Technical Manual (Revision 7-10) CM7625
Contents
1. 7 14 SECTION8 VALVE TECHNICAL DATA To request copy of Valve Technical Data please contact Superior Manufacturing amp Hydraulics 4225 Hwy 90 East Broussard LA 70518 Phone 337 837 8847 Fax 337 837 8839 www superior manf com SUPERIOR Manufacturing amp Hydraulics 7 5 8 CLIN CHERE CHROMEMASTER Revision 05 06 Page 8 1 Page 8 22. THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS 08 05 09 REV LOG DATE Page 7 8 1 LATCH ASSEMBLY ASSEMBLY NO CM7652 1008 B2 1 4 HI COLLAR LOCKWASHER 1 4 FLAT WASHER 1 4 20 x 1 2 HHCS Part Description 1 1 7601 SHANK 2 1 CM7602 A DOOR SPRING 3 1 CM7603 A DOOR LATCH PIN 4 1 CM7649 CATCH 5 1 CM7650 LATCH HOUSING 6 1 CM7651 PLUNGER 7 1 CM7653 COMPRESSION SPRING 8 1 CLE1209 B LATCH PIN HANDLE 4 1008 B1 2 2 2 11 1008 B3 1008 C 1 1028 EANAN si cl SIR NND la 1 4 20 1 2 5 5 3 8 16 1 4 SET SCREW 2 2 4 9 SECTION VIEW Ab SUPERIOR 5 Manufacturing amp Hydraulics 318 837 8847 HWY 90 EAST SSARD LA 70518 MAY NOT BE USED DISCLOSED COPIED OR REPROI FORM WITHOUT THE EXPRESS WRITTEN CONSENT MANUFACTURING amp HYDRAULICS DUCED IN ANY F SUPERIOR 04 03 06 LOG DATE lals Equip Manuals Dwgs REF 7625 7652 h wpg Page 7 9 Item Qty Part Number Part Descri
3. SUPERIOR ey Manufacturing amp Hydraulics TECHNICAL MANUAL CLINCHER 7 5 8 CHROMEMASTER MOUNTS ON 7 5 8 CLINCHER TONG amp 7 5 8 ECKEL amp FARR TONGS 7 5 8 CHROMEMASTER Mounted on CLINCHER 7 5 8 Tong amp Backup COVERS CHROMEMASTER MODELS CM7625 CM7625 E CM7625 F CM7625F 02 CM7625F 03 CM7625F 04 4225 Highway 90 East Broussard Louisiana 70518 Phone 337 837 8847 Fax 337 837 8839 Published 052006 www superior manf com Alb SUPERIOR Manufacturing amp Hydraulics TECHNICAL MANUAL CLINCHER 7 5 8 CHROMEMASTER MOUNTS ON 7 5 8 CLINCHER TONG amp 75 8 ECKEL amp FARR TONGS COVERS CHROMEMASTER MODELS CM7625 CM7625 E CM7625 F CM7625F 02 CM7625F 03 CM7625F 04 4225 Highway 90 East Broussard Louisiana 70518 Phone 337 837 8847 Fax 337 837 8839 Published 05 2006 www superior manf com Copyright 2006 SUPERIOR Manufacturing amp Hydraulics Inc All rights reserved This document is the property of SUPERIOR Manufacturing amp Hydraulics Inc Itis supplied as reference information to users of our products This document is considered confidential and is not to be disclosed copied or reproduced transmitted transcribed in any form or stored in any type of system without the express written consent of SUPERIOR Manufacturing amp Hydraulics Inc CLINCHER CHROMEMASTER LOCKJAW HYTOPS Drillmaster GRIT FACE amp Low Friction
4. Part Number Part Description 1 1 11936 SNAP RING 2 1 25001375 SEAL 3 1 CM7627 PUMP HOUSING WELDMENT 4 1 CM7628 INTENSIFIER GLAND 5 1 7630 PUMP PLUNGER 6 1 7632 SPRING 7 4 175 1 2 13 2 3 4 HHCS 8 4 1103 1 2 LOCKWASHER gt PUMP CYLINDER ASSEMBLY B 2744472 17 274 ASSEMBLY NO CM7626 Page 7 8 Ab SUPERIOR Manufacturing amp Hydraulics 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8 03 28 06 REV amp LOG DATE Manuals Dwgs Pune Item Number Part Name 1 1 86011 CYLINDER MOUNTING PLATE 2 2 CM15007 S3 SPACER 3 1 86024 CYLINDER MOUNTING BRACKET 4 1 CM15007 S6 SPACER 5 1 CM15007 S7 CYLINDER ROD COVER 6 1 CM45102 BREAK AWAY TAB 7 2 1522 SHOULDER BOLT 1 4 X 1 1 4 8 2 1025 3 8 FLAT WASHER 9 2213 3 8 16 NYLOC NUT 213 10 1 7633 LYNAIR CYLINDER 11 4 1106 SHCS 1 2 13 X 1 1 4 12 6 1040 3 8 16 x 3 4 SHCS 13 211027 WASHER LOCK 3 8 14 4 CMF7636 PUSH CYLINDER FRONT MOUNT LEG SHORT 15 1 246 1 2 13 x 1 SHCS 16 ___11CMF7638 REAR MOUNT WELDMENT F 7 5 8 PUSH CYLINDER ASSEMBLY ASSEMBLY NO CM86010 03 __sUPERIOR_ Manufacturing amp Hydraulics 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8847
5. F G H D J K Problem Restricted or clogged intake line Contaminated fluid Restricted vent Air in fluid Damaged or worn parts Excessive RPM Increased friction Damaged or worn relief valve Damaged or worn check valve Restricted discharge Valve system restricted Excessive Wear to Hydraulic Components Problem A Fluid contamination B Components misaligned C High operating pressures D Exhausted fluid depletion of additives E Airinfluid Shortened bearing life Slow Tong Speed Problem A Restricted supply line B Low fluid level C Airleak D Pump speed insufficient E Damaged or worn equipment F Pump not primed G Low or no flow from supply line H Hydraulic bypass valve malfunction SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CHROMEMASTER Revision 05 06 Solution Clean line check for contamination Flush system change fluid Clean or replace air vent Check for leaks and be certain fluid suction in tank is well below hydraulic fluid in reservoir Repair or replace damaged parts check fluid for contamination Check PTO gears and recommended speed to assure proper pump is installed for operation Make sure pump has been assembled using correct torque valves Replace relief valve Replace check valve Check to make sure relief valve is set to proper pressure Inspect and repair or replace defective parts check system for contamination
6. Solution Flush fluid system replace with new fluid Inspect and realign Gauge and set to proper pressure Flush fluid system replace with new fluid Check for leaks and be certain fluid suction in tank is well below hydraulic fluid in reservoir Check alignment insure proper lubrication to non sealed bearings Solution Clear supply line and check intake on reservoir Add fluid to proper volume Locate and repair leak Assure proper pump speed for application Isolate pump and check pressure to determine whether motor or pump is defective Repair or replace defective part Check fluid viscosity and restrictions of intake line Replace fluid if inadequate for operating temperature Check to assure couplings are securely fastened Inspect Adjust unloading pressure Replace or repair as necessary Page 5 5 TROUBLESHOOTING HYDRAULIC TONG SYSTEM Insufficient Torque A B D E F G H D Problem Door switch malfunctioning Relief valve malfunctioning Damaged or worn pump parts Slow pump speed Improper system fluid Directional control valve set improperly Damage tong motor Restriction of supply line excessive back pressure Defective gauge or load cell Difficulty Shifting Gears Problem A Broken key in shifting yoke B Worn or damaged shifting yoke pins Insufficient lubrication D Detent ball bearing spring set too tight Failure to Grip Tubulars P
7. Manuals Equip Manuals Dwgs CM7625 Installation sht1 Manufacturing amp Hydraulics 318 837 8847 __sUPERIOR_ 9 e B z 7 5 8 CHROMEMASTER INSTALLATION 8 ONIANLOVANNYN MOREINS JO INSSNOO NEL ANY NI COCOS Caio CSS 38 39 901 NOIIMARIOINI SIL SI ANY lt 0 9 PONTUALOVANNYW HORBANS SAL SI 1 SIHL 1799 168 818 2 Surinpejnuew di S3A TVA SONILLIJ oidans Np a MSISVINSINOSHO 8 6 7 NOLLVOIARIVIO 1910 ONOL aqyioya anowo LINSNOO SNOIL JAVA un E 1 A THW3SSV 33S 2 4 SNISRLL t L 8 5 LO Sy SLYOd 8 SNTWA vYS9 NO 9 0 C V5 3888 HANIVALS 75819 E 3141988 OZOWNID _ be LOANNOOSIGMOINO SWE 61 Lez 8 6 YSSHINO __L
8. 13 FITTINGS amp VALVES ILLUSTRATION 7 5 8 CHROMEMASTER 1 Generation eee 7 14 SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 05 06 Page 7 1 SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 05 06 Page 7 2 Item Qty Part Number Part Description 1 1 4582 STRIKE PIN 2 1 7645 CM COVER WELDMENT 2 CM7618 DOOR PIN 4 1 CYLINDER ASSEMBLY 5 1 7626 PUMP CYLINDER ASSEMBLY 6 1 CYLINDER 7 1 CM7635 PUSH CYLINDER MOUNT 1 LATCH ASSEMBLY 9 1 CM7657 DOOR SET ASSEMBLY 10 1 CM TOP BODY WELDMENT 11 1 CM7661 S TANK WELDMENT 12 2 PIVOT RETAINER 13 2 1181 7 8 9 x 2 1 4 SHCS 14 2 1182 7 8 COLLAR LOCKWASHER 15 2 1 2 LOCKWASHER 16 2 1 2 13 EYE BOLT 17 2 1 8 ZERT 18 1 1 4 FILLER BREATHER 19 1 3 4 x 1 4 REDUCER BUSHING 20 14 245 1 2 13 x 3 4 SHCS 21 1 GAUGE 0 5000 NOT SHOWN 22 4 1027 3 8 LOCKWASHER 23 4 1046 3 8 16 x 3 4 HHCS Sr 5 WH 1 88 7 5 8 CHROMEMASTER ASSEMBLY ASSEMBLY NO CM7625 Page 7 3 USE BLUE LOCTITE APPROX WEIGHT LBS 600 Ab SUPERIOR 255906457 Manufacturing amp Hydraulics BROUSSARD LA 70518 318 837 8847 THIS DOCUMENT 1 THE PROPERTY OF SUPERIOR MANUFACTURING a
9. HYDRAULICS Page 7 5 1 Part Number Part Description CM4582 STRIKE PIN CM5538 COVER M7618 DOOR PIN MF7621 S1 BOTTOM PLATE PIVOT PIN RETAINER 1181 7 8 9 x 2 1 4 5 5 7 8 HI COLLAR LOCKWASHER 1103 1 2 LOCKWASHER 1100 1 2 13 EYE BOLT 1 8 NPT ZERT 3 8 LOCKWASHER 3 8 16 x 3 4 HHCS 7 5 8 CHROMEMASTER ASSEMBLY Ab SUPERIOR Manufacturing amp Hydraulics 318 837 8847 d ARI d ONG THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 05 08 06 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION A MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY REV LOG DATE SSEMBLY NO CM 7625 02 FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR REF P Manuals Equip Manuals Dwgs MANUFACTURING amp HYDRAULICS CM7625 CM7625 F 02 Assy Page 7 6 aa 205 2290 ritz Egee aoo gt 6 9 amp gorz 12 gt 22 25 22952 29 5 Somer 0252 8522 2 5 20258 ZZ ASSEMBLY NO CM7621 CYLINDER ASSEMBLY Qty
10. N O N FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR REF P Manuals Equip Manuals Dwgs MANUFACTURING amp HYDRAULICS CM7625 Dimensions wpg Page 2 2 CLINCHER WRAP AROUND DIES CLINCHER Wrap Around Dies are available in three types Fine Toothed Steel Dies for low to ultra high torque applications on carbon steel tubulars including tubing casing and drill pipe Smooth Faced Aluminum Dies for low to moderate torque applications on fiberglass and corrosion resistant alloy stainless steel tubulars GRIT FACE Dies for low to high torque applications on fiberglass and corrosion resistant alloy stainless steel tubulars where the use of steel dies Is prohibited as well as on carbon steel tubulars where reduced marking is desired CLINCHER Dies are designed to match the OD of the tubing casing coupling or accessory being made up or broken out Each die is stamped on the top or side to identify its size Using Fine Toothed Steel Dies which are slightly larger than the tubular is acceptable provided the difference in diameters is less than 3 32 0 093 Aluminum and GRIT FACE Dies should be matched with the specific tubular diameters required Note The use of improperly sized dies can result in reduced torque capacity increased pipe marking and reduced die life DIE Nomenclature for CM7625 CHROMEMASTER and BUCT7625 Backup BUC7625 xxxx Fine Toothed Steel dies fo
11. are trademarks of SUPERIOR Manufacturing amp Hydraulics Inc The products described in this manual are covered by U S and foreign Patents and or pending Patent Applications This manual is not a controlled document and 1 subject to revision without notice To receive updates and insure you have access to the latest information concerning the 7 5 8 CLINCHER CHROMEMASTER M we request you complete this form and return the lower half to SUPERIOR Manufacturing and Hydraulics by mail or facsimile Access to our manuals can also be acquired through our web site www superior manf com Select the tab CLINCHER Products select the equipment from the list to get Specs page select the tab Download Manual Name Company Address Address City State Postal Code Country Telephone Fax CM Model No Serial No Tong Model No Serial No Backup Model No Serial No Assembly Date 7 5 8 CLINCHER CHROMEMASTER Technical Manual Registration Form Name Return To SUPERIOR Mfg amp Hyd Address 4225 Hwy 90 East Address Broussard LA 70518 City Postal Code Country Telephone 337 837 8847 gt Facsimile 337 837 8839 Telephone Fax Web Site www superior manf com CM Model No Serial No Tong Model No Serial No Backup Model No Serial No Assembly Date TABLE CONTENTS Hazard Warnings Description Features amp Specifications Die Information Operation
12. degree angle to the tong and at the same level to insure proper readout of torque indicator A SNUBBING LINE should always be attached even when an integral backup is in use to provide additional safety in the event of a backup slippage WARNING Users must provide a means of safely controlling the tong and backup movements in all directions when it is in use Failure to account for its size weight movement and the amount of torque developed could result in personnel injury or death CLINCHER Tongs CHROMEMASTER and Backups utilize high pressure hydraulic fluids Portions of the tong CHROMEMASTER and backup control valves hydraulic lines and cylinders may contain high pressure fluid even when the power unit is de energized and the fluid supply hoses are disconnected During normal operation the temperature of the hydraulic fluids as well as hoses piping valves etc can rise to a level which can cause burns WARNING Personal protective gear including safety glasses face shields protective gloves and protective clothing must be worn to guard against the hazards of high pressure fluids Tight fitting clothing is required to prevent entanglement in rotating components These tools should be serviced by thoroughly trained and qualified hydraulic technicians using procedures to safely insure hydraulic pressure is bled from these circuits The CLINCHER Tong is equipped with a door interlock system which prevents tong rotation when
13. device when trans porting equipment PINHOLE LEAKS If you observe a pinhole leak discontinue use of the component If oil has penetrated your skin or contacted your eye seek medical attention immediately Page 2 DESCRIPTION and FEATURES The CLINCHER 7 5 8 CM7625 CHROMEMASTER can be added to 7 5 8 CLE7625 02 CLINCHER Tong The CLINCHER 7 5 8 7625 CHROMEMASTER can be added to 7 5 8 Eckel Tong The CLINCHER 7 5 8 7625 CHROMEMASTER be added to 7 5 8 Farr Tong with the old style ring gear The CLINCHER 7 5 8 CM7625F 02 and CM7625F 03 CHROMEMASTER can be added to 7 5 8 Farr Tong with the new style ring gear The addition of these CHROMEMASTER allows the use of smooth non marking non penetrating dies to run CRA corrosion resistant stainless steel alloy or fiberglass tubing strings These smooth dies are manufactured from aluminum to prevent marking and to avoid contaminating CRA tubing strings with materials which could initiate corrosion problems GRIT FACE Dies may also be used with CRA tubulars to provide high torque performance while protecting these tubulars from damage contamination The CHROMEMASTER will also accept fine tooth dies for applications where conventional steel tubulars are being run The CHROMEMASTER has three wrap around dies which provide up to 340 degrees of pipe coverage These dies are hydraulically activated by means of a system which
14. door safety switch Engage low gear open tong door and push rotor control lever forward as if to rotate rotor If safety device is operational then the rotor will not rotate Check lifting hanger test date Check lifting hanger for damage Ensure that a load test and inspection was carried out within the last 9 months Check condition of all hydraulic hoses and fittings Visually inspect all hydraulic hoses fitted to the tong and in the backup for any signs of leaks cuts or wear Remove CHROMEMASTER doors paint strip MPI magnetic particle inspection Pull pins out of the CHROMEMASTER doors after releasing grub screws Paint strip doors overnight by placing in paint strip solution Doors should then be cleaned and checked before submitting them for MPI testing All cracks should be noted on the service sheet Replace doors using grease on pins and ensure securing devices are fitted to the hinge pins Check CHROMEMASTER cam bolts Ensure that the bolts which secure the cam lugs on_ the CHROMEMASTER are tight These can be reached from inside the bore of the tool Check CLINCHER retaining lugs on CHROMEMASTER and tong Check condition of bottom lugs on CLINCHER Backup These are welded in place and buffed flush and should show no signs of damage or cracking The CHROMEMASTER door bottom lugs should be checked during MPI of these items Ensure all top lugs are present with bolts Ensure they are not bent
15. lt lt 06 LANA 8 X LANA 8 6 ez 06 SENL W 8 X LANN 8 TVE SS 8 EN I8 OS HOS OL X 8 210 SBILdVOV 38nLWN X LANG 196 9 9 9 8 6 0 9 8 X 2 9 SAL w e He 154 0006 0 39NY ONIENL 8 2 8 5 ZA IVA VI JAVA MO3HO OSSHNOJ Z OL 2912140 M3 IddIN 8 2 sanoj 6 55 33S 19199015 8 5 9 4 Nanay ZL 86 u V X 8 5 987 e S N m e ex sai 0 d SOS aveau BI X Z NONO pe 06 SENL W X 99 c i vd MSSADN Lewd ALO IAB LI Sc Ve NVOHS LON Page 7 13 MEME NN EM sk ANY CASN AYN 4901 AdH HORIaNS SHI SI SIH
16. mental capacity No work of any type including changing of dies is to be carried out while the tong and backup are connected to any hydraulic power unit CLINCHER Tongs CHROMEMASTER and Backups are heavy tools They should be suspended from a secure high strength 7 8 IWRC minimum diameter wire cable with a 31 ton minimum breaking strength The wire rope should be hung as close to the center of the wellbore as possible without interfering with drilling equipment operation to allow the tong to be readily swung into the working position Vertical position control should be achieved by means of a CLINCHER hydraulically operated lift cylinder spring hanger WARNING Users must insure the entire suspension system including cables rig mounting points lift cylinders tong lifting brackets bridles winches pulleys counter weights etc are capable of handling the static weight of the tong and backup plus any loads which could be transferred to it during the makeup or breakout process PLUS any shock loads which may be seen during operation This system must readily allow downward movement equal to a minimum of the thread makeup distance to avoid overloading the suspension system and or damage to equipment A 1 IWRC minimum diameter wire cable with a 51 7 ton minimum breaking strength or better should be attached at a SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTERTM Revision 04 06 Page 1 1 90
17. set screw on the CHROMEMASTER Bleeder Valve CM4556 See Illustration of Maintenance Instructions evidence of packing leakage is observed the packing nut should be tightened using the procedures shown on the illustration If valve continues to leak after adjustment it should be replaced F Clean and inspect backup operating cylinder Insure spline area is free from damage and any rust or dirt is removed Replace any missing or damaged die retainer clips and die retainer bolts G Inspect all hoses for wear replace as necessary H Inspect hanger assembly to assure all parts are returned and in operating condition i e H Plates spring leg springs leg spring caps and pins D Replace jaw and pins in tng CHROMEMASTER SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 04 06 Page 5 1 J Lubricate tong s cam followers upper and lower dumbell roller shafts upper and lower zerts door shaft idler gear shafts pinion gear and secondary gear assemblies Pinion gear and secondary gear assemblies are sometimes installed with sealed bearings There is no provisions to grease these bearings However if replaced by non sealed bearings the 1 8 N P T flush plugs should be replaced with zerts PN 1001 and both gear assemblies should be added to the regular lubrication schedule low gear housing and shift housing and re pack tong body cavity Lubricate zerts in backup plates
18. the backup to prevent a false torque reading Check that the tong and backup are correctly aligned with full torque applied and check that the break out bar fitted is the proper length and does not give false torque readings The number of the tong should be stamped on the break out bar Check CHROMEMASTER ram pressure set to 2 500 psi Pressurize CHROMEMASTER head WITH jaws and pipe to grip Ensure pressure limiting valve is set to restrict the maximum pressure available to 2 500 psi Check Backup pressure control valve Adjust valve fully anti clockwise then while fully depressing the backup spool handle adjust the pressure control valve clockwise to increase pressure up to 2 000 psi on the backup gauge Readjust pressure back down to 1 200 psi Remove the pressure and then reapply ensuring only 1 300 psi is applied and that the pressure is held Check lift cylinder valve Connect lift cylinder to power tong If the load valve is operating properly the tong should rise smoothly and there should be no sudden movements When lift cylinder is half its stroke the tong should be left suspended for 2 minutes The lift cylinder should not be seen to extend during this period SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTERTM Revision 04 06 Page 5 4 15 2 3 29 30 31 32 33 Check for hydraulic leaks Once the hydraulic oil has reached a temperature of approximately 4
19. transfers hydraulic power from the stationary section of the tong to the rotating section of CHROMEMASTER M This completely eliminates the need to connect and disconnect hoses every time a joint is made up or broken out This transfer of hydraulic energy is accomplished by means of a push cylinder which is fixed to the stationary portion of the tong and operated by the CHROMEMASTER directional control valve The push cylinder s rod acts against a pump plunger located on rotating section of the CHROMEMASTER Every time the rod is extended the pump is stroked to generate pressure within the CHROMEMASTER W S hydraulic circuit The piston areas in the push cylinder and the pump are sized to cause pressures to be intensified within the CHROMEMASTER to 4 500 psi when the hydraulic power unit pressure is limited to 3 000 psi SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTERTM Revision 04 06 Page 2 SPECIFICATIONS The torque capability of CLINCHER when dressed with fine tooth dies matches the rating of its companion tong Ratings for CLINCHER Tongs are tabulated below MAXIMUM TORQUE RATING FT LBS MAXIMUM TUBING SIZE INCHES The torque capacity of the smooth CHROMEMASTER die is a function of the radial load applied to the die and the coefficient of friction of the contact interface between the die and the tubing Extremely small di
20. valve MISAPPLICATION Always use the proper valve for the job CONVERTA CD CS or CA valves should never be used for metered heavy load lifting loaders or similar applications Use an open center valve for open center applications and a closed center valve for closed applications If in doubt check with your tractor dealer Contact CROSS if the valve allows the hydraulic equipment to creep excessively MAINTENANCE Make sure all bolts are tightened and torqued to the recommended specification Bent or broken parts should not be used Replace immediately Always use exact replacements Always protect valve spool from paint overspray Faulty quick disconnects can cause high back pressures and sticking spools Check quick discon nects periodically to make sure they are functioning properly If valve spool does not center or appears to stick do not use PUMPS amp MOTORS SAFETY A A relief or bypass in your hydraulic system is necessary to prevent pump from breakage due to overpressurization Use correct fittings and proper oil as noted in the technical service manual packed with each unit Change oil as recommended by your implement or tractor manufacturer CYLINDER SAFETY Check clevis clearances before during and after extending the cylinder and before using the cylinder under pressure to avoid possible injury or bent or broken rods caused by binding Never operatea cylinder above recommended pressures Never use a cylinder as a safety
21. 0 operate the backup retract or the lift cylinder while visually checking all components for oil leaks i e Spool valve assemblies hoses connections and rams in backup Check case drain oil flow rate Stall power tong motor at 2000 psi with a flow meter in the case drain line Measure the volume of oil flowing from the case drain The flow must not exceed 18 liters per minute Lubricate tong backup and CHROMEMASTER according to maintenance schedule preceding this section Paint remembering to mask off surfaces not intending to paint with grease or masking tape Complete dated inspection report giving details of all duties performed along with complete list of items replaced DU BEARING DRY WEAR PROCESS 242 S Hits MA io AB POSTEUR 1 2 3 Running in completed Low wear rate starts when up to 10 of the bronze is exposed Typical surface appearance when DU bearing approaches its half life with 40 to 50 of the bronze exposed Bronze is beginning to smear near the end of DU s useful life as a dry bearing Over 75 of the bronze is visible at the surface Coltec Industries For additional information about DU bearings please contact Garlock Bearings Inc 700 Mid Atlantic Parkway Thorofare New Jersey 08086 609 848 3200 FAX 609 848 5115 Garlock Bearings Inc TROUBLESHOOTING HYDRAULIC SYSTEM Hydraulic Pump Making Excessive Noise A B D E
22. 0 6 000 3 590 3 875 3 900 3 950 4 000 4 050 4 053 6 045 6 050 6 051 6 075 6 079 6 100 6 150 4 069 4 138 4 200 4250 4 313 4 375 4 460 6 180 6 240 6 248 6 500 6 625 6 750 7 000 4 500 4 600 4 620 4 862 4 968 5 000 5 012 7 020 7 191 7 290 7 390 7 413 7 625 7 644 5 150 5 181 5 250 5 350 5 500 5 550 5 563 7 681 7 700 7720 7731 7772 7 190 7 852 5 577 5 590 5 650 5 653 5 700 5 750 5 870 5 890 5 960 6 000 6 025 6 050 6 051 6 071 6 075 6 100 6 125 6 135 6 150 6 153 6 156 Contact SUPERIOR Manufacturing amp Hydraulics for 6 170 6 200 6 250 6 400 6 500 6 625 6 750 information concerning availability of stock and special die 6 940 7 000 7 250 7 390 7 430 7 440 7 579 sizes 7 625 7 656 7 675 7 681 7 700 7 50 SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 05 06 Page 3 2 OPERATIONAL INSTRUCTIONS SUSPENSION A B D Tong should be hung by a 7 8 IWRC minimum O D wire cable with a 31 ton minimum breaking strength It should be hung as close to the center of the drill rotary without interfering with operation of drill string and lifting equipment It is recommended the operator make use of the CLINCHER Lift Cylinder The CLINCHER Lift Cylinder incorporates a hydraulic cylinder and manual lift spring The hydraulic cylinder portion is used to assist in the raising and lowering of the tong and backup while the spring allows for movement during make up and break out WARNING The suspension s
23. AINTENANCE INSTRUCTIONS CLINCHER recommends that owners of CLINCHER Hydraulic Power Tongs Backups CHROMEMASTER and accessories adapt a regularly scheduled maintenance program Implementation of this type of program offers several benefits First you increase the life of your equipment secondly you may find a problem before it escalates to a costly repair or down time on the job and most importantly prevent injury to operating personnel A major inspection described at the end of this section should be carried out if equipment is suspected to have been damaged during transit or is to be mobilized to a remote location where maintenance operations are difficult to carry out Routine Maintenance Cleaning Upon return from each and every job Pre wash unit to remove majority of dirt and grease build up as to allow removal of dies and inspection of overall condition of unit B Remove and inspect dies from tong and backup Note any missing or damaged die retainers and or die retainer bolts C Remove side jaws from tong CHROMEMASTER and inspect side jaw for missing or broken parts damaged splines broken ears locking hooks on front portion of side jaws D Clean and inspect side jaws and jaw pins for damage or excessive wear cracks breakage and uneven wear patterns Reassemble jaw sections replacing any damaged parts Lubricate pins and reinstall in tong E Inspect position of the handle and its securing
24. DMENT 3 2 2 7618 DOOR PIN 4 1 1 7621 CYLINDER ASSEMBLY 5 1 1 CM7626 CYLINDER ASSEMBLY 6 1 1 7633 CYLINDER 7 1 1 1 CMF7635 PUSH CYLINDER MOUNT 7 2 4 4 CMF7619 PUSH CYLINDER MOUNT LEG 8 1 1 7652 LATCH ASSEMBLY 9 1 1 7657 DOOR SET ASSEMBLY 10 1 0 CMF7617 CM TOP BODY WELDMENT 10 0 1 CMF7617 01 CM TOP BODY WELDMENT 11 1 0 7621 WELDMENT 11 0 1 CMF7621 01 TANK WELDMENT 12 2 2 7696 PIVOT RETAINER 13 212 1181 7 8 9 x 2 1 4 SHCS 14 2 2 1182 7 8 COLLAR LOCKWASHER 15 2 2 1103 1 2 LOCKWASHER 16 2 2 1100 1 2 13 EYE BOLT 17 2 2 1001 1 8 ZERT 18 1 1 7622 1 4 FILLER BREATHER 19 1 1 1493 3 4 x 1 4 REDUCER BUSHING 20 4 4 245 1 2 13 3 4 SHCS 21 1 1 1651 GAUGE 0 5000 SHOWN 22 4 4 1027 3 8 LOCKWASHER 23 4 4 11046 3 8 16 3 4 5 1 88 7 5 8 CHROMEMASTER ASSEMBLY FOR FARR TONG ASSEMBLY NO CM7625 F ASSEMBLY NO CM7625F 03 Page 7 5 USE BLUE LOCTITE APPROX WEIGHT LBS 600 Ab SUPERIOR Manufacturing amp Hydraulics 4225 HWY 90 EAST BROUSSARD LA 70518 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFAC
25. L 90 60 80 2788 263 gig s uneupan 3 Sunpesnuen dOldddns Wy SANTVA 8 wi YALSVINSINOUHD 8 4 2 x DES CRM 71 1 Sino m NOLLVOHISY TO 404 NOY E TWNNVW 9NOL L1NSNOO AHVA SNOIL Gun JAVA LON NMA 13710170 T LOANNOOSIC AANO TWN 8 ZA TVA MOSHO 86 YSSHNO 06 LdN4 8 X LANA 8 G L 6X g 06 JIANLIN 8 X LANN 8 JAWA SS 8 eL 6X 8 6 UYALAVOV 3anr 8 X LANA 8 UYALAVOV 8 X LANN 8 5 8 X LANN SOCMLYVO M AA TWA MOSHO dO LO Td AA WA MOSHO 2912130 E E M 3 Idd IN 8 8 19199015 8 6 A IddIN 8 6 YSONGSAY X 8 A2AONI UD 19199015 ONIHSNE X v 6 8 4 154 0006 0 6 06 SENL WX 4 v co NOLLdIOS3Q Ltd ai 89475584 ONIENL 8 5
26. Open door Release backup by pulling back on right control lever on rear valve bank assembly until backup jaws are completely retracted High and low gear is adjusted by use of shifting handle PN 45142 located to the left side of the shifting housing With the lever in the upwards position the tong is in high gear With the shifting lever in the downward position the tong is in low gear TYPICAL TONG INSTALLATION NOTE TONG IS PERPENDICULAR TO TUBING IMPORTANT NOTE Insure CHROMEMASTER push cylinder rod is fully retracted The push cylinder is located on bottom sides of CLE7625 02 or equivalent 7 5 8 Tong Refer to Step 11 for retraction instructions Failure to retract rod before rotating will result in severe equipment damage Rotate CHROMEMASTER to align arrows on Tong and CHROMEMASTER head by manipulating tong directional control valve IMPORTANT NOTE These items must be aligned to insure proper operation and to avoid severe equipment damage when the CHROMEMASTER push cylinder is extended OPERATIONAL INSTRUCTIONS manipulating CHROMEMASTER directional control valve Operating this 3 Pull up CHROMEMASTER latch handle
27. TURING amp HYDRAULICS 05 08 06 REV 4 LOG DATE REF P Manuals Equip Manuals Dwgs CM7625 CM7625 F Assy wpg Item Qty Number__ Part Name 1 1 CMF7617 01 7 5 8 CM TOP BODY WELDMENT F NEW FARR RING GEAR 2 1 7621 01 TANK WELDMENT 3 21181 7 8 9 X 2 1 4 SHCS 4 21182 7 8 HI COLLAR LW 5 2 7696 PIVOT RETAINER 6 21001 1 8 ZERT 7 41027 WASHER LOCK 3 8 8 41046 HHCS 3 8 16 3 4 9 21100 1 2 13 EYE BOLT 10 ___2 1118 a 1 2 13 JAM NUT 11 1 7626 PUMP CYLINDER ASSEMBLY 12 1 7621 CYLINDER ASSEMBLY 13 1 7657 DOOR SET ASSEMBLY 14 1 7645 CHROMEMASTER COVER WELDMENT 15 1 7652 LATCH ASSEMBLY 16 1 4582 STRIKE 17 2 7618 18 1 86010 03 PUSH CYLINDER ASSEMBLY F FARR 7 5 8 19 1 1493 3 4 1 4 REDUCER BUSHING 20 1 7622 1 4 FILLER 7 5 8 CHROMEMASTER ASSEMBLY FOR FARR TONG ASSEMBLY NO CM7625F 04 Ab SUPERIOR 2550 02257 BROUSSARD LA 70518 Manufacturing amp Hydraulics 318 837 8847 THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 08 05 09 HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION REV LOG DATE MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp
28. al Instructions Maintenance Instructions amp Trouble Shooting Spare Parts Recommendations CHROMEMASTER Illustrations Valve Technical Data IN IN 7 5 S CLINCHER CHROMEMASTER TABLE SUPERIOR SUPERIOR Manufacturing amp Hydraulics Inc amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 05 06 Page 0 1 0 2 7 5 8 CLINCHER CHROMEMASTER HAZARD WARNING Nomenclature used in this manual WARNING concerns an operating procedure or practice that if not strictly observed can result in injury to personnel or loss of life Caution concerns an operating procedure or practice that if not strictly observed can result in damage to or destruction of equipment Note concerns an operating procedure or practice that needs highlighting CLINCHER Tongs CHROMEMASTER and Backups are manufactured to provide a means of making up or breaking out high torque tubular connections They utilize high pressure hydraulic fluid power which can cause the tong to move suddenly and with great force if the tong is not properly rigged up and operated CLINCHER Tongs CHROMEMASTER and Backups contain rotating and reciprocating parts which can severely or fatally injure personnel who are operating repairing or near this equipment during its operation WARNING Tongs CHROMEMASTER and Backups are not to be operated by untrained personnel or personnel with diminished physical or
29. and pins K Install dies of a size needed for testing purposes and attach hydraulic power unit to tong Before energizing power unit make certain no one is working on tong or backup and all tools and parts are removed from the tong and backup L Insert test mandrel of the exact same size as the dies which are installed in the tong and backup Caution Testing the function of the backup without the proper size dies installed and or without the proper sized mandrel in place you risk serious damage to the backup cylinder M After power unit has reached operating R P M and temperature operate the backup control valve and close backup around test mandrel using sufficient flow and pressure to clamp mandrel and maintain pressure to backup Recommended operating pressure of 2 500 psi Backup pressure gauge should match system operating pressure After release of control valve you may experience a slight drop in backup pressure up to 300 psi this is normal If backup pressure drops more than 300 psi within 2 minutes you may be experiencing a hydraulic leak N While maintaining pressure on backup visually inspect hoses stainless steel lines fittings etc for seepage of hydraulic fluid Repair or replace parts causing leaks If you see no visible external leaks and your backup is still losing pressure there may be an internal leak in the operating cylinder or load holding valve allowing fluid to bypass the piston It is recommended th
30. and that the threads are clean free and greased Check CHROMEMASTER bottom plate bolts Check that the bottom plate bolts on the Chrome master are tight and that there is no sign of movement of the bottom plate relative to the top plate These bolts hold the CHROMEMASTER together 21 22 23 24 25 26 27 28 MAINTENANCE INSTRUCTIONS Check CHROMEMASTER oil level Remove the filling level plug from the side of the reservoir and fill with hydraulic oil level with the plug Remove bolts securing CLINCHER side plates and remove plates Steam clean tong and backup ensuring all foreign material is removed Take care not to remove lubrication from tong and backup cylinders Remove retaining bolts at the back of CLINCHER hydraulic rams 4 total and check They should be free from damage cracks and bends Replace with grease and ensure they are secure and sufficient threads engage into the nuts Function test tong ensuring turns counter works Operate the tong and record the maximum torques in both high and low gears Ensure turns counter if installed registers correct number of turns per revolution Check front and rear legs for clearance Fit torque gauge to backup Connect tong to hydraulic power supply Position suitable pup joint in tong and backup With maximum torque applied in both directions visually check that there is sufficient clearance between the front and rear legs of the tong and
31. at the backup be returned to the manufacturer for repair If at this time your backup is functioning correctly open and close unit several time to insure consistent operation P With the proper dies installed in the tong and backup and test mandrel locked in the backup place reversing pin into the make up position set tong into low gear and operate tong through several cycles of locking biting and torquing to required torque Change reversing pin to break out position and repeat Repeat same procedure in high gear Note Torque developed in high gear is considerably less than torque developed in low gear MAINTENANCE INSTRUCTIONS Q Test door interlock system by opening door slightly with tong rotating Remove test mandrel for this procedure The tongs rotation should stop If tong rotation fails to stop close door cease rotation deactivate power unit and inspect door interlock switch for damage Insure that adjustment collar is oriented to allow wheel of door switch to fit into recess on collar Warning If door switch system is not functioning properly tong must not be used MAINTENANCE INSTRUCTIONS CHROMEMASTER BLEEDER VALVE CM4556 2 Tang on handle must overlap tang on body NI gt 7 LB S FIGURE 1 General Two Way Valve Cross Sectional Assembly with Standard Teflon Packing Ab BROUSSARD LA 7051 8 Manufactur
32. cedure as outlined in your owners manual supplied by the manufacturer In the event hoses are not tightened securely possible failures to hydraulic system can occur 1 If pressure supply hoses are restricted or flow is blocked pressure will increase in the hydraulic power unit resulting in increased RPM in the power unit 2 If return line hoses are restricted or flow is blocked pressure will increase in the hydraulic power unit and the hydraulic system to the tong itself resulting in the tong motor increasing to maximum pressure and possible motor seal failure After completion of A through E restart the power unit and allow engine to idle for approximately 10 minutes Slowly close bypass valve to allow circulation of hydraulic oil through tong and hoses Place shifting lever into low and rotate several times Repeat in reverse If correct jaw die combination is installed the unit is now ready to run pipe Adjust height of tong to proper height using the control valve located all the way to the right of rear valve bank assembly OPERATIONAL INSTRUCTIONS H Stand in the normal operators position insert the locking pin into the rear cage plate hole on operators side This pin allows ring gear to rotate clockwise make up and engage the cam to close jaws on pipe I Swing tong and backup onto tubing making sure to align tubing on rear jaw of backup Close backup jaws by pushing middle control lever forward The design o
33. een the tang on the handle and the tang on the valve body Without contact between the tangs the operator can not properly position the ball valve in the closed position CHROMEMASTER clamping cylinder fails to retract HYDRAULIC BACKUP SYSTEM Failure to hold tubulars Problem A Incorrect die for size tubular Dies have material compacted in tooth area worn teeth Power unit pressure set incorrectly D Counter balance valve not holding pressure E Internal leakage in backup cylinder F Jaws will not retract Counter balance valve is stuck G External leakage of cylinder H Control valve set to neutral but jaws extend SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 04 06 Solution Inspect and replace defective parts Replace control valve Replace spring plunger Replace motor shaft seal Improperly maintained bleeder valve Follow Maintenance Instructions for CHROMEMASTER Bleeder Valve CM4556 Remove and clean exterior of cylinder and recess where cylinder operates to remove any rust or dirt Lubricate with clean grease If everything looks good when you examine the cylinder and recess you should disassemble the cylinder and check for internal damage and or seal swelling Seal swelling is the most likely cause of the problem If the cylinder continues to fail to retract replace the springs with new ones If the cylinder continues to fail to ret
34. ever the door is open This system is to be tested before each mobilization and at every shift change Should this system be determined to be inoperative the tong is to be removed from service and tagged as in operative until repairs are made CAUTION Operating the tong with the door in the open position could result in severe damage to the equipment and will void all manufacturer warranties WARNING Operating the tong with the door open by means of a defective or bypassed door interlock system exposes the operator and nearby personnel to potentially fatal hazards No attempt should be made to operate the CLINCHER Tong CHROMEMASTER and Backup for any purpose other than which it is intended This system is capable of generating very large clamping forces and torsional loads which if improperly applied or controlled could result in damage to the tubular to the tong and backup or could possibly result in injury or death of personnel Do not attempt to operate the unit without correct dies and the proper size tubular being in the tong CHROMEMASTER and backup See Section 3 for more information concerning the selection and use of dies CAUTION Operating this equipment without the correct size type and orientation of dies can result in damage to the equipment or tubulars being handled HYDRAULIC PRODUCT GENERAL INFORMATION SAFETY HYDRAULIC PRODUCT SAFETY WARNING Valve lever spool may stick not center under cer
35. f the CLINCHER Integral Backup centers pipe in the backup and tong Close tong door J Rotate ring gear clockwise by pushing motor control lever on the front valve bank assembly forward until jaws lock on pipe and continue to rotate until desired amount or torque is applied 9 TYPICAL SNUB LINE INSTALLATION NOTE SNUB LINE IS PERPENDICULAR TO AXIS OF TONG CAUTION DO NOT operate cylinders on CLINCHER Backup or CHROMEMASTER without installing proper sized dies or without installing tubing in unit 1 Refer to Tong Operating Instructions to insure Hydraulic Power Unit is properly rigged up for level operation Insure load cell and torque gauge are properly filled with fluid Check hydraulic connections to tong and backup assembly Set Power Unit s pressure relief valve to 2 500 psi for normal applications Note This setting can be increased to a maximum of 3 000 psi for applications requiring high makeup or breakout torques SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 04 06 Page 4 2 K After correct amount of torque specific to that connection has been applied release tong jaws by pulling back on motor control lever until jaws release and throat in cage plate is aligned with door opening
36. fferences in this contact interface caused by pipe varnish mill scale eccentricity or pressure of a lubricant such as thread dope oil or water can cause a large variance in the torque capacity of a non marking die In extreme high torque applications it may be necessary to install silicon carbide paper between aluminum dies and the tubing in the CHROMEMASTER as well as in the CLINCHER Backup One piece is required for each aluminum jaw Sheets should be folded along one edge to allow it to be hooked over edge of dies The sheets of silicon carbide paper should be visually inspected after each joint and replaced when torn or worn BACKUP APPLICATION The CLINCHER Backup s front jaws are hydraulic cylinders During a jaw closing cycle the front jaws advance and clamp the pipe against the fixed rear jaw Once locked on the pipe pressure is locked in the backup cylinder by a load holding valve When opening the front jaws retract to allow the pipe to be removed CLE7625 7 5 8 TONG TOP VIEW 211 O D 8 13 16 16 1 4 MAX HEIGHT 7625 CLINCHER 7 5 8 TONG 1 3 16 FRONT VIEW A SUPE RI O R 4225 HWY 90 EAST BROUSSARD LA 70518 7 5 8 Uy manutactur ring amp Hydraulics 918 837 8847 Neue UTE ME rox DATE MAY NOT BE USED DISCLOSED COPIEI PROI D IN At D
37. ing amp Hydraulics 818 837 8847 1 04 27 06 REV LOG DATE REF P Manuals Equip Manuals Dwgs ILL1089 rev1 wpg THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 05 06 Page 5 2 Re inspect tong and backup hydraulic system for leaks S Ifat this time the unit is functioning as intended replace all covers and grease splines in tong and backup side jaws and back jaws tape or grease spools on control valves to prevent paint from adhering to polished spool surface prime and paint unit for storage WARNING Failure or improper selection or improper use of the products and or systems described herein or related items can cause death personal injury and property damage Maximum Allowable Working Pressure amp Temperature Valve Body Material Stainless Steel 6000 psi 70 F Seat Material Kel F Packing Adjustment For B Series Ball Valves with Teflon Stem Packing Packing adjustments may be occasionally necessary depending on the many and varied uses for the valve It is recommended an adjustment be made shortly after initial installation and just prio
38. k Valve CM7656 01 3 Backup Die Clip DVG35 HMRV 1 Relief Cartridge SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 05 06 Page 6 1 6 2 SECTION 7 CHROMEMASTER ILLUSTRATIONS 7 5 8 CHROMEMASTER ASSEMBLY Assembly 7625 7 3 7 5 8 CHROMEMASTER ASSEMBLY FOR ECKEL TONG Assembly No 7625 scce 7 4 7 5 8 CHROMEMASTER ASSEMBLY FOR FARR TONG Assembly 5 CM7625 F amp 7625 03 7 5 7 5 8 CHROMEMASTER ASSEMBLY FOR FARR TONG Assembly No 7625 04 0 0 7 5 1 7 5 8 CHROMEMASTER ASSEMBLY FOR FARR TONG Assembly CM7625F 02 seen 7 6 CYLINDER ASSEMBLY Assembly No CM7621 ssecsscsevcssevesevessevssenenenenensecenencusesesenensacusesasenenessesenesonsaenensnnenenensaaes 7 7 PUMP CYLINDER ASSEMBLY Assembly 7626 7 8 PUSH CYLINDER ASSEMBLY Assembly No 86010 03 7 8 1 LATCH ASSEMBLY Assembly 7652 2 100 era no a aia ai a 7 9 DOOR SET ASSEMBLY Assembly 7657 000 de ea bee a aaa a 7 10 CHROMEMASTER INSTALLATION Shit 2 4 4 00 000000000000000000 0 7 1 CHROMEMASTER TM INSTALLATION Sht 1 eese tenete nennt tnnt ttn te nette intense 7 12 FITTINGS amp VALVES ILLUSTRATION 7 5 8 CHROMEMASTER 2 Generation 7
39. located on shift housing Inspect and relieve pressure by adjusting set screw spring plunger on shifting gear PN 55084 02 Solution Inspect die size and replace with correct dies for pipe Wrong size dies for tubulars Assure suspension of tong is perpen dicular to tubulars Adjust hanger as necessary Inspect for excessive wear on brake band Inspect and replace defective cam followers Remove rust and debris from jaws and jaw pockets Inspect jaw rollers and pins for wear flats and lubrication Repair replace and lubricate as needed Inspect for excessive wear on brake band Inspect and replace defective cam followers Remove rust and debris from jaws and jaw pockets Inspect jaw rollers and pins for wear flats and lubrication Repair replace and lubricate as needed Inspect and replace defective gears Inspect and repair or replace defective shifting parts Page 5 6 TROUBLESHOOTING HYDRAULIC TONG SYSTEM Failure to Grip Tubulars Problem E F G H D J Tong binds under light load Worn or damaged cam followers dumbell roller bearing or idler bearing Ring gear rotates while control lever is in neutral Shift will not stay in set position Lost spring plunger Hydraulic fluid leaking from motor Damaged or worn motor shaft seal CHROMEMASTER not holding pressure Bleeder Valve set screw which retains the handle loosens allowing the handle to move until no overlap exists betw
40. mp HYDRAULICS AND IS CONSIDERED CONFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR MANUFACTURING amp HYDRAULICS 1 05 08 06 REV 1 DATE P Manuals Equip Manuals Dwgs RE CM7625 Assembly rev1 wpg Part Number Part Description CM4582 STRIKE PIN CM7638 COVER CM7696 PIVOT PIN RETAINER 7 8 9 x 2 1 4 SHCS 1182 7 8 HI COLLAR LOCKWASHER 1103 1 2 LOCKWASHER 1100 1 2 13 EYE BOLT 1001 1 8 NPT ZERT 1 4 NPT FILLER BREATHER 1493 3 4 x 1 4 REDUCER BUSHING 245 1 2 13 x 3 4 SHCS 1651 GAUGE 0 5000 NOT SHOWN 1027 3 8 LOCKWASHER 1046 3 8 16 x 3 4 HHCS 4522 52 VALVE PROTECTOR CME7620 RING GEAR LUG NOT SHOWN USE BLUE LOCTITE 1 88 7 5 8 CHROMEMASTER Ab SUPERIOR 2550 0 55 BROUSSARD LA 70518 Manufacturing amp Hydraulics 318 837 8847 FOR ECKEL TONG Lt 090806 MAY USED DISCLOSED COPIED REPRODUCED PAManualEquip Manuals Dwgs ASSEMBLY NO CM7625 E MANUFACTURING HYDRAULICS n SONET 6 6 Assy pg Page 7 4 Item Qty Qty Part Number Part Description 1 1 1 CM4582 STRIKE PIN 2 1 1 CM7645 CM COVER WEL
41. ng F Shift housing G Re pack tong cavity H Pinion and secondary gear shafts if sealed bearings have been replaced by non sealed bearings D Jaw rollers and pins Remove jaw pins and rollers clean and lubricate with gear grease J Inspect hydraulic fluid for foreign material and contami nants Filter or replace Your must filter or replace entire system including power unit tank and lines along with tong to insure all contaminants are removed Annual Major Maintenance Inspection and repair Routine preventative maintenance will significantly extend the operating life of your equipment reduce operating cost and avoid downtime CLINCHER recommends a program of frequent routine inspection and if equipment is suspected to have been damaged during transit or is to be mobilized to a remote location where maintenance operations are difficult to carry out perform the following Visually inspect components on power tong or backup which could possibly have been damaged either during operation or transit i e Damage to hanger assembly hydraulic backup mounting legs or hydraulic valve assembly 2 Check test date Ensure that a load test and inspection was carried out within the last 9 months 3 Checkring gear Check for any signs of damage or wear 4 Remove motor and valve assembly from the tong body 5 Check motor seal Apply hydraulic power run motor and visually check motor seal for any signs of leakage 6 Check d
42. oor Note The tong door incorporates an required for each aluminum jaw Sheets should be interlock system which prevents the hydraulic system folded along one edge to allow it to be hooked over from developing significant pressure if the tong door is edge of dies The sheets of silicon carbide paper should in the open position CAUTION Severe personnel be visually inspected after each joint and replaced when hazards and equipment damage will result if the torn or worn interlock system is deactivated and the tong is operated 12 Select tong gear required and rotate tong to 8 Close both valves located on the makeup breakout tubular joint as required by CHROMEMASTER head manipulating tong directional control valve Refer to 9 Close the Backup jaws by manipulating backup Tong Operating Manual for additional information directional control valve Monitor backup pressure 13 Release tong directional control valve after reaching gauge to insure pressure is at a minimum of 2 500 psi desired makeup torque or breaking out joint Note Applications requiring extremely high torque for makeup breakout may require higher pressures Do not 14 Disengage CHROMEMASTER jaw by opening exceed 3 000 psi maximum operating pressure either one of the two valves located on the CHROMEMASTER Head These two valves In extreme high torque applications it may be necessary operate in a parallel circuit and are provided for the to install silicon ca
43. oothed Steel Dies are normally stocked in our Broussard Louisiana facility A partial listing of commonly manufactured sizes is shown below Aluminum and GRIT FACE Dies are normally made to order although a limited range of sizes and small quantities may be available from stock Contact SUPERIOR Manufacturing amp Hydraulics for information concerning availability of stock and special die sizes BUC7625 xxxx Fine Toothed steel dies for CM amp Backup 2 375 2 600 2 700 2 707 2 875 3 000 3 062 3 125 3 230 3 240 3 250 3 375 3 400 3 500 3 625 3 668 3 750 3 862 3 875 3 886 3 900 3 910 3 941 4 000 4 025 4 053 4 125 4 250 4 375 4 460 4 500 4 505 4 530 4 625 4 750 4 767 4 862 4 875 4 892 4 900 4 921 4 935 4 961 5 000 5 005 5 125 5 137 5 150 5 215 5 250 5 290 5 313 5 439 5 470 5 500 5 530 5 563 5 570 5 587 5 620 5 695 5 750 5 780 5 826 5 866 5 875 5 931 6 000 6 035 6 050 6 051 6 075 6 100 6 125 6 150 6 250 6 260 6 325 6 350 6 375 6 400 6 500 6 625 6 650 6 750 6 875 7 000 7 020 7 191 7 250 7 350 7 375 7 380 7 390 7 400 7 413 7 500 7 625 7 656 7 681 7 732 7 750 7 790 Page 3 1 CLINCHER WRAP AROUND DIES BUCA7625 xxxx Aluminum dies for CM amp Backup BB7625 xxxx GRIT FACE dies for CM amp Backup 1 900 2 250 2 375 2 400 2 679 2 707 2 735 2 375 2 875 3 250 3 500 3 878 3 900 4 000 2 776 2 875 2 910 3 062 3 125 3 130 3 230 4 053 4 250 4 500 4 750 4 901 4 950 5 000 2 240 3 300 3 327 3 375 3 400 3 500 3 523 5 200 5 500 5 563 5 577 5 736 5 89
44. ption LEFT DOOR WELDMENT RIGHT DOOR WELDMENT DIE CLIP 3 8 16 x 3 4 SHCS DOOR SET ASSEMBLY 999 0 anufacturin ydraulics THIS DOCUMENT IS THE PROPERTY OF SUPERIOR MANUFACTURING amp 03 29 06 HYDRAULICS AND IS CONSIDERED COI Y NFIDENTIAL THIS INFORMATION MAY NOT BE USED DISCLOSED COPIED OR REPRODUCED IN ANY REV LOG DATE ASSEMBLY NO CM7657 FORM WITHOUT THE EXPRESS WRITTEN CONSENT OF SUPERIOR REF P Manuals Equip Manuals Dwgs 5 MANUFACTURING 8 HYDRAULICS CM76251CM7657 Doors wpg Page 7 10 SUPERIOR BROUSSARD LA 70518 amp 318 837 8847 Miia e ls Dwgs 03 29 06 Manual CM7625 installation sht2 wpg REF FACTURING amp INFORMATION REV LOG DATE Eau 5355 5 ucdo9 Gui d 5 936 Out BI o Ek o 52062 lor zur 2022 gt 22 26 gt 2 gt lt lt 7 5 8 INSTALLATION Page 7 11 Page 7 12 ILLUSTRATION OF CLINCHER 7625 INSTALLATION INTO CLINCHER CLE7625 02 DIMENSIONS ARE IN INCHES 8 amp 8 4225 HWY 90 EAST BROUSSARD LA 70518 REF P
45. r jaws 3 per CHROMEMASTER 3 reqd per backup BUCA7625 xxxx Aluminum dies for jaws 3 per CHROMEMASTER 3 reqd per backup BB7625 xxxx GRIT FACE dies for jaws 3 reqd per CHROMEMASTER 3 reqd per backup ORDERING EXAMPLE fine toothed steel dies are needed to run 2 7 8 OD tubing Qty three 3 BUC7625 2875 dies for CM Qty three 3 BUC7625 2875 dies for backup replace xxxx with size required in inches SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 05 06 CAUTION Do not attempt to grip tubular diameters which are larger than the dies being used Failure to observe this precaution can result in damage to the tubular or tong jaws In emergencies where correct die sizes are unavailable some operators have successfully used two different sizes of dies to accommodate unusual nonstandard diameters CLINCHER Wrap Around Dies are manufactured in specific diameters to match standard tubing and casing diameters API coupling diameters selected work string connection diameters and certain commonly used premium connection coupling diameters CLINCHER Wrap Around Dies should not be used on tubulars which are larger than the nominal die size Steel Toothed Dies can be used on tubulars which are no smaller than 3 32 0 093 less than the nominal die size Aluminum and GRIT FACE Dies should be matched with the specific tubular diameters required Note Fine T
46. r to flow startup Always consult Superior if questions arise 1 Remove the handle by turning the set screw counter clockwise with a 3 32 size hex socket wrench 2 Tighten the packing nut 1 8 to 1 4 turn or to 70 in lbs using a 7 16 size hex wrench 3 Re install the handle and secure by turning the set screw clockwise and torque to 15 in lbs Valve Connector Make Up Instructions CAUTION Whenever installing or removing a ball valve from a system always place a back up wrench on the ball valves end connector NOT the valve body Tube Fitting Connectors Insert the tube into the filter port until the tube bottoms out in the filter body Care should be exercised to insure the tube is properly aligned with the filter body and port 2 Normal make up for port size 4 thru 16 1 4 thru 1 inch is 1 1 4 turn from finger tight Please follow the above directions for counting the number of turns for proper fitting make up Do not make up the tube fittings by torque or feel Variables such as tubing and fitting tolerances tube wall thickness and lubricity of nut lubricants can result in an improperly assembled tube fitting connection MAINTENANCE INSTRUCTIONS Recommended Lubrication Schedule Performed After Completion Of Each Job Hydraulic Tong A Cam followers upper and lower all Dumbell roller shafts upper and lower all C Door shaft upper and lower D Outboard Idler shafts 2 E Low gear housi
47. ract check for restrictions in the hydraulic return lines Check that the operation of the releasing valve is correct If the handle is loose the valve may not fully open which would restrict the flow Solution Check pipe OD and match die size to pipe OD Clean dies with wire brush and inspect Replace with new dies if necessary Inspect relief valve on power unit to make sure enough system pressure is being delivered to backup Remove side plates on backup Bench test and replace the defective counter balance valve Disconnect lines and bench test cylinder Repair or replace as necessary Replace counter balance valve Repair or replace cylinder Inspect control valve for damage and or incorrect spool Repair or replace as necessary Page 5 7 Page 5 8 SECTION 6 SPARE PARTS RECOMMENDATIONS Part Number Quantity Description 12501437 1 Seal for Rineer Motor 1001 8 1 8 NPT Zerts SLV 1000 04 1 N C Door Valve Assembly 45072 1 Shifting Yoke CM7656 6 CM Door Jaw Clips amp Cylinder Clips 1040 A 20 Clip Bolts 3 8 16 x 3 4 SHCS 25001375 1 Seal for Pump CM7626 ASAP2312 1 Seal Kit for 7621 Clamp Cylinder 4551 1 Check Valve Cartridge CLE1209 B 1 Latch Pin Handle 1028 1 3 8 16 x 1 4 Set Screw CM7603 A 1 Latch Pin CM7649 1 Latch Catch CM7601 A 1 Shank CM7602 A 1 Door Spring CM7651 1 Plunger CM7653 1 Compression Spring CM4020 1 Filter SS 6TF2 LE 1651 1 Pressure Gauge BAC 5M 25 CM4554 2 Chec
48. rbide paper between aluminum dies convenience of the operator Insure the spring loaded and tubing in the CLINCHER backup One piece is jaw returns to its retracted position required for each aluminum jaw Sheets should be folded along one edge to allow it to be hooked over 15 Rotate CHROMEMASTER to align arrows on Tong edge of dies The sheets of silicon carbide paper should and CHROMEMASTER head by manipulating tong be visually inspected after each joint and replaced when directional control valve ORL or Worm 16 Release pressure and retract the Backup cylinders a k a 10 Insure proper alignment of CHROMEMASTER and front jaws to their fully open position by manipulating Tong IMPORTANT NOTE Severe equipment backup directional control valve damage will result if the CHROMEMASTER push 17 Open CHROMEMASTER swing jaws by pulling up cylinder is actuated when incorrectly aligned CHROMEMASTER latch handle to unlock 11 Insure both valves on CHROMEMASTER head swing jaws Spread both jaws are in the closed and block position to their maximum open position Open tong door to its ee fully open position For applications using the CLE7625 or equivalent 7 5 8 Tong activate CHROMEMASTER to grip pipe by 18 Swing tong away from pipe to prepare for next joint SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTERTM Revision 04 06 Page 4 3 Page 4 4 M
49. rive gear high and low pinion gears Check for excessive sign of wear on motor gear 7 Check condition of control valve spools Activate valves and check for any sign of wear pitting or scoring of the chrome surface of spools If spool is damaged in any way the complete section must be changed out Spools are not interchangeable 8 Check gear selector and shaft Visually inspect the shifting shaft for alignment straightness SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTERTM Revision 04 06 Page 5 3 10 11 12 13 14 15 16 17 18 19 20 9 Check Hi Low Gear assembly Visually inspect high and low clutch and gears for any sign of chipped broken or worn teeth Check dumbell rollers shafts and bushings Check for excess movement on either bearings bushings shafts or dumbells Check idler gears and center pinion shaft gears and bearings Check that there are no signs of worn chipped or broken teeth on idler and center pinion shaft gears Check door bearings Visually check excess movement on bearings at door assembly If excess movement is found door must be removed making careful note of bearing washers positions for reassembly Check door switch system Visually check that door switch valve has sufficient strength to hold door in closed position If this is not the case then repairs are required Check door safety device Functionally check tong
50. roblem A B C D Jaws move out from neutral but fail to penetrate pipe Tong not perpendicular Jaws fail to move out of neutral Brake band not tight enough faulty cam followers rust debris or damage to jaws Tong will not release from tubular Brake band not tight enough defective cam followers in cage plate insufficient lubrication to jaw pin and roller Tong motor runs but ring gear does not rotate Broken gears or defective shift in hydraulic tongs system SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTER Revision 04 06 Solution Check to make sure door is completely closed Inspect door switch and dump valve Replace or repair door switch and or dump valve Relief set too low broken valve spring contamination or defective seals Inspect repair or replace Assure proper pump speed for application Check fluid viscosity and replace fluid if inadequate for operating temperature Check relief and directional control valve Neutral should return slightly to reservoir Inspect repair or replace Check to assure couplings are securely fastened Inspect repair or replace Assure unit has been calibrated to proper arm length NOTE When using CLINCHER integral backup system itis the length of backup arm NOT the tong arm length Solution Inspect and replace key stock in shifting yoke Inspect and replace broken or worn pins Pump grease into both zerts
51. roper dies to bite O D of tubular and insert as follows Remove sliding head jaws 2 from cage plate pockets Insert one jaw with proper dies into pocket assuring the jaw roller pin faces upward Repeat procedure for other side SUPERIOR Manufacturing amp Hydraulics Inc 7 5 8 CLINCHER CHROMEMASTERTM Revision 04 06 Page 4 1 Hydraulic Lines A Be sure all power to unit is off and power unit itself is B C shut down Always inspect hoses prior to installation for abrasions kinks and other visible damage Install hydraulic supply hose and hydraulic return hose between tong and hydraulic power unit Be advised that the standard installation on CLINCHER tong calls for 1 Hydraulic Supply hose and 1 1 4 Hydraulic Return hose The differing hoses eliminates the possibility attaching the wrong hose to the wrong outlet while at the same time reducing back pressure in your hydraulic system Tong Operation A Insure proper dies are installed Connect hydraulic hoses verify reservoir is full of hydraulic fluid and insure suction valve is open Open bypass valve to hydraulic system then check to make sure all hose connections are secure and hydraulic system is free of leaks Be certain door is completely closed before operation to insure safe operation The CLINCHER Tong is equipped with a door switch which prevents operation of the tong when door is even partially open Use power unit to start up pro
52. tain conditions allowing the hydraulic equipment to continue to operate and could cause serious injury death or equipment failure VALVE SAFETY Read and follow instructions carefully Failure to observe instructions and guidelines may cause serious injury death or equipment failure A sticking valve spool bind may be caused by one or more of the following factors DIRTY OIL Oil must be filtered to a minimum of 25 microns Filters should be changed regularly spin on types after 50 hours of initial use and then after every two hundred fifty hours of use Use of a condition indicator is recommended Consult your tractor or implement owner s manual for filtra tion and changing recommendations for internal systems OIL REQUIREMENTS Premium quality anti wear type oil with a viscosity between 100 and 200 SSU at operating temperatures Certain synthetic oils may cause spool seals to swell and the valve to stick If in doubt call CROSS Engineering IMPROPER HOOK UP OR MOUNTING Always use the proper size fittings Hook up in amp out as noted on the valve body Do not overtorque pipe fittings Mounting surfaces should be flat and care should be used when tightening mounting bolts Over tightened bolts can cause spool bind and casting breakage When hooking a valve in series always use a power beyond sleeve Con sult your tractor or implement manual to make sure you have the proper quick disconnect line connected to the inlet of the remote
53. to unlock valve causes the CHROMEMASTER push cylinder Chrome master swing jaws Spread both jaws to their rod located on the bottom side of the tong to operate maximum open position Open tong door to its fully open the CHROMEMASTER pump located opposite the position push cylinder which pressurizes the 4 Insure both backup cylinders a k a front jaws are fully se alea al ge c ee E retracted by manipulating backup directional control Op LUN ED cylinder rod pulling the handle toward the operator will retract the push cylinder rod Repeat these operations as 5 Adjust height of tong and backup assembly to straddle many times as required to reach the desired operating tubing coupling by manipulating lift cylinder directional pressure range of 4 200 to 4 500 psi Note A pressure control valve reducing valve which is located near the push cylinder may require adjustment to insure proper operating 6 Swing tong and backup assembly with pressures are achieved IMPORTANT NOTE Insure CHROMEMASTER onto pipe last action taken fully retracts push cylinder rod Failure 7 Close CHROMEMASTER Swing Jaws and insure to retract rod will result in severe equipment damage Chrome master latch handle drops down into its fully In extreme high torque applications it may be necessary engaged position to install silicon carbide paper between aluminum dies and tubing in the CHROMEMASTER One piece is Close tong d
54. ystem must allow the tong to easily move down a distance equivalent to the thread make up length If significant resistance is encountered the suspension system may be subject to load which could cause its failure damage equipment or expose personnel to severe or fatal hazards Assure that tong is suspended in level manner Both tong and the backup must be level at the point they contact the tubular Using adjustment screws and slots in rigid hanger assembly adjust tong so that it hangs level on horizontal axis and is parallel to tubular on vertical axis Make certain that floor space is adequate to maneuver tong on and off pipe The space must be clear of obstructions to allow safe and unrestricted operation Attach 1 IWRC minimum wire cable with a 51 7 ton minimum breaking strength or better as a tong back up line at 90 degree angle to tong and at same level to insure proper readout of torque indicator You should always have snubbing line attached Use of a integral hydraulic backup is safer than manual backup but operators should maintain additional safety of snubbing line to prevent injury in case of hydraulic failure or the failure of operator to have backup properly applied to tubular This equipment generates extreme torque and should be used with caution Jaw and Die Installation A B Be sure all power to unit is off and power unit itself is shut down Determine O D of tubular to be made up or broken out Use p
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