease dirt or solvent Touch up using a solvent based acrylic McCoy Grey is paint color number 7015 contact Farr sales for number for custom paint applica tions Allow sufficient time for paint to dry before proceeding 1 1 Inspect all external welds Any weld that is cracked separating must be repaired and repainted before returning the tong to service DRILLING amp 322 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong in service Also inspect all chains master links and turnbuckles 1 2 C again if any damage is noted replace the damaged part s before placing the tong in service Refer to Section 2A of the technical manual Sling Load Bearing Device Safety for information on recommended testing and recertification Please note that turnbuckles with part number 101 3086 short turnbuckles use a high strength pin which must be supplied by Farr SHORT TURNBUCKLES HAVING PART NUMBER 101 3086 EMPLOY HIGH STRENGTH PINS WHICH MUST BE
12. Stand alone tongs have three legs to install two front one rear and backup ready tongs have two front leg mounts to install Stand Alone Tongs Models 80 0420 5 80 0420 12 i Remove the 3 8 x 1 1 2 hex bolts and 3 8 lock washers two each per side from the bottom plate adjacent to the front leg mounting locations see illustration top of next page il Slide the front leg weldments RH weldment PN 101 0873 LH weldment 101 0877 into place over each exposed support roller shaft Secure each leg weldment on to the support roller shafts using a 7 8 UNF thin nylock nut no wash ers are used in this application Further secure the leg weldments in place using the 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers removed in the previous step iii Remove the four 3 8 x 1 1 2 hex bolts and 3 8 lock washers two each per side from the locations furthest back the bottom plate behind the clutch bearing cap iv Attach the rear leg weldment to the bottom plate using the four 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers removed in the previous step DRILLING amp 316 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K Mechanical Assembly Procedure Continued 54 Install the tong legs continued Secure the front leg mount mount weldments LH weldment PN 101 0786 RH
13. GA 10 5 25 0150414 STATOR GA 11 5 25 0150419 STATOR GA 5 17 10150300 18 10150313 VANE 10 19 10150320 VANE SPRING OUTER 20 20 0150521 VANE SPRING INNER 20 2110150410 STATOR VANE 22 0150420 5 VANE SPRING 25 0150429 OWEL PINS REAR 0 0 0 0 150843 5 5 D NEEDLE BEARING R R R EAR HOUSING TS 63 EAR HOUSING TS 64 RINEER HYDRAULICS CORPUS CHRISTI TEXAS RECORD REFERENCE DRAWN BY JERRY W DATE 6 19 00 DWG NO 0150044 NCO Y MOVING GLOBAL ENERGY FORWARD 7 10 SECTION CONTENTS TECHNICAL MANUAL INFORMATION 5500 5 1 18 7K WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION REMOVAL OF SHAFT SEAL 1 Remove snap ring WARNING Use caution when removing snap ring If released accidentally it can become an airborne hazard 1 Two of the 3 8 bolt holes are provided with jack screw threads 2 Insert a piece of 1 4 round stock by 2 1 2 long into each jack screw hole 3 Screw two 7 16 14 bolts into the Jack screw threads until the bearing box is free of the motor Lift up on the bearing box 1 Pry out shaft seal plate to remove from motor with two screw drivers 2 Remove seal plate 0 ring from groove in bearing bor
14. Remove and clean or replace Replace section Disassemble clean amp ressemble Keplace poppet Check amp pressure replace Add od fo Clean ot replace Check Imes Check pressure seing Replace relief vijve Check spool linkage travel DRILLING amp COMPLETIONS
15. eu thee spad aud anoe Togor 1 halt qm eroas conmer Tie Bolt Tonus Values 29 lba 342 Ibs VG20 42 ft ibs 804 in 16 VAIS 34 fi 408 in bs VG35 75 Ibi 900 in 150 ft Iba 7000 Iba 7 30 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION KT5500 5 18 7K 22 Cutaways for Main Relief Valves Main System Rolicf Valve main vnlye protects dtie hyllir ey stern against overload pressures It is rvpaeally located in the inlet casting and the ied in ihe valve hank Fur the arrangement ef the parts and seals har the dittereetal ores nein relie Figure 7 ht terviceable components fend n Ihe g ilak operated maim These cumdge nype relief valves are removed from ibe salvi as subassenibly ded neplaczx ow serviced Ium Description VAIVOGZOTM 1 391 2881 332 2 ack up Ring 391 2681 373 4 Oring 391 2881 156 4 Backup Ring 391 2681 163 5 Gasxet Washer 1 381 158 013 All SERVICE PARTS LIST Figure amp 491 2881 3436 7 mpi 301 2881 137 391 2581 165 381 1583 D4 2 saals coat by inrer nod VAZU VG20 VA35 V 335 Main Differentia
16. Farr recommends that an anti corrosive agent such as Tectyl amp 506 be applied to all external unpainted surfaces 3 8 and chain slings EXCEPT cylinder rods jaw rollers and rotary gear camming surfaces Refer to manufacturer data sheets for proper application and safety information Once all of the above maintenance checklist items have been satisfactorily completed the tool may be returned to service DRILLING amp 324 SEcTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K K DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER UNIT Farr recommends that the following inspections and maintenance procedures be performed before each use and at least once per day when the equipment is in steady use in the sequence in which they are listed Rigorous inspection and maintenance especially lubrication is essential in order to ensure that your equipment always meets specifications and to prevent catastrophic failures that can severely damage your equipment and cause worker injury If using a stand alone power unit perform the following inspection and maintenance procedures before each use and at least once per day when the power unit is in steady use Do not perform any maintenance while the power unit is energized electric or if the engine is running diesel Ensure the electri cal supply is locked out or if using a diesel power supply ensure t
17. Flat Die 13 0008 314 0 WRAPAROUND JAW DIE KITS Inserts Not Included Description Part Number 2 3 8 3 1 2 Wraparound Jaw Die Kit 1064 WJK 350 4 5 1 2 Wraparound Jaw Die Kit 1064 WJK 550 2 3 8 Wraparound Insert for use in 1064 WJK 350 12 2001 2 7 8 Wraparound Insert for use in 1064 WJK 350 12 2003 3 1 2 Wraparound Insert for use in 1064 WJK 350 12 2006 4 Wraparound Insert for use in 1064 WJK 550 12 2007 4 1 2 Wraparound Insert for use in 1064 WJK 550 12 2009 5 Wraparound Insert for use in 1064 WJK 550 12 2011 5 1 2 Wraparound Insert for use in 1064 WJK 550 12 2012 DRILLING amp 212 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 5500 5 1 18 7K 2 Jaw Jaw Die Removal The tong jaws will often require removal to change jaw size or replace worn jaw die inserts Support the jaw being removed from the bottom and use a wrench to loosen and remove the jaw pivot bolt Slide the jaw away from the rotary gear towards the centre of the cage plate assembly and lift clear of the tong Repeat for the other jaw Note that removal process for jaws with wraparound dies 15 identical Removal and replacement of die inserts Removing the centre keeper screws Insert a narrow punch through the slot at the bottom of the jaw groove and lightly tap the die from the bottom until it loos
18. KT5500 5 1 18 7K SuPPoRT ROLLER A H Nal DRILLING amp 54 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SUPPORT ROLLER KT5500 5 1 18 7K 5 i Type Description Qty PartNumber at suorroerstanna 08 _ Part Suport Roler Shaft Backup Ready Tongs Oni ________ 1019040 fmt _ D Pat Support Roller Sleeve 1064 182 Tapered Roller Bearing 02 0099 Support Roller Shaft Spacer 1064 183 Support Roller 1064 181 7 8 UNF Hex Thin Nylock Nut 09 5722 1 Stand alone tongs use 11x support roller shaft PN 101 3942 amp 1x door pivot shaft PN 101 3944 2 tongs use 7x support roller shaft PN 101 3942 Use four long support roller shafts PN 101 3943 where coincidental with the front leg mount weldments The door pivot shaft remains PN 101 3944 3 Top and bottom flat washers are not used where the support roller shaft is coincidental with the brake band lug weldments Bottom flat washers are not used where the support roller shaft is coincidental with the front leg mount weldments DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 55 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K Rotary IpLER ASSEMBLY DRILLING amp 56 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD
19. PASSO mc 5 32 eee Section 6 SOC UON ce neta uM MM MEUM MEE Section 7 Hydraulic Motor IMONMAUON 7 1 Valve oM M 7 13 MOVING GLOBAL ENERGY FORWARD DRILLING amp AACCCOY TECHNICAL MANUAL KT5500 5 1 18 7K The information presented in this document will provide setup operating and maintenance instructions for your 5500 tong Due to the wide variety of operating conditions these instructions must be considered guidelines rather than absolute operating procedures It is the responsibility of the user to use these guidelines together with an experienced manager to develop operating procedures that conform to all policies set forth by the op erating authority ies IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS INSTALLATION GUIDE McCoy Drilling amp Completions uses three indicators to describe items of three degrees of importance A HAZARD to operators or equipment is represented by an exclamation point within a red triangle and identifies items of the highest importance Failure to heed information identified by a HAZARD symbol may result in bodily injury death catastrophic equipment damage or an
20. TECHNICAL MANUAL 150429 DOWEL PINS REAR 150720 NEEDLE BEARING 150800 REAR HOUSING SERIES MODEL CODE 015 6 1 1 015 30 B 1 TB XXX 15 STANDARD MOTOR DATE RINEER HYDRAULICS REFERENCE 4 14 98 CORPUS CHRISTI TEXAS DRAWN BY DWG NO JERRY W 0150041 AACCOY MOVING GLOBAL ENERGY FORWARD Motor INFORMATION KT5500 5 1 18 7K SERIES MODEL CODE 015 62 15 0 15 30 31 1 15 expropen STANDARD TWO SPEED SERIES 15 STD TWO SPEED EXP VIEW 24 25 150720 150841 150842 EAR HOUSING TS 62 ITEM PART NO DESCRIPTION QTY 1 10150111 SEAL PLATE SNAP RING 2 01501535 SEAL PLATE 3 11250161 SEAL SHAFT 4 NOT USED 5 10150114 SEAL PLATE O RING 6 0150750 SNAP RING BEARING 7 10150710 BALL BEARING 0150701 SHAFT KEYED 8 0150702 SHAFT SPLINED 9 0150901 BOLT 4 10 0150102 HOUSING INTERNAL 1 1110150428 DOWEL PINS FRONT 2 12 0150610 0 4 15 0150902 CHECKS 4 14 0150620 PLATE SCREW 4 15 0150609 TWO SPEED 2 16 0150401 STATOR 15 1 0150402 STATOR GA 13 0150403 STATOR GA 9 5 0150404 STATOR GA 8 0 0150407 STATOR GA 6 0150408 5
21. This manual has been prepared to assist you in the proper maintenance of the VAZO VY AIS and VOI YGIS VGRO directional valves Before any work done we suggest that Vou read the assembly and disassembly Instructions completely The first rule of good maintenance 15 cleanliness which includes a clean environment MAKE SURE YOU DISASSEMBLE AND ASSEMBLE YOUR HYDRAULIC EQUIPMENT IN CLEAN AREA Dirt is the natural enemy of any hydraulic System GENERAL INFORMATION The VA and VG model valves are updated versions of our proven and A351 units The VG models are cast from compacted graphite high strength iron alloy which allows the valve to be ratel to 3500 psi rmodels cast from pray mon and ane rated at 2500 psi These opeu center directional control valves are available in tandem and series circuitry As needed the sectional stack type construction provides the addon of subtraetion of work lo an existing valve bank This design also perculs the combination of parallel tandem and senes in a single The conng of esch valve section determines iis circuitry and the number of gasket seals required All sectioas with optional features such s por relie valves crossover relied valves and ant checks are dimensionally larger when measured from the top of rhe to the of the
22. 2m Step 3 Back be Pack siia rius seres Fig i d Timhten to a final torque of 34 tmn im Caution Excessive torque will damage the hock cap ears COY TECHNICAL MANUAL 7 29 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K VALVE INFORMATION 10 Valve Assembly Instructions Step 4 Install Transition Check hen mansmen clos check popped Pag 1 ero 13i ipio ie transition check eae Align the Fig h iem square te ihe poppet ihen canelolly place the check Fig 01 aver the poppa and spam Tammy by hand engage threads a final torgus pl TS f eu i bs Step 5 Relief Valves Retire all valves t tiesr proper pomisans zr b i 7 ame pred piian emile in inert dunme Step B Install Tie Bolts Sa ihe the the Polti thigh per ket IT cap acres place a Waher cap screw pnr 00 Pen Ike valve po Wie Die baila proper sse page d by humid engnge aver thieoda the YG assem bee mit ami lo
23. Install main inlet and outlet lines and the remainder of the hydraulic connections See the hydraulic schematic for hydraulic connections 65 Attach the rigid sling to the rigid sling hanger weldments using two rigid sling pins PN 1053 C 1C Secure each pin with two 0 148 X 2 938 hitch pins 66 Install grease fittings i Install one 1 4 straight thread grease fitting PN 02 0097 into the top side of each support roller shaft including the door pivot rollers 10 locations total i Install one 1 4 straight thread grease fitting PN 02 0097 into the top side of the latch adjustment iit Install one 1 8 NPT grease fitting PN 02 0005 into the top of each idler shaft or half shaft four locations total iv Install one 1 8 NPT grease fitting PN 02 0005 into the end of the clutch shaft in the centre of the clutch bearing cap v Install two 1 8 NPT 90 grease fittings PN 02 0093 in each pinion bearing cap four locations total vi Install two 1 8 NPT 90 grease fittings PN 02 0093 in clutch bearing cap two locations total vil Install one 1 8 NPT 90 grease fitting PN 02 0093 in the top of the motor mount Install 1 8 NPT grease fitting PN 02 0005 into each cam follower in the top and bottom cage plates 26 locations total 67 When installing the load cell and load cell tie off use LC anchor tie off bolt assembly PN 101 0078 consisting of heavy hex bolt modified PN 101 0040
24. Load bearing devices shall be protected from snagging and shall not be further obstructed by any object e Suspended loads shall be kept clear of all obstruction All employees shall be kept clear of loads about to be lifted and of suspended loads Hands or fingers shall not be placed between the sling its load while the sling is being tightened around the load Shock loading is prohibited Do not stand directly under a load during lifting 3 Storage Of Load Bearing Devices Proper storage of out of service load bearing devices is important to ensure full integrity of the device once it is returned to service Farr recommends observing the following practices e Wipe off all excess grease Use a solvent based cleaner on rags to wipe all external surfaces to remove residual grease or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove residual solvent e Farr recommends that an anti corrosive agent such as Tectyl8 506 be applied to all external surfaces Refer to manufac turer data sheets for proper application and safety information Allow the anti corrosive coating ample time to dry refer to manufacturer data sheets for drying times at room temperature e Store in a clean dry location When returning to service note that a full inspection of the device must be performed DRILLING amp TECHNICAL MANUAL 23 MOVING GLOBAL ENERGY FORWAR
25. MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K 1 3 Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have E visible signs of wear from contact with a rigid object 14 Perform a complete greasing of the tong refer to Maintenance section of technical manual 1 5 Ensure supply and return connections to the tong are fully made up Re connect remainder of the hydraulic lines if applicable the electrical line to the turns counter FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE If using a stand alone power unit start it now refer to the power unit technical manual for startup procedures Listen to power unit for a moment to see if there are any unusual mechanical sounds rubbing grinding excessive pump noise If using a diesel unit allow sufficient time for the engine to reach operating temperature before increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 1 6 Ensure that supply pressure is at or above the tong s specified operating pressure and that return pressure is less i than 350 psi 1 f Perform a visual inspection of pressurized hydraulic lines Document and correct any hydraulic fluid leaks 1 8 Perform full functional test
26. Paral Sealing Foca Includes and regir ers Not naquunsd Sections MOVING GLOBAL ENERGY FORWARD 7 22 TECHNICAL MANUAL SECTION CONTENTS VALVE INFORMATION KT5500 5 18 7K Spring Centered and Detent Spool Operators 14 Stripper Bott 1 391 1432 022 15 Cantering Spring 1 391 3581 608 16 5pring Guides 2 391 16424 5 17 Datent Sienve 1 391 3283 015 18 Detent Balts 2 391 0282 010 19 Detent Spring 391 3581 130 20 Detent Poppat Retainer 381 2583 008 217 Detent Spacer 1 DTE TEMPI AACCCODY MOVING GLOBAL ENERGY FORWARD see Figure 2 391 1432 021 391 3581 633 301 1642 013 391 3283 008 391 0282 0099 391 3581 015 381 2583 006 381 1402 452 391 3581 330 391 1642 151 381 3384 310 391 0282 01 1 391 3581 316 391 3384 371 191 3782 208 TECHNICAL MANUAL SECTION CONTENTS 7 23 5500 5 1 18 7K VALVE INFORMATION Valve Disassembly Instructions Reference exploded view and parts list un CY page 2 amd 3 for work section detail _ 0 4 4 Step 1 Valve Bank Thes seep 15 the ereat ie the disussemblv pasadis N be Ba icit ein arm sabre bank properiv reassembled alter repairs weer made Wph s quick airvinjt m rker mark cas hrsg wiih nember Sari ty marking thc m
27. can Da Seg DH Dr tandem and wei peni m Aden citei ODE Theta Tg mum Peers ie Can Is ida Parallel Circuits Farid zin tus rece caymma cs GOLA f Wo ge mote abeimipg al ffe suma hada ha lice Wrba by fei Arr BEAT cl hg soocs reme cr Au ius hey of ch Ihre open oinin pass and DAR Da Ua a0 ef uid HYDRAULIC VALVE INFORMATION Tandem Circuils preme nr sm marcan img seciinns demi Her CU passage ade cee Dui Ta mium Pages deectes nr he ren AUT Lancome ron a losen oy prr ars e ewe in erg ong re Daria Ae ER er rema E En rant Typical Work Section Schematics NT P RCM S 42 Cylinder OLA Cylinder Parallel fandem DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL SECTION CONTENTS 7 20 VALVE INFORMATION 5500 5 18 7K VA VG Valve Service Instructions INTRODUCTION
28. 6 Tighten all seal plate bolts 1 Reverse the procedures Steps 17 16 15 and 14 2 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 1 Install dowel pins into rear housing 2 Install ballchecks into rear housings 3 Install main body o ring 1 Place rotor stator cartridge onto rear housing 2 NOTE Make sure assembly marks from step 3 are lined up Press shaft and bearing assembly into front housing by pressing on the outer race of bearing 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 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 DRILLING amp 7 14 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor INFORMATION 5500 5 17 18 7K WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 1 Install dowel pins into rotor stat
29. AND POWER 11 5 CID TORQUE ft Ibf ze 700 500 RPM 200 A 100 RPM c PRESSURE psid ACTUAL FLOW 11 5 CID FLOW gpm 400 RPM a 300 100 1500 2000 PRESSURE psid ACTUAL FLOW 15 CID FLOW gpm PRESSURE psid 2000 PRESSURE psid The above performance data was obtained at 140 F with ISO 46 DTE 25 These values must be maintained to obtain the performance indicated Contact Rineer Hydraulics Inc for additional displacements 7 6 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS HYDRAULIC Motor INFORMATION KT5500 5 1 18 7K Model Code M015 61 62 15 015 31 1 TV 000 Special Code Designator Seal Package Selection Bearing Package Selection M015 61 015 Single Speed M015 62 015 Two Speed Options 62 Two Speed Single Pilot 30 Keyed Shaft 31 Splined Shaft 32 Wheel Motor 006 6 in 98cc rev 010 10 5 in 172cc rev 34 Double Key 007 7 ins 1 15cc rev 011 11 5 113 189cc rev 50 Retractable 1S Std 008 8 in3 131cc rev 013 13 in3 213cc rev 53 API Thread 1H High Speed 009 9 5 in 156cc rev 015 15 18 246 Open During Cross
30. Inspect the jaw roller pins for signs of damage replace pins if necessary If the pins are welded T in place replace the entire jaw assembly Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely Check to ensure the size of the loaded jaws match the size of casing or pipe you are running Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal 8 replace damaged part s before placing tong service Also inspect all chains master links and turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service 9 Inspect tong signs of premature wear or moving parts that are rubbing bare metal where there used to be is good indication of wear 10 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the 7 7 brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands 1 2 Perform visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued have visible signs of wear from contact with a rigid object DRILLING amp 320 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS
31. PLACES EE EM SAE 14T 12 24 OPTIONAL SHAFT FLAT ROOT SIDE FIT INVOLUTE SPLINE LI REAR VIEW TECHNICAL MANUAL SECTION CONTENTS 7 3 KT5500 5 1 18 7K Technical Information All Styles VANE CROSSING VANE The Rineer patented vane crossing vane design produces much higher volumetric and mechanical efficiencies than 15 possible with a standard vane type design This design provides a sealing vane between cavities to improve mechanical and volumetric efficiencies STARTING AND STALL TORQUE The Rineer motor produces torque curves which are virtually flat with starting and stall torque equal to approximately 90 94 of theoretical torque MORE POWER STROKES PER REVOLUTION The 15 Series has four stator cavities and 10 rotor vanes Each rotor vane works in each stator cavity once per revolution which results in 40 power strokes per revolution This helps produce higher mechanical efficiency and flatter torque curves BEARING LOADING The bearings in the 15 Series can accept radial load per the radial capacity chart Thrust load is not recommended under most conditions Consult with a Rineer Application Engineer for optional bearing configurations to match your application SEALS Buna N seals are supplied as standard on the Rineer 15 series motors Viton seals may be ordered as an option ROTATING GROUP 15 or 1H Under most operating conditions 15 standard rotating group parts should be used Under some high
32. Rotary IpLER ASSEMBLY 5500 5 1 18 7K 8 fa osm D at ler Bearing Spacer 2 ooroo _ 000 _ 2 jaw _ 3 Cd rw poe DRILLING amp AACCCON COMPLETIONS TECHNICAL MANUAL 57 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Pinion IDLER ASSEMBLY DRILLING amp 58 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Pinion IDLER ASSEMBLY KT5500 5 1 18 7K tem Type Description Pt Nr _ _ er ear Le meten e pre i pue Part _ 5 8 UNC x 2 1 4 Hex Bolt DRILLING amp AACCCOY COMPLETIONS TECHNICAL MANUAL 59 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Pinion ASSEMBLY DRILLING amp 510 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Pinion ASSEMBLY KT5500 5 1 18 7K Type Description 4 Grease Faing 1 NPTx90 Degree a _ _ 8 0 G moam Prion Bearing e Pion ter Bearing z eor iwem 171 994588 _ _ en ear rr High 1 DRILLING amp AACCCON COMPLETIO
33. SUPPLIED BY FARR Rotate the gear train by hand and use a flashlight to perform a visual inspection of the gear train through the access 1 3 C panel and the opening of the rotary gear while the gear train is being rotated If gear damage or chips of metal are seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is complete Inspect all jaws and dies in use for the maintenance interval Inspect the jaw roller pins for signs of damage replace 14 pins if necessary If the pins are welded in place remove and quarantine the jaw until the weld is repaired Ensure dies are secure in the jaw replace worn dies if necessary Ensure that the jaw rollers rotate freely 15 Inspect backing pin s If cracked broken or bent it they must be replaced Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the 7 6 brake band tension is not evenly adjusted Refer to the maintenance section of the manual for instructions on properly adjusting brake bands 1 7 Inspect door springs Ensure the springs retain sufficient strength to be able to assist the opening the door and to keep the door open The springs should also help to snap the door shut Inspect backup springs if applicable The rear extension springs should be equally extended and the front leg springs 1 8 should be equally compresse
34. 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 Position the tong body gear case on a Suitable stationary support such that the bottom body plate is accessible 2 Assemble ten support roller dumbbell assemblies Insert an inner support roller spacer PN 1064 183 into each dumbbell support roller PN 1064 181 Press support roller bearing PN 02 0099 into each end of the dumbbell rollers Slide a support roller bearing spacer PN 1064 182 over each support roller shaft 5 x PN 101 3942 4 x PN 101 3944 1 x PN 101 3943 Insert a support roller shaft through completely through each dumbbell assembly 3 Place four support roller assemblies along one side of the cage plate opening 4 Install rotary gear PN 1064 D1 making sure the backing pin slots are on the side facing up Ensure one side is sup ported by the support rollers installed in Step 3 and the opening in the rotary gear is oriented toward an open support roller space as shown in the following illustration 312 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Mechanical Assembly Procedure Continued 5 Install support roller assemblies in the locations exposed by the opening in the rotary gear Continue to rotate the r
35. discretion of neper uan Following Substantial YES YES YES T Repair or Alteration 1 Lifting test as per S 7 3 BS EN 12079 or DNV 2 7 1 May 1995 T Proof Test non destructive examination VN non destructive examination and visual examination V visual examination Dependant upon whether non destructive examination has been carried out For the purposes of this standard a substantial repair or modification is defined as any repair and or modification that has been carried out which may in the opinion of the inspection body affect the load bearing elements of the container or lifting device or elements that contribute directly to its structural integrity IF MECHANICAL DAMAGE IS SEEN OR SUSPECTED ON A LOAD BEARING DEVICE OR IF THE LOAD BEARING DEVICE HAS BEEN OVERLOADED IT MUST BE REMOVED FROM SERVICE AND QUARANTINED UNTIL RECERTIFIED Written records of the most recent periodic inspection shall be maintained and shall include the condition of the sling 2 Proper Use Of Load Bearing Devices Whenever any load bearing device is used the following practices shall be observed Load bearing devices that are damaged or defective shall not be used Slings shall not be shortened with knots or bolts or other makeshift devices e Sling legs shall not be kinked e Load bearing devices shall not be loaded in excess of their rated capacities e Slings shall be securely attached to their load
36. ensure that the motor gear is securely attached to the motor shaft 9 Remove the cotter pin and clevis pin connecting the shifter handle to the shifter shaft it is not necessary to disconnect the handle from the pivot lug weldment 10 Unbolt the pivot lug weldment from the top plate and remove the pivot lug and handle assembly 11 Remove the four hex socket head cap screws securing the motor mount to the top plate Use care not to dislodge and lose the two positioning dowels 12 Remove the snap ring securing the drive gear to the top of the clutch shaft Carefully remove the drive gear from the clutch shaft 13 Remove the two 10 24 x 3 4 hex socket head cap screws securing the top clutch bearing retainer to the top plate DRILLING amp AACCCOY TECHNICAL MANUAL 39 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K REMOVAL PLATE 14 Remove the top clutch bearing retainer and bearing retainer spacer The top clutch bearing and clutch bearing bushing may come off with the bearing retainer 15 Pull the top bearing cap and spacer for the pinion drive gear by removing the four 1 2 bolts which secure the bearing cap Thread two of the removed bolts into the extra holes on top of the bearing cap and use them as lifting lugs to lift the bearing cap out of place IF THE BEARING REMAINS ATTACHED TO THE GEAR SHAFT AFTER THE BEARING CAP IS PULLED MCCOY DRILLING am
37. from service until it can be properly repaired or replaced Removal A load bearing device shall be removed from service if conditions such as the following are present Missing or illegible sling identification Cracks or breaks Evidence of tampering is seen sling tag has been modified or obscured or tamper proof nuts are missing Signs of impact on load bearing components including spreader bars lifting lugs rigid slings amp rigid sling weldments and legs amp leg mounts Broken or damaged welds Excessive wear nicks or gouges Refer to the chart below to ensure minimum thickness on chain links supplied is not be below the values listed Refer ASME B30 9 Stretched bent twisted or deformed chain links or components Evidence of heat damage Excessive pitting or corrosion Lack of ability of chain or components to hinge articulate freely Weld splatter For hooks removal criteria as stated in ASME B30 10 Other conditions including visible damage that cause doubt as to the continued use of the sling Inspect all lugs and fixing points for signs of elongation and or bending or for material build up around the hole Repair or replace components that appear distorted Ensure all hardware is tight and in good condition Replace missing hardware if necessary All hardware must be free of rust and corrosion Additional inspections shall be performed during sling use where serv
38. housing These ane referred to as hr boy sechons Those witliaut work pon oplians can usc the low profile castings which are called lo boy sections MOVING GLOBAL ENERGY FORWARD REPLACEMENT PARTS The illustrations and instructions in this manual apply to the series assemblies subassemblies and components valve components except for spools and housangs are available as replacement parts or subassemblies Spools are hoae fitted to their housings so d mage o either of these components means tlie entire section must be replaced We recommend that you use only genuine series replacement parts in your sereice program Manufactured to the same exaeting tolerances and corrals as the anginal equipment genuine replacement parts may help prevent premalure compon m ailure and costhy downtime Service parts and assemblies are available through your anginal equipment dealer or any authorized distributor MAINTENANCE Valves are offen used hazardous environimenis Inspect them requemly for dimage due lo improper usc eornosron or nomal wear If needed repairs should be made immediately Always refer to the machine manual for the proper procedure to remove the valve from machine Remove the valve hank from the equipment disco necing all hoses filings control handles and Imkag connectors hal be attached to the valv
39. narrow flat washer 58 If your tong is equipped with the safety door option it may now be installed See 7 32 7 33 using the following procedure i Attach safety door latch block PN 101 1103 to safety door latch plate 101 1105 using three 3 8 NC x 7 8 flat head countersunk cap screws i Place safety door latch plate PN 101 1105 onto the bottom plate of the safety door guard weldment PN 101 1481 and align the bolt holes Secure to the top plate using three 3 8 NC x 2 1 4 hex bolts and lock washers ili Attach the safety door latch block PN 101 0914 to the top of the door plate using two 3 8 NC x 1 1 2 hex bolts and lock washers and two 3 8 NC x 1 1 2 flat head countersunk cap screws iv Attach safety door latch block PN 101 1104 to the safety door latch block installed in step 42 iii using four 3 8 NC x 7 8 hex cap screws and lock washers Insert load plunger PN AE12 306 into LH safety door latch block vi Attach three 1 4 NPT JIC elbows to the Deltrol safety door valve PN 08 0337M Position a 15 16 valve lock nut as shown below and secure the safety door valve to the safety door latch block using the valve lock nut see illustration below vil Attach the safety door switch guard plate PN 101 1480 to the safety door switch guard weldment using three 3 8 NC x 8 4 hex bolts and lock washers 59 Thread door cylinder mounting post PN 1050 12 001 into top plate just adjac
40. nuts with the exception of the two shafts directly behind the brake band lug weldments These two shafts will serve as leg mounts in a future step Backup Ready Tongs Models 80 0420 3 80 0420 9 80 0420 14 80 0420 15 i Slide a 7 8 narrow flat washer over the remaining short support roller shaft PN 101 3942 and four long support roller shafts PN 101 3944 Insert the short shaft into the support roller assembly directly in front of the RH brake band lug weld ment and insert the four long shafts into the four remaining support roller assemblies two per side directly behind each brake band lug weldment i Secure the bottoms of the short support roller shaft directly in front of the RH brake band lug weldment with 7 8 narrow flat washer and 7 8 UNF thin nylock nut Do not place fasteners on the four long shafts at this time 45 Install thirteen cam followers PN 02 0016 into the bottom cage plate PN 1400 22 Secure each with a 5 8 UNF nylock jam nut 46 Install thirteen cam followers PN 02 0016 into the top cage plate PN 1400 21 Secure each with a 5 8 UNF nylock jam nut 47 Support the bottom cage plate in position beneath the rotary gear ensuring the cam followers are nested within the groove in the rotary gear Place the top cage plate in position over the rotary gear ensuring the cam followers are nested within the groove in the rotary gear 48 Place cage plate spacers PN 1064 38 b
41. ooa _ 1 o 86 WF Hox tg G Fat Carbon Stee Lock Waster 4 09586 _ Wetdment _____________ 10 008 m m DRILLING 8 TECHNICAL MANUAL 5 15 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K 1 PLATE ASSEMBLY DRILLING amp 5 16 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD CAGE PLATE ASSEMBLY KT5500 5 1 18 7K 1 2 UNC x 8 Hex Bolt 1 2 Narrow Flat Washer 1064 D1 A C Backing Pin Spacer Jaw Pivot Bolt 1 2 x 6 Hex Bolt Mem EC DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 517 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K ASSEMBLY DRILLING amp 518 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD ASSEMBLY 5500 5 1 18 7K Em prem Motor amp Motor Mount See Pp 7 26 7 27 LR Pe topper LG r oram LR Pat Baton Pate _ Brake Bana Assonby Seo Pa 720 725 Mem LA DRILLING 8 TECHNICAL MANUAL 519 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K LEG ASSEMBLIES
42. periodically adjusted to continue to provide smooth and efficient jaw cam action If the cage plate turns with the rotary gear the jaws will not cam properly and therefore will not bite on the tubing or casing Tightening the brake band against the cage plates will increase frictional resistance allowing jaws to cam properly and grip the casing Adjust the brake band using the adjustment nut and bolt set as shown in the illustration below Use caution as over tightening will cause excessive wear to the brake bands Brake Band Adjustment Mechanism TOP AND BOTTOM BRAKE BANDS MUST BE ADJUSTED SIMULTANEOUSLY AND EQUALLY 2 Door Latch Adjustment Normal operation of the tong may cause wear of the door latch which will cause the door to develop a loose fit at the latch A latch cam plate is located at the top face of the door The cam plate has eight positioning holes located on a 360 degree bolt circle The latch cam shaft extends down through the door and is secured at the top by 3 8 hex head To make adjust ments in door alignment remove the 3 8 bolt and turn the cam with a wrench When the door has been adequately aligned replace the 3 8 bolt see illustration next page 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
43. place to prevent environmental contamination from residual hydraulic fluid DEPRESSURIZATION PROCEDURE IN PREPARATION FoR STORAGE 1 2 3 4 5 7 8 1 2 3 4 5 6 8 9 10 11 12 3 26 Rotate tong that opening in rotary gear faces gear train towards the rear of the tong Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder if equipped If mounted in a frame retract the float cylin ders if equipped De energize the power unit Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure in the valve and motor Remove the hydraulic SUPPLY line from the equipment Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system Disconnect the hydraulic RETUHN line from the equipment Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSUHE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INDUCED INJURIES Perform an initial wash of tool order to remove majority of dirt and grease build up Ensure adequate ment is in p
44. remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE 15 CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INJURIES 3 Perform an initial wash of the tong in order to remove the majority of dirt and grease build up Ensure adequate contain ment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease 4 Remove the access panel on side of tong directly adjacent to the shifter mechanism Use a flashlight to perform a visual inspection of the gear train through the access panel and the opening of the rotary 5 gear If gear damage or chips of metal seen the tong should be removed service and overhauled to avoid further damage Replace access panel when inspection is complete Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp outlet 6 line supports tong legs shifter handle pivot lugs Tighten or replace loose missing fasteners Farr recommends damaged or missing body parts be repaired or replaced as soon as possible Inspect the jaws and dies
45. speed conditons 1H can be specified ROTATION The 15 Series Motor rotates equally well in either direction and smoothly throughout its entire pressure and speed range Looking into the end of the shaft rotation is clockwise when oil is supplied to port A HORSEPOWER LIMITATION Maximum horsepower limitations may vary with different applications When using the 15 Series Motor above 75 HP consult a Rineer Application Engineer Motor INFORMATION FILTRATION 25 micron minimum FLUID We suggest premium grade fluids containing high quality rust oxidation and foam inhibitors along with anti wear additives For best performance minimum viscosity should be maintained at 100 SSU or higher Fluid temperature should not exceed 180 F Elevated fluid temperature will adversely affect seal life while accelerating oxidation and fluid breakdown Fire resistant fluids may be used with certain limitations Contact Rineer for additional information CASE DRAIN The 15 Series Motor is designed for either internal or external case drain Two case drain ports are supplied When using internal case drain simply plug the two ports When using external case drain use the port at the highest elevation We recommend case drain pressure of 35 PSI or less when using the standard seals CASE DRAIN CIRCULATION Fluid should be circulated through the case when a temperature differential exists between the motor and the system
46. the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 23 need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved DRILLING amp AACCCOY TECHNICAL MANUAL 321 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K J MONTHLY MAINTENANCE CHECKLIST POWER TONG The following maintenance checklist is intended as a guideline rather than a definitive maintenance schedule Your equipment may require more or less maintenance depending upon the frequency of use the percentage of maximum torque that your equipment is routinely subjected to and the field conditions under which your equipment operates Farr recommends that the following inspection and maintenance procedures be performed monthly or in conjunction with your maintenance foreman s experience and best estimate of when your equipment is due for this maintenance 7 Rotate cage plate rotary gear until the opening in rotary gear faces towards the rear of the tong DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON NECTED TO ANY HYDRAULIC POWER SUPPLY FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CON
47. the weight of the tong or simply tied off in the derrick to form a dead line When using a dead line arrangement it is necessary to use a spring hanger assembly see specification page for recommended spring hanger This spring hanger compensates for the downward move ment of the casing as the thread is made up and imparts additional force to the suspension cable a single spring hanger typically applies 420 Ibs 191 kg to the suspension line for every inch of thread made up a double spring hanger typically applies 840 155 382 kg to the suspension line for every inch of thread made up If you do not know which specific spring hanger is in use check the specification page in this manual for information on the recommended spring hanger for this application McCoy Drilling amp Completions will not guarantee or specify spring hangers other than what has been supplied by McCoy Drilling amp Completions Many applications use a lift cylinder for adjusting the height of the tong Ensure the weight of the lift cylinder is known if it has not been included in the total weight of the tong forces upon the suspension line must be considered when calculating necessary strength of the suspension line The weight of the tong the weight of the lift cylinder the weight of the spring hanger and the force imparted on the suspension line by the spring hanger must all be added together in order to arrive at the total force supported b
48. weldment PN 101 0787 to the bottom of the tong over the exposed support roller shafts using 7 8 UNF thin nylock nuts E DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 317 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K Mechanical Assembly Procedure Continued 55 Attach the door latch weldment PN 1064 C7 15 to the door weldment PN 1400 10 using the door latch cam PN 1400 14 ensure that the door latch springs PN 997 16 are installed between the door latch and the door weldment Thread the door latch cam into the door weldment until in bottoms out and then back it off until the first adjustment hole in the latch cam aligns with the threaded hole on the top of the door weldment Secure the latch cam to the door weldment with a 3 8 UNC x 1 hex bolt and 3 8 lock washer 56 Insert the the door pivot shoulder bushings top bushing PN 101 5110 bottom bushing PN 101 5111 in the door weldment note that the bushings are installed from the insides of the door plates 57 Align the door pivot holes with the pivot holes in the top and bottom plates and insert the door pivot roller shaft PN 101 3943 it may have to be tapped lightly with a soft metal or rubber hammer Use caution when sliding the shaft through the support roller components Once the shaft has been tapped all the way through secure the bottom of the shaft with a 7 8 UNF thin nylock nut and 7 8
49. 1 1 4 NC heavy hex nut and 0 148 x 2 938 hitch pin DRILLING amp TECHNICAL MANUAL 3 19 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K I DAILY INSPECTION amp MAINTENANCE CHECKLIST POWER Farr recommends that the following inspection and maintenance procedures be performed before each use and at least once per day when the tong is in steady use in the order in which they are listed 7 Rotate cage plate rotary gear until the opening in rotary gear faces towards the rear of the tong DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON NECTED TO ANY HYDRAULIC POWER SUPPLY FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMI NATION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HyDRAULIC SYSTEM IN PREPARATION FOR MAINTENANCE Rotate the tong to the open throat position Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure 2 in the valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers INBOTH DIRECTIONS to dissipate any residual pressure in the
50. 7 E Part O Ring 1 02 0350 F Part O Ring 1 08 0596 G Part Load Cell Piston 1 1 99 101 H Part Load Cell End 1 LC99 003 J Part Flange Gasket 1 02 0073 K Part Load Cell Rod 1 1 99 002 L Part Wiper 1 08 1558 M Part 3 8 NC x 3 8 Cup Point Hex Set Screw 2 09 0106 Seal Kit Replacement Seal Kit 4 08 in Tension Load Cell 02 4578 TENSION Loap CELL EXPLODED MOVING GLOBAL ENERGY FORWARD 5500 5 17 18 7K This is the standard tension load cell sup plied by McCoy Drilling amp Completions Farr Contact our sales department for information about optional application specific tension load cells TECHNICAL MANUAL Section CONTENTS 63 5500 5 1 18 7K TORQUE MEASUREMENT This is the standard hydraulic com Description Qty Part Number 4 Assembly Compression Load Cell 8 in 1 10 0008C 522 p gs 2 5 16 UNC x 1 Hex Socket Head Screw 1 09 2026 our sales department for information B Part Load Plate 1 E360 A about optional application specific 5 16 UNC x 3 4 Hex Socket Head Cap Screw 6 09 2024 compression load cells D Part Retainer Ring 1 E360 8 Electronic compression load cells are E Part Diaphragm 1 E358 2 used for some WinCatt applications F Part Diaphragm Casing 1 E360 C G Part Street Elbow 1 H Part 1 4 NPT Brass Plug 1 COMPRESSION Loap CELL EXPLODED DRILLING amp 64
51. AD CELL AND TORQUE GAUGE MUST BE RETURNED TO THE FACTORY FOR RE CALIBRATION BEFORE PLACED INTO SERVICE DRILLING amp TECHNICAL MANUAL 61 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K MEASUREMENT BASIC TORQUE MEASUREMENT Continued The images on the preceding page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supplied with your equipment Please note that the parts listed in the following table are correct for accurate torque measurement while using the equipment for which this manual is supplied THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE THE PART NUMBERS LISTED IN THE FOLLOWING TABLE ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED Part Number Assembly 36 Arm 20K Tension Load Cell and Gauge 10 0033T 10 0033G Torque Gauge 20 000 Ft Lbs 36 Arm 02 0069 Hydraulic Hose 62 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD ToRQUE MEASUREMENT Description Qty Part Number Assembly Tension Load Cell 4 08 in 1 10 0008T A Part O Ring 1 02 0800 B Part Load Cell Body 1 LC99 104 1 4 x 1 2 Binding Head Machine Screw 1 09 0045A D Part Stat O Seal 1 02 030
52. AT SPECIFIED TORQUE A CLOSED DOOR ALSO ENSURES SAFETY OF OPERATING PERSONNEL DRILLING amp COMPLETIONS TECHNICAL MANUAL 37 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K Door Latch Adjustment Continued x _ E LE P 4 D Latch Adjustment Cam 3 Shifter Detent Force Adjustment Over time wear to the shifting shaft wear to the detent ball and loss of spring tension in the detent spring may result in a loose or sloppy fit within the top shifter bushing The detent pressure may be increased or otherwise adjusted by loosening the 7 16 UNF locking jam nut and turning the 7 16 UNF detent bolt Should adequate detent action not be achieved the shifting shaft detent ball or detent spring or possibly all three may need to be replaced see Pp 5 16 5 17 DRILLING amp 38 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K RECOMMENDED PERIODIC CHECKS 7 Door Stop Spring The spring inside the actuator cylinder must be of sufficient strength to enable the door latch mechanism to snap closed prop erly and to hold the door in the open position when opened Door stop spring fatigue will result in sluggish latch operation Replace the latch spring i
53. BAL ENERGY FORWARD KT5500 5 18 7K TROUBLESHOOTING C TONG RUNNING TOO SLOWLY 1 POSSIBLE PROBLEM Obstruction in tong hydraulic circuit preventing adequate flow SOLUTION Inspect self sealing couplings to ensure they are properly engaged SOLUTION The main hydraulic lines supply and discharge to the tong are obstructed Remove and clean if required 2 POSSIBLE PROBLEM Power unit is not producing adequate flow or pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit 3 POSSIBLE PROBLEM Tong motor is excessively worn and is leaking hydraulic fluid past the vanes SOLUTION Replace motor or rebuild as per Section 7 of this manual 4 POSSIBLE PROBLEM Bearings in gear train and rotary section are excessively worn SOLUTION Overhaul tong See Section 3 of this manual for tong overhaul procedures 5 POSSIBLE PROBLEM Shifter has malfunctioned and the tong is not shifting to high gear SOLUTION Inspect and repair shift mechanism as necessary 6 POSSIBLE PROBLEM Two speed hydraulic motor if equipped is not set to correct speed SOLUTION Check motor and set to the correct speed if required 7 POSSIBLE PROBLEM Safety door system is not properly adjusted hydraulic fluid leak past Deltrol valve SOLUTION Check and adjust safety door system 8 POSSIBLE PROBLEM Hydraulic fluid viscosity too high SOLUTION Ensure hyaraulic fluid meets McCoy Drilling amp Completions spec
54. CCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K M TUBULAR CONNECTION EQUIPMENT RE COMMISSIONING PROCEDURE Perform the following recommissioning procedures when removing tubular connection equipment from short or long term storage back into regular service These procedures are essential for ensuring proper equipment preparation and operation The following procedures also assume that the decommissioning and storage procedures recommended by Farr have been strictly observed 1 Remove all protective plastic wrapping If there are desiccant packs with the assembly they may be disposed of with regular garbage 2 Remove the access panel on side of tong directly adjacent to the shifter mechanism 3 Wipe excess grease or heavy oil from exposed cylinder rods If applicable re connect chain sling to lifting lugs Perform a visual inspection of all lifting points if visible damage is seen including cracks broken lugs distorted metal etc replace damaged part s before placing tong in service Also inspect 4 chains master links and turnbuckles again if any damage is noted replace damaged part s before placing the tong in service If your company requires yearly certification of lifting equipment ensure that the most recent test date falls within the past year Perform recertification if necessary Perform a liberal lubrication of the equ
55. D 5500 5 1 18 7K MAJOR COMPONENT IDENTIFICATION SETUP amp OPERATION 24 SECTION CONTENTS 1 Master Lifting Link 2 Rigid Sling 3 Tong Leveling Adjustment 4 Safety Door Switch amp Guard Assembly 5 Tong Door Latch 6 Torque Gauge Mounting Plate 7 Manual Shift Assembly 8 Backing Pin Assembly 9 Cage Plate Assembly 10 Tong Door Cylinder 11 Tong Door TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS SETUP amp OPERATION KT5500 5 18 7K 12 Hydraulic Valve Bank Assembly 13 Hydraulic Motor 14 Motor Mount 15 Hydraulic Inlet 16 Hydraulic Outlet DRILLING amp COMPLETIONS TECHNICAL MANUAL 25 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K 2 6 SECTION CONTENTS Description Brake Band Adjustment Tong Jaws with Die Inserts Safety Door Valve Block Access Panel Brake Band TECHNICAL MANUAL SETUP amp OPERATION MOVING GLOBAL ENERGY FORWARD DRILLING amp COMPLETIONS 5500 5 17 18 7K SETUP amp OPERATION C HYDRAULIC SCHEMATIC COMPONENT IDENTIFICATION Your tong may be equipped with one or two control valves as well as safety door switch and hydraulics depending upon the specific model Disregard the control valves indicated on th
56. ENTS CHAIN SLINGS RIGID SLINGS LEGS MUST BE TIGHTENED TO THE PROPER TORQUE REMOVAL OF TOP PLATE 1 Remove the rigid sling assembly by disconnecting the leveling devices from the hanger brackets 2 Remove the two rigid sling hanger brackets 3 Disconnect the three hydraulic connections from the motor Undo the restraints securing the inlet and outlet lines from their supports and lift the hydraulic valve section away from the tong Remove the inlet and outlet support pieces 4 Remove top brake band assembly leave adjustment lug weldments in place for now 5 Remove the tong door stop cylinder 6 Remove door assembly by removing the door roller shaft Support door assembly as the roller shaft is removed Remove the nut from the top of the roller shaft and use a soft alloy material e g brass rod etc to lightly tap the shaft down through the support roller assembly until it comes free at the bottom Use caution that the threads on the ends of the support roller shafts are not damaged Do not lose the door shoulder bushings Remove the hitch pin securing the torque gauge holder to the torque gauge mount weldment and remove the mount Remove the four hex socket head cap screws securing the motor and the torque gauge mount weldment Remove the torque gauge mount weldment then lift the motor up and away from the motor mount Inspect the motor gear located at the bottom of the motor shaft for gear clashing or tooth damage Also
57. ERIES WORK SECTIONS SPL TION INLETS 391 1971 041 WORK SECTION REPAIR KIT 5 MANTAL PARALLEL AND 391 1902 722 TANDEM WORK SECTIONS 39 103 2i WORK SECTION REPAIR KiT ALL SEALSI MA NUAL SERIES WORK SECTION j91 i2 146 WORK SECTION REPAIR KIT ALL SEALS REMOTE PARALLEL AND TANDEM WORKSECTIONS 1873 444 RELIEF VALVE SEAL KIT 39 1873 043 355 9107 013 39 803 277 ALL SERVICEALLE SEALS 39 NTA 4 355 9107 045 191 1873 117 155 9107 385 191 1503 MAIS RELIEF VALVE SEAT KIT A 1871 005 CONVERTIBLE OUTLET PLUG SEAL KIT 301 003 041 SCREW ADIUSTELD PILOT OPERATED 301 1873 006 454 900 115 39 1803 717 PORT RELIET VALVE WITH ANTI CAVITATION SEAL KIT ALL SERVICEADLE SEALS 391 1223 00 PORT ACCESSORY SEAL KIT 391 1873 086 155 9001115 EXTERNAL SEALS ONLY 391 1 amp 73 007 DUO 145 GOON 143 355 900 1644 MI 1871 011 19 228310735 391 873 017 SLUC ADIUSTED RELIEF VALVE RIT 191 873 07 009 S90 RSS 127 ALL SERVICE ABLE SEALS AET I 43 191 X73 207 PREUMATIC ENDC Af SEAL AG 4373 243 104 1503 34 1805 387 COMMERCIAL PNTERTECH DESIGN 1803 695 PROUEMATIC EXDC ARP SEAL KIT 191 1873 243 391 7 DESIGN Fay 4RZY T WORK SECTION REFAIR KIT SERIES WORK SECTIONS ALL SEALS DRILLING amp AACCCNY COMPLETIONS TECHNICAL MANUAL 7 33 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K
58. IED 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 amp COMPLETIONS MCCOY DRILLING amp COMPLETIONS DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD BEARING DEVICES UNLESS THOSE MODIFICATIONS ARE PERFORMED BY MCCOY DRILLING amp COMPLETIONS McCoy Drilling amp Completions recommends following an industry accepted standard such as OSHA ASME B30 9 2006 or manu facturer s guidelines when performing any rigging and overhead lifting Use by untrained persons is hazardous Improper use will result in serious injury or death Do not exceed rated capacity Slings will fail if damaged abused misused overused or improperly maintained Only grade 80 or grade 100 alloy chain should be used for overhead lifting applications Working Load Limit WLL is the maximum allowable load in pounds which may be applied to the load bearing device when the device is new or in as new condition and when the load is uniformly and directly applied The WLL must never be exceeded Working Load Limit WLL is the maximum working load for a specific minimum sling angle measured from the horizontal plane The Working Load Limit is identified on the sling The Wo
59. ILLING amp TECHNICAL MANUAL Vii MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K Summary Of Revisions Continued Date Section Page Description Of Revision 5 529 Corrected all erroneous references in B O M idi 5 528 529 Replaced door bushings with new parts Fons Corrected torque and flow rates Corrected list of available jaw dies DRILLING amp Mil SEcTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS m MOVING GLOBAL ENERGY FORWARD TABLE OF CONTENTS KT5500 5 1 18 7K UON m P Section 1 introduci n and Corporate eed Doe ies adem 1 1 01010 RETINET 1 2 ODE TNR 1 4 Setup amp Section Two Sling Load Bearing Device Safety 2 1 Major Component 2 4 Hydraulic Schematic Hydraulic Valve Identification essen 27 Hydraul CONRCCHONS ATE OE E EE AAEE _ ___ E EA EE iS 2 11 Tong Jaw Availability amp 88 2 12 Tong Rig Up Leveling 1 Suspension amp Loa
60. ION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SPECIFICATIONS KT5500 5 1 18 7K Torque Table Single Speed Motor High Gear Low Gear Torque Table Two Speed Motor Pressure Gear Displacement Lbs Ft PSI MPa Low Full 1000 6 89 7400 1400 9 66 11000 1800 12 41 14600 2250 15 51 18700 MAXIMUM RATED TORQUE 18700 LBS FT 25354 Nm Speed Table Single Speed Motor Speed Table Two Speed Motor 227 Gear Displacement RPM These are ideal values Actual achieved torque is highly dependant upon tong efficiency final posi tion of rotary gear when full torque load 15 reached and the motor with which the tong 15 equipped Maximum Hydraulic Requirements 60 US GPM 227 1 LPM Required to achieve maximum rated speed 2500 PSI 17 2 KPa Required to achieve maximum rated torque Note Maximum torque is only available in low gear at full motor displacement Length Doors Closed 52 inches 132 1 cm Height 33 1 4 84 5 cm Width 25 1 2 inches 64 8 cm Weight Approximate 1250 Ib 568 2 kg Space Required on Pipe 6 3 4 17 1 Maximum Elevator Diameter N A Torque Arm Length 36 inches 91 4 cm Centre line of pipe to centre line of anchor Casing Jaws Available inches See Pg 2 12 Recommended Spring Hanger 85 0106 DRILLING amp TECHNICAL MANUAL 13 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K
61. K VALVE INFORMATION Doubie Acting Sector 4 S Poation Fipal in Motor Spoo DAS Double Acting Section 4 3 Position Hold in Se Sector ne teen yee in DRILLING amp 7 18 SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K VALVE INFORMATION Lo Boy Work Sections Parallel Circuits r LL a ee z z _ A EHE ii 7 19 QO z O TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Brief Circuit Descriptions Series Circull Av aaabie us OV AG sarzena oniy P a pem Te 24 operon c WT Eu hya Nuno 8 nem cra ho ma Hr wii canum pues Tous Bm mn cafum Tun ies Pic cele ui nd ir reri leur mus opea pa pO 5 ud Fe mdi bom ine Eri Mad Pack quio iom tacens cand nir
62. N KT5500 5 1 18 7K Valve Disassembly Instructions 9 Step 4 Valve Back a large remimve me sx pow Frs 1 der 4 Taster Dec beer pap ihe work scelus Lightls tap end nf the serewdnver Rundle wih 5ammer r freak adlecive Remote The back cap T item 5 Step 5 Control Spool and Seals rre lve spemg end of e spool wtf a clean art free and pall the insi of the uxing 3 iin ly ide rear render plas Fig hac k up pig Lu H wall came woth spool CAUTION For detenled spool models be careful nol to remove he deteni pappet sleeve Fig 2 Hem 17 unless It 14 to be servicad a ange Phillipe head remove me two rebaimessplaie screws Pig 1 serm front the sposi clang eu af the werk Laghily mp the end al screw iriver handie s rs to break uve Kamove ifie iwo phaina pales 1 fr inue mig 7 and die poi ual aom Vase r mani with fhe werk secius niamba See Step D 5 poot scd Faq 1 aper amd ganas Fas 7 LEE Step 6 Transition Check he ination check ui Located in tne center
63. NS TECHNICAL MANUAL SIL MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K CLUTCH ASSEMBLY DRILLING amp 512 Bea ena TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD CLUTCH ASSEMBLY KT5500 5 17 18 7K Type Pa Nr at r orea _ D Fat Top Bearg Reamer DITE _ Fat Top Bearing Retainer Spacer roosa at Cuch Bearing Busting G Fat oeoo Tw at Cuen Bearing eon Fat Cuch Bearg Cao soar Fat own amp engtm oroma _ Fat carbon Steel Lock Waster 4 09586 _ z Z DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 513 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K SHIFTER ASSEMBLY DRILLING amp 514 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD SHIFTER ASSEMBLY KT5500 5 1 18 7K Type meno Pa Nr 4 Wetiment orom Fat sex 12 ANSIASME 861 Cous m 2 5 fm Je D Fa MOT at far Shiner Detent al _ Shiter Detent Spmg 87094 H Fa memen 3 58 nme _
64. PLETIONS TECHNICAL MANUAL 29 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K SETUP amp OPERATION DRILLING amp 210 TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT5500 5 18 7K D HYDRAULIC CONNECTIONS A pair of hydraulic lines a 1 supply line and a 1 1 4 return line connect the tong to the power unit see illustration below Ancillary devices hydraulic motors hydraulic cylinders etc are connected through the valve block Perform any hydraulic connection when the power unit is not running or when the hydraulic pump 15 disengaged The possibility of error in inter changing the high pressure supply hose and the low pressure return hose has been eliminated because the supply side coupling is smaller than the return side Hydraulic Supply 1 Hydraulic Return 1 1 4 These hose couplings are self sealing and care should be taken to ensure complete engagement to prevent partial closure of the check valve in the coupling Ensure that the nut female side is completely made up onto the male connector there is a line on the male fitting that indicates complete make up Snug the female fitting right up to the line Make up female fitting to Marked point on male fitting DRILLING amp NALCO Y TECHNICAL MANUAL 21 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K SETUP amp OPERATION TONG JAW A
65. Problem Solution Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solution Possible Problem Solution Possible Problem Solution Possible Problem Solution SECTION CONTENTS TORQUE MEASUREMENT IF TROUBLESHOOTING REVEALS THAT THERE 15 INSUFFICIENT FLUID IN THE SYSTEM BEFORE RECHARGING CHECK THAT ALL SYSTEM COMPONENTS ARE FREE FROM DAMAGE THIS WILL ENSURE THAT FLUID LOSS WILL NOT CONTINUE AFTER RELOADING No indication on gauge Obstruction in hydraulic hose Check hydraulic hose for kinks Replace hydraulic hose Loss of hydraulic fluid Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Internal mechanism of torque gauge is damaged Replace gauge Gauge indication unexpectedly high Excessive hydraulic fluid Completely drain hydraulic fluid from torque gauge load cell system Recharge following the procedure in Section 6 C Internal mechanism of gauge is damaged gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication unexpectedly low Insufficient hydraulic fluid Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque g
66. RD 5500 5 1 18 7K SAFETY Door COMPONENTS DRILLING amp 530 SECTION CONTENTS TECHNICAL MANUAL NCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SAFETY COMPONENTS 5500 5 17 18 7K 3 8 x 3 4 Hex Bolt Switch Guard Top Plate 4 NN 7777777 ee Door Laton Block Safety DoorLaton Pato E 28 NC x 1 1 2 Head Countersunk Gap Screw 2 _ Safety DoorLaten lock Fat Gauge __ Watsment Safty Door Swich Guard Weme 7 Head Countersunk Gap Screw 3 2 1 3 1 1 1 1 2 1 1 DRILLING NCCOY COMPLETIONS TECHNICAL MANUAL 5 31 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K SLING A DRILLING amp 5 32 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD SLING KT5500 5 1 18 7K C Weldment 1 5 3 Rigid Sling 1053 C 1C 387 Carbon Seel Lock Washer e fa _ a ey _ 3 8 NC x 1 Hex Bolt 09 1170 rt rt DRILLING amp TECHNICAL MANUAL 5 33 MOVING GLOBAL ENERGY FORWARD This page intentionally l
67. SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD ToRQUE MEASUREMENT 5500 5 17 18 7K 9 VL C Assembly Part Part Part Part Part Part Part Part Part gt Description Standard Turn Counter Encoder Mount 6 32 x 3 8 Hex Socket Head Set Screw Helical Flexible Encoder Shaft Coupling Internal Retainer Ring Bearing Encoder Housing Internal Retainer Ring Encoder Shaft Encoder Gear 10 24 x 1 1 4 Hex Socket Head Set Screw Qty Part Number 1 60 0001 4 1 60 0130N 2 1376 13 2 1376 05 1 1392 104A 1 02 0436 1 1392 103A 01 1 01 0320A M um TuRN ENcopER Mount EXPLODED AACCCOY MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL SECTION CONTENTS 65 KT5500 5 1 18 7K TROUBLESHOOTING Under normal operating conditions and with proper maintenance the torque gauge and load cell system are designed to give lasting trouble free performance Faulty indication on the gauge will very often define a fault within the gauge Symptom Possible Problem Solutions Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solutions Possible Problem Solution Possible Problem Solution Symptom Possible Problem Solution Possible Problem Solutions Possible
68. SED OR MALFUNCTIONING SAFETY DOOR While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 23 need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved 24 When all of the previous steps are completed you may return your re commissioned equipment to service DRILLING amp 330 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING KT5500 5 18 7K Adequate maintenance and proper fluid selection is essential for minimizing hydraulic related failures All troubleshooting must be performed by a technician trained in hydraulic systems and familiar with the equipment design assembly and operation The following troubleshooting instructions are intended to be guidelines only Any faults not solved through the use of this guide should be referred to our engineering department for their evaluation and recommendations A TONG WILL NOT DEVELOP SUFFICIENT TORQUE 1 Malfunctioning relief valve on tong hydraulic circuit a POSSIBLE PROBLEM Relief pressure set too low SOLUTION Increase setting To check block the oil line beyond the relief valve and determine pressure with a gauge b POSSIBLE PROBLEM Relief valve is stuck SOLUTION Check for contamination of oil that may inhibit the way the valve actuates Remove valve and clean ensur ing tha
69. TAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMI NATION FROM RESIDUAL HYDRAULIC FLUID DEPRESSURIZE HYDRAULIC SYSTEM IN PREPARATION FOR MAINTENANCE Rotate the tong to the open throat position Ensure tong and backup doors if equipped are closed Fully extend the lift cylinder 2 De energize the power unit 3 Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure 2 in valve and motor 4 Remove the hydraulic SUPPLY line from the equipment 5 Repeatedly actuate the remaining control valve levers INBOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Disconnect the hydraulic RETURN line from the equipment 8 Disconnect remaining hoses such as case drains or lines connected to the turns counter HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP MENT IS USED TO GUARD AGAINST PRESSURE INJURIES Clean the exterior of the tool thoroughly using either water if using a pressure washer ensure a low pressure wash wand 3 is used an appropriate solvent based cleaner such as Varsol Ensure adequate containment is in place to prevent environmental contamination from residual hydraulic fluid dirty grease and
70. TITE ANY REPLACEMENT FASTENER BOLTS NUTS CAP SCREWS MACHINE SCREWS ETC USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED NAC COY DRILLING amp MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL This page intentionally left blank 5500 5 1 18 7K Copyright 2007 2012 McCoy Corporation including its wholly owned subsidiaries McCoy all rights reserved This document is the property of McCoy and is supplied as reference information for users of our products This document and the contents within are considered confidential information not to be disclosed copied transmitted transcribed in any form or stored on any type of data stor age media without the express written consent of McCoy McCoy has made every effort to ensure the information contained in this document is accurate and current This manual is intended to provide equipment operation and safety instructions for your equipment However McCoy does not warrant or guarantee that the information is either complete or accurate in every respect and the user of the manual should consult with its McCoy sales representa tive for any clarifications and updates The user of the manual shall protect indemnify and hold harmless McCoy and its directors officers employees and agents from and against all liability for personal injury death or property damage resulting directly or indirectly fr
71. VAILABILITY amp INSTALLATION 1 Jaw Availability The following table lists all jaw die kits that are available as standard stocked sizes for this model of tong McCoy Drilling amp Completions Farr offers a good selection of standard jaw sizes However please note that we can custom engineer and manufacture any size of jaw within the range of the tong Jaw systems are available to allow use of die inserts intended for specialized applications Call our sales office for information on jaw and die systems designed for higher or lower grip or non marking applications The table lists standard contoured flat and wraparound die inserts that are available as spare parts However a wide variety of diamond tooth GRITFACE aluminium and wrap around fine tooth dies are available for specialized applications Please refer to our website for complete information http www mccoyglobal com index php dies inserts STANDARD JAW DIE KITS Inserts Not Included Description Part Number 2 3 8 Jaw Die Kit 7 1064 JDK 65 2 7 8 Jaw Die Kit 1064 JDK 70 3 Jaw Die Kit 1064 JDK 71 3 1 2 Jaw Die Kit 1064 JDK 75 4 Jaw Die Kit 1064 JDK 80 4 1 2 Jaw Die Kit 1064 JDK 85 5 Jaw Die Kit 1064 JDK 90 5 1 2 Jaw Die Kit 9 1064 JDK 95 1 Uses 2 375 Contour Die 12 0004 2 Uses 2 875 Contour Die 12 0007 3 Uses 1 x 3 875 Flat Die 12 0006 314 0 All other Standard Die Kits use 1 1 4 x 3 875
72. W A x DRILLING COMPLETIONS TECHNICAL MANUAL 35 MOVING GLOBAL ENERGY FORWARD KT5500 5 17 18 7K 9 Door Latch Apply grease to the door latch through the grease fitting located in the top of the adjustment cam 10 Door Spring Cylinders Periodically disassemble the door stop cylinders and coat the spring and cylinder with a general purpose lubricating oil Recommended lubrication amount at the completion of each job 1 Cage Plate Guide Ring Cam Followers Upper and lower 1 shot grease 2 Rotary Roller Bearings Upper and lower 3 shots grease 3 Rotary Idler Bearings 4 shots grease 4 Pinion Idler Bearings 4 shots grease 5 Pinion Bearings Upper and lower 2 shots grease 6 Clutch Shaft Bearings 1 shot grease 7 Motor Mount Housing 10 shots grease 8 Shifting Shaft as required 9 Door Latch Adjustment Cam 1 shot grease Farr recommends that a liberal coating of grease be applied to the cam surface of the rotary drive gear prior to jaw installa tion Also the clutch inspection plate should periodically be removed and a liberal coating of grease applied to the clutch drive gears and shifting shaft DRILLING amp TECHNICAL MANUAL NEO COMPLETIONS MOVING GLOBAL ENERGY FORWARD 36 SECTION CONTENTS KT5500 5 1 18 7K E ADJUSTMENTS 1 Brake Band Tension Adjustment The top and bottom brake bands must be
73. _ NN 2217 n NS e 2 Made in USA 63 PUBLICATION 05151005 8 03 gii DRILLING COMPLETIONS TECHNICAL MANUAL 71 MOVING GLOBAL ENERGY FORWARD KT5500 5 17 18 7K HYDRAULIC Motor INFORMATION 15 Series Two Speed Weight 51 Ibs All available displacements of standard motor Spool valve shift from full to partial displacement Standard shift ratio is 2 1 Some special ratios available Shift on the run Typical applications winch track and wheel drives Cross Section Two Speed Motor gt DRILLING 8 7 2 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Motor INFORMATION 15 Series Standard Motor Envelope SAE STD 1 25 4 BOLT FLANGE NEAR AND FAR 15 Series Two Speed Envelope 7 80 1 4 O RING BOSS O TIC m SAE STD 1 25 4 BOLT FLANGE NEAR AND FAR SAE 1 4 O RING ALTERNATE BOSS RT 1 1 4 O RING BOSS AACCOY MOVING GLOBAL ENERGY FORWARD 5500 5 18 7K CENTER LINE 3 8 O RING BOSS CASE DRAIN 9 16 DIA 4 HOLES 2 PLACES FT 38 SAE 14T 12 24 PITCH OPTIONAL SHAFT FLAT ROOT SIDE FIT INVOLUTE SPLINE 3 8 O RING Bore 9 16 DIA 4 HOLES CASE DRAIN CENTER LINE 2
74. ______ ____ _ 1 MORBUIC DEG 36 2 029 fm Us _ _ fa E a 2 oroen at HwmuchadeAwdlayPm 1 __ a _ 2 orooro O am 7717 DRILLING amp AACCCODY TECHNICAL MANUAL 5 27 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K Door ASSEMBLY DRILLING amp 528 SECTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD Door ASSEMBLY KT5500 5 1 18 7K Type PatNumbe 4 Fa _ mum _ Aem DoorGyinder _ gt Par ae caton seoa m Weldment Door Weldment 1400 10 3 8 UNC Hex Nut 2 09 5806 Wr H Pat 3E NCxiT2 HexBot 11 091669 0 E I Cen SSS a Pat Deo Busting Botany E persi 3 _ P a 76 Fiat Washer 058 G Pan Door Cylinder Mouning lug i onon R a Thin _ C C Pan 147 sraigh Grease rorshow 1 1020097 5 DRILLING amp AACCCOY TECHNICAL MANUAL 529 MOVING GLOBAL ENERGY FORWA
75. ally until tong hangs level front to back Lock adjusting bolts in place with the jam nuts Loosen 1 2 hex jam nut be fore rotating adjustment bolt AI Y 216 Section CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD SETUP 6 OPERATION 5500 5 1 18 7K G TONG OPERATION 1 Initial Start up and Break in Procedure YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY HOWEVER WE ADVISE INSPECTION AND TESTING OF YOUR NEW TONG AFTER TAKING POSSESSION IN ORDER TO ELIMINATE THE POSSIBILITY OF SHIPPING DAMAGE McCoy Completions amp Drilling recommends that the following pre operating tests be performed after receipt from the factory or after extended storage prior to releasing the tong to operations Perform a complete inspection of all fasteners to ensure none have loosened during transport Connect the tong to the power unit and apply full hydraulic pressure Inspect and correct any leaks Operate the tong at full soeed and in high gear for a duration of one half hour Hot bearing caps may indicate impending bearing failure Switch to low gear and operate for an additional one half hour at full speed Run the backup through several clamp un clamp sequences to ensure functionality Inspect all components and hydraulic fittings for possible defects following completion of the tests All FARR Tongs have been thoroughly tested a
76. are personnel from inadvertently exposing themselves to a hazard Use tape rope or signage to clearly indicate off limits area Replacement of large heavy individual parts and or heavy structural components must be performed using an approved lifting device of sufficient lifting capacity Use care when attaching the lifting device and safeguard area to avoid endangering personnel or equipment All spare parts must meet or exceed OEM specifications in order to maintain equipment integrity especially protective equipment McCoy Drilling amp Completions recommends that disconnection of hydraulic connectors be performed with the power unit off and the hydraulic circuit depressurized Your equipment uses materials that may be harmful to the environment if improperly disposed of hydraulic fluid grease etc Dispose of all materials according to your company s proscribed environmental protection regulations B CLEANING Clean tong thoroughly cleaned with a good petroleum based cleaning agent after each job prior to storage Farr recommends that the motor and valve assembly be periodically removed along with the top tong plate so that guides rollers and gears can be prop erly cleaned Ensure that cleaning solvents and chemicals are captured to prevent environmental contamination and dispose of all materials according to your company s proscribed environmental protection regulations C PREVENTIVE MAINTENANCE PRACTICES Regular main
77. auge are repaired to prevent further fluid loss Obstruction in hydraulic hose Check hyaraulic hose for kinks Replace hydraulic hose Snub line not at right angle to tong handle Check angle of snub line and correct if necessary Internal mechanism of gauge is damaged Replace gauge Incorrect torque gauge in use not part of the original torque gauge load cell pair Replace gauge with gauge properly calibrated for the load cell in service Gauge indication is erratic or sluggish Insufficient hydraulic fluid in torque measurement section Recharge hydraulic fluid see Section 6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Loss of damping fluid in torque gauge Top up or refill damping fluid NOTE Ensure leakage points in gauge are identified and repaired to prevent further loss of damping fluid Air bubbles in hydraulic fluid in the torque measurement system Bleed air from load cell and torque gauge and top up fluid if necessary as per Section 6 C Internal mechanism of gauge is damaged Replace gauge DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL TORQUE MEASUREMENT 5500 5 1 18 7K C PERIODIC INSPECTION AND MAINTENANCE 1 Inspection The torque measurement system supplied with your equipment is designed and built to provide years of trouble free service with minimum mainte
78. cleaning agents 4 Remove the access panel on side of tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment 15 in place to prevent environmental con 5 tamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the gear train cavity if shavings or metal pieces are seen the tong must be overhauled before it is returned to service 6 Inspect fasteners and fastener safety wires if equipped Replace any missing fasteners use Grade 8 bolts only less otherwise specified Re torque all external fasteners to SAE specifications 7 Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Perform a visual inspection of all fasteners and protruding body pieces example hydraulic valve mounts inlet amp outlet 8 line supports tong legs shifter handle pivot lugs Tighten or replace loose or missing fasteners Farr recommends that damaged or missing body parts be repaired or replaced as soon as possible Inspect tong signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is good indication of wear
79. close the Bypass Valve to allow hyaraulic fluid to circulate through the hoses and to the tong circulating pressure should not exceed 200 psi Place the tong gear shifter in low gear and rotate the tong slowly forward and then reverse with the throttle valve control lever Once this has been done and the proper size jaws have been installed the tong is then ready to run pipe Valve Operation 4 way proportional valves control operation of hydraulic devices on the tong assembly such as hydraulic motors and cylinders When any one valve is centered or in the detent position there is no hydraulic output from the valve When the valve is pushed forward there is an effect and when the valve is pulled back there is an opposite effect These valves feature proportional con trol which means that further extension of the valve handle thereby further opening the valve orifice results in proportionally higher hyaraulic output to the controlled device The illustrations on the next two pages list the type and effect of the hydraulic valves this tong may be equipped with DRILLING amp TECHNICAL MANUAL 2 17 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K SETUP amp OPERATION Valve Operation Continued MOTOR This is a proportional valve Pushing the valve handle forward will cause the tong motor to rotate in a clockwise direction as seen from the top of the tong This is the desired direction of rotati
80. d Tie Off iue 2 14 2 TONG ACV CHINO C 2 16 Tong Operation 1 Initial Start up amp 2 17 E 2 17 om A CS c ae E _ A 2 19 4 General Operational 2 20 Extreme Cold Weather Operation Procedures 2 20 Section Three General Maintenance Safety 3 1 707 T A 3 1 Preventive Maintenance PIacCiCe AMA RUN FH En m 3 1 1 T RR T HER 3 2 Adjustments LE ae Ea A RES are tere renner 3 7 2 Boor Can E 3 7 3 8 Recommended Periodic CHECKS a du de Pu cru 3 9 Disassembly amp Overhaul Procedures uiuis iie D DR a 3 9 3 11 Daily Maintenance Checklist Power 3 20 Monthly Maintenance Checklist Power nnn 3 22 Daily Maintenance Checklist Power
81. d Ensure that neither of the rear backup springs have been over extended and lack sufficient tension adequately support backup Ensure that neither of front leg springs have been over com pressed and still retain enough spring strength to support the front of the backup 1 Extend all hydraulic cylinders and inspect cylinder rods for signs of mechanical damage flaking rust recom mends damaged cylinders be replaced prior to storage Perform a visual inspection of all hydraulic lines Replace flexible lines if they appear to be cracked fatigued or have 20 visible signs of wear from contact with a rigid object If your tong is equipped with rigid hydraulic lines replace any line that is dented or appears to be stressed or cracked 2 1 Generously fill the gear train housing with grease through the access panel and also through opening in the rotary gear Perform a full lubrication refer to Maintenance section of manual to determine lubrication points 2 2 Ensure supply and return connections to the tong are fully made up Re connect remainder of the hydraulic 2 lines and if applicable the electrical line to the turns counter FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE If using a stand alone power unit start it now refer to the power unit technical manual for startup proce
82. dures Listen to power unit for a moment to see if there are any unusual mechanical sounds rubbing grinding excessive pump noise If using a diesel unit allow sufficient time for the engine to reach operating temperature before increasing engine RPM Once engine is warm gradually increase engine RPM until operating speed is reached 2 3 Ensure that supply pressure is at or above the tong s specified operating pressure and that return pressure is less than 350 psi 2 4 Perform a visual inspection of pressurized hydraulic lines If any hydraulic fittings or hoses are leaking they must repaired or replaced before proceeding Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of 25 rotary gear facing the gear train De energize the power and perform another generous lubrication of the gear train including the gear housing 2 6 Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending 2 with the opening of the rotary gear facing the gear train 27 De energize the power unit and perform a third generous lubrication of the gear train including the gear housing DRILLING amp AACCCOY TECHNICAL MANUAL 3 23 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K 2 8 Re energize power unit and extend hydraulic cylinders Inspect c
83. e 1 Loosen and remove 8 each 10 32 bolts 2 Pry off seal plate with screw driver 1 Loosen clamp screw in lock nut 2 Unscrew lock nut and remove Loosen and remove 8 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 amp 12 DRILLING amp TECHNICAL MANUAL 71 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K HYDRAULIC Motor INFORMATION WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION DISASSEMBLY OF FRONT DISASSEMBLY OF ROTOR STATOR HOUSING AND SHAFT CARTRIDGE SECTION CONTENTS 1 Mark one side of the motor for proper assembly paying careful attention that the cartridge will not be installed upside down 2 Secure the motor prior to loosening the 5 8 11 bolts 1 Remove front housing 2 Note Two 5 16 ball checks and one main body o ring may be dislodged and fall free With the seal plate removed press shaft and ball bearing out of front housing 1 Remove snap ring from Shaft 2 Press shaft out of bearing TECHNICAL MANUAL Lift up rotor stator cartridge and remove from the rear housing 1 Place cartridge on any object which will hold it off the table 2 Remove two each 10 32 place screws 3 Remove timing plate 1 Remove o ring and Springs with a small screwdriver 2 Remov
84. e Plug all ports and thoroughly clean the exterier of the valve bunk then the port plugs be removed TECHNICAL MANUAL SECTION CONTENTS 7 21 KT5500 5 1 18 7K VALVE INFORMATION Exploded View of Work Section 2 3 net shown Parts List For Work Section Description Oty VA VGED Part VANGIS Part No VSD Section Seals See Figure 1 1 Square Sea s a 391 231 206 3912884 200 331 2881 433 2 Square Seal 1 341 2881 200 391 2581 404 321 2081 670 Serea Socton 1 Square Seals 281 2 4 208 391 2581 200 3 Square Saal 4 2821 827 301 2851 528 Parailai and Series Section Component Parts See Figure 1 4 Back zonws 491 1433 0U5 41 DH Lock EUN 71 37 8 Back Cap 1 3A EOUO 00 J42 B0OQ 100 341 0585 059 Plobes 3 391 418300 301 2 183 008 581 21 83 157 7 Back up Hings 391 2681 3 8 1 258144 28 391 268 245 H Spa 3971 1885 014 197122887272 1056 Reinga Fiole Screws 2 391 14 33115 391 143 3 007 4 391 402 0015 10 Check Valve 391 0581 044 109 56 1 044 Jg1 02 B5 ugb Lir Valve Gap FJ N I 1 301 2251 015 i 11 C Ring j 309 2 81 204 39 2881 204 331 2881 2407 7 ra Check Spring 1 201 358 1 713 191 168 1 713 d481 3581 775 13 Chock 1 Deu 391 2383 061
85. e dowels pins 1 Replace plate on rotor stator cartridge 2 Turn rotor stator cartridge over 3 Repeat steps 14 amp 15 AACCCODY MOVING GLOBAL ENERGY FORWARD HYDRAULIC Motor INFORMATION KT5500 5 1 18 7K WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION 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 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 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 Inspect all springs and seals We recommend replacement of all seals and springs whenever the motor has been disassembled 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 sli
86. e end of the shifting shaft in the lower shifter bushing typically welded to the bottom plate and mesh the shifting fork with the shifting collar 20 Slip the low clutch gear PN 997 A1 52 over the top of the clutch shaft and seat on remaining two needle bearings ensuring the smaller diameter on the high clutch gear is oriented toward the center gear on the clutch shaft 21 Slide the pinion idler half shaft PN 997 D17 105 through the remaining idler gear assembly Place a bearing seal over the end of the half shaft and secure the gear assembly to the half shaft with a retainer ring PN 02 0008 22 Place the end of the pinion idler half shaft through the bottom plate and mesh the pinion idler gear with the two rotary idler gears Secure the half shaft to the bottom plate with the half moon idler pad PN 1400 109 three 5 8 UNC x 2 1 4 hex bolts and 5 8 lock washers and a 1 1 2 UNF hex nylock nut 23 Install the low pinion gear PN 997 A5 88 shoulder side up over the top of the pinion gear shaft meshing with the low clutch gear 24 Carefully remove all support roller shafts using caution not to shift the position of the installed support roller assemblies or to damage the threads on the end of the shafts 25 Insert three 3 8 x 1 1 4 hardened production ground dowel pins into the top edge of the side body one in the rear center and one in the untapped holes on either side of the door opening 26 Position the top plate
87. e following schematics that do not apply to your model ees INE gt C 09345 2 H LIM 1010 on paads ajbuls EN 72 VIE n Duo Apeau dnyoeg OML 40 140 5 YOLOW 9NOL 3ATVA 2 7 O o TECHNICAL MANUAL AACCODY MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT5500 5 1 18 7K 4 paads ajbuls buoy Apeay dnyoeg A AACCODY MOVING GLOBAL ENERGY FORWARD HOLOW 09345 2 HLIM i 9361 NMOHS 46 HO LIMS 43385 YO LOW OML 140 140 YOLOWONOL 1 2 28 TECHNICAL MANUAL SETUP amp OPERATION KT5500 5 18 7K Backup Section DVA35 DA8 4WAY SAE PORTS Optional 10 9019 10 Safety Door Switch 08 0337 Pilot To Operate Cartridge Valve 08 1625 3 Check Valve Optional 02 9022 14 Dump Valve Optional 08 9284 15 Dump Valve Body Optional 08 9283 16 3000 PSI Pressure Gauge 02 0245 2 3 0 G0 6 8 DRILLING amp AACCCOY COM
88. e to the top plate using four 1 2 UNC x 2 hex socket head cap screws 38 Insert a 5 16 x 5 16 x 1 1 2 square key into the key slot on the motor shaft Secure the motor gear PN 997 A10 149 to the hydraulic motor shaft using two 3 8 UNC x 3 8 flat point hex socket set screws Ensure that the motor gear is oriented so that the machined end of the motor gear the end in which the set screws are threaded is flush with the end of the motor shaft 39 Mount hydraulic motor PN 87 0110 to motor mount Secure the RH side of the motor as seen from the back of the tong with two 1 2 UNC x 1 1 4 hex socket head cap screws and 1 2 lock washers The torque gauge holder weldment PN 1500 09 04A is secured by the two LH motor screws position the torque gauge holder weldment in place and secure it and the LH side of the motor with two 1 2 UNC x 1 1 2 hex socket head cap screws and 1 2 lock washers 40 Attach the two 20 1 1 4 x JIC 1 flange elbows PN 02 9216 to the motor ports using two 20 split flange kits PN 02 921 7 41 Attach the shifter lug weldment PN 101 0016 to the top plate of the tong next to the top shifter bushing weldment using four 3 8 UNC x 1 1 4 hex bolts and 3 8 lock washers 42 Connect the shifter handle weldment s PN 1037 D 20B pivot point to the pivot point of the shifter lug weldment using a 5 16 1 1 2 clevis pin Connect the end of the shifter handle weldment to t
89. ear of equipment 1 2 4 Contaminated hydraulic fluid due to overuse overheating or inadequate fluid filtration Unsuitable hydraulic fluid especially in extreme climatic conditions Defective packing or seals in components of the hydraulic system Poor or incomplete hydraulic system training Users must be fully qualified to operate the equipment and have complete understanding of the hydraulic system If your hydraulic troubleshooting procedures involve flow and pressure tests at the power unit McCoy Completions amp Drilling recom mends construction of a test rig that can easily be connected to the main suction and discharge ports of the power unit 4 6 NCO Y MOVING GLOBAL ENERGY FORWARD SECTION CONTENTS TECHNICAL MANUAL KT5500 5 17 18 7K PARTS AND ASSEMBLIES CCCN DRILLING amp COMPLETIONS TECHNICAL MANUAL 5 1 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K GEAR TRAIN LAYOUT DRILLING amp 5 2 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 17 18 7K O GEAR TRAIN LAYOUT a Moto Gear ra sus O Asemby ker Assembly Pa 66 69 Assembly Suppor RoteriPp 64 65 Shifter Shaft Assembly Pp 5 16 5 17 DRILLING COMPLETIONS TECHNICAL MANUAL 53 MOVING GLOBAL ENERGY FORWARD
90. een damaged must be repaired prior to storage Prepare areas to be painted to ensure they are free of grease dirt or solvent Touch up using a solvent based acrylic paint McCoy Grey is paint number RAL7015 Allow sufficient time for paint to dry before proceeding Perform a liberal lubrication of the equipment refer to Maintenance section of manual to determine lubrication points Generously fill the gear train housing with grease through the access panel and also through the opening in the rotary gear Connect equipment to a hydraulic power unit Ensure all lines fully made up to prevent equipment damage from excessive back pressure Do not neglect to connect the motor drain Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with the opening of the rotary gear facing the gear De energize the power unit and perform another generous lubrication of the gear train including the gear housing DRILLING amp SECTION CONTENTS TECHNICAL MANUAL MCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K 1 3 Energize power unit Rotate tong for one minute stop and reverse the direction of rotation for another minute ending with opening of the rotary gear facing the gear train 14 De energize the power unit and perform a third generous lubrication of the gear trai
91. eft blank TORQUE MEASUREMENT 5500 5 1 18 7K A BASIC TORQUE MEASUREMENT Basic torque measurements are performed using a simple hydraulic measurement system A hydraulic load cell connects to brated torque gauge through a reinforced flexible hydraulic hose The torque gauge 15 factory calibrated to display accurate torque measurements for a tong or tong and backup assembly with a particular arm length The arm length is a measurement from the centre of the pipe or casing to the centre of the force being applied to the load cell Two load cell options are available A tension load cell is typically used with a suspended stand alone tong This application requires that the load cell be attached to the rear of the tong as part of the restraint line that opposes the force generated when the tong makes up or breaks out a joint A compression load cell is used in a tong and backup assembly is typically located on the rear of the backup between the backup and a stationary frame The load cell must be located in the centre of the compression force vector generated between the backup and the frame Hydraulic force generated by a load cell is transmitted to the torque gauge a reinforced flexible hydraulic line The hydraulic force is displayed as torque in units of Ft Lbs The torque gauge has a red peak torque indicator that tracks with the torque gauge needle to the point of highest torque and remains at the point of h
92. embly Step 1 Spool Assembly Detant Parker ihe seal i Fig 1 mem 8 and slide it the spool Slide the back up ring Fig h 7 ome Erg iber oan the Position these Hes nod The spon 4x they do Wib die spool apraiar mocha during assembly Do non alle O ring in comme in etl Ue matches Apply 2 3 drops of Lone 2682 ar an equivalent anaerobic middle of the female im tha CAUTION Follow the adhetive manufacturer s Failure 10 clean prepare parts property may Step 2 Spool Assembly Detent real ball rumia Fig 2 iem ZU ana an ilie ileran Fw IT 18 TA 4 im ss This be seveniplished by erowr foot socks On ihe Maw of the chev n and the muerting n roumi sect rad cr sonewisriver hole in the ball retainer Step 3 Detent Balls and Spring behy cons balls Erg 2 darent 2 9i and uide diameter 91 ibe amp leeve Fip 2 17h higihedemperatise grec the deteni ong iter iier harena ghi lode denen hall namer Place glee weel balki cn
93. ens enough to remove Reverse the process to install new jaw dies Do not neglect to reinstall the keeper screws DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 2 13 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K SETUP amp OPERATION Jaw Jaw Die Removal Continued You may be using jaw die kits that use wraparound dies Jaws typically require removal in order to replace the die inserts Once the jaws have been removed extract and replace the die inserts using this procedure Use a flat head screwdriver to hold the keepers on the front of the die stationary Use a wrench to loosen and remove the screw holding the keeper from the back of the jaw f the die does not come loose when the two keepers are removed lightly tap the die to break it free from the jaw e Ensure the face of the jaw is free from dirt debris or large deformations gouges scrapes etc before reinstalling new die inserts i ue ree R TONG RIG UP 4 LEVELING 1 Suspension amp Tong Restraint Suspend the tong from a location as near to the centre of the drill rotary as possible and from a location high enough on the mast to ensure easy handling The lower the point from which the tong is suspended the more effort will be required to move the tong to and from the connection point The suspension line may be extended over a pulley and balanced by a counterweight equal to
94. ent to the top LH brake band lug weldment 60 Install door cylinder PN 101 0069 secure onto posts with 1 2 NC x 1 2 hex socket head shoulder bolts UNC DRILLING amp 318 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Mechanical Assembly Procedure Continued 61 Attach the rigid sling hanger weldments LH weldment PN 101 0150 RH weldment PN 101 0151 to the top plate using two 3 8 NC x 1 3 4 bolts outside two 3 8 NC x 1 bolts inside and four 3 8 lock washers per hanger 62 Install inlet coupling support assembly PN 1050 C 175 to the top plate between the RH pinion idler and RH rotary idler using two 3 8 NC x 1 hex bolts and 3 8 lock washers Attach the outlet coupling support base PN 101 0023 to the top plate right of the pinion bearing cap using two 3 8 NC x 1 hex bolts and 3 8 lock washers and attach the adjusting plate PN 101 0022 to the support base using two 3 8 NC x 1 hex bolts two 3 8 flat washers and two 3 8 UNC nylock nuts 63 Install two hydraulic valve mount weldments PN 101 1442 to the top plate on either side of the brake band retainer using one 3 8 NC x 1 hex bolt and 3 8 lock washer per weldment 64 Install the hydraulic valve assembly to the valve mount weldments using one 1 2 NC x 4 1 2 hex bolt and 1 2 narrow flat washer per valve mount
95. est speed Ensure motor is in low speed 12 POSSIBLE PROBLEM Incorrect tong gear selected SOLUTION Maximum torque can only be developed when tong is in low gear Ensure tong is in low gear MCCOY DRILLING amp COMPLETIONS GUARANTEES CALIBRATION OF A LOAD CELL TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR MCCOY DRILLING amp COMPLETIONS SUGGESTS THAT THE LOAD CELL TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE CALIBRATION ON A YEARLY BASIS DRILLING amp 4 2 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING 5500 5 1 18 7K B FAILURE OF JAWS TO GRIP PIPE 1 POSSIBLE PROBLEM Dies have become too dull to provide adequate grip SOLUTION Replace dies 2 POSSIBLE PROBLEM Incorrect jaws are being used SOLUTION Double check jaw size to ensure they are rated for the diameter of pipe or casing being run 3 POSSIBLE PROBLEM Incorrect dies are being used SOLUTION Ensure dies loaded in the jaws are appropriate for the type of pipe or casing being run 4 POSSIBLE PROBLEM Brake band s is are insufficiently adjusted not allowing jaws to cam properly SOLUTION Adjust brake bands to give proper resistance to cage plates 5 POSSIBLE PROBLEM Jaw roller broken or worn SOLUTION Hemove jaw assembly and inspect Replace rollers that are visibly flat spotted or otherwise damaged DRILLING amp AACCQDY TECHNICAL MANUAL 4 3 MOVING GLO
96. etween the two cage plates at their connection points one in the rear centre and one each side just inside the rotary gear 49 Slide a 1 2 narrow flat washer followed by the backing pin spacer PN 101 4093 over a 1 2 UNC x 8 hex bolt Slide the larger diameter hole in the backing pin retainer PN 101 4095 over the backing pin spacer 50 Attach the bottom cage plate to the top cage plate Use two 1 2 NC x 6 hex bolts at the front and the 1 2 x 8 bolt and spacer assembly in the rear ensuring the backing pin spacer remains between the head of the bolt and the top of the top cage plate 51 Thread the 3 8 UNC x 1 1 2 threaded stud PN 101 4097 into the backing PN 101 4042 52 Insert the backing pin and stud through the bottom of the backing pin retainer installed in Step 49 Slide the short backing pin spacer PN 101 4096 over the top of the stud and thread the backing pin knob PN 02 0017 on to the top of the threaded stud Lift the backing pin and insert into one of the two receptacles in the rear of the top cage plate 53 Install the top and bottom lined brake band lug weldments 1064 D4 29 Secure the brake bands to the top and bottom plates using one brake band retainer PN 101 0140 and two 3 8 UNC x 3 4 hex bolts and 3 8 lock washers at the rear of each brake band and a 3 8 UNF x 2 hex bolt and 3 8 UNF hex nylock nut at each brake band lug weldment 54 Install the tong legs ASSEMBLY NOTE
97. ff providing access to the inside of the gear case LIFT THE TOP PLATE STRAIGHT UP TO AVOID SNAPPING THE DOWEL PINS A SNAPPED BENT OR OTHERWISE DAMAGED DOWEL PIN CAN BE EXTREMELY DIFFICULT TO REMOVE DRILLING amp 3 10 SEcTION CONTENTS TECHNICAL MANUAL AACCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD MAINTENANCE KT5500 5 1 18 7K H ASSEMBLY PROCEDURES Assembly of Farr Hydraulic Power Tongs is straightforward and can be accomplished without the use of special tools The instructions on this page are presented as a guide only and are similar to the assembly sequence our technician would use while assembling the tong in our plant 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 TIGHTENING TORQUE GUIDE SAE GRADE 8 FINE THREAD OO SAE GRADE 8 COARSE THREAD 5 16 18 3125 18 ft Ibs 7 16 14 4375 52 ft Ibs 9 16 12 5625 115 ft Ibs REPLACEMENT FASTENERS MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE SPECI FIED BY MCCOY DRILLING amp COMPLETIONS DRILLING amp COMPLETIONS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K MAINTENANCE NOTE ON INSTALLATION PRACTICES Ensure all bearings are liberally greased before installing over
98. full and partial displacement Motors with 63 or 67 designations are closed during crossover These motors contain an internal factory preset relief valve This valve protects the motor during shifting only and is not a system relief valve PILOT PRESSURE A minimum of 100 PSI over case drain pressure is required to shift the spool The maximum allowable pressure to port C or D is 3 500 PSI SHIFT ON THE RUN The 15 Series Two Speed Motor may be shifted on the run while loaded or unloaded MAXIMUM SPEED Maximum rated speed is the same for either full or partial displacement as stated in the performance data CASE DRAIN AND CROSS PORT LEAKAGE The combined case drain and cross port leakage of the 15 Series Two Speed Motor is approximately 1 GPM per 1 000 PSI This will vary with the oil viscosity OTHER INFORMATION All other information as specified under Techinal Information also applies to the 15 Series Two Speed Motor See page 5 75 KT5500 5 1 18 7K Performance Data Selected Displacements ACTUAL TORQUE AND POWER 6 CID Motor INFORMATION 1300 RPM 900 RPM es ee ae eee 7 a POWER HP PRESSURE psid ACTUAL FLOW 6 CID PRESSURE psid ACTUAL FLOW 9 5 CID 11 5 C I D PRESSURE psid ACTUAL TORQUE
99. ghtly affect volumetric efficiency Inspect all parts and replace any parts which obviously show excessive wear or damage Note Measure the rotor and stator length to the fourth decimal point and supply measurement when ordering rotor stator or vanes VANES Normal wear results in slight flattening of vane tips which does not impair motor performance Replace vane if radius is reduced by 5096 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 DRILLING amp MCCOY COMPLETIONS TECHNICAL MANUAL 713 MOVING GLOBAL ENERGY FORWARD KT5500 5 17 18 7K HYDRAULIC Motor INFORMATION WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION RINEER WARNING RINEER RECOMMENDS FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION FOLLOWING ALLSTANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION ASSEMBLY OF ROTOR STATOR ASSEMBLY OF WHEEL MOTOR CARTRIDGE FRONT HOUSING 1 Reverse the procedures in 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 9 5 Tighten clamp screw
100. h shaft with retaining snap ring PN 02 0001 Install rotary idler pads PN 997 D20 125 over the top of the rotary idler shafts and secure with 1 1 2 UNF hex nylock nuts Press remaining pinion bearing into the top pinion bearing cap PN 997 D15 89 and secure over the top of the pinion gear shaft with four 1 2 UNC x 1 1 4 hex bolts and 1 2 lock washers Slide the top shifter bushing PN 101 0020 over the shifting shaft and thread in to the top plate until snug Thread the detent tube PN 101 0019 into the top shifter bushing as shown Thread three 5 8 NC x 5 8 hex socket set screws into the remaining three ports in the top shifter bushing do not bottom out the set screws on the shifting shaft or the shaft will not move 3 14 TEcHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K Mechanical Assembly Procedure Continued 35 Insert the detent ball PN 02 0018 through the end of the detent tube attached to the top shifter bushing followed by the detent spring PN 997 0 64 Thread a 7 16 UNF jam nut on to a 7 16 UNF x 1 1 4 hex bolt and then thread the end of the bolt into the detent tube on the top shifter bushing 36 Insert two 5 16 x 3 4 production ground dowel pins into the top plate one on either side of the motor shaft and gear cut out directly behind the clutch assembly 37 Position the motor mount PN 1400 150 over the dowel pins and secur
101. hat the engine is locked out or the starting mechanism otherwise disabled DiEsEL ONLY 1 Check engine oil levels add if necessary 2 Check diesel fuel tank fill if necessary 3 Visually inspect all fan belts 4 Activate mechanical shut off device ensure that shut off switch on engine is engaging when manual shut off switch is actuated ELEcTRIC ONLY Visually inspect all electrical lines and visible connections If your unit is NOT explosion proof open the electrical en 1 closure and VISUALLY inspect contacts and connections signs of corrosion or arcing Do not open explosion proof enclosures NEVER PLACE HANDS INSIDE AN ELECTRICAL ENCLOSURE UNLESS YOU HAVE CONFIRMED THAT THE POWER HAS BEEN DISCONNECTED AND LOCKED OUT 2 Visually inspect main electrical line between main power source and power unit ALL UNITS 5 Perform visual inspection of all parts Check to ensure there are loose missing fasteners 6 Check hydraulic fluid level ensure cold level is approximately half way up the sight glass on the hydraulic fluid res ervoir f Perform a visual inspection to ensure there are no hydraulic fluid leaks correct if necessary 8 Check that the main supply and return lines the hydraulic fluid reservoir are both fully open 9 Apply grease to any grease fittings that your power unit may have Apply grease to each fitting until grease is visibly disp
102. he top of the shifter shaft using a 5 16 x 1 clevis pin Secure the clevis pins with 093 X 1 125 hitch pins 43 Position the two top brake band lug weldments RH Lug Weldment PN 101 0132 LH Lug Weldment PN 101 0134 on the top plate over the holes for the support roller shafts as shown in the following illustration Insert four short support roller shafts PN 101 3942 through the weldments and support roller components until the shoulders of the shafts are tight to the lug weld ments Slide the two bottom brake band lug weldments LH Lug Weldment PN 101 0132 RH Lug Weldment PN 101 0134 over the bottom of the support roller shafts and secure with 7 8 UNF thin nylock nuts ASSEMBLY NOTE The support roller assemblies coincidental with the brake band lug weldments DO NOT use flat washers 5 DRILLING amp TECHNICAL MANUAL 3 15 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K Mechanical Assembly Procedure Continued 44 Install the remaining support roller shafts excluding the door pivot roller shaft Stand Alone Tongs Models 80 0420 5 80 0420 12 i Slide a 7 8 narrow flat washer over the remaining five support roller shafts PN 101 3942 and insert into the remaining support roller assemblies excluding the door pivot support roller i Secure the bottoms of the support roller shafts with 7 8 narrow flat washers and 7 8 UNF thin nylock
103. ia cerne with the T finish bv masking the enden wiih ihe por boss Chest bo tie back on cach with sorlias will a H Tor beck cap Tham ie quon baas bii each work acho will a 07 for clesia end trai af vule cx rerioved Ire thee ane bank They m t be marked wiih the qumber e he md pert locanon HB or from Which they ceri Ine relief vales are wa a casimy anie Stop 2 Tie Bolis rhal hold ye tank aepuraie NOTE V A valve balis treu iio ihe uwii Vis valve Dolls pasa Through he entire hank washers apil mars va Ie fastened at bed ly enda of the bolt Step 3 Section Seals he zai peraliel sectio have seals Diari 1 Zyondbe iain lec work sectors and the qui fib mid hare iire seccion irala ar the do wmiaream faece Pig due 3 These section scalis oud be rete acd REMINDER ALL WORK MUST PERFORMED IN CLEAN AREA 7 24 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD VALVE INFORMATIO
104. ice conditions warrant Periodic inspection intervals shall not exceed one year The frequency of periodic inspections should be based on Frequency of use of the load bearing device Severity of service conditions Nature of lifts being made Experience gained on the service life of load bearing devices used in similar circumstances Guidelines for the interval are Normal Service yearly Severe Service monthly to quarterly Special Service as recommended by a qualified person DRILLING amp SECTION CONTENTS TECHNICAL MANUAL NMCCOY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION 5500 5 1 18 7K Units designed and manufactured in accordance with 12079 and DNV 2 7 1 should be tested and examined in accordance with the following schedule of examination and test The user of the load bearing device shall place a permanent placard or plate upon which the type and date of the last test shall be recorded To avoid confusion the plate shall not carry the date of the next test or examination only the most recent Test Examination Non DESTRUCTIVE THOROUGH Surrix To BE MARKED ExAMINATION NDE VISUAL ON PLATE ATTACHED TIME INTERVAL LIFTING TESTS OF LIFTING POINTS EXAMINATION To UNIT Initial Certification By YES YES YES T Farr Superior Interval Not Exceeding the discretion of At the discretion of YES T or VN 12 Months inspection body inspection body Interval Not Exceeding At the
105. ifications SOLUTION Ensure hyaraulic fluid is appropriate for climatic conditions especially during cold weather operation 9 POSSIBLE PROBLEM By pass valve not functioning SOLUTION Check and repair DRILLING amp 44 Section CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD TROUBLESHOOTING KT5500 5 18 7K Tone FAILURE OR DIFFICULTY OF TONG TO SHIFT 1 POSSIBLE PROBLEM Bent or broken shifter handle SOLUTION Replace shifter handle 2 POSSIBLE PROBLEM Bent or broken shifter yoke SOLUTION Inspect and replace shifter yoke 3 POSSIBLE PROBLEM Frozen or hard to move shifter handle SOLUTION Grease shifter shaft 4 POSSIBLE PROBLEM Bent or broken shifter shaft SOLUTION Replace 5 POSSIBLE PROBLEM Locking nuts on shifting shaft have loosened and position of yoke has changed SOLUTION yoke and re tighten locking nuts 6 POSSIBLE PROBLEM Shifting yoke has come loose from shifting shaft SOLUTION Inspect yoke and inspect for damage If free of damage replace on shaft and tighten locking nuts 7 POSSIBLE PROBLEM Tong pops out of gear SOLUTION Ensure that detent ball amp spring assembly has been correctly set DRILLING amp AACCQDY TECHNICAL MANUAL 45 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K TROUBLESHOOTING E GENERAL COMMENTS The following factors generally contribute to poor hydraulic operation and premature w
106. ighest torque until manually reset Note that every model of tong and tong and backup assembly has a unique arm length and the torque gauge must be calibrated for that arm length Torque gauges that are not calibrated for the arm length of the tool in service will not display correct torque To ensure correct torque measurement ensure the arm length or handle as displayed on your torque gauge matches the arm length of the tool in service as listed on the specifications page of the technical manual The images on this page are for illustration purposes only and may not accurately represent the torque gauge and load cell that have been supplied with your equipment THE IMAGES DISPLAYED ARE SUPPLIED FOR ILLUSTRATION PURPOSES ONLY TENSION Loap CELL ToRQuE GAUGE For ILLUSTRATION Purposes ONLY Compression Loap CELL Torque gauges and load cells are supplied as a matched calibrated pair Substituting one or the other will render the calibration inaccurate even if the actual model numbers appear to be identical The serial numbers of matching load cell and torque gauges are clearly identified on the calibration certificate Should you suspect the accuracy of your torque measurements or wish to replace either component the pair should be returned to the factory for re calibration before placing into service TORQUE GAUGES AND LOAD CELLS ARE FACTORY SUPPLIED SUPPLIED AS MATCHED CALI BRATED PAIRS IF REPLACING EITHER COMPONENT THE LO
107. in excess of 50 F Should this occur contact a Rineer Application Engineer MOUNTING The mounting position is unrestricted The shafts pilots and mounting faces should be within 002 TIR INTERMITTENT CONDITIONS Intermittent conditions are to be less than 10 of every minute OTHER AVAILABLE MOTORS For information on additional Rineer Motors request one of the following publications Gi SONGS Publication DS371003 57 Series Publication DS571003 TOS eerte Publication 051251003 MOVING GLOBAL ENERGY FORWARD 74 SECTION CONTENTS TECHNICAL MANUAL Motor INFORMATION Technical Information Two Speed Motor DISPLACEMENT CHANGE When a motor 15 shifted from full to partial displacement the motor is changed to 50 35 or 28 of its original displacement depending on its shift ratio STANDARD SHIFT RATIO The standard 15 Series displacements of 15 13 9 5 8 7 and 6 CID are available in the 15 Series Two Speed with a shift ratio of 2 1 For example a 15 CID motor shifted to partial displacement becomes a 7 5 CID motor SPECIAL SHIFT RATIOS There are two special displacements available in the 15 Series Two Speed which offer higher shift ratios the 10 5 and the 11 5 CID The 10 5 CID motor has a shift ratio of 3 5 1 which when shifted becomes a 3 CID motor The 11 5 CID motor has a shift ratio of 2 875 1 which when shifted becomes a 4 CID moto
108. in its proper location Use caution not to damage threads when aligning the top plate with the rotary idler and support roller shafts Ensure the top of the shifting shaft is smoothly guided through the associated hole in the top plate ENSURE THE TOP PLATE REMAINS PARALLEL TO THE SIDE BODY TO AVOID BINDING ON THE DOWEL PINS 27 Use a rubber or wooden mallet to evenly tap the circumference of the top plate until it is flush with the side body DRILLING amp TECHNICAL MANUAL 3 13 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K MAINTENANCE Mechanical Assembly Procedure Continued 27 Secure the top plate with fourteen 3 8 UNC x 1 1 2 hex bolts and 3 8 lock washers and five 3 8 UNC x 1 low head height hex socket head cap screws Do not install fasteners coincidental with the rigid sling brackets shown circled in green or the door cylinder post shown circled in red 28 29 30 31 32 33 34 wA Slide the clutch bearing retainer spacer PN 1400 594 over the bottom of the top clutch bearing retainer PN 997 D1 1 59 and mount top clutch bearing retainer and spacer to the top plate with two 10 24 x 3 4 hex socket head cap screws Press top clutch bearing PN 02 0002 into top clutch bearing retainer Insert clutch bearing bushing PN 997 60 shoulder side up between bearing and clutch shaft Secure clutch drive gear PN 997 61 to the top of the clutc
109. ings recessed into the top of each shaft on the top face of the tong two locations total _ 9 4 Pinion Idler Apply grease to the pinion idler bearing through the grease fitting recessed into the top of the half shaft located on the bottom face of the tong one location only DRILLING amp NCCOY COMPLETIONS TECHNICAL MANUAL 33 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K MAINTENANCE 5 Pinion Apply grease to the pinion bearings through the grease fittings located on the bearing caps on the top and bottom faces of the tong two locations top two locations bottom 6 Clutch Bearings Apply grease to the clutch bearings through the two grease fittings located on the clutch bearing cap on the bottom face of the tong and the single grease fitting recessed into the end of the clutch shaft three locations total DRILLING amp 34 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K 7 Motor Mount Apply grease to the motor gear clutch drive gear through the grease fitting located on the top of the motor mount one location only f E p i 8 Shifting Shaft Apply grease to the shifting shaft and top shifting shaft bushing The shaft and shifting yoke can be accessed through the cover plate on the side of the tong Access shifter components through this panel
110. ipment refer to Maintenance section of manual to determine lubrication points 5 Generously fill the gear train housing with grease through access panel and also through the opening in the rotary gear 6 Connect equipment to a hydraulic power unit Ensure all lines fully made up to prevent equipment damage from excessive back pressure Do not neglect to connect the motor drain FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE Energize power unit 8 Ensure that supply pressure is at or above tong s specified operating pressure and that return pressure 15 less than 350 psi 9 Perform a thorough inspection of pressurized hydraulic lines and fittings Any leaking hydraulic fluid lines or fittings must j be replaced before the equipment is returned to service 1 0 Perform a thorough inspection of all seals Any seal that is leaking or weeping must be replaced before equipment i is returned to service Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines If a seal line or fitting begins 1 1 to leak while tong is rotating it must be replaced before the equipment is returned to service Finish this step with the rotary gear opening facing the gear train De energize the power unit 1 2 Inspect all flexible hydraulic lines signs of wear blis
111. l Area Relief Valve Part Numbers 355 0107 035 355 0107 061 355 9107 013 355 9001 082 355 9107 385 MOVING GLOBAL ENERGY FORWARD When installing relief valve barque fe 75 bhs SERVICE PARTS LIST Figure 7 item Description Oty Q ring 351 2851 3242 391 2681 303 1 391 2881 344 301 2851 208 391 1581 001 All seals the relief cartrkige are net Sew vicia VGBU Main Pilot Operated Relie Valve Part Numbers 355 0001 008 355 9001 031 TECHNICAL MANUAL SECTION CONTENTS 7 31 KT5500 5 1 18 7K VALVE INFORMATION Screw Adjustable Relief Valve Pressure Ranges and Adjustments Riv Valve Pressure 1 4 turns Part Series Range PSI Eauals 355 0107 035 VA VG20 BOO 2500 165 355 9001 0861 VA VG2 2501 3800 160 355 0107 013 VA G35 2000 80 355 9107 062 VANGIS 2001 2500 121 355 9107 385 VA VG35 2501 3500 249 355 9001 008 VGB80 1000 2500 196 355 9001 031 2500 3500 290 355 9001 115 VAIVG20 35 80 500 5000 446 355 9001 308 VA VG20 35 80 500 1250 95 355 9002 308 VANG20 35 80 1251 2650 138 355 9003 308 VAIVG20 35 80 2651 4200 188 Adjustment pressures are approximate Guidelines for Setting Hydraulic Relief Valve Pressure Release hydraulic pressure before connecting or disconnecting any gauge Install an accurate pressure gauge as close to
112. lace to prevent environmental contamination from residual hydraulic fluid and dirty grease Remove the access panel on the side of the tong directly adjacent to the shifter mechanism Clean the interior of the tong thoroughly using either water do not use a pressure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental con tamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the gear train cavity if shavings or metal pieces are seen the tong must be overhauled before it is returned to service Clean the exterior of the tool thoroughly using either water do not use a pressure washer an appropriate solvent based grease cutting cleaner such Varsol Ensure adequate containment is in place to prevent environmental contami nation from residual hydraulic fluid dirty grease and cleaning agents Inspect all fasteners and fastener safety wires Replace any missing fasteners use Grade 8 bolts only all external fasteners to SAE specifications Inspect backing pin s If cracked broken or bent it they must be replaced Repair or replace any damaged or missing external body parts such as torque gauge mounts hydraulic supports safety door protectors etc Inspect all paint locations in which the paint has b
113. laced from bearing or as recommended by your power unit manual 7 0 Ensure supply and return connections at the power unit and at equipment use are fully made up FAILURE TO ENSURE THAT THE SELF SEALING SUPPLY AND RETURN LINES ARE FULLY MADE UP MAY RESULT IN CATASTROPHIC EQUIPMENT FAILURE 1 1 Check hydraulic fluid filter back pressure must be done while fluid is circulating If needle on indicator gauge 15 in j the red zone the filter should be changed the next time the unit is shut down DRILLING amp AACCCOY TECHNICAL MANUAL 3 25 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K L TUBULAR CONNECTION EQUIPMENT DE COMMISSIONING PROCEDURE Perform the following decommissioning procedures when removing tubular connection equipment from service with the intent of short to long term storage These procedures are essential for ensuring proper protection of the equipment from environmental attack and to aid in the quick turnaround when returning the equipment to service Store all o rings seals packings gaskets etc in strong moisture proof airtight containers Ensure that these items are not crushed nicked or otherwise damaged Do not perform any further actions or maintenance while the tong is connected to any hydraulic power supply Farr recommends that all hydraulic lines are fully disconnected and residual hydraulic pressure is bled off Ensure adequate containment 15 in
114. ling amp safety door NOTE Some illustrations used in this manual may not exactly match your model of tong DRILLING amp TECHNICAL MANUAL iii MOVING GLOBAL ENERGY FORWARD This page intentionally left blank 5500 5 17 18 7K WARNINGS A LOAD BEARING DEVICE IS A CHAIN SLING RIGID SLING SPREADER BAR ASSEMBLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH THIS MANUAL HAS BEEN PRODUCED THE LOAD BEARING DEVICE SUPPLIED BY MCCOY DRILLING amp COMPLETIONS IS DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL MCCOY DRILLING amp COMPLE TIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO SUPPORT ANY OTHER PART ASSEMBLY OR COMBINATION OF PARTS AND ASSEMBLIES MCCOY DRILLING amp COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD BEARING DEVICE OR ANY ADDITIONS TO THE EQUIP MENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT UNLESS SUP PLIED BY MCCOY DRILLING amp COMPLETIONS WHEN RE ASSEMBLING LOAD BEARING DEVICES CHAIN SLINGS RIGID SLINGS BACKUP LEGS ETC NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE OF FASTENER SEE SECTION 3 OVER HAUL ANY THREADED FASTENER IN A LOAD BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOC
115. ll in the clampnut Spin clampnut onto shaft with the B face towards bearings After the nut threads are fully engaged but prior to the nut contacting the bearings 0 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 1 Tighten clamping bolt on clampnut to 70 inch pounds and recheck rolling torque Apply inspectors lacquer to head of the bolt Ji Allow a minimum of 24 hrs to dry CUTAWAY Note The slit in the clampnut allows for loose assembly on the shaft Once in position the clampnut clamping bolt MUST be tightened to a slight drag in order to correctly engage the threads on the shaft to achieve the clamp force required Figure 1 DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL Section ConTENTS 7 15 KT5500 5 1 18 7K Information Bolt Torque Main Bolts 5 8 11 Seal Plate 3 8 16 Wheel Motor only 45 ft 105 Grease used for bolt threads and o ring retention Pennzoil 707L RED Shaft seal assembly lube Mobilgrease special with Moly 190 ft 105 77 ZZ m s Mn _ NSS WA SZ NI NY mne EK ger 1 444 y E EM V 8 NS ZZ Vor
116. lve housing This should nat be stoned or ground off 7 20 SECTION CONTENTS TECHNICAL MANUAL 2 Wash all pans thoroughly ina cleaning and how dry begieneng Pa aerial aen tothe number and heieri marked dra e pur 1 Hf any marks are removed duni bearings Ie n 4 Clean from dreads of spoal stripper bale cap et wall Loctibet t Chine AACCCOY MOVING GLOBAL ENERGY FORWARD VALVE INFORMATION KT5500 5 18 7K Valve Assembly Instructions Preparation of Parts af the halt Fig 2 dens 14 Lappsd Ureadad spial tod serowa and screw hols on Rath humming LOOT Primers Gesule and Tet dry Spring Center Spool Assembly CAUTION the adhesive imsiructioas lor proper cleaning und curing Failure tu clean ami prepare parts pruperlv resuli in MOVING GLOBAL ENERGY FORWARD CAUTION Failure to follow the recommended assembly instructions can result poor performance product malfunction Product should be thoroughly tested to ensure proper operation before the valve is placed back into Service Step 1 Spool Assembly Spring Centered ibe dew the central
117. n including the gear housing 1 5 Energize power unit and rotate the tong for a final time one minute one direction stop and reverse the direction of rotation another minute this ending with rotary gear in the open throat position 1 6 Extend hydraulic cylinders and inspect cylinder rods signs of mechanical damage flaking or rust Farr recom mends that damaged cylinders be replaced prior to storage If you are using a frame mounted tool the tong must be lowered onto the backup in order to remove the risk of sudden and catastrophic movement when pressure is removed from the float cylinders Cover the top of the backup with protec tive cloth to protect the paint on the backup Place two wooden beams across the top of the tong ensuring that the beams 1 f have a minimum size of 4 x 4 x the width of tong Cover tops of the wooden beams with more protective cloth to prevent paint damage to the tong When lowering the tong onto the beams ensure that the beams come into flat contact with the bottom of the tong away from bearing caps brake bands or other protrusions on the bottom of the tong Ensure that the tong hanger chains are loose but not dangling into contact with the hangers or top plate of the tong DEPRESSURIZATION PROCEDURE FoR STORAGE 1 Rotate the tong to the open throat position 2 Exercise each hydraulic cylinder several times open the tong and backup doo
118. nance Periodic inspections of the load cell hydraulic lines and fittings are recommended in order to keep the system in top operating condition A thorough inspection should be made at each rig up 2 Fluid Recharge Recharge hydraulic system with W15 16 fluid through the check valve on the torque indicating gauge Recharging must only be performed when there is no load on the load cell Refer to the illustrations on pages 6 3 amp 6 4 for guidance if required a Place the torque indicating gauge higher than the load cell Remove the brass 1 4 cap from the fitting on the check valve on the top of the gauge b Connect the hand pump to the check valve fitting c Elevate the load cell so it is higher than the torque gauge and hand pump UN CONTAINED SPILLAGE OF THE HYDRAULIC FLUID IN THIS SYSTEM MAY CONTRAVENE GOVERNMENTAL ENVIRONMENTAL REGULATIONS THE ENVIRONMENTAL REGULATIONS AND POLICIES OF YOUR COMPANY MCCOY DRILLING amp COMPLETIONS HIGHLY RECOMMENDS PLACING YOUR LOAD CELL IN A CONTAINMENT BASIN BEFORE PROCEEDING WITH THE BLEEDING amp REFILLING PROCESS d Fill hand pump bowl with W15 16 hydraulic fluid MAINTAIN GREATER THAN HALF FULL FLUID LEVEL IN THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO THE SYSTEM DO NOT ALLOW THE LEVEL TO FALL BELOW ONE HALF FULL e Remove the vent plug screw and Stat O Seal Items C and D on Illustration 6 A 4 or item Hon Illustration 6 A 5 to allow trapped air to escape f Pump fl
119. ng and corporate information Revised list of supported models Updated hazard caution warning symbols and statements throughout manual 12 13 Corrected amp updated specifications Added torque and speed information for two speed motor 2 Removed hydraulic schematic tong without safety door no longer supported Appendices All lii 7 2 7 2 9 Added revised hyaraulic schematics that show all hydraulic options Updated hydraulic 2 12 2 14 Hevised jaw section 2 14 2 15 Revised Section 2 F 1 Tong Rig up amp Leveling Suspension amp Tong Restraint 21 Added section 3 C Preventive Maintenance Practices 3 2 3 6 Revised section 3 0 Lubrication 3 9 3 10 Revised section 3 G Overhaul Procedures 3 11 3 19 Revised section Tong Assembly Procedures 3 20 3 30 Moved all maintenance checklists from appendix to Maintenance section 5 2 5 3 Revised Gear Train Layout to reflect engineering changes July 2011 5 4 5 5 Revised Support Rollers to reflect engineering changes 5 16 5 17 Revised Cage Plate Assembly to reflect engineering changes 5 24 5 25 Revised Motor Mount Assembly 5 28 5 29 Revised Door Assembly to reflect engineering changes All Complete revision of Torque Measurement section Continued on next page Date Section o DR
120. nside the cylinder when this occurs 2 Backing Pin Perform a visual inspection of the backing pin after each job Replace the if stress cracks or excessive wear 15 found or if either pin is bent 3 Shifting Shaft The shifting yoke is secured to the shifting shaft by one hex jam nut above the shifting yoke and one locknut on the bottom of the yoke Check these nuts after each job Do this by removing the clutch inspection plate and ensuring a snug fit prior to lubrication 4 Torque Gauge Assembly Periodic calibration of the torque gauge is recommended to assure accurate torque readings When having the torque gauge serviced and calibrated it is critical to note the arm length of the tong as indicated in the Specifications section Farr recom mends that the torque gauge assembly be calibrated yearly Periodically check to ensure the load cell is filled with oil see Section 6 G OVERHAUL PROCEDURES The tong may be overhauled following the disassembly instructions in the following procedure Access to the gear train is possible by removing the top plate of the tong ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED REPLACEMENT 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 COMPON
121. of work section botsing Caref lly clare he wirk secun vie peres Dos ec mec hene Hemove the eheckevalve cap Fig aral it Qunng Pup Ei Dicari seal Remove due check spei Pip 1 ion La and the gappet ilre 1 m 11 AUTE Only work sections ports blocked ip hava a check Mame have ani cap plu COY TECHNICAL MANUAL 7 25 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K The spriny assemblv rien the piris need to fres ike work section bounng be handled Mace the sel venticallv oec ean patus oe the Ta spon and remove ihe stripper halt Vig 1 VALVE INFORMATION Valve Disassembly Instructions Spool Disassembly Spring Centered Spool A with wrench tap zie suripper wilh a Farmer a punch to help break the adhesive of heat may be required fpes ripper bolt once ain tse adhesive was uud dering ids Asse natis CAUTION Tog much hoal may distort tiv spool As Phe threads the sprmg Fig Leim 15 and spring gusdes Fig 2 loh will rebeuse rom rhe epoul Detent Spool The denen
122. of tong Report and correct any hydraulic leaks from the hydraulic valve bank from any hyaraulic cylinders that are used Perform a visual inspection of the load cell If using a tension load cell replace any cracked broken or distorted com 1 9 ponents including links and chains If using compression load cell replace any component that has been crushed or otherwise distorted through compression 2 0 If applicable inspect load anchor pins tension load cell only Replace anchor pins if cracking or metal distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression 2 1 load only If the integrity of the weld has been compromised tong must be removed from service until the weld is repaired The load beam will need to be disconnected and removed so weld is visible Before re installing beam liberally grease the anchor pin before reinserting into the load cell beam Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low 2 2 gear in both directions makeup and breakout If cage plate begins rotating the safety door mechanism is not func tional and the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once
123. of desiccant for each cubic metre of space or 3 5 g per cubic foot CALCULATION Or REQUIRED DESICCANT 1 Calculate the trapped air volume by measuring the outside dimensions of the tool to be stored and treat that as the volume to be stored For example the external dimensions of a KT20000 20 power tong are 80 25 x 50 5 x 28 which calculates to an approximate volume of 113500 or 66 1 87 m 2 Multiply the calculated air volume in cubic feet by the recommended amount of desiccant per cubic foot Carrying forth the example used in the previous step the required desiccant charge would be 3 5 g x 66 18 equaling 231 g Several manufacturers offer silica gel desiccant in packaged quantities of 125 grams per bag so two packages of desiccant would be required Please keep in mind that this is a guideline only more or less desiccant may be required in extreme environ mental conditions For best corrosion resistance the equipment should be removed from storage and exercised on a regular basis depending on the storage environment Farr recommends that for equipment stored in a salt water maritime or exposed dusty environment repeat steps 9 through 24 monthly For equipment stored in isolated storage in a non maritime environment repeat steps 9 through 24 quarterly Replace desiccant packs at this time depleted desiccant packs may be treated as regular dunnage DRILLING amp 328 SEcTION CONTENTS TECHNICAL MANUAL AA
124. om the use of the information contained in this manual Observance of all descriptions information and instructions set out in this manual is the full responsibility of the user This manual is intended for guidance and informational purposes and must be used in association with adequate training and on the job supervision to provide safe and effective equipment use It is the responsibility of the user to conform to all regulations and requirements issued by an authority or agency which may affect the operation safety or equipment integrity that may overrule the content of this documentation The user will acknowledge and obey any general legal or other mandatory regulation in force relating to accident prevention safety and equipment integrity Summary Of Revisions N A Initial Release N A Added information for backup ready tong Moved assembly procedures to Maintenance section Section 3 Section 2 becomes Setup amp Operation All 2 1 Added Sling amp Load Bearing Device Safety 2 14 Added Tong Rig up amp Leveling procedures 3 7 2007 Sep 2007 2009 Added shifter detent adjustment procedures 7 17 Added Hydraulic Valve Service instructions Added appendices to include power tong daily amp monthly maintenance checklists power unit daily maintenance checklist power tong decommissioning checklist and power tong recom missioning checklist Updated manual to reflect new brandi
125. on for making up a joint Pulling the valve handle in the opposite direction results in counter clockwise rotation which is the desired direction of rotation for breaking out a joint LIFT CYLINDER If Equipped This is a direct acting valve Pushing the valve handle forward will cause the lift cylinder to lift the tong vertically Pulling the valve handle in the opposite direction will cause the lift cylinder to lower the tong 218 Section CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT5500 5 1 18 7K Valve Operation Continued BACKUP If Equipped Depending on the type of backup with which your system is equipped Wedge Clincher or FARR using this valve will activate a backup cylinder or a sequence valve Pulling backward towards the operator reverses the action 3 Shifting Gears The shifting shaft has three detent positions identifying the low speed high torque position the neutral or free spinning posi tion and the high speed low torque position The detent strength may be adjusted by releasing the locknut on the detent tube and increasing or relaxing pressure on the detent spring Ensure the locknut 15 tightened once the desired detent pressure has been set To shift to the high speed gear move the shifting handle upward from neutral position To shift to the low speed gear move the shifting handle down through the neutral detent to its l
126. or cartridge 2 Pour a small amount of Clean oil into the cartridge 3 Install front housing onto rotor stator cartridge 1 Rotate shaft in both directions to assure that the shaft turns smoothly 2 Torque motor to 190 ft Ibs 3 Rotate shaft again in both directions to assure that the shaft turns smoothly 4 Make sure alignment marks are lined up SPOOL ASSEMBLY FOR THE 1 Install 5 8 11 bolts TWO 2 Torque bolts to 50 ft Ibs NOTE Spool should be oriented as shown for two Speed motors with model codes 62 63 68 amp 69 NOTE Slight design variations may exist in motors manufactured either before or after the printing of this manual WHEEL MOTOR SHAFT AND BEARING ASSEMBLY PROCEDURE 1 Clean ALL assembly parts w lacquer thinner 1 Dip clampnut and clamping bolt separately in lacquer thinner Steps 3 thru 10 must be conducted to completion ONE assembly at a time Press bearing cups into bearing housing Make sure they are pressed completely against bearing shoulders Coat inner race of large cone with 609 green Loctite and press cone onto the shaft Make sure the cone is completely against the shoulder of the shaft Insert shaft and large cone into bearing housing Coat inner race of small cone with 609 green Loctite and press small cone onto shaft 1 Apply 272 red Loctite to the clampnut threads of the shaft Apply 242 blue Loctite to the threads of the clamping bolt and insta
127. otary gear installing support roller assemblies in the rotary gear opening as it is rotated Finish with the rotary gear aligned with the opening in the bottom plate 6 Press pinion bearing PN 02 0007 into bottom pinion bearing cap PN 997 D15 89 and install bearing cap into bottom plate of tong using four 1 2 UNC x 1 1 4 hex cap screws and four 1 2 lock washers ASSEMBLY NOTE Do not neglect to install the clutch bearing cap spacer PN 1400 89A between the bearing cap and the bottom plate of the tong 7 Press bottom clutch bearing PN 02 0004 into clutch bearing PN 997 D11 54 and install bearing cap into bottom plate of tong using four 3 8 UNC x 1 1 4 hex cap screwsand four lock washers ASSEMBLY NOTE Do not neglect to install the clutch bearing cap spacer PN 1400 54A between the bearing cap and the bottom plate of the tong 8 Install a retainer clip PN 02 0009 into all three idler gears PN 997 A2 119 Press an idler bearing PN 02 0011 into each gear and secure with a second retainer clip 9 Lightly grease the larger circumference of the two rotary idler shafts PN 997 D19 117 and slide them through two bearing and gear assemblies centering the gear on the shaft 10 Slide two bearing seals PN 02 0010 over each end of the idler shafts and press against the retainer clips See the exploded view of the rotary idler assembly on pp 5 8 5 9 for correct orientation of the bearing seals 11 Slide a bearing space
128. over 63 Two Speed Single Pilot Closed During Crossover 65 Two Speed Double Pilot Open During Crossover 67 Two Speed Double Pilot Closed During Crossover 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 Limited Warranty Policy Rineer Hydraulics Inc warrants that at the time of shipment to Purchaser our product will be free of defects in the material and workmanship The above warranty is LIMITED to defective products returned by Purchaser to Rineer Hydraulics Inc freight prepaid within four hundred and fifty five 455 days from date of shipment or one 1 year from date of first use whichever expires first We will repair or replace any product or part thereof which is proved to be defective in workmanship or material There is no other warranty expressed or implied and in no event shall Rineer Hydraulics Inc be liable for consequential or special damages Dismantling the product operation of the product beyond the published capabilities or for purposes other than that for which the product was designed shall void this warranty S me DRILLING amp MCCOY COMPLETIONS TECHNICAL MANUAL 7 7 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K Motor INFORMATION air Manual 15 Series _
129. owest position Note that the high clutch gear or the low clutch gear may not be exactly aligned when shifting so the operator may need to bump the motor control handle slightly to turn the main clutch gear shaft and shifting collar into alignment This is most effective when applying a small amount of pressure on the gear shift lever in the direction you want to shift the tong ensuring the shifting collar will catch when the main clutch gear aligns with either the high or low clutch gear SEE ILLUSTRATION NEXT PAGE SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN CATASTROPHIC GEAR TRAIN FAILURE DRILLING amp NALCO Y TECHNICAL MANUAL 219 MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K SETUP amp OPERATION Shifting Gears Continued Move Shifting Handle This Direction To Shif To Low Gear Move Shifting Handle This General Operational Comments a Position rotary gear in contact with both idler gears when breaking out joints or collars where high torques are required b When making up integral shouldered joints it is essential to make up the last turn of the threads in low gear This reduces the tendency of an instant stop or a sudden increase in torque which induces extremely high stresses on the gear train c DO NOT employ the snap break method of breaking out joints when pulling a string By definition the snap break method is a procedure u
130. p COMPLETIONS SERVICE PERSONNEL RECOMMENDS LEAVING IT IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED 16 Remove the jaw pivot bolts and the jaw assemblies 17 Ensure the bottom cage plate is supported before beginning this step Remove the two front cage plate bolt and nut sets Remove the backing pin assembly and the rear cage plate bolt and the cage plate spacers The top and bottom cage plates may now be removed Note that the cam followers are fastened to the top and bottom cage plates so use caution not to dam age them 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 18 Remove the top nuts and pads for the rotary idler gears 19 Remove the remaining top roller shaft nuts Note that the top brake band adjustment lug weldments are removed at this point 20 Loosen but do not remove the detent bolt on the top shifter lug weldment Once the force from the detent ball has been removed from the shifter shaft the top shifter bushing can be un threaded from the top plate Take care not to lose the detent ball when the bushing comes free of the shaft 21 Remove the hex head bolts and hex flat head cap screws around the perimeter of tong that secure the top plate 22 With all the above steps taken the top tong plate can be lifted o
131. promised the tong must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam 7 9 Re energize power unit DRILLING amp AACCCOY TECHNICAL MANUAL 3 29 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K MAINTENANCE 2 0 Perform a full functional test of equipment including if applicable backup components and float components Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that used If using a frame mounted tong and backup system raise the tong off the beams that it is resting upon Remove the beams 2 7 and protective cloths inspect on top of the backup and the bottom tong to ensure it has been dam aged by the beam Test safety door feature if equipped Open the tong door s and attempt to rotate the cage plate at low speed low gear 2 2 both directions makeup and breakout If cage plate begins rotating the safety door mechanism is functional and the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPAS
132. r SHIFTING METHOD Selecting between full and partial displacement is accomplished by shifting the two position spool valve incorporated in the motor Motors are available in either single or double pilot configurations SINGLE PILOT single pilot motors require a pilot line to be connected to port When port is pressurized the spool shifts the motor to partial displacement When port C is vented to tank an internal spring shifts the spool returning the motor to full displacement DOUBLE PILOT Double pilot motors require two pilot lines One line is connected to port while the other line is connected to port D The motor is in full displacement when port D is pressurized and port is vented to tank The motor is in partial displacement when port C is pressurized and port D is vented to tank NCO Y MOVING GLOBAL ENERGY FORWARD TECHNICAL MANUAL SECTION CONTENTS 5500 5 1 18 7K OPEN DURING CROSSOVER SPOOLS Open during crossover spools allow port A to be directly connected to port when the spool is shifting between full and partial displacement Motors with 62 or 65 designations are open during crossover WARNING IN SOME WINCH APPLICATIONS OPEN DURING CROSSOVER SPOOLS 62 or 65 ARE NOT RECOMMMENDED CLOSED DURING CROSSOVER SPOOLS Closed during crossover spools do not allow port A to be directly connected to port when the spool 16 shifting between
133. r Hyarolytic Stability Cu Mass Loss mg cm2 Copper Corrosion Test Filterability Denison Wet amp Dry Afnor Wet amp Dry Cincinatti Milacron Spec Approved Denison HF 0 Denison P 46 Piston Pump Denison T6C Vane Pump Vickers 35VQ25 Vane Pump Test Vane pump test total ring and vane wear mg Oxidation Stability Turbine Oil Stability Test Life hours Rotary Bomb Oxidation Test minutes FZG Spur Gear Test Failure Load Stage FLS 14 SECTION CONTENTS TECHNICAL MANUAL 878 68 8 8 7 97 22 30 432 222 1 5 0 40 No Rust No Rust 0 04 1A Pass Pass P69 Approved Pass Pass Pass lt 10 2500 325 12 DRILLING amp COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT5500 5 1 18 7K Adequate setup and proper hydraulic connections are essential in ensuring reliable operation of your tong For best results and long term reliability read and obey the start up instructions in this section DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR A SLING LOAD BEARING DEVICE SAFETY THE SUPPLIED LOAD BEARING DEVICE CHAIN SLING RIGID SLING SPREADER BAR ASSEM BLY FRAME OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT DESCRIBED IN THIS MANUAL HAS BEEN SPECIF
134. r PN 997 D20 121 over each end of the rotary idler shafts 12 Place each rotary idler assembly through the bottom plate ensuring the ends of the shafts with the threaded holes for the grease fittings are pointed upward 13 Place an idler pad PN 1400 125 over the bottom side of each rotary idler shaft and secure each with a 1 1 2 UNF nylock nut 14 Place high pinion gear PN 997 A4 87 shoulder side down over the lower bearing and bearing cap centering as best as able 15 Install pinion gear shaft PN 997 A7 86 into the spline of the bottom pinion gear and the lower pinion bearing 16 Slide 4 needle bearings PN 02 0003 onto clutch shaft PN 997 A8 50 two on either side of the center gear Press bearings firmly against centre gear 17 Slide high clutch gear PN 997 A1 51 over the bottom end of the clutch shaft and seat gear on the needle bearings ensuring the smaller diameter on the high clutch gear is oriented toward the center gear on the clutch shaft Place lower end of clutch shaft into the lower clutch bearing that has been pre mounted in the lower body plate and mesh the high clutch gear with the high pinion gear 18 Install shifting collar PN 997 A9 62 over the top of the clutch shaft and mesh with the center clutch gear 19 Slide the shifting fork PN 997 D13 72 over the end of the shifting shaft PN 1400 71 and secure the fork in place with a 5 8 UNF hex jam nut followed by a 5 8 UNF regular hex nut Place th
135. red to maintain peak operating condition of your equipment or to match your equipment with the operating environment Examples of minor repairs are e replacement of damaged hydraulic hoses and fittings e replacement of malfunctioning pressure gauges and valves replacement of door cylinders replacement of fasteners Any replaced component must be an identical component supplied by McCoy Drilling amp Completions Replaced fasteners must be Grade 8 or equivalent or whatever fastener is specified by McCoy Drilling amp Completions A GENERAL MAINTENANCE SAFETY PRACTICES The practices identified here are intended as a guideline All personnel are responsible for performing their tasks in a manner that ensures worker equipment and environmental safety and may require taking additional steps that are not identified in this section Equipment maintenance shall be performed only by designated qualified maintenance personnel Wear approved eye wear and footwear and follow all of your company s safety guidelines Do not begin a maintenance task without the proper tools or materials on hand or the proper drawings and documentation necessary Schedule planned maintenance with operators to avoid conflicts unnecessary downtime and the danger of accidental equipment activation Notify operations when maintenance procedures are complete and equipment functionality is restored Isolate the location of the maintenance under way to prevent unaw
136. rking Load Limit or Design factor may be affected by wear misuse overloading corrosion deformation intentional al terations sharp corner cutting action and other use conditions Shock loading and extraordinary conditions must be taken into account when selecting alloy chain slings See OSHA Regulation for Slings 1910 184 ANSI ASME B30 9 SLINGS ANSI ASME B30 10 HOOKS and ANSI AMSE B30 26 RIGGING HARDWARE for additional information THE MINIMUM SLING ANGLE THE ANGLE OF THE LEG OF THE SLING MEASURED FROM THE HORIZONTAL MUST NEVER FALL LOWER THAN THE ANGLE SPECIFIED FOR THE SLING IN USE Sling Angle DRILLING amp AACCCOY TECHNICAL MANUAL 21 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K SETUP amp OPERATION 1 22 Inspection Of Slings McCoy Drilling amp Completions strongly recommends the following practices A complete inspection of new load bearing devices and attachments shall be performed by a qualified designated person prior to initial use Each link and component shall be examined individually taking care to expose and examine all surfaces including the inner link surface The sling shall be examined for conditions such as those listed in the removal criteria below In addition daily inspection of slings fastenings and attachments shall be performed by a designated person If damage or defects are found at either inspection the damaged or defective component shall be quarantined
137. rs if equipped retract and extend the remote backing pin ramp if equipped retract and extend the float cylinders Leave all cylinders except for the door cylinders in their fully retracted position The general idea is to have as little of the chrome cylinder rods exposed as possible 3 De energize the power unit 4 Repeatedly actuate the tong motor control valve lever INBOTH DIRECTIONS to dissipate any residual pressure in the valve and motor 5 Remove the hydraulic SUPPLY line from the equipment 6 Repeatedly actuate the remaining control valve levers INBOTH DIRECTIONS to dissipate any residual pressure in the remainder of the hydraulic control system 7 Connect a low pressure air supply line 10 PSI or less to the hydraulic supply line and force a small amount of the remaining hydraulic fluid from the valve assembly this will allow for thermal expansion of the hydraulic fluid if the equipment is stored or transported in high ambient temperatures Failure to do this may result in damaged or destroyed seals in the equipment 8 Disconnect the hydraulic RETURN line from the equipment 9 Disconnect remaining hoses such as case drains or lines connected to the turns counter 7 8 If any hydraulic fittings or hoses are leaking they must be repaired replaced before proceeding Wipe all excess grease from outside of equipment the access door panel Use a solvent based cleaner on 19 rags to wipe e
138. sed by some operators to break out connections accomplished by leaving slack in the jaw pipe engagement and then quickly pulling the throttle valve control lever allowing the tong to snap into its loaded or high torque condition Although this method is very effective in breaking out joints the extremely high stress placed on the gear train frequently causes gear breakage THE SNAP BREAK METHOD IS HAZARDOUS TO PERSONNEL AND EQUIPMENT H EXTREME COLD WEATHER OPERATION PROCEDURES 1 2 3 4 5 220 Consult the power unit engine operator s manual for all cold weather operating procedures and precautions Select gear and bearing lubricants that are compatible with expected climatic conditions Select hyaraulic fluid that is compatible with expected climatic conditions Allow hydraulic fluid to circulate for approximately 20 minutes after starting the power unit prior to activating the bypass valve to allow fluid to circulate to tong If the power unit is equipped with an oil temperature gauge ensure that the fluid has reached operating temperature as specified by hydraulic fluid data sheet Allow for adequate drying of moisture prior to lubricating when cleaning tong parts in cold weather AACCCODY MOVING GLOBAL ENERGY FORWARD SECTION CONTENTS TECHNICAL MANUAL KT5500 5 1 18 7K McCoy Drilling amp Completions recognizes that minor on site repairs and modifications are requi
139. spaci si taf jawed Apply Parker Super DO Labens qo the spool seal Pa ead alice ii ono thee d the ipeo aov from Hi ceu Side on ie back up ring iiem 7 and peripe plane rmm ft Peres dit ets apto ihe won rar they do not miers the parol operati iex chase Dui nog the O ring come m amia aii ilie ades ar ponl noches Step 2 Attach Spring Guides and Spring Apply Z 3 dria of Lote 26279 equivalent adhesive imer the middle af rhe female m the spon Assemhle the spring gudes 2 fim 6 FRU 2 15 nd supper Fay 2 ines 14 jamn the Heverse id 7 Torque the smpper bolt 73 39 3 irt dim CAUTION Care mast be to ensure that the retainer i nor pinched onder the halt during This result in burrs titar m y comer pan binding Check for binding spring pilde mearcst the hoesing sna tlie cenierng apong wells hyh Temperature press ho prevni Set te pob assembly aside and hei 6 eure miami hour A cunng fom the smpper holt 40 make chian ti eum 124 lbs ol TECHNICAL MANUAL SECTION CONTENTS 7 27 KT5500 5 1 18 7K VALVE INFORMATION 9 Valve Assembly Instructions Detent Spool Ass
140. t the factory prior to shipping but shipping damage must be identified before running the tong in an operational environment Carefully inspect the safety door components and test to ensure that the safety device on each door is operating correctly before releasing the tong to the operating environment TONG DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE THE POWER UNIT IS ENER GIZED INORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL Ensure adequate lube oil and hydraulic oil levels before starting engine Use start up procedures as recommended by the power unit engine operator s manual Open the Bypass Valve on the hydraulic system and inspect all pressure and return line hose connections to ensure correct and secure installation IMPROPERLY SECURED HYDRAULIC CONNECTIONS WILL INTERRUPT HYDRAULIC FLUID FLOW AND COULD RESULT IN THE FOLLOWING FAILURES e A restriction in the pressure supply hose will result in high pressure within the power unit hydraulic system which will activate the hydraulic governor and increase the engine speed to as high as maximum RPM e A restriction in the return line will result in high pressure within the power unit and the tong hydraulic system causing engine speeds as high as maximum RPM and possible failure of the motor seal Following inspection of the hoses energize the hydraulic power unit and allow it to idle until warm Allow hydraulic fluid to cir culate for approximately 10 minutes then slowly
141. t the valve spring operates smoothly c POSSIBLE PROBLEM Relief valve is leaking SOLUTION Check valve seat for scouring Check oil seals Check for particles stuck under the valve system 2 POSSIBLE PROBLEM Directional valve is leaking SOLUTION Check directional valve Neutral position should return fluid directly to the reservoir Replace or repair valve to ensure correct operation 3 POSSIBLE PROBLEM Power unit is not producing adequate pressure SOLUTION Troubleshoot power unit see user s manual for your particular unit 4 POSSIBLE PROBLEM Poor hydraulic pressure at the tong despite adequate pressure at the power unit or excessive back pressure in the return line SOLUTION Restrictions exist in line between power unit and tong Inspect integrity of self sealing couplings to ensure they are allowing full fluid flow Check to ensure no other restrictions exist contaminated catch screens or filters for example 5 POSSIBLE PROBLEM Fluid viscosity is not appropriate too high or too low SOLUTION Ensure hydraulic fluid being used is the viscosity recommended by McCoy Drilling amp Completions Power unit pump may not prime if fluid is too heavy and the hydraulic system will overheat if fluid is too light Replace with proper viscosity fluid SOLUTION Hydraulic fluid viscosity is affected by environmental conditions Ensure the fluid being used 15 suitable for high or low temperatures Replace with proper viscosi
142. tenance programs are necessary and must be established to assure safe dependable operation of your Hydraulic Tubular Connection System and to avoid costly breakdown maintenance The following maintenance procedures provides informa tion required to properly maintain your equipment Your equipment may require more or less maintenance depending upon the frequency of use and the field conditions under which your equipment operates These maintenance procedures are designed for equipment operating at 10 to 35 ambient temperature for 10 hours per day McCoy Drilling amp Completions recommends that the inspection and maintenance procedures in this section be performed as recommended in the maintenance checklists see Appendices or in conjunction with your maintenance foreman s experience and best estimate of when your equipment is due for this maintenance Purchased components included with your hydraulic tubular connection equipment for example motors valves etc may specify maintenance tasks and intervals over and above what McCoy Drilling amp Completions recommends as part of their recommended procedures Users of this equipment may choose to perform or ignore these additional tasks at their discretion Premature fouling of particulate filters within your prime mover or ancillary hydraulic power unit requires immediate hyaraulic fluid laboratory analysis to prevent premature wear of hydraulic system due to high levels of wear metals in the fl
143. tering or any other signs of potential failure replace if signs of potential failure are identified 1 3 Inspect gear train housing If the amount of grease is inadequate liberally grease the gear train through the access panel and through the opening in the rotary gear Inspect top and bottom brake band linings replace if necessary Unequal wear of the brake bands indicates that the 1 4 brake band tension is not evenly adjusted Refer to the maintenance section of manual instructions on properly 1 adjusting brake bands Ensure that all grease is wiped from brake band linings and the parts of the cage plates that come into contact with the brake band linings 15 Re install access panel Install a set of pre inspected jaws that are the correct size the pipe or casing being run Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted 7 6 components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 1 7 If applicable inspect load anchor pins tension load only Replace anchor pins if cracking or metal distor tion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression 1 8 load only If the integrity of the weld has been com
144. the ends of ibe pnan C ompress halls ind then ilip on the deseni sleeve The detent sleeve nod sememetrical onc end of mec sleeve has a lead in candice TI Jamier ace he spon cleviw Masa deter claeve vs ac middle portion to prevent ihe fon separa subsequeni 7 28 SECTION CONTENTS TECHNICAL MANUAL COY MOVING GLOBAL ENERGY FORWARD HYDRAULIC VALVE INFORMATION KT5500 5 1 18 7K Valve Assembly Instructions 9 step 1 Spool Subassembly Apply 2 262 or t te screw balas an Tua crs al the Apply a of clear mi ie valve ao the zisembly ite lansing se ciiin ua arid hers camii fit vor 1 or eT Mal sore Ihe Spo amd housimp are in the proper p ge 6 Step 2 Spool Seal and Back up Apply Pater Superd Il to lhe apd Fig Hj ami Mile cui egi nma Pig 7h Push both items into the thay bottpen aur rhe wis Gorm meina plases inem e using Io aluet Fillistez screw 4 Fig 1 atem 9 heck waia pilates fer proper dipoen l ighsen ma erue uf S4 in hs
145. the pump as possible the relief valve adjustment screw without removing it Warn Ihe hydraulic by idling the engine with Ine power take off and hydraulic angaged As applicable fully engage the control valve for ihe circull being tested Allow the cylinder to reach full extension Raise the engine RPM to operating speed f adjustmant is necessary do not bnng the pressure to a higher setting then lower il to Ihe desired getting Obtain each final pressure by bringing the pressure gradually up to the proper setting Tighten the lock nut and apply a sealant to avoid tampering Warning Relief valve pressures should be set according to the original equipment manufacturer s specifications Exceeding the specifications could cause a failure in lhe hydraulic system or with the mechanical structure of Ihe equipment These failures could cause serious personal injury or death DRILLING amp 7 32 SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD HYDRAULIC VALVE INFORMATION KT5500 5 1 18 7K DVA35 DVG35 VA35 VG35 VALVE SEAL KITS PART NUMBERS IN BOLD ARE DISTRIBUTOR PROGRAM ITEMS PART NUMBER KIT DESCRIPTION APPLICATION WHERE USED SECTION SEAL XIT BETWEEN SECTIONS INLETSECTIONS 0 WORK SECTIONS COMBINED TLOW MIDSECTION INLETS MIDSLE DON SELECTORS 39i 1803 180 SECTION SEAL KIT DETWEEN SECTIONS S
146. the tong the load cell connects to is dependant upon whether make up or break out activities are underway To ensure accurate torque measurement the torque measurement line must be connected perpendicular to the lengthwise axis of the tong and perpendicular to the hang line see following illustra tions Connect the second snub line on the opposite side of the load cell perpendicular to the lengthwise axis of the tong and perpendicular to the vertical DRILLING amp NALCO Y TECHNICAL MANUAL 215 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K SETUP amp OPERATION 2 Tong Leveling The tong must be leveled side to side and front to rear before placing into service The following guidelines will assist you when leveling your tong Place a level axially side to side across the tong ensuring that it is parallel with the surface of the tong Use a thin wrench on the flat of the adjusting helix to rotate the helix forcing the lift link to move towards the outer supports of the sling The 3 4 nylock nut on the pin may have to be slightly loosened to allow the helix to rotate Adjust the helix until the level shows that the tong is level side to side Place a level lengthwise front to back along the tong ensuring that it is parallel with the surface of the tong Loosen the 3 4 jam nuts on the adjusting bolts on rigid sling brackets Completely loosen the adjusting bolts Turn each adjusting bolt equ
147. the weld is visible Before re installing the beam liberally grease the anchor pin before reinserting into the load cell beam 3 4 Inspect load cell for damage or signs of stress Check oil level load cell and fill if necessary refer to technical manual Section 7 or Section 8 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands 35 need to be tightened Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is achieved Refer to the maintenance section of the manual for instructions on properly adjusting brake bands Perform a full functional test of the tong including if applicable backup components lift cylinder and float frame com 3 6 ponents Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used Test safety door feature if equipped Begin rotating the tong at low speed and open the tong door s If rotation does 3 7 C not immediately stop this is an indication that the safety door mechanism is not operating correctly and the tong must 8 be removed from service until the mechanism is repaired Repeat the test while operating the tong in the opposite direc tion If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latched NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR
148. ty fluid for the operating conditions if necessary 6 POSSIBLE PROBLEM Worn or damaged tong motor causing slippage SOLUTION Replace or repair worn or damaged motor 7 POSSIBLE PROBLEM Damaged bearings or gears causing excessive drag SOLUTION Replace or repair worn or damaged gears or bearings 8 POSSIBLE PROBLEM Jaws slipping on pipe SOLUTION Ensure jaw dies are not worn to the point that they cannot grip Ensure the correct sized jaws are in use 9 POSSIBLE PROBLEM Torque gauge 15 indicating incorrectly SOLUTION Incorrect gauge is being used Ensure gauge is the proper range and has been properly calibrated for the arm length of the equipment in use SOLUTION Gauge has been damaged Check gauge operation and calibration on independent system MOVING GLOBAL ENERGY FORWARD DRILLING amp AACCCOY TECHNICAL MANUAL 41 KT5500 5 18 7K TROUBLESHOOTING TONG WILL NOT DEVELOP SUFFICIENT TORQUE Cont d 10 POSSIBLE PROBLEM Load cell is measuring incorrectly SOLUTION Incorrect load cell is being used SOLUTION Air is trapped in torque measuring circuit load cell hydraulic line or gauge Refer to torque measurement trouble shooting in Section 6 of this manual SOLUTION Load cell has been damaged Replace load cell or return to McCoy for repair and re calibration 11 POSSIBLE PROBLEM Incorrect motor speed selected SOLUTION Maximum torque can only be developed when motor is in the low
149. uid McCoy Drilling amp Completions recommends tracking all maintenance activity including the lubrication schedule This may be a simple as keeping a paper log or using a software based maintenance tracking utility A maintenance log is a valuable tool that can be used for easily retrieving maintenance history or identifying trends that require correction DRILLING amp TECHNICAL MANUAL 31 MOVING GLOBAL ENERGY FORWARD KT5500 5 1 18 7K D LUBRICATION Use a quality multipurpose bearing lubricant that will remain within its viscosity range at expected operating temperatures In addition recommends the following lubrication procedure at the completion of each job prior to storage 1 Cage Plate Cam Followers Apply grease to the grease fittings recessed in both the top and bottom cage plates 26 locations total 13 top 13 bottom 2 Support Rollers Apply grease to the support roller bearings through the grease fittings recessed into the top and bottom of each support roller shaft NOTE the safety door cam assembly needs to be removed to access the grease fitting in the top of the door pivot roller shaft ten locations top ten locations bottom 32 SECTION CONTENTS TECHNICAL MANUAL MOVING GLOBAL ENERGY FORWARD 5500 5 1 18 7K 3 Rotary Idlers Apply grease to the rotary idler bearings through the grease fitt
150. uid into the system until no more air is seen escaping from the vent port g Replace the vent plug screw Stat O Seal and tighten securely Remove load cell from containment vessel and wipe clean Reclaim the hydraulic fluid if it is clean or dispose of all waste materials according to governmental or your company s proscribed environmental protection regulations i Disconnect the hand pump from the torque gauge 1 Replace the brass the torque gauge check valve fitting 3 Repair And Calibration Load cell and indicator gauge should be returned to authorized repair facility for any repairs or calibration required DRILLING amp TECHNICAL MANUAL 67 MOVING GLOBAL ENERGY FORWARD This page intentionally left blank HYDRAULIC Motor INFORMATION KT5500 5 1 18 7K POWER to be the Best MOTOR SELECTION GUIDE Features of the 15 Series Standard Motor Standard Motor 3000 PSI Code 61 B Fight fixed displacement motors ranging from 6 ins to 15 113 Starting and stall torques equal to 90 94 of theoretical torque Speed to 2 000 RPM continuous B Up to 75 HP continuous Conforms to SAE mounting specification Weighs 43 lbs CROSS SECTION 7 N 22124 Qn NN gt Lim NS Citi X 5 7 3 a
151. xternal surfaces to remove residual grease or hydraulic fluid Once the outside surfaces have been de greased wipe all external surfaces with clean water to remove residual solvent 20 Farr recommends that chain slings be removed and stored separately Rigid slings and other rigid suspension devices may remain in place 27 Apply grease or heavy oil to all exposed cylinder rods 2 2 Farr recommends that an anti corrosive agent such as Tectyl 506 be applied to all external surfaces EXCEPT cylinder s rods including chain slings Refer to manufacturer data sheets for proper application and safety information DO NOT ALLOW ANTI CORROSIVE AGENTS TO CONTACT CYLINDER RODS CYLINDER ROD DAMAGE WILL OCCUR 2 3 Allow the anti corrosive coating ample time to dry refer to manufacturer data sheets for drying times at room tempera ture 2 4 Wrap entire assembly 100 gauge 1 mil corrosion inhibiting wrap least layers thick Attempt to ensure that the tool is well sealed within the wrapping including the bottom DRILLING amp AACCCOY TECHNICAL MANUAL 3 27 MOVING GLOBAL ENERGY FORWARD KT5500 5 18 7K MAINTENANCE If possible store in a sealed climate controlled environment If isolated storage is not available Farr recommends storing your wrapped equipment in a secure out of the way location using silica gel desiccant to reduce the humidity within the wrapping As a guideline use 125 g
152. y combination of these A HAZARD may also indicate the potential for dangerous environmental contamination This identifies a HAZARD to operators or equipment A WARNING is represented by an exclamation point within an orange triangle and contains information that will alert per sonnel to a potential safety hazard that is not life threatening A WARNING may also serve to alert the user to information critical to the correct assembly or operation of the equipment in use This identifies a WARNING to users A CAUTION is represented by an exclamation point within a yellow triangle and highlights information that may aid the user during assembly or operation of your equipment CAUTIONS are also used to ensure common errors are not made during assembly or operation of your equipment This identifies a CAUTION to users Observance of the following is the full responsibility of the user e all descriptions information and instructions set out in this manual e any regulation or requirement issued by an authority or agency which may influence operation safety or integrity of the equipment that overrules the content of this document e any legal or other mandatory regulation in force governing accident prevention or environmental protection DRILLING amp X SECTION CONTENTS TECHNICAL MANUAL COMPLETIONS MOVING GLOBAL ENERGY FORWARD INTRODUCTION KT5500 5 1 18 7K Congratulations on the purchase of your
153. y the suspension line Select your suspension line based upon the total force and the margins of safety dictated by the policies of your company and by estab lished engineering practices Ultimately calculating the force on the suspension line and selection of the suspension line is the complete responsibility of the customer McCoy Drilling amp Completions recommends using dual backup snub lines of sufficient strength to withstand the force imparted by the maximum rated torque of the tong in use Calculate the force on the snub lines by dividing the maximum torque of the DRILLING amp 2 14 SECTION CONTENTS TECHNICAL MANUAL AACCCY COMPLETIONS MOVING GLOBAL ENERGY FORWARD SETUP amp OPERATION KT5500 5 1 18 7K Suspension amp Load Tie Off Continued tong by the tong s torque arm expressed in feet For example an 18 000 Ibs ft tong with a 36 inch 2 583 ft torque arm will generate 6000 Ibs of force against the snub line Select your snub lines based upon the total force and the margins of safety dictated by the policies of your company and by established engineering practices Ultimately calculating the force on the snub line and selection of the snub line is the complete responsibility of the customer Snub lines must be securely connected to the rear of the tong and tied off to a suitable anchor One snub line must be secured to the load cell which is then secured to the rear of the tong The side of
154. ylinder rods for signs of mechanical damage flak or rust Farr recommends that damaged cylinders be replaced 29 Rotate tong low gear 5 minutes while monitoring pressurized seals and hydraulic lines If a seal line or fitting k begins to leak while tong is rotating it must be replaced before the equipment is returned to service Rotate tong in high gear for 5 minutes while monitoring temperature of top and bottom bearing caps If the bearing caps 3 0 are hot to the touch higher than approximately 50 C replace the applicable bearings Likewise if the tong is making unusual noises check for damaged bearings see Maintenance Manual for all bearing locations Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted 3 1 components including links and chains If using compression load cell replace any component that has been crushed or otherwise distorted through compression 3 2 If applicable inspect the load anchor pins tension load cell only Replace anchor pins if cracking or metal distortion is seen If applicable the weld securing the single load cell anchor to the bridge bar main plate must be inspected compression 3 3 load cell only If the integrity of the weld has been compromised tong must be removed from service until the weld is repaired The load cell beam will need to be disconnected and removed so

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