TECHNICAL MANUAL KT (LW)13625 - TIOT€¦ · KT(LW)13625 13-5/8” Tong & FARR® BAcKup TechnicAL MAnuAL SecTion conTenTS iii This technical manual covers the following models: oVeRALL

KT (LW)1362513-⅝” (34.6cm) 35K (25K) Lbs-FtHydraulic Power Tong & FARR® Backup

•Specifications•Operation•Maintenance•Assembly

©2011 McCoy Corporation. All rights reserved.Published by McCoy Corporation, Technical Publications Department14755 - 121A Avenue • Edmonton, AB, Canada, T5L 2T2

mccoyglobal.com

TECHNICAL MANUAL

KT(LW)13625 13-5/8” Tong & FARR® BAcKup

SecTion conTenTS iii TechnicAL MAnuAL

This technical manual covers the following models:

oVeRALL MoDeL

Tong MoDeL BAcKup MoDeL

ReV DeScRipTion

80-0935-4 80-0931-3 85-0900 0 13-5/8”KTTong,13-5/8”FARR®Backup,motorvalve,backupvalve,liftcylindervalve,safetydoor.

80-0935-5 80-0931-9 85-0900 1 13-5/8”KTTong,13-5/8”FARR®Backup,motorvalve,backupvalve,liftcylindervalve,safetydoor.Closed-centresystem.

80-0912-1 80-0931-3-LW 85-0900 0 13-5/8”LWTong,13-5/8”FARR®Backup,motorvalve,backupvalve,liftcylindervalve,safetydoor.

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

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

PATENTED & PATENTS PENDING

ORIGINAL INSTRUCTIONS

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SecTion conTenTS v TechnicAL MAnuAL

WARNINGS

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

WHEN RE-ASSEMBLING LOAD-BEARING DEVICES (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS, ETC.) NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE OF FASTENER (SEE SECTION 3 - OVERHAUL). ANY THREADED FASTENER IN A LOAD-BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE™.

A “LOAD-BEARING DEVICE” IS A CHAIN SLING, RIGID SLING, SPREADER BAR ASSEMBLY, FRAME, OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH THIS MANUAL HAS BEEN PRODUCED

THE LOAD-BEARING DEVICE SUPPLIED BY MCCOY DRILLING & COMPLETIONS IS DESIGNED TO SUP-PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL. MCCOY DRILLING & COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, ASSEM-BLY OR COMBINATION OF PARTS AND ASSEMBLIES. MCCOY DRILLING & COMPLETIONS WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD-BEARING DEVICE, OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT, UNLESS SUPPLIED BY MCCOY DRILLING & COMPLETIONS.



SecTion conTenTS vii TechnicAL MAnuAL

Summary Of RevisionsDate Section Page Description Of Revision Approved

Sep2008 N/A N/A InitialRelease K.Isaacson

Mar2010 8 8.1 ChangeditemAdescriptionandpartnumber K.Duhon

Jul2011

All All Re-branded&reformattedmanual

S.Hargreaves

All All Replacedallhazard,warning,&cautionsymbolswithimprovedsymbols&text.

Intro iii Revisedlistofsupportedmodels

1 1.3 Revisedspecificationstoincludelightweightversion(ifrequested).

2

All MovedAssemblyInstructionsto“Maintenance”section.

All Renumbered“Setup&Operation”asSection2.

2.6 Removedhydraulicschematic,tongwithoutsafetydoor(nolongersupported).

2.8-2.9 Revisedhydraulicschematics

2.13 Correctedlistofavailablejawdiekits

2.16 Revisedsection2.F.1,“Suspension&Restraint”.

2.21 Addedsection2.G.3,“ShiftingGears”.

3

All Renumbered“Maintenance”asSection3.

3.1 Revisedsection3.A,GeneralMaintenanceSafetyPractices

3.1 AddedSection3.C,“PreventiveMaintenancePractices

3.2 ReplacedgraphicSection3.D.1,“Lubrication,CagePlate/GuideRing”.

3.10 AddedSection3.E.3,“DoorAlignment”.

3.11 AddedSection3.E.4,“ShifterDetentForceAdjustment”.

3.12-3.13 RevisedSection3.G,“OverhaulProcedures”.

3.14-3.22 AddedrevisedSection3.H,“AssemblyProcedures”.

3.23 AddedSectionI,“DailyPowerTongInspection&MaintenanceChecklist”.

3.25 AddedSectionJ,“DailyBackupInspection&MaintenanceChecklist”.

3.26 AddedSectionK,“MonthlyPowerTongMaintenanceChecklist”.

3.29 AddedSectionL,“DailyPowerUnitInspection&MaintenanceChecklist”.

3.30 AddedSectionM,“TubularConnectionEquipmentDe-CommissioningChecklist”.

3.33 AddedSectionN,“TubularConnectionEquipmentRe-CommissioningChecklist”.

4 All Renumbered“Troubleshooting”asSection4.

DeletedSection,“StorageRecommendations”(seeSections3.M&3.N).

Continued on next page

Copyright©2007 -2012McCoyCorporation, including itswhollyownedsubsidiaries, (“McCoy”),all rights reserved.Thisdocument is thepropertyofMcCoyandissuppliedasreferenceinformationforusersofourproducts.Thisdocumentandthecontentswithinareconsideredconfidentialinformation,nottobedisclosed,copied,transmitted,transcribedinanyform,orstoredonanytypeofdatastoragemediawithouttheexpresswrittenconsentofMcCoy.

McCoyhasmadeeveryefforttoensuretheinformationcontainedinthisdocumentisaccurateandcurrent.Thismanualisintendedtoprovideequipmentoperationandsafetyinstructionsforyourequipment.However,McCoydoesnotwarrantorguaranteethattheinformationiseithercompleteoraccurateineveryrespectandtheuserofthemanualshouldconsultwithitsMcCoysalesrepresentativeforanyclarificationsandupdates.

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

Observanceofalldescriptions,informationandinstructionssetoutinthismanualisthefullresponsibilityoftheuser.Thismanualisintendedforguidanceandinformationalpurposesandmustbeusedinassociationwithadequatetrainingandon-the-jobsupervisiontoprovidesafeandeffectiveequipmentuse.

Itistheresponsibilityoftheusertoconformtoallregulationsandrequirementsissuedbyanauthorityoragencywhichmayaffecttheoperation,safetyorequipmentintegrity,thatmayoverrulethecontentofthisdocumentation.

Theuserwillacknowledgeandobeyanygenerallegalorothermandatoryregulationinforcerelatingtoaccidentprevention,safety,andequip-mentintegrity.


SecTion conTenTSviii TechnicAL MAnuAL

Summary Of Revisions ContinuedDate Section Page Description Of Revision Approved

Jul2011

5

All Renumbered“Assemblies&Parts”asSection5.

SHargreaves

5.2-5.3 Revisedgraphics&BOM,“GearTrainLayout”.

5.30-5.31 Addedgraphic&BOM,“CagePlateAssembly(LightweightTong)”.

6All Renumbered“TorqueMeasurement”asSection6.

All Completerevisionoftorquemeasurementsection

OCT2011 5 Checked&correctedpartnumbersforfastenerswherenecessary-allB.O.M.sinSection5 DBowles

SEP2012

Introxii InsertedListofIllustrations

SPanchal

xiv AddedCEMarkedmodifierstatementandidentificationsymbol

1

1.2 Correcteddimensions,addedhazardand“safe-to-handle”legend

1.3 Insertedillustrationofadditionalhazardareas

1.4 Insertedillustration&identificationofFARRCENameplate

1.5-1.6 Correctedspecifications

2

2.1 Insertednewsection“InitialReceipt&InspectionofEquipment”

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

2.7 Insertednewsection2.D,“LiftCylinderInstallation”

2.10 Renumberedsection2.E,“Hydraulics”

2.12-2.13 InsertedCE-applicablehydraulicschematics

2.16 Movedsection“HydraulicConnections”intoSection2.E,Hydraulics.

2.17 Insertednewsubsection2.E.4,“HydraulicCircuitDescription”

2.18 Renumberedandrevisedsection2.F,“TongJawAvailability&Installation”.AddedCE-specificinformation.

2.22 Renumberedsection2.G,“TongRig-Up&Leveling”

2.25 Renumberedsection2.H,“TongOperation”

2.25 Insertednewsubsection2.H.1,“OperatorTraining”

2.25 Insertednewsubsection2.H.2,“OperatorSafety”

Removedsubsection“InitialStartup&Break-inProcedure”

2.25 Renumberedandrevisedsubsection2.H.3,“ValveOperation”

2.26 AddedCE-specificinformationtoliftcylindervalveoperation

2.27 Renumberedsubsection2.H.4,“ShiftingGears”

2.28 Insertednewsubsection2.H.5,“Pre-OperationalChecks”

2.29 Renumberedsubsection2.H.6,“GeneralComments”

2.40 Renumberedsection2.I,“ExtremeColdWeatherOperations”

2.32 Insertednewsection2.J,“MakingandBreakingConnections”

3

3.2 Insertednewsection3.D,“HydraulicSystemDe-Pressurization”

3.2 Renumberedsection3.E,“LubricationInstructions”

3.9 Renumberedsection3.F,“Adjustments”

3.9 Revisedsubsection3.F.1,“BrakeBandAdjustment”

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

3.12 Insertednewsubsection3.F.5,“SafetyDoorAdjustment”

3.13 Renumberedsection3.G,“RecommendedPeriodicChecks”

3.14 Renumbered& revised section 3.H,Overhaul Procedures -Disassembly.Cor-recteddisassemblyproceduresandaddedCE-specificinformationandwarnings.



SecTion conTenTS ix TechnicAL MAnuAL

Summary Of Revisions ContinuedDate Section Page Description Of Revision Approved

SEP2012

3

3.16-3.29 Renumbered& revisedsection3.I,AssemblyProcedures.CorrectedassemblyproceduresandaddedCE-specificinformationandwarnings.

SPanchal

3.30 RenumberedSection3.J“DailyInspection&MaintenanceChecklist(PowerTong)”.AddedCE-Specificinformation.

3.32 RenumberedSection3.K“DailyInspection&MaintenanceChecklist(Backups)”.

3.33 RenumberedSection3.L “Monthly Inspection&MaintenanceChecklist (PowerTong)”.

3.36RenumberedSection3.M “TubularConnectionEquipmentDe-Commissioning”.Revisedsectiontoaddpackagingandshippinginstructionsandretitled“TubularConnectionEquipmentDe-Commissioning&Shipping”.

3.41 RenumberedSection3.N“TubularConnectionEquipmentRe-Commissioning”.

4

4.1 Revisedsection4.A,Troubleshooting-TongWillNotDevelopSufficientTorque

4.2 Insertednewsection4.B,Troubleshooting-ReliefValve

4.4 Insertednewsection4.C,Troubleshooting-SafetyDoor

4.5 Renumberedsection4.D,Troubleshooting-TongRunningTooSlowly

4.6 Renumberedsection4.E,Troubleshooting-FailureofJawstoGripPipe

4.7 Renumberedsection4.F,Troubleshooting-Shifting

5

5.2 Insertedlistofcriticalspareparts

5.3 Insertedlistofrecommendedspareparts

5.4 Insertedlistofpartsneededforcompleteoverhaul

RemovedImagesandB.O.M.s,“TongBodyAssembly”

5.22-5.23 Insertednewillustration&B.O.M.,HydraulicValveAssemblySupports

5.26-5.27 Replacedillustration&updatedB.O.M.,MotorMountAssembly

5.30-5.31 Replacedillustration&updatedB.O.M.,CagePlateAssembly(KT13625)

5.33 UpdatedB.O.M.,CagePlateAssembly(LW13625)

5.37 AddedadditionB.O.M.forCE-specificcomponents,TongSafetyDoor

5.38-5.39 Replacedillustration&revisedB.O.M.,RigidSling.AddedadditionillustrationandupdatedB.O.M.toshowCE-specificcomponents.

5.40-5.41 Replacedillustration&updatedB.O.M.,LegAssemblies

5.44-5.45 Replacedillustration&updatedB.O.M.,BackupRotaryAssembly

6

6.1 Revisedsection6.A,BasicTorqueMeasurement

6.2 Addedpartsinformationformetrictorquemeasurementassembly

6.6 Insertedsubsection6.C.3,ReferenceCheckingTorqueMeasurementSystem


SecTion conTenTSx TechnicAL MAnuAL

SECTION ONE: INTRODUCTION Introduction&ContactInformation................................................................................................................................... 1.1 EquipmentSpecifications................................................................................................................................................. 1.2 LubricantSpecifications................................................................................................................................................... 1.6SECTION TWO: SETUP & OPERATION

A. INITIALRECEIPTANDINSPECTIONOFEqUIPMENT....................................................................................... 2.1B. MAJORCOMPONENTIDENTIFICATION............................................................................................................. 2.1C. SLING/LOADBEARINGDEVICESAFETY

1. InspectionOfSlings......................................................................................................................................... 2.52. ProperUseOfLoad-BearingDevices............................................................................................................. 2.63. StorageOfLoad-BearingDevices.................................................................................................................. 2.6

D. LIFTCYLINDERINSTALLATION1. InstallationProcedure...................................................................................................................................... 2.72. LiftCylinderConnection.................................................................................................................................. 2.83. LiftCylinderSafety.......................................................................................................................................... 2.8

E. HYDRAULICS1. HydraulicSchematics...................................................................................................................................... 2.102. HydraulicComponentIdentification................................................................................................................ 2.143. MainHydraulicConnections............................................................................................................................ 2.164. HydraulicCircuitDescription........................................................................................................................... 2.17

F. TONGJAWAVAILABILITY&INSTALLATION1. JawAvailability................................................................................................................................................ 2.182. Jaw/JawDieRemoval................................................................................................................................... 2.193. BackupJaws.................................................................................................................................................... 2.21

G. TONGRIG-UP&LEVELING1. Suspension&Restraint................................................................................................................................... 2.222. TongLeveling................................................................................................................................................... 2.223. LoadCellConfiguration................................................................................................................................... 2.24

H. TONGOPERATION1. OperatorTraining............................................................................................................................................. 2.252. OperatorSafety............................................................................................................................................... 2.253. ValveOperation............................................................................................................................................... 2.254. ShiftingGears.................................................................................................................................................. 2.275. Pre-OperationalChecks.................................................................................................................................. 2.286. GeneralOperationalComments..................................................................................................................... 2.29

I. EXTREMECOLDWEATHEROPERATIONPROCEDURES............................................................................... 2.29J. MAKINGANDBREAKINGCONNECTIONS

1. MakingAConnection...................................................................................................................................... 2.302. BreakingOutAConnection............................................................................................................................. 2.37

SECTION THREE: MAINTENANCEA. GENERALMAINTENANCESAFETYPRACTICES.............................................................................................. 3.1B. CLEANING.............................................................................................................................................................. 3.1C. PREVENTIVEMAINTENANCEPRACTICES........................................................................................................ 3.1D. HYDRAULICSYSTEMDE-PRESSURIzATION.................................................................................................... 3.2E. LUBRICATION......................................................................................................................................................... 3.2F. ADJUSTMENTS

1. BrakeBandAdjustment:.................................................................................................................................. 3.92. DoorLatchAdjustment.................................................................................................................................... 3.103. DoorAlignment................................................................................................................................................ 3.114. ShifterDetentForceAdjustment:.................................................................................................................... 3.125. SafetyDoorAdjustment:................................................................................................................................. 3.12

G. RECOMMENDEDPERIODICCHECKS1. DoorStopSpring............................................................................................................................................. 3.132. ShiftingShaft................................................................................................................................................... 3.133. BackingPin...................................................................................................................................................... 3.134. TorqueGaugeAssembly................................................................................................................................. 3.13

H. OVERHAULPROCEDURES.................................................................................................................................. 3.14I. ASSEMBLYPROCEDURES................................................................................................................................... 3.16J. DAILYINSPECTION&MAINTENANCECHECKLIST(POWERTONG).............................................................. 3.30K. DAILYINSPECTION&MAINTENANCECHECKLIST(BACKUPS)...................................................................... 3.32L. MONTHLYMAINTENANCECHECKLIST-POWERTONG.................................................................................. 3.33M. TUBULARCONNECTIONEqUIPMENTDE-COMMISSIONING&SHIPPING................................................... 3.36N. TUBULARCONNECTIONEqUIPMENTRE-COMMISSIONINGPROCEDURE................................................ 3.41

Continued on next page...

TABLe oF conTenTS


SecTion conTenTS xi TechnicAL MAnuAL

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

SECTION FIVE: PARTS AND ASSEMBLIESCriticalSparePartsList.................................................................................................................................................... 5.2RecommendedSparePartsList...................................................................................................................................... 5.3PartsList-CompleteOverhaul........................................................................................................................................ 5.4

GearTrainLayout............................................................................................................................................................. 5.6 SupportRollerAssembly.................................................................................................................................................. 5.8 DoorPivotSupportRoller................................................................................................................................................. 5.10 RotaryIdler....................................................................................................................................................................... 5.12 PinionIdler...................................................................................................................................................................... 5.14 PinionAssembly............................................................................................................................................................... 5.16 ClutchAssembly............................................................................................................................................................... 5.18 ShiftingAssembly............................................................................................................................................................. 5.20 Supports-HydraulicAssembly........................................................................................................................................ 5.22 BrakeBandAssembly...................................................................................................................................................... 5.24 Motor&MotorMount........................................................................................................................................................ 5.26 HydraulicAssembly.......................................................................................................................................................... 5.28 CagePlateAssembly(KT13625)..................................................................................................................................... 5.30 CagePlateAssembly(LW13625).................................................................................................................................... 5.32 TongDoorAssembly........................................................................................................................................................ 5.34 SafetyDoorComponents................................................................................................................................................. 5.36 RigidSlingAssemblies..................................................................................................................................................... 5.38 LegAssemblies................................................................................................................................................................ 5.40 FARR®Backup................................................................................................................................................................ 5.42 FARR®BackupRotaryAssembly.................................................................................................................................... 5.44SECTION SIX: TORQUE MEASUREMENTA. BASICTORqUEMEASUREMENT............................................................................................................................ 6.1B. TROUBLESHOOTING................................................................................................................................................. 6.5C. PERIODICINSPECTIONANDMAINTENANCE

1. Inspection............................................................................................................................................................. 6.62. FluidRecharge..................................................................................................................................................... 6.63. ReferenceCheckingTheTorqueMeasurementSystem..................................................................................... 6.64. RepairAndCalibration......................................................................................................................................... 6.7

SECTION SEVEN: HYDRAULIC COMPONENT INFORMATION

TABLe oF conTenTS


SecTion conTenTSxii TechnicAL MAnuAL

LiST oF iLLuSTRATionS

IllustratIon 1.a.1: Kt13625 tong & Farr© BacKup (Model 80-0935-4 shown) ............................................... 1.1IllustratIon 1.a.2: Kt13625 tong & Farr© BacKup dIMensIons ........................................................................ 1.2IllustratIon 1.a.3: Kt13625 tong & Farr© BacKup hazard areas (ce-MarKed Model shown) ....................... 1.3IllustratIon 1.a.4: Farr® ce naMeplate .......................................................................................................... 1.4IllustratIon 2.B.1: Kt13625 tong & Farr© BacKup Major coMponent IdentIFIcatIon 01 .................................. 2.1IllustratIon 2.B.2: Kt13625 tong & Farr© BacKup Major coMponent IdentIFIcatIon 02 .................................. 2.2IllustratIon 2.B.3: Kt13625 tong & Farr© BacKup Major coMponent IdentIFIcatIon 03 .................................. 2.3IllustratIon 2.c.1: slIng angle ........................................................................................................................... 2.4IllustratIon 2.d.1: lIFt cylInder & sprIng hanger InstallatIon ........................................................................... 2.7IllustratIon 2.d.2: lIFt cylInder hydraulIc connectIon ...................................................................................... 2.8IllustratIon 2.e.1: Kt13625 tong & Farr© BacKup hydraulIc scheMatIc ........................................................ 2.10IllustratIon 2.e.2: Kt13625 tong & Farr© BacKup hydraulIc (closed centre) .............................................. 2.11IllustratIon 2.e.3: Kt13625 tong & Farr© BacKup hydraulIc scheMatIc (ce MarKed) ................................... 2.12IllustratIon 2.e.4: Kt13625 tong & Farr© BacKup hydraulIc (closed centre, ce MarKed) ........................... 2.13IllustratIon 2.e.5: Kt13625 tong & Farr© BacKup hydraulIc coMponent Id 01 ............................................. 2.14IllustratIon 2.e.6: Kt13625 tong & Farr© BacKup hydraulIc coMponent Id 02 ............................................. 2.14IllustratIon 2.e.7: Kt13625 tong & Farr© BacKup hydraulIc coMponent Id 03 ............................................. 2.15IllustratIon 2.e.8: Kt13625 tong & Farr© BacKup hydraulIc coMponent Id 04 ............................................. 2.15IllustratIon 2.e.9: Kt13625 tong & Farr© BacKup hydraulIc coMponent Id 05 ............................................. 2.16IllustratIon 2.e.10: Kt13625 tong & Farr© BacKup hydraulIc connectIons 01 .............................................. 2.16IllustratIon 2.e.11: Kt13625 tong & Farr© BacKup hydraulIc connectIons 02 .............................................. 2.17IllustratIon 2.F.1: jaw dIe reMoval .................................................................................................................... 2.20IllustratIon 2.F.2: jaw reMoval .......................................................................................................................... 2.21IllustratIon 2.g.1: tong levelIng (sIde-to-sIde) ................................................................................................ 2.23IllustratIon 2.g.2: tong levelIng, Front-to-BacK .............................................................................................. 2.23IllustratIon 2.g.4: load cell conFIguratIon, BreaK-out .................................................................................... 2.24IllustratIon 2.g.3: load cell conFIguratIon, MaKe-up ....................................................................................... 2.24IllustratIon 2.h.1: Motor control valve ........................................................................................................... 2.26IllustratIon 2.h.2: lIFt cylInder control valve ................................................................................................. 2.26IllustratIon 2.h.3: Farr© BacKup control valve ............................................................................................. 2.27IllustratIon 2.h.4: shIFtIng gears ...................................................................................................................... 2.27IllustratIon 2.j.1: rIgId slIng Master lInK .......................................................................................................... 2.30IllustratIon 2.j.2: settIng BacKIng pIn to “MaKe-up” posItIon ............................................................................. 2.31IllustratIon 2.j.3: openIng rh tong door ......................................................................................................... 2.31IllustratIon 2.j.4: openIng lh tong door .......................................................................................................... 2.32IllustratIon 2.j.5: openIng BacKup door ............................................................................................................ 2.32IllustratIon 2.j.6: lIFt cylInder control - raIse (non ce-MarKed tongs) ......................................................... 2.33IllustratIon 2.j.7: BacKup control - claMp......................................................................................................... 2.34IllustratIon 2.j.8: Motor control - MaKe-up ...................................................................................................... 2.34IllustratIon 2.j.9: usIng Motor control to release jaws In “MaKe up” Mode ................................................... 2.35IllustratIon 2.j.11: usIng lIFt cylInder control to lower asseMBly (non ce-MarKed tongs only) ................. 2.36IllustratIon 2.j.10: usIng BacKup control to release BacKup jaws .................................................................. 2.36IllustratIon 2.j.12: settIng BacKIng pIn to BreaK-out posItIon .......................................................................... 2.37IllustratIon 2.j.13: Motor control - BreaK out ................................................................................................. 2.38IllustratIon 2.j.14: usIng Motor control to release jaws In “BreaK out” Mode .............................................. 2.39IllustratIon 3.e.1: Kt13625 guIde rIng luBrIcatIon ........................................................................................... 3.2IllustratIon 3.e.2: lw13625 caM Follower luBrIcatIon ..................................................................................... 3.3IllustratIon 3.e.3: support roller BearIng luBrIcatIon ..................................................................................... 3.3IllustratIon 3.e.4: rotary Idler luBrIcatIon ....................................................................................................... 3.4IllustratIon 3.e.5: pInIon Idler luBrIcatIon ......................................................................................................... 3.4IllustratIon 3.e.6: pInIon luBrIcatIon top plate ................................................................................................. 3.5IllustratIon 3.e.7: pInIon luBrIcatIon BottoM plate ............................................................................................ 3.5IllustratIon 3.e.8: clutch shaFt luBrIcatIon ...................................................................................................... 3.6IllustratIon 3.e.9: shIFtIng shaFt luBrIcatIon ..................................................................................................... 3.6IllustratIon 3.e.10: Motor Mount luBrIcatIon .................................................................................................... 3.7IllustratIon 3.e.11: door latch caM luBrIcatIon ................................................................................................ 3.7IllustratIon 3.e.12: door stop sprIng luBrIcatIon ............................................................................................. 3.8IllustratIon 3.e.13: Farr© BacKup caM rIng caM Follower luBrIcatIon .......................................................... 3.8

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SecTion conTenTS xiii TechnicAL MAnuAL

LiST oF iLLuSTRATionS

IllustratIon 3.F.1: BraKe Band adjustMent ......................................................................................................... 3.9IllustratIon 3.F.2: door latch caM adjustMent .................................................................................................. 3.10IllustratIon 3.F.3: door alIgnMent ..................................................................................................................... 3.11IllustratIon 3.F.4: shIFter detent Force adjustMent ......................................................................................... 3.12IllustratIon 3.F.5: saFety door swItch plate adjustMent .................................................................................. 3.13IllustratIon 3.I.1: tong asseMBly - rotary gear InstallatIon ............................................................................. 3.17IllustratIon 3.I.2: tong asseMBly - gear asseMBly posItIonIng ........................................................................... 3.18IllustratIon 3.I.3: tong asseMBly - top plate Fasteners .................................................................................... 3.19IllustratIon 3.I.4: tong asseMBly - support roller InstallatIon 01 .................................................................... 3.20IllustratIon 3.I.5: tong asseMBly - support roller InstallatIon 02 .................................................................... 3.21IllustratIon 3.I.6: tong asseMBly - support roller InstallatIon 03 .................................................................... 3.22IllustratIon 3.I.7: tong asseMBly - top shIFter BushIng InstallatIon .................................................................. 3.23IllustratIon 3.I.8: tong asseMBly - Front leg Mount weldMent InstallatIon ...................................................... 3.25IllustratIon 3.I.9: tong asseMBly - saFety door valve InstallatIon .................................................................... 3.26IllustratIon 3.I.10: tong asseMBly - levelIng Bolt InstallatIon .......................................................................... 3.27IllustratIon 3.I.11: tong asseMBly - valve handle guard InstallatIon (ce MarKed tongs) ................................ 3.28IllustratIon 3.M.1: shIppIng InstructIons - pallet ............................................................................................... 3.38IllustratIon 3.M.2: shIppIng InstructIons - wrappIng chaIn slIng ....................................................................... 3.39IllustratIon 3.M.3: shIppIng InstructIons - BacKup support ................................................................................ 3.39IllustratIon 3.M.4: shIppIng InstructIons - strappIng equIpMent to pallet ......................................................... 3.40IllustratIon 4.B.1: relIeF valve trouBleshootIng - teMporary gauge InstallatIon ............................................. 4.2IllustratIon 6.a.1: torque gauge (For IllustratIon purposes only) .................................................................. 6.1IllustratIon 6.a.2: tensIon load cell ................................................................................................................. 6.1IllustratIon 6.a.3: coMpressIon load cell .......................................................................................................... 6.1IllustratIon 6.a.4: coMpressIon load cell exploded .......................................................................................... 6.3IllustratIon 6.a.5: turn counter encoder Mount exploded ............................................................................... 6.4


SecTion conTenTSxiv TechnicAL MAnuAL

Theinformationpresentedinthisdocumentwillprovidesetup,operating,andmaintenanceinstructionsforyourKT13625orLW13625tongandbackupassembly.Duetothewidevarietyofoperatingconditions,theseinstructionsmustbeconsideredguidelinesratherthanabsoluteoperatingprocedures.Itistheresponsibilityoftheusertousetheseguidelinestogetherwithanexperiencedmanagertodevelopoperatingproceduresthatconformtoallpoliciessetforthbytheoperatingauthority(ies).

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

McCoyDrilling&Completionsusesthreeindicatorstodescribeitemsofthreedegreesofimportance.

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

AWARNINGisrepresentedbyanexclamationpointwithinanorangetriangle,andcontainsinformationthatwillalertper-sonneltoapotentialsafetyhazardthatisnotlife-threatening.AWARNINGmayalsoservetoalerttheusertoinformationcriticaltothecorrectassemblyoroperationoftheequipmentinuse.

This identifies a HAZARD to operators or equipment

This identifies a WARNING to users

ACAUTIONisrepresentedbyanexclamationpointwithinayellowtriangleandhighlightsinformationthatmayaidtheuserduringassemblyoroperationofyourequipment.CAUTIONsarealsousedtoensurecommonerrorsarenotmadeduringassemblyoroperationofyourequipment.

This identifies a CAUTION to users

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

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

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

protection.

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

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


SecTion conTenTS 1.1 TechnicAL MAnuAL

inTRoDucTion

CongratulationsonthepurchaseofyourKT-13625/LW-1362513-5/8”tongandFARR®backup.Thisunitwillprovideyouwithyearsofout-standingperformance.Simplemaintenanceandcarewillextenditslifeandensureyearsofexcellentperformanceandreliability.Thesetup,operating,andmaintenanceinstructionsinthismanualwillassistyouingivingyourequipmentthecareitrequires.Pleasecarefullyreadthemanualbeforeinstallingandusingyourequipment.ReplacementpartsarereadilyavailablefromMcCoyDrilling&Completions|FARRinEd-montonAlberta.NotethatmanypartsaretransferablebetweenFARR®tongsandbackups.Shouldyouneedreplacementparts,orshouldyouexperienceanydifficultynotcoveredinthismanual,pleasecontact:

McCoy Drilling & Completions | FARR14755121AAvenueEdmonton,AlbertaCanadaT5L2T2

Phone:780.453.3277Fax:780.455.2432

SalesFax:780.481.9246EmailEngineering:[email protected]:[email protected]

CustomerCare:[email protected]

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

IllustratIon 1.a.1: Kt13625 tong & Farr© BacKup (Model 80-0935-4 shown)


SecTion conTenTS1.2 TechnicAL MAnuAL

SpeciFicATionS

IllustratIon 1.a.2: Kt13625 tong & Farr© BacKup dIMensIons

59-1/2”

32”

36-1/2”

76-3

/8”

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



SpeciFicATionS

IllustratIon 1.a.3: Kt13625 tong & Farr© BacKup hazard areas (ce-MarKed Model shown)

THIS PAGE ILLUSTRATES THE “SAFE TO HANDLE” AND “HAZARD” AREAS OF THIS EQUIPMENT

In addition to the HAZARD areas of this equipment that are coated YELLOW, a rotating cage plate assembly and backup clamp cylinders pose significant hazards when the equipment is active. Keep hands clear of the cage plate and backup clamp cylinders when equipment is energized. SAFE areas to handle while the equip-ment is energized are indicated by GREEN coating

Keep hands clear of cage plate when equipment is energized

TORQUE GAUGEMOUNTS IN THIS

LOCATION

SYSTEMPRESSURE

GAUGE



Torque Table (Standard Tong) **Pressure High Gear Low GearPSI / MPa Lbs.-ft. Nm Lbs.-ft. Nm

1500/10.34 3530 4786 17640 239172000/13.79 4970 6738 24840 336792500/17.24 6410 8691 32040 434402750/18.96 7130 9667 35640 48321

MAXIMUM RATED TORQUE: 35000 LBS.-FT. / 47450 Nm

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

10/37.9 1.6 820/75.71 3.2 1640/151.4 6.4 3260/227.1 9.6 48

Specifications - KT13625

CEcompliant.ConformswiththeessentialrequirementsoftheapplicableConformitéEuropéennedirectives.

EUExplosiveAtmospherecertified

II EquipmentGroup(surface,non-mining)

2 EquipmentCategory-highlevelofprotection

Gc GasGroup(Acetylene&Hydrogen)-Certifiedforuseinanacetylene/hydrogenenvironment

T6 Maximumsurfacetemperatureof85oC.

IllustratIon 1.a.4: Farr® ce naMeplate

II 2 G c T6

SpeciFicATionS



** These are ideal values. Actual achieved torque is highly dependant upon tong efficiency, final posi-tion of rotary gear when full torque load is reached, and the motor with which the tong is equipped.

Torque Table (Lightweight Tong) **Pressure High Gear Low GearPSI / MPa Lbs.-ft. Nm Lbs.-ft. Nm

1000 / 6.895 1696 2299 8482 115001500 / 10.34 2866 3886 14332 194322000 / 13.79 4036 5472 20181 273622400 / 16.55 4972 6741 24861 33707

MAXIMUM RATED TORQUE: 25000 LBS.-FT. / 33895 Nm

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

10 / 37.9 1.8 9.220 / 75.71 3.7 18.540 / 151.4 7.4 36.960 / 227.1 11.1 55.4

Specifications - LW13625

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

ONLY USE SPRING HANGER SUPPLIED BY MCCOY. IF USING SPRING HANGER REFER TO SEC-TION 2.H FOR PROPER RIGGING INSTRUCTIONS.

Maximum Hydraulic Requirements (KT13625)60 GPM (227.1 LPM)

3000 PSI (20.684 MPa)

Maximum Hydraulic Requirements (LW13625)60 GPM (227.1 LPM)

2500 PSI (17.237 MPa)

Maximum DimensionsLength (Doors Closed) 59-3/8” / 150.8 cm

Height 47” / 119.4 cm

Width 33-3/4” / 85.7 cm

Maximum Elevator Diameter Unlimited (tong comes off pipe)

Torque Arm Length (Pipe center to anchor center) 36” / 91.4 cm

Dead Weight (Approximate) 2370 lbs / 1077 kg

Max. Working Weight (inc. Spring Hanger) 3320 lbs / 1509 kg

Sound Level (dBa) 87 dB A @ 1m / 88 dB C @ 1m

Jaws available (inches) All standard sizes from 3-1/2” to 13-5/8” (See Pg. 2.14)

Recommended Spring Hanger 85-0106X (Capacity = 1800 lbs / 818 kg)

SpeciFicATionS



SpeciFicATionS

Use an EP synthetic grease that meets or exceeds the following specifications: Thickener LithiumComplex NLGIconsistencygrade 2 NLGIperformancegrade GC-LB Penetration-ASTMD217(25°C[77°F] 265-295minimum0.1mm)worked60strokes Droppingpoint,°F[°C]-ASTMD2265 550[288]minimum Hightemperaturelife,hours-ASTMD3527 160minimum Oxidationstability,psi-ASTMD942 (100hr/300hr)0/3 Waterwashout,percent-ASTMD1264 1.8max Rustandcorrosion-ASTMD1743 pass Oilseparation,percentloss-ASTMD1742 1.1max(24hours,25°C[77°F] Leakage,glost-ASTMD4290 1.0max Fourballweartest,mmscar-ASTMD2266 0.40max Frettingwear,mg-ASTMD4170 3.4max FourballEP,kgf-ASTMD2596: Weldpoint: 400minimum Loadwearindex: 50minimum TimkenOKloadtest,lbs-ASTMD2509 50 Lowtemperaturetorque,N*m-ASTMD4693 1.3max(-40°C[-40°F]) LT-37pumpability,g/min 360/7(60°F/0°F[16°C/-18°C]) Coppercorrosion-ASTMD4048 1B Oilviscosity:40°C[104°F],cSt 151 100°C[212°F],cSt 19.2 Flashpoint,°F[°C]-ASTM92 450[232]

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

Oxidation Stability: TurbineOilStabilityTestLife,hours 2500+ RotaryBombOxidationTest,minutes 325 FzGSpurGearTest,FailureLoadStage(FLS) 12



SeTup & opeRATion

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

Performavisualinspectionfollowingremovalofallpackagingmaterial.Immediatelyidentifyanyshippingdamagetotheshippingcom-pany,andcorrectalldamagebeforeconnectingequipmenttoahydraulicpowersource.

B. MAJOR COMPONENT IDENTIFICATION

Adequatesetupandproperhydraulicconnectionsareessentialinensuringreliableoperationofyourtong.Forbestresultsandlongtermreli-ability,readandobeythestart-upinstructionsinthissection.

A. INITIAL RECEIPT AND INSPECTION OF EQUIPMENT

Item Description1 RigidSling

2 Tong

3 FrontLegAssembly

4 RearLegWeldment

5 FARR®Backup

IllustratIon 2.B.1: Kt13625 tong & Farr© BacKup Major coMponent IdentIFIcatIon 01

4

5

1

2

3



Item Description6 BackingPinAssembly

7 CagePlateAssembly

8 BrakeBandAdjustment

9 TongDoorSpringStopCylinder

10 RHDoorAssembly

11 TongLevelingAdjustment

12 BrakeBand

13 TongJawswithDieInserts

14 SafetyDoorAssembly

15 LHDoorAssembly


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12

13

14

15

6

7

8

11

9

10 16

18

17

19



Item Description16 TongDoorLatch

17 HydraulicValveAssembly

18 ManualShiftAssembly

19 InspectionPanel

20 TorqueGaugeMountingPlate

21 BackupClampCylinder

22 BackupCamRingAssembly

23 HydraulicFluidInletquick-ConnectCoupling

24 HydraulicFluidOutletquick-ConnectCoupling

25 BackupBackingPinAssembly

26 BackupJawsc/wDies

27 BackupDoor

SeTup & opeRATion


23

24

21

22

20

26

25

27



SeTup & opeRATion

IllustratIon 2.c.1: slIng angle

McCoyDrilling&Completionsrecommendsfollowinganindustry-acceptedstandardsuchasOSHA,ASMEB30.9-2006,ormanufacturer’sguidelineswhenperforminganyriggingandoverheadlifting.Usebyuntrainedpersonsishazardous.Improperusewillresultinseriousinjuryordeath.Donotexceedratedcapacity.Slingswillfailifdamaged,abused,misused,overused,orimproperlymaintained.

● Onlygrade80orgrade100alloychainshouldbeusedforoverheadliftingapplications.● WorkingLoadLimit(WLL)isthemaximumallowableloadinpoundswhichmaybeappliedtotheload-bearingdevice,whenthedeviceisneworin“asnew”condition,andwhentheloadisuniformlyanddirectlyapplied.TheWLLmustneverbeexceeded.● WorkingLoadLimit(WLL)isthemaximumworkingloadforaspecificminimumslingangle,measuredfromthehorizontalplane.TheWorkingLoadLimitisidentifiedonthesling.● TheWorkingLoadLimitorDesignfactormaybeaffectedbywear,misuse,overloading,corrosion,deformation,intentionalalterations,sharpcornercuttingactionandotheruseconditions.● Shockloadingandextraordinaryconditionsmustbetakenintoaccountwhenselectingalloychainslings.● SeeOSHARegulationforSlings1910.184,ANSI/ASMEB30.9-”SLINGS”,ANSI/ASMEB30.10-”HOOKS”andANSI/AMSEB30.26“RIGGINGHARDWARE”foradditionalinformation.

THE SUPPLIED LOAD-BEARING DEVICE (CHAIN SLING, RIGID SLING, SPREADER BAR ASSEM-BLY, FRAME, OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT DESCRIBED IN THIS MANUAL) HAS BEEN SPECIFIED OR DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS DOCUMENT. FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, ASSEMBLY OR COMBINATION OF PARTS AND ASSEMBLIES, OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT, UNLESS SUPPLIED BY MCCOY DRILLING & COMPLETIONS.

MCCOY DRILLING & COMPLETIONS DOES NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD-BEARING DEVICES, UNLESS THOSE MODIFICATIONS ARE PERFORMED BY MCCOY DRILLING & COMPLETIONS.

THE MINIMUM SLING ANGLE (THE ANGLE OF THE LEG OF THE SLING MEASURED FROM THE HORIZONTAL) MUST NEVER FALL LOWER THAN THE ANGLE SPECIFIED FOR THE SLING IN USE

C. SLING / LOAD BEARING DEVICE SAFETY

Sling Angle



SeTup & opeRATion

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

Inspectalllugsandfixingpointsforsignsofelongationand/orbending,orformaterialbuild-uparoundthehole.Repairorreplacecomponentsthatappeardistorted.Ensureallhardware is tightand ingoodcondition.Replacemissinghardware ifnecessary.Allhardwaremustbefreeofrustandcorrosion.

Additionalinspectionsshallbeperformedduringslingusewhereserviceconditionswarrant.Periodicinspectionintervalsshallnotexceedoneyear.Thefrequencyofperiodicinspectionsshouldbebasedon:

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

Guidelinesfortheintervalare:

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

1. Inspection Of Slings

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

RemovalCriteria:

Aload-bearingdeviceshallberemovedfromserviceifconditionssuchasthefollowingarepresent:

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

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

Minimum Allowable Chain Link Thickness at Any PointNominal Chain Size Minimum ThicknessInches MM Inches MM

7/32 5.5 0.189 4.80

9/32 7 0.239 6.07

5/16 8 0.273 6.93

3/8 10 0.342 8.69

1/2 13 0.443 11.26

5/8 16 0.546 13.87

3/4 20 0.687 17.45

7/8 22 0.750 19.05

1 26 0.887 22.53

1-1/4 32 1.091 27.71

Refer To ASME B30.9



SeTup & opeRATion

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

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

Test / Examination

tIMe / Interval lIFtIng tests1

non-destructIve exaMInatIon (nde) oF

lIFtIng poInts

thorough vIsual

exaMInatIon

suFFIx to Be MarKed on plate attached

to unIt

InitialCertificationByFarr/Superior YES YES YES T

IntervalNotExceeding12Months

Atthediscretionofinspectionbody

Atthediscretionofinspectionbody YES TorVN3

IntervalNotExceeding60Months

Atthediscretionofinspectionbody YES YES TorVN

FollowingSubstantialRepairorAlteration YES YES YES T

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

Writtenrecordsofthemostrecentperiodicinspectionshallbemaintained,andshallincludetheconditionofthesling.

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

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

3. Storage Of Load-Bearing DevicesProperstorageofout-of-serviceloadbearingdevicesisimportanttoensurefullintegrityofthedeviceonceitisreturnedtoservice.McCoyrecommendsobservingthefollowingpractices.

• Wipeoffall excessgrease.Useasolvent-basedcleaneron rags towipeall external surfaces to remove residualgreaseorhydraulicfluid.Oncetheoutsidesurfaceshavebeende-greased,wipeallexternalsurfaceswithcleanwatertoremoveresidualsolvent.

• McCoyrecommendsthatananti-corrosiveagentsuchasTectyl®506beappliedtoallexternalsurfaces.Refertomanufac-turerdatasheetsforproperapplicationandsafetyinformation.Allowtheanti-corrosivecoatingampletimetodry-refertomanufacturerdatasheetsfordryingtimesatroomtemperature.

• Storeinaclean,drylocation.Whenreturningtoservice,notethatafullinspectionofthedevicemustbeperformed.



SeTup & opeRATion

IllustratIon 2.d.1: lIFt cylInder & sprIng hanger InstallatIon

D. LIFT CYLINDER INSTALLATIONTheliftcylinderisnotorientation-specific;thatis,theliftcylinderwillfunctionthesamewayindependentofwhichendisconnectedtothecraneandwhichendisconnectedtothemainliftinglugofthetong(orthespringhanger,ifused).However,McCoyrecommendsorient-ingtheliftcylinderwiththehydraulichoseconnectionatthebottomofthecylindertoensurethehoseisnotstressedwhencylinderisatfullextension.

TEST LIFT CYLINDER BEFORE INSTALLATION. REFER TO THE LIFT CYLINDER TECHNICAL MANUAL FOR DETAILED TESTING AND OPERATING PROCEDURES, AND DETAILED SAFETY GUIDELINES.

1. Installation Procedurei. Useacranetohoisttheliftcylinderbytheshackle,ensuringthehydraulichoseconnectionisatthebottomofthecylinder

whenitishoisted.

ii. RemovethetwoR-clipssecuringtheclevispin,andremovetheclevispin.

iii. Orientthespringhangersothepistonwillextenddownduringthreadmake-up,preventingwateranddebrisfromgatheringaroundtheseal.

iv. PlacetheweldedU-connectioninsidetheclevis.Replacetheclevispin,andsecuretheclevispinwiththetwoR-clips.

v. Hoisttheliftcylinderandspringhanger.

vi. Placea1”shacklearoundthemasterliftinglinkonthetongsling.Securetheshackletotheextendingendofthespringhangerusingthe1-1/8”UNCx4-3/4”modifiedhexboltand1-1/8”UNChexjamnut.Securethejamnuttotheboltusinga3/16”x1-1/4”cotterpin.

IF USING A SPRING HANGER ITS WEIGHT MUST BE ACCOUNTED FOR WHEN CALCULATING TOTAL SUSPENDED WEIGHT.



2. Lift Cylinder ConnectionInspectthehydraulichosebeforeconnection,ensuringthelineisfreeofruptures,cracks,cuts,orotherdamage.Inspectthefemalequick-connectfittingtoensureitisfreefromdamage.Connectthefemalequick-connectontheliftcylinderhydraulichosetothemalequick-connectfittingattachedtotheneedlevalveonthetongvalvebank.Oncethefittinghassnappedintoplacegivethehydrauliclinealighttugupwardstoensurethefittingissecurelyseated.

Ifnotalreadydone,connectthemainhydraulicsupplytothepowertong(seesection2.Fforproperhydraulicconnectionproce-dure).Energizethehydraulicsupplytothepowertong.

Lift the power tong approximately three inches off the work surface, and suspend the tong for approximately thirty seconds.Followingthesuspensionalternatelyliftandlowerthetongslightlytoconfirmthatliftandlowerfunctionseachoperatecorrectly.

3. Lift Cylinder Safety

A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR.

McCoyDrilling&Completionsrecommendsfollowinganindustry-acceptedstandardsuchasOSHA,ASMEB30.9-2006,ormanufac-turer’sguidelineswhenperforminganyriggingandoverheadlifting.Usebyuntrainedpersonsishazardous.Improperusewillresultinseriousinjuryordeath.Donotexceedratedcapacity.

WorkingLoadLimit (WLL) is themaximumallowable load inpoundswhichmaybeapplied to the load-bearingdevice,when thedeviceisneworin“asnew”condition,andwhentheloadisuniformlyanddirectlyapplied.TheWLLmustneverbeexceeded.

TheWorkingLoadLimitorDesignfactormaybeaffectedbywear,misuse,overloading,corrosion,deformation,intentionalaltera-tions,sharpcornercuttingactionandotheruseconditions.

SeeOSHARegulationforSlings1910.184,ANSI/ASMEB30.9-”SLINGS”,ANSI/ASMEB30.10-”HOOKS”andANSI/AMSEB30.26“RIGGINGHARDWARE”foradditionalinformation.

IllustratIon 2.d.2: lIFt cylInder hydraulIc connectIon

SeTup & opeRATion



SeTup & opeRATion

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

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

REPLACE LIFT CYLINDER HYDRAULIC LINE EVERY TWO YEARS

Theprotectivewrapalsopreventswearofthehydrauliclinethoughabrasion.Donotremovetheprotectivewrapfromtheliftcylin-derline,andreplaceprotectivewrapifitismissing,torn,orsplit.Regardlessofuseorcondition,thehydrauliclinesupplyingtheliftcylindermustbereplacedeverytwoyears.

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

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

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

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



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E. HYDRAULICS1. Hydraulic Schematics

Item Description Part Number Page1 InletValve,DVA35-A880 10-9016

2 ReliefValve,DVA35-MMRV-1 10-0010R

3 MotorSection,DVA35-MA8 10-9014

4 BackupSection,DVA35-DA8,SAEPORT 10-9019

5 LiftCylinderSection,DVA35-SA8,(1”ORBPORT) 10-9015

5A LiftCylinderSection,CE-MarkedTongsOnly 10-9019

6 OutletSection,DVA35-TR99,SAEPORT 10-0086

6A OutletSection,DVA35,PressureBeyond 08-1825

7 FlowControlValve 08-9062

8 LKHC-XDNPilot-To-OperateCartridgeValve 08-1625

9 SafetyDoorValveBlock 101-0727

10 SafetyDoorSwitch 08-0337

11 CheckValve 02-9022

12 RineerGA15-15HydraulicMotor 87-0112

RineerGA15-13HydraulicMotor(Lightweightmodel) 87-0110

IllustratIon 2.e.1: Kt13625 tong & Farr© BacKup hydraulIc scheMatIc

P T

1 2 3 4 5 6

713

1415

1617

1112

10 9 8

MOTOR

BACKUP

LIFT CYLINDER



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Ifyourtonghydraulicsareconfiguredas“closedcentre”a“powerbeyond”outletsectionwillbeused.Refertotheschematicabove,andtotheoutletsectioninformationonpg.7.25.

Item Description Part Number Page13 FlowControlValve 08-0089

14 ReliefValveBlock 08-0096

15 ReliefValve 08-0095

16 BackupCylinder 1364-902

17 3000psiPressureGauge 02-0245

18 LiftCylinderOrifice(CE-MarkedTongsOnly)

IllustratIon 2.e.2: Kt13625 tong & Farr© BacKup hydraulIc (closed centre)

P

T

1 2 3 4 5 6A

713

1415

1617

1112

10 9 8

MOTOR

BACKUP

LIFT CYLINDER



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IllustratIon 2.e.3: Kt13625 tong & Farr© BacKup hydraulIc scheMatIc (ce MarKed)

P T

1 2 3 4 5A 6

713

1415

1617

1112

10 9 8

18

MOTOR

BACKUP

LIFT CYLINDER



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IllustratIon 2.e.4: Kt13625 tong & Farr© BacKup hydraulIc (closed centre, ce MarKed)

P

T

1 2 3 4 5A 6A

713

1415

1617

1112

10 9 8

18

X

MOTOR

BACKUP

LIFT CYLINDER



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2. Hydraulic Component Identification

IllustratIon 2.e.5: Kt13625 tong & Farr© BacKup hydraulIc coMponent Id 01


7

1

6

5

4

3

2

9

8

12



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10

11



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3. Main Hydraulic ConnectionsApairofhydrauliclines-a1”supplylineanda1-1/4”returnline-connectthetongtothepowerunit(seeillustrationbelow).Ancillarydevices(hydraulicmotors,hydrauliccylinders,etc.)areconnectedthroughthevalveblock.

Performanyhydraulicconnectionwhenthepowerunitisnotrunning,orwhenthehydraulicpumpisdisengaged.Thepossibilityoferrorininter-changingthehighpressuresupplyhoseandthelowpressurereturnhosehasbeeneliminated,becausethesupplysidecouplingissmallerthanthereturnside.


IllustratIon 2.e.10: Kt13625 tong & Farr© BacKup hydraulIc connectIons 01

Hydraulic Return (1-1/4”)

Hydraulic Supply (1”)

16

13 14

15



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Main Hydraulic Connections (Continued):Thesehosecouplingsareself-sealing,andcareshouldbetakentoensurecompleteengagementtopreventpartialclosureofthecheckvalveinthecoupling.Ensurethatthenut(female)sideiscompletelymadeupontothemaleconnector-thereisalineonthemalefittingthatindicatescompletemake-up.Snugthefemalefittingrightuptotheline.

4. Hydraulic Circuit DescriptionThemainhydraulicpowersourcesupplieshydraulicfluidtothehydraulicvalveblockinletsection(Item1onthehydraulicschematicandonpage2.7)througha1”threadedpositive-shutoffconnection.Hydraulic fluidcirculatesthroughthe inletsection, themotorcontrolsection(Item3onthehydraulicschematicandonpage2.7)andtheoutletsection(Item4onthehydraulicschematicandonpage2.7)atmaximumtongpressurebeforereturningtothehydraulicfluidreservoir(the“tank”)througha1-1/4”threadedpositive-shutoffconnection.Thereliefvalve(Item2onthehydraulicschematicandonpage2.7)isfactoryadjustedtolimitthemaximumoperatingpressureofthetongtothatwhichwillallowmaximumtorque.Maximumoperatingpressureandmaximumtorquearelistedinthespecificationsonpage1.3.

Actuatingthevalvehandleonthemotorcontrolsectiondirectshydraulicfluidtothehydraulicmotor(Item9onthehydraulicsche-maticandonpage2.7),throughthesafetydoorreliefvalveblock(Items5&6onthehydraulicschematicandonpage2.7),causingrotationofthemotor.Duringnormaloperationpilotpressurefromthesafetydoorswitch(Item7onthehydraulicschematicandonpage2.8)directspilotpressuretoactuatethesafetydoorcheckvalves,allowingfullhydraulicpowertothemotor.Theconfigurationoftheplumbingbetweenthemotorvalvesectionandthemotordeterminesthedirectionofrotationforagivenvalveaction.McCoyDrilling&Completions|FARRnormallyconfigurestheplumbingonthistongsothatpushingthevalvecontrolhandletowardsthecentreofthetongsupplieshydraulicpressuretothe“clockwiserotation”sideofthemotor,whichisthedesireddirectionofrotationformakingupatubularconnection.Conversely,pullingthevalvecontrolhandletowardstheoperatorsupplieshydraulicpressuretothe“counter-clockwiserotation”sideofthemotor,whichisthedesireddirectionofrotationforbreakingoutatubularconnection.Releasingthevalvehandleenablesthevalvetogotoaneutralposition,directingallhydraulicfluidtotheoutletsectionand“backtotank”.Acheckvalve(Item8onthehydraulicschematicandonpage2.7)installedonthecasedrainlinebetweenthemotorandthemaintankreturnline,ortheinternalcasedrain,protectsthemotorfromexcesspressureintheeventofblockageinthetankline.

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

Turnoffpowerunitanddepressurizehydraulicsystembeforedisconnectingthemainhydrauliclinesundernormalworkingconditions.SeeSection3.Dforhydraulicsystemdepressurization.McCoyrecommendsplacingprotectivecapsovertheexposedconnectorstoprotectthemfromwaterandimpactdamage.

ALWAYS TURN OFF HYDRAULIC POWER AND DEPRESSURIZE HYDRAULIC SYSTEM BEFORE DIS-CONNECTING MAIN HYDRAULIC LINES.

IllustratIon 2.e.11: Kt13625 tong & Farr© BacKup hydraulIc connectIons 02

Make up female fitting to Marked point on male fitting



Actuatingthevalvehandleonthebackupcontrolsectiondirectshydraulicfluidtothedouble-actingbackupclampingcylinder.Thisisnotproportionalcontrol,meaningthatactuatingthecontrolvalveenablesafixedhydraulicoutputtothecylinder.Theconfigurationoftheplumbingbetweenthebackupvalvesectionandthebackupcylinderdeterminestheclampingactionofthebackupcylinderforagivenvalveaction.McCoyDrilling&Completions|FARRnormallyconfigurestheplumbingonthistongsothatpushingthevalvecontrolhandletowardsthecentreofthetongclampsthebackupformake-upoperations,andpullingthevalvecontrolhandletowardtheoperatorclampsthebackupforbreak-outoperations.Adjustableneedlevalvesoneachbackupcylinderlineallowstheoperatortosettherateatwhichhydraulicfluidissuppliedtothebackupcylinder,thuscontrollingtherateatwhichthecylinderclampsandun-clamps.Adjustablereliefvalvesoneachbackupcylinderlineallowstheoperatortosettheclampingpressureforbothmake-upandbreak-outoperations.

Hydraulicfluidatmaximumtongpressureflowsfromthevalveinletsectiontothesafetydoorswitch.Duringnormaloperationtheplungeronthesafetydoorswitchisdepressedwhenthetongdoorisclosed,directingahydraulicpilotsignaltobothsafetydoorreliefvalves(Item5onthehydraulicschematicandonpage2.7).Thispilotpressureactuatesthesafetydoorcheckvalves,allowingfullsystempressuretothemotorwhenthemotorcontrolvalveismanipulated.Releasingtheplungeronthesafetydoorswitchbyopeningthetongdoordivertsallhydraulicfluidfromthesafetydoorswitchtothetankline,interruptingpilotpressuretothesafetydoorcheckvalves.Thereliefvalvesclose,immediatelyinhibitingsystempressuretothemotor.Fullhydraulicpowertothemotorcannotberestoreduntiltheplungeronthesafetydoorswitchisdepressedbyfullyclosingthetongdoor.

F. TONG JAW AVAILABILITY & INSTALLATION1. Jaw Availability

Thefollowingtablelistsalljawdiekitsthatareavailableasstandardstockedsizesforthismodeloftong.McCoyDrilling&Completions|Farroffersagoodselectionofstandardjawsizes.However,pleasenotethatMcCoycancustom-engineerandmanufactureanysizeofjawwithintherangeofthetong.Jawsystemsareavailabletoallowuseofdieinsertsintendedforspecializedapplications.Calloursalesofficeforinformationonjawanddiesystemsdesignedforhigherorlowergrip,ornon-markingapplications.

The table listsstandardcontoured, flatandwraparounddie inserts thatareavailableasspareparts.However,awidevarietyofdiamond-tooth,GRITFACE®,andwrap-aroundfine-toothdiesareavailableforspecializedapplications.Pleaserefertoourwebsiteforcompleteinformation:

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

AllCE-markedtongsareconfiguredsothatpushingtheliftcylindercontrolvalvehandletowardthecentreofthetongsupplieshydraulicpressuretotheliftcylinder,retractingthecylinderandcausingtheequipmenttolift,whilepullingontheliftcylindercontrolvalvehandle(towardtheoperator)willcausetheequipmenttolower.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.

Aspeed-limitingorificeisinstalledinplaceofabreatheronallCE-markedliftcylinders.Thisorificelimitstherateatwhichtheequipmentwilllowerintheeventofequipmentfailure(arupturedhydraulichose,forexample).

Hydraulic Circuit Description (continued):Actuatingthevalvehandleontheliftcylindersectiondirectshydraulicfluidtotheliftcylinder,whichisconnectedtothemasterlinkontherigidslingandprovidesraisingandloweringfunctionstothetongandbackupassembly.Althoughtheliftcylinderisdesignedtobeadouble-actingcylinder,normallyonlythe“lift”sideisconnectedtohydraulicpressurefromtheliftcylindervalve.Actuatingtheliftcylindervalveinthe“lower”directionprovidesapathtotankforthehydraulicfluidintheliftcylinderandallowstheloadsuspendedontheliftcylindertoforcethehydraulicfluidfromthecylinder,throughthevalve.Inotherwordsthe“lowering”actionisafunctionofgravity,notactivehydraulics.Thepositionoftheliftcylindervalvecontrolstherateatwhichthecylinderlowersthetongandbackupassembly.Anadjustableneedlevalveonthepressurelinetotheliftcylinderallowsanoperatortosettherateatwhichhydraulicfluidissuppliedtotheliftcylinder,thuscontrollingtherateatwhichthecylinderraisesandlowers.Abreatherportinstalledintheoppositesideoftheliftcylinderallowsthecylindertobreatheasthepistonintheliftcylindermoves.Theconfigurationoftheplumbingbetweentheliftcylindervalvesectionandthecylinderdeterminestheactionoftheliftcylinderforagivenvalveaction.McCoyDrilling&Completions|FARRnormallyconfigurestheplumbingonthistongsothatpullingthevalvecontrolhandletowardstheoperatorsupplieshydraulicpressuretotheliftcylinder,whichcausesthecylindertoretract,thusprovidingaliftingaction.Converselypushingthevalvecontrolhandletowardsthecentreofthetongallowsapathbacktotank,whichallowsgravitytoextendthecylinderandlowerstheequipment.Allowingthehandletogotoneutralstopsallhydraulicfluidmovementtoorfromtheliftcylinder.

USE OF ALUMINUM DIES IS FORBIDDEN ON CE-MARKED EQUIPMENT

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Jaw Availability (continued):

Description Part Number Description Part Number

3-1/2”JawDieKit(1) 997-WJK-350 7”JawDieKit 997-JDK-310

4”JawDieKit(2) 997-WJK-550 7-5/8”JawDieKit 997-JDK-315

4-1/2”JawDieKit(3) 997-WJK-550 8-5/8”JawDieKit 997-JDK-320

4-1/2”JawDieKit(4) 997-JDK-290 9-5/8”JawDieKit 997-JDK-325

4-3/4”JawDieKit 997-JDK-291 10-3/4”JawDieKit 997-JDK-330

5”JawDieKit 997-JDK-295 11-3/4”JawDieKit 997-JDK-335


6”JawDieKit 997-JDK-306 13-3/8”JawDieKit 997-JDK-340


(1)WraparoundjawdiekitusesinsertPart#12-2006NOTE: THIS JAW IS TORQUE-LIMITED TO 9000 LBS-FT(2)Wraparoundjawdiekitusesmulti-rangejaw(997-WJK-550)andwraparoundinsertPart#12-2007.(3)Wraparoundjawdiekitusesmulti-rangejaw(997-WJK-550)andwraparoundinsertPart#12-2009.(4)Optional4-1/2”jawdiekitusesflatjawdieinsertPart#13-0008-314-0. AllremainingjawdiekitsuseflatdiePart#13-0008-314-0.

DO NOT EXCEED 9000 LBS-FT OF TORQUE WHEN USING THE 3-1/2” JAW DIE KIT

DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED.

2. Jaw / Jaw Die Removal

JAWS MAY PRODUCE METAL SLIVERS. WEAR STURDY GLOVES WHEN REMOVING AND INSTALLING JAW DIE KITS.

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• Pushagainstthefrontofthejawtocausetheassemblytoswivelaroundthepivotbolt.

• Removethedieretainer,whichismostoftenaflangedmachinescrew.

• Removethereardie-ifitdoesnotloosenitmayhavetobelightlytappedoutofthejaw.

• Pushagainsttherearofthejawtocausetheassemblytoswiveltheoppositewayaroundthepivotbolt.

• Removetheretainerforthefrontdie,andremovethefrontdie

Reversethisproceduretoinstallnewjawdies.

(Seeillustration2.F.1nextpage)



Jaw / Jaw Die Removal (continued):

IllustratIon 2.F.1: jaw dIe reMoval

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IllustratIon 2.F.2: jaw reMoval

Jaw / Jaw Die Removal (continued):Thetongjawswilloftenrequireremovaltochangejawsizeorreplacewornjawdieinserts.Openthetongdoortodisabletongrota-tion(rotationisinhibitedbysafetydoorsystems).Supportthejawbeingremovedfromthebottom,anduseawrenchtoloosenandremovethejawpivotbolt.Slidethejawawayfromtherotarygeartowardsthecentreofthecageplateassembly,andliftclearofthetong(seeIllustration2.F.2).Repeatfortheotherjaw.

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Oncethejawhasbeenremovedthejawdiesmaybereplacedbyremovingthekeeperscrewabovethedie,andtapthediefromjawusingahammer.Replacethedie,tappingitintoplaceifnecessary,andreplacethekeeperscrews.

3. Backup JawsThejawdiekitsusedintheFarrbackupareidenticaltothoseusedinthetong(seePg.2.19).Followthesameremovalandinstal-lationinstructionsasforthetongjawdiekits.



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

Suspendthetongandbackupfromalocationasneartothecentreofthedrillrotaryaspossible,andfromalocationhighenoughonthemasttoensureeasyhandling.Thelowerthepointfromwhichthetongissuspended,themoreeffortwillberequiredtomovethetongtoandfromtheconnectionpoint.

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

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

Ifyoudonotknowwhichspecificspringhangerisinuse,checkthespecificationpageinthismanualforinformationontherecom-mendedspringhangerforthisapplication.McCoyDrilling&CompletionswillnotguaranteeorspecifyspringhangersotherthanwhathasbeensuppliedbyMcCoy.

Manyapplicationsusealiftcylinderforadjustingtheheightofthetong.Ensuretheweightoftheliftcylinderisknownifithasnotbeenincludedinthetotalweightofthetong.

Allforcesuponthesuspensionlinemustbeconsideredwhencalculatingnecessarystrengthofthesuspensionline.Theweightofthetong,theweightoftheliftcylinder,theweightofthespringhanger,andtheforceimpartedonthesuspensionlinebythespringhangermustallbeadded together inorder toarriveat the total forcesupportedby thesuspension line.Selectyoursuspensionlinebaseduponthetotalforceandthemarginsofsafetydictatedbythepoliciesofyourcompanyandbyestablishedengineeringpractices.Ultimately,calculatingtheforceonthesuspensionlineandselectionofthesuspensionlineisthecompleteresponsibilityofthecustomer.

McCoyDrilling&Completionsrecommendsusingdualbackup(snub)linesofsufficientstrengthtowithstandtheforceimpartedbythemaximumratedtorqueofthetongandbackupassemblyinuse.Thesnublineswillarrestuncontrolledmovementofthetongandbackupintheeventslippingofthebackupjaws.Calculatetheforceonthesnublinesbydividingthemaximumtorqueofthetongbythetong’storquearm(expressedinfeet).Forexample,a35,000lbs-fttongwitha36inch(3ft)torquearmwillgenerate11667lbsofforceagainstthesnubline.Selectyoursnublinesbaseduponthetotalforceandthemarginsofsafetydictatedbythepoliciesofyourcompanyandbyestablishedengineeringpractices.Ultimately,calculatingtheforceonthesnublineandselectionofthesnublineisthecompleteresponsibilityofthecustomer.

Snublinesmustbesecurelyconnectedtotherearofthetongandbackupassembly,andtiedofftoasuitableanchor.

MCCOY DRILLING & COMPLETIONS ACCEPTS NO RESPONSIBILITY FOR DESIGNING AND SELECTING AN ADEQUATE SUSPENSION AND RESTRAINT SYSTEM FOR YOUR DRILLING EQUIPMENT

ALL SELECTED FASTENERS, SHACKLES, CLAMPS, ETC. USED FOR CONSTRUCTING THE SUSPENSION AND SNUB LINES MUST BE RATED FOR THE CALCULATED FORCES.

2. Tong LevelingThe tongmustbe leveledside-to-sideand front-to-rearbeforeplacing into service.The followingguidelineswil assist youwhenlevelingyourtong.

FAILURE TO PROPERLY LEVEL TONG MAY RESULT IN JAW SLIPPAGE OR FAILURE OF JAW COMPONENTS

i. Placealevelaxially(sidetoside)acrossthetong,ensuringthatitisparallelwiththesurfaceofthetong.Useathinwrenchontheflatoftheadjustinghelixtorotatethehelix,forcingtheliftlinktomovetowardstheoutersupportsofthesling.The1”jamnutonthepinmayhavetobeslightlyloosenedtoallowthehelixtorotate.Adjustthehelixuntilthelevelshowsthatthetongislevelside-to-side-retightenthenutifnecessary



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Tong Leveling (continued):

Tong Leveling Continued:ii. Placealevellengthwise(fronttoback)alongthetong,ensuringthatitisparallelwiththesurfaceofthetong.Loosenthe3/4”

jamnutsontheadjustingboltsonrigidslingbrackets.Completelyloosentheadjustingbolts.Turnfrontorrearadjustingboltequallyoneachhangerluguntiltonghangslevelfront-to-back.Lockadjustingboltsinplacewiththejamnuts.

IllustratIon 2.g.2: tong levelIng, Front-to-BacK

IllustratIon 2.g.1: tong levelIng (sIde-to-sIde)

ONLY USE THE MASTER LINK TO SUSPEND THE TONG ASSEMBLY. THE RIGID SLING IS DESIGNED TO BE USED FOR VERTICAL LIFTING ONLY.

Rotate helix using flat

3/4” nylock nut may require loosening



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3. Load Cell ConfigurationThebackupisdirectlycoupledtothecompressionloadcellviathebackupbodypaddle.Theloadcellhangerissimplyhungonthepaddleandsecuredthroughthetopofthe“U”byaboltandwasherset,andinnormaloperationdoesnotneedtobeadjustedorremoved.Theassemblyinthefirstofthefollowingtwoillustrationshasbeenconfiguredinthe“make-up”configuration;toconverttheassemblytothe“break-out”configurationremovetheboltandwashersetsecuringtheloadcellholdertothepaddle,andmovetheentireassemblytotheothersideofthepaddle.

IllustratIon 2.g.3: load cell conFIguratIon, MaKe-up

IllustratIon 2.g.4: load cell conFIguratIon, BreaK-out

Load cell configured for make-up operations

Load cell configured for break-out operations



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H. TONG OPERATION1. Operator Training

Manycompaniessetqualificationstandardsthatmustbemetbeforeequipmentmaybeoperatedwithoutsupervision.McCoyDrilling&Completions recommends operator training,which typically consists of operation of the equipment under the supervision of atrainedequipmentoperatoruntilasatisfactorylevelofcompetenceisachieved.Typicaloperatortrainingshouldinclude:

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

2. Operator SafetyMcCoyrecommendsthatahazardassessmentoftheworkareabeperformedbyadesignatedsafetyrepresentativebeforecom-mencingoperations.Adesignatedsafetyrepresentativeisresponsibleforverifyingthatalloperatorshaveadequateequipmentandsafetytraining.

Thesafetydoorsystemistheprimarydeviceprotectingthetongoperatorandnearbypersonnelfromtherotarygear.Confirmthecorrectoperationofthesafetydoorbeforeeveryjob.Neverdisablethesafetydoordevice.

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

Ensurehydraulicpowerisdeactivatedandtonghydraulicsarede-pressurizedbeforedisconnectingthemainhydrauliclines.McCoyrecommendsdepressurizingthetonghydraulicsystembeforeconnectingordisconnectingquick-connectfittings.

DEPRESSURIZE EQUIPMENT BEFORE DISCONNECTING MAIN HYDRAULIC LINES.

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

Adequatelightingoftheworkareaisrequired.Allwarnings,labels,gauges,andsignsmustbeclearlyvisible

Thecomponentsofthetongcommonlymanipulatedorrequiringcontrolinputarepaintedgreen,andaresafeforcontinuoushan-dling.Areaspaintedyellowaredesignatedashazardousareas,andcontactwith thoseareasmustbeavoidedduringoperation.Alwayswearall personalprotectiveequipment (PPE)specifiedbyyour company’sHSEpolicy,and followall of your company’ssafetyguidelines.

Inspectanti-tamperdevicesonsafetydoorcomponentsbeforebeginningjob.Equipmentshowingsignsoftam-peringonanysafetysystemmustbeimmediatelyremovedfromserviceandtested.Anti-tamperdevicesmustberestoredbeforeallowingequipmenttobereleasedtoanoperatingenvironment.

3. Valve Operation

4-wayproportionalvalvescontroloperationofhydraulicdevicesonthetongassemblysuchashydraulicmotorsandcylinders.Whenanyonevalveis“centered”orinthedetentposition,thereisnohydraulicoutputfromthevalve.Whenthevalveispushedforwardthereisaneffect,andwhenthevalveispulledback,thereisanoppositeeffect.Thesevalvesfeatureproportionalcontrol,whichmeansthatfurtherextensionofthevalvehandle(therebyfurtheropeningthevalveorifice)resultsinproportionallyhigherhydraulicoutputtothecontrolleddevice.

The illustrations on the following pagesdemonstrate the typeandeffect of the hydraulic valveswithwhich this tong ismaybeequipped.



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TONGMOTOR

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

LIFTCYLINDERCONTROLVALVE

Thisisadirect-actingvalve.Pullingoutonthevalvehandlewillcausetheliftcylindertoliftthetongvertically.Pushinginonthevalvehandlewillcausetheliftcylindertolowerthetong.Releasingthevalvehandlewillimmediatelystoptheliftingorloweringaction.

Pushingontheliftcylindercontrolvalvehandle(towardthecenterofthetong)willcausetheequipmenttolift,whilepullingontheliftcylindercontrolvalvehandle(towardtheoperator)willcausetheequipmenttolower.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.

LIFTCYLINDERNEEDLEVALVE(Seeillustration2.H.2)

Thisneedlevalveregulateshydraulicfluidflowtotheliftcylinder.Closingtheneedlevalve(rotatingtheknobclockwise)willincreas-inglyrestricttheflowrateofthefluid,resultinginsloweractuationofthecylinderinbothdirections(lifting&lowering).

IllustratIon 2.h.1: Motor control valve

IllustratIon 2.h.2: lIFt cylInder control valve

Lift Cylinder Needle Valve



SeTup & opeRATion

BACKUPThisisatwo-waydirectactingvalve,withoutproportionalcontrol.Pushingthevalvehandleforwardwillcausethebackuptoengage.Pullingbackward,towardstheoperator,reversestheoperation.

IllustratIon 2.h.3: Farr© BacKup control valve

4. Shifting GearsTheshiftingshafthasthree“detent”positionsidentifyingthelowspeed/hightorqueposition,the“neutral”orfree-spinningposition,andthehighspeed/lowtorqueposition.Thedetentstrengthmaybeadjustedbyreleasingthelocknutonthedetenttubeandincreas-ingorrelaxingpressureonthedetentspring.Ensurethelocknutistightenedoncethedesireddetentpressurehasbeenset.

Toshifttothehigh-speedgear,movetheshiftinghandleDOWNfromneutralposition.Toshifttothelow-speedgear,movetheshift-inghandleUPthroughtheneutraldetenttoitsHIGHESTposition.Notethatthehighclutchgearorthelowclutchgearmaynotbeexactlyalignedwhenshifting,sotheoperatormayneedto“bump”themotorcontrolhandleslightlytoturnthemainclutchgearshaftandshiftingcollarintoalignment.Themosteffectivewayofachievingthisistoapplyasmallamountofpressureontothegearshiftleverinthedirectionyouwanttoshiftthetong,ensuringtheshiftingcollarwill“catch”whenthemainclutchgearalignswitheitherthehighorlowclutchgear(seeIllustration2.I.3nextpage)

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

IllustratIon 2.h.4: shIFtIng gears

Move Shifting Handle This Direction To Shift To Low Gear

Move Shifting Handle This Direction To Shift To High Gear



SeTup & opeRATion

5. Pre-Operational ChecksMcCoyrecommendsthatthefollowingpre-operatingtestsbeperformedpriortoreleasingthetongassemblytoaoperationalenvi-ronment:

a. Connect the tong toahydraulicpowersource inacontrolledenvironment.Ensure thepowerunit’soperatingparametersarewithinthespecificationsasidentifiedonPg.1.3.Ensurethehydraulicconnectionsfromthepowerunitareproperlyandsecurelymadeup(seeSection2.E).Donotneglecttoconnectthemotordrainline.

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

A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR.

DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE TONG ROTATION IN ORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL.

c. Allowhydraulicsystemtowarmbycirculatingfluidforabout10minutes,thenslowlyclosethebypassvalvetoallowhydraulicfluidtocirculatethroughthehosesandtong.Ensurecirculatingpressuredoesnotexceed200psi.

d. Inspectallhydraulichosesandconnectionsonthetong.Immediatelycorrectanyhydraulicfluidleaks.

e. Inspectallgauges.Replaceleakingorcrackedgauges,oranygaugenotregisteringareading.

f. Confirmthatallload-bearingpinsandR-clipretainersareinstalledandingoodcondition(rigidslingpins,liftcylinderpins).

g. Confirmallhydraulichoses(withtheexceptionofthesupply&returntothebackup)aresecurelyfastenedtothetong,andarenotincontactwiththecageplateorcreatingasnagginghazard.

h. Ensurethetongdoorissecurelyclosedbeforerotatingtong.

i. Shiftthetongtolowgear(seeSection2.H.4)androtatethetongslowlyforwardforapproximatelyaminute.Stopthetongandthenreversetherotationdirectionforapproximatelyanotherminute.Stopthetong,shifttohighgear,andoperateinhighgearforapproximatelyanotherminute.Stopthetongandrotateintheoppositedirectioninhighgearforapproximatelyanotherminute.Ifatanytimeabnormaloperationissuspected(surging,grinding,squealing,orothernoisesdeemedtobeunusual,orfailuretooperate)discontinueoperationofthetongandcontactMcCoyDrilling&Completionsimmediately.

j. Re-inspectallhydrauliclinesandconnectionsonthetong,andcorrectallleaks.

k. Thesafetydoorsystemistheprimeprotectivemeasureseparatingtheoperatorfromtherotarygear,andmustbeinworkingconditionwhenoperatingtong.Carefullyinspectthesafetydoorcomponents,andtesttheoperationofthesafetydoorusingthefollowingprocedure:

i. Keepnon-essentialpersonnelclearoftheunitundertest.Thistestprocedurewillonlyincludetwopeople:onetorunthecontrolvalveandonetooperatethedoor.

ii. Ensurethetongdoorissecurelyclosed.

iii. ShifttoLOWgear.

iv. Beginrotatingthetong(directionofrotationisnotimportant).

v. Openthetongdoorwhiletherotatingthetong.Thetongmustimmediatelyandcompletelystoprotatingassoonasthedoorisopened.

vi. Continuetoapplyrotationcontrol,andopen&closethedoorthroughoutitscompleterange.Slowlyclosethedooruntilitlatches.Rotationmustnotbeginuntilthedooriscompletelyclosedandsecurelylatched.

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

Thesafetydoorswitchisprotectedfromimpactbyasturdymetalguard,paintedyellow.Thisguardmustbeinspectedbeforeeachuseofthetong.Allcomponentsoftheguardmustbeinplace,andallfastenerssecuringtheguardmustbeintactandtight.Ensurewireties(whereapplicable)onsafetydoorcomponentsarepresentandsecure,anddonotshowsignsoftampering.

DO NOT OPERATE TONG WITH A MALFUNCTIONING OR NON-OPERATING SAFETY DOOR SYSTEM.



SeTup & opeRATion

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

2) Selectgearandbearinglubricantsthatarecompatiblewithexpectedclimaticconditions.

3) Selecthydraulicfluidthatiscompatiblewithexpectedclimaticconditions.

4) Allowhydraulic fluid tocirculate forapproximately20minutesafterstarting thepowerunit,prior toactivating thebypassvalvetoallowfluidtocirculatetotong.Ifthepowerunitisequippedwithanoiltemperaturegauge,ensurethatthefluidhasreachedoperatingtemperatureasspecifiedbyhydraulicfluiddatasheet.

5) Allowforadequatedryingofmoisture(priortolubricating)whencleaningtongpartsincoldweather.

THE “SNAP-BREAK’ METHOD IS HAZARDOUS TO PERSONNEL AND EQUIPMENT

6. General Operational Commentsa) Positionrotarygearincontactwithbothidlergearswhenbreakingoutjointsorcollarswherehightorquesarerequired.

b) Whenmaking-upintegral(shouldered)joints,itisessentialtomakeupthelastturnofthethreadsinlowgear.Thisreducesthetendencyofaninstantstoporasuddenincreaseintorque,whichinducesextremelyhighstressesonthegeartrain.

c) DONOTemploythe“snapbreak”methodofbreaking-outjointswhenpullingastring.Bydefinition,the“snapbreak”methodisaprocedureusedbysomeoperatorstobreakoutconnections,accomplishedbyleavingslackinthe“jaw-pipe”engage-ment,andthenquicklypullingthethrottlevalvecontrolleverallowingthetongtosnapintoitsloadedorhightorquecondition.Although thismethod isveryeffective inbreakingout joints, theextremelyhighstressplacedon thegear train frequentlycausesgearbreakage.



J. MAKING AND BREAKING CONNECTIONS

SetupandprepareyourequipmentforoperationasperSection2ofthismanualRefertothefollowingsections:● 2.D-LiftCylinderInstallation● 2.E.3-HydraulicConnections● 2.F-TongJawInstallation● 2.G.1-TongRig-upandLeveling(Suspension)● 2.G.2-TongRig-upandLeveling(Leveling)

Yourtongandbackupassemblyshouldbeproperlysuspended,connectedtoahydraulicpowersource,andreadytomakeorbreakcon-nectionsatthispoint.

1. Making A Connectiona) Ensurehydraulicpowersupplytothetongisenergized.Themasterlinkontherigidslingmustbeusedtosuspendthetong.

Donotsuspendthetongdirectlyfromtherigidsling.

THESE OPERATING PROCEDURES ASSUME THE USER HAS PROPERLY SET UP AND PREPARED THE EQUIPMENT FOR OPERATION AS PER SECTIONS 2D, 2E, AND 2F OF THIS MANUAL.

THE MASTER LINK MUST BE USED TO SUSPEND THE TONG ASSEMBLY

IllustratIon 2.j.1: rIgId slIng Master lInK

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b) Ensurethebackingpinisinthe“makeup”position.Fromthefrontofthetong,thebackingpincorrectlyconfiguredformakeupwillbeinthe10o’clockposition(seeIllustration2.J.2nextpage).Ifitisnot,simplyliftupandplaceinthecorrectposition(seeIllustration2nextpage).Thecageplateopeningmustbealignedwiththedooropeningwhensettingthebackingpinposition.Setthepositionofthebackingpinonthebackupinexactlythesamefashion.



Making A Connection (Continued)

IllustratIon 2.j.2: settIng BacKIng pIn to “MaKe-up” posItIon

c) Properlyconfiguretheloadcellformakingupconnections(seeSection2.G.3).Connectsnublinestotherearofthetongtoarrestuncontrolledrotationoftheassemblyintheeventofbackupjawslippage.Thesnublinesmustberatedfortheappliedtorquepluswhateversafetymarginsstatedbyyourownoperatingpolicies.Thesnublineconnectionpointsonthedrillfloormustbesturdyenoughtoabsorballappliedforces.Whenmakingupjointsthesnublineisattachedtothedriller’ssideofthetong,whichistheleftsideofthetongasseenfromtherear.Foraccuratetorquemeasurementthesnublinemustbeperpen-diculartothevertical,andperpendiculartothecentre-lineofthetong.

d) Graspthegreentongdoorlatchhandleontheright-handdoorassembly(onthelefthandsideasseenfromthefront)andpullthedoortoreleasethelatchandopenthedoor.(SeeIllustration2.J.3).Openingthetongdoorwillactivatethesafetydoorsystemandpreventrotationofthecageplate.

SeTup & opeRATion

IllustratIon 2.j.3: openIng rh tong door



SeTup & opeRATion

Making A Connection (Continued)e) Graspthegreentongdoorhandleontheleft-handdoorassembly(ontheright-handsideasseenfromthefront)andpullthe

doorcompletelyopen.(SeeIllustration2.J.4).

IllustratIon 2.j.4: openIng lh tong door

f) Graspthegreentongdoorhandleonthebackupdoorweldmentandpullthedoorcompletelyopen(SeeIllustration2.J.5).Asthebackupdoorisopenedthe“kickerbar”,whichisacomponentofthedoorweldment,willswingintotherotaryopening.Thiskickerbarmechanicallycausesthebackupdoortoswingshutasthetongandbackupassemblyismovedontoapipestring.

IllustratIon 2.j.5: openIng BacKup door



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

IllustratIon 2.j.6: lIFt cylInder control - raIse (non ce-MarKed tongs)

Making A Connection (Continued) g) Actuatetheliftcylindercontrolvalvetolifttheassemblyfromthedrillfloor.Pullingonthevalvehandletowardtheoperatorwill

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

h) Manuallyengagethethreadsofthetubingconnectionbeingmadeup.Ensurethreadsarenotcross-threaded.

i) Movethetongandbackupassemblyontothetubingjoint.Usetheliftcylindertoensuretheassemblyisatthecorrectheightsothatthebackupjawsarelocatedbelowtheconnectionpoint,andthetongjawsarelocatedabovetheconnectionjoint.

j) Astheassemblyismovedontothejointthepipewillcontactthe“kickerbar”ontherearofthebackupdoor,causingthebackupdoortoclose.Ensurebackupdoorandtongdoorarefullyclosedagainstthelatchposts.

k) Firmlyclosethetongandbackupdoors.Ensurethetongdoorsaresecurelylatched(tugonthetongdoorhandletoensureitremainslatched).

l) Ensuretubingisroughlycenteredwithinthetongandbackupjaws-rigpersonnelarerequiredtostabilizethetongandbackuparoundtheconnectionuntilthejawshavebeenclampedshut.Actuatethebackupclampingvalve(pushittowardthecentreof the tong) toclampthebackup jawson to the tubingbelowtheconnectionpoint.Note that thebackupcontrol is “clampandrelease”,meaningthatoncethebackupjawsareclamped,thejawsremainunderclampingpressureuntiltheoperatormanipulatesthebackupcontrolhandletoreleasepressure(seeIllustration2.J.7nextpage).

Pushingontheliftcylindercontrolvalvehandle(towardthecenterofthetong)willcausetheequipmenttolift.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.

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SeTup & opeRATion

m) Beginrotationwiththetonginhighgear(highspeed/lowtorque).SeeSection2.H.4toproperlysetthetongtohighgear.Donotshiftgearswhilethetongisrotating.

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

n) Pushthemotorcontrolvalvetowardthetongtorotatethecageplateinthemake-updirection.Gentlypushtherotationcontrolvalvetowardthecentreofthetongtoslowlyrotatethecageplateuntilthetongjawscamontothetubing(seeIllustration2.J.8).

IllustratIon 2.j.8: Motor control - MaKe-up

Making A Connection (Continued)

IllustratIon 2.j.7: BacKup control - claMp



Making Up A Connection (Continued)o) Whenthetongjawscamontothetubingpushtherotationcontrolhandleallthewayintothreadtheconnectiontogetherat

highspeed.Asthejointbecomesfullymadeuptheincreasingtorquedemandwillstallthemotor,anddisplayedtorquewillincrease.

p) Stoprotation,andsetmotortolowspeedandshifttolowgear(lowspeed/hightorque-SeeSection2.H.4forshiftingtolowgear).Thiswillenablethetongtoproduceadequatetorquetomakeupthejointtospecification.

q) Pushtherotationcontrolhandleallthewayintocompletetheconnectionatlowspeed/hightorque.Observethetorquegauge-whenthespecifiedmake-uptorqueisreachedstoprotation.Ifyoursystemisequippedwithanautomaticdumpvalvethesystempressurewill“dump”totankwhenthepresettorquehasbeenreached,andallrotationwillstop.Reversetherotationcontrolvalvetoreleasethetongjawsfromthetubing(seeIllustration2.J.9).

IllustratIon 2.j.9: usIng Motor control to release jaws In “MaKe up” Mode

r) Whentongjawsarefreereleasethebackupjawsbypullingthebackupclampcontrolhandleawayfromthetongtowardtheoperator(seeIllustration2.J.10)nextpage.

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

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SeTup & opeRATion

IllustratIon 2.j.10: usIng BacKup control to release BacKup jaws

Pullingontheliftcylindercontrolvalvehandle(towardtheoperator)willcausetheequipmenttolower.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.

Making Up A Connection (Continued)

s) Unlatchandopenthetongdoortofreetheassemblyfromthetubing.Notethatrigpersonnelmayberequiredtostabilizetheequipmentasitcompletelyreleasesfromthetubing.Guidetheassemblyawayfromthestring.Pushtheliftcylindercontrolvalvetowardthecentreofthetongtolowertheequipmenttothedrillfloor.

IllustratIon 2.j.11: usIng lIFt cylInder control to lower asseMBly (non ce-MarKed tongs only)

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



2. Breaking Out A ConnectionYourtongandbackupassemblyshouldbeproperlysuspended,connectedtoahydraulicpowersource,andreadytomakeorbreakconnectionsatthispoint.

a) Ensurehydraulicpowersupplytothetongandbackupisenergized.Themasterlinkontherigidslingmustbeusedtosuspendthetong.Donotsuspendthetongdirectlyfromtherigidsling.SeeIllustration2.J.1.

b) Set thebackingpin for “breakout”operation.Liftupon thebackingpinand rotate it to the “breakout”position,which is2o’clockasseenfromthefrontofthetong.Theopeningintherotarygearmustbealignedwiththetongdooropeninginordertoproperlysetthebackingpin.

IllustratIon 2.j.12: settIng BacKIng pIn to BreaK-out posItIon

c) Properlyconfiguretheloadcellformakingupconnections(seeSection2.G.3).Connectsnublinestotherearofthetongtoarrestuncontrolledrotationoftheassemblyintheeventofbackupjawslippage.Thesnublinesmustberatedfortheappliedtorquepluswhateversafetymarginsstatedbyyourownoperatingpolicies.Thesnublineconnectionpointsonthedrillfloormustbesturdyenoughtoabsorballappliedforces.

d) Unlatchandopenthetongandbackupdoors(seeIllustrations2.J.3-2.J.5).

e) Actuatetheliftcylindercontrolvalvetolifttheassemblyfromthedrillfloor.Pullthevalvetowardtheoperatortoretracttheliftcylindertolifttheassembly(seeillustration2.J.6).Notethatrigpersonnelarerequiredtostabilizethetongandbackupasitisbeingliftedsoitdoesnotswingandcollidewithotherrigequipment.


f) Astheassemblyismovedontothejointthepipewillcontactthe“kickerbar”ontherearofthebackupdoor,causingthebackupdoortoclose.Ensurebackupdoorandtongdoorarefullyclosedagainstthe latchposts.Usethe liftcylindertoensuretheassemblyisatthecorrectheightsothatthebackupjawsarelocatedbelowtheconnectionpoint,andthetongjawsarelocatedabovetheconnectionjoint.

g) Firmlyclosethetongandbackupdoors.Ensurethetongdoorsaresecurelylatched(tugonthetongdoorhandletoensureitremainslatched).

Pushingontheliftcylindercontrolvalvehandle(towardthecenterofthetong)willcausetheequipmenttolift.ThisvalvehandleactionappliestoallCE-markedtongsandisirregardlessofcontrolvalvebankorientation.

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Gentlypushtherotationcontrolvalvetowardthecentreofthetongtoslowlyrotatethecageplateuntilthetongjawscamontothetubing.


IllustratIon 2.j.13: Motor control - BreaK out

Breaking Out A Connection (Continued)h) Ensuretubingisroughlycenteredwithinthetongandbackupjaws-rigpersonnelarerequiredtostabilizethetongandbackup

aroundtheconnectionuntilthejawshavebeenclampedshut.Actuatethebackupclampingvalve(pushittowardthecentreofthetong-seeIllustration2.J.7)toclampthebackupjawsontothetubingbelowtheconnectionpoint.Notethatthebackupcontrolis“clampandrelease”,meaningthatoncethebackupjawsareclamped,thejawsremainunderclampingpressureuntiltheoperatormanipulatesthebackupcontrolhandletoreleasepressure.

i) Breakouttorqueisonlyavailableinlowgear.SeeSection2.H.4toproperlysetthetongtolowgear.Donotshiftgearswhilethetongisrotating.

j) Pushtherotationcontrolhandleallthewayintoensurefullbreakouttorqueisbeingdeliveredtothejoint.

k) Whenthejointreleases,stoprotationandshifttongtohighgear(seeSection2.H.4toproperlysetthetongtohighgear).Pressmotorcontrolvalvetowardthecentreofthetongtocompletelyun-threadtheconnection.Donotshiftgearswhilethetongisrotating.




Breaking Out A Connection (Continued):l) Oncetheconnectionhasbeenun-threadedreversetherotationcontrolhandle(pulltowardoperator)toreleasethetongjaws

fromthetubing(seeIllustration2.J.14).

IllustratIon 2.j.14: usIng Motor control to release jaws In “BreaK out” Mode

m) Whentongjawsarefreereleasethebackupjawsbypullingthebackupclampcontrolhandleawayfromthetongtowardtheoperator(seeIllustration2.J.10).

n) Unlatchandopenthetongdoortofreetheassemblyfromthetubing.Notethatrigpersonnelmayberequiredtostabilizetheequipmentasitcompletelyreleasesfromthetubing.Guidetheassemblyawayfromthestringandusetheliftcylindercontroltolowerittothedrillfloor.

o) Useyourrig’sstandardpipehandlingprocedurestoremoveandrackthefreedtubingsectionorstand.

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


SeTup & opeRATion




MAinTenAnce

McCoyCompletions&Drillingrecognizesthatminoron-siterepairsandmodificationsarerequiredtomaintainpeakoperatingconditionofyourequipment,ortomatchyourequipmentwiththeoperatingenvironment.Examplesofminorrepairsare

● replacementofdamagedhydraulichosesandfittings.● replacementofmalfunctioningpressuregaugesandvalves.● replacementofdoorspringstopcylinders● replacementoffasteners

AnyreplacedcomponentmustbeanidenticalcomponentsuppliedbyMcCoyCompletions&Drilling.ReplacedfastenersmustbeGrade8orequivalent,orwhateverfastenerisspecifiedbyMcCoy.

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

Equipmentmaintenanceshallbeperformedonlybydesignatedqualifiedmaintenancepersonnel.Wearallpersonalprotectiveequipment(PPE)specifiedbyyourcompany’sHSEpolicy,and followallofyourcompany’ssafetyguidelines.Donotbeginamaintenance taskwithoutthepropertoolsormaterialsonhand,ortheproperdrawingsanddocumentationnecessary.

Scheduleplannedmaintenancewithoperatorstoavoidconflicts,unnecessarydowntime,andthedangerofaccidentalequipmentactiva-tion.Notifyoperationswhenmaintenanceproceduresarecompleteandequipmentfunctionalityisrestoredandtested.

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

Replacementoflarge,heavyindividualpartsand/orheavystructuralcomponentsmustbeperformedusinganapprovedliftingdeviceofsufficientliftingcapacity.Usecarewhenattachingtheliftingdevice,andsafeguardareatoavoidendangeringpersonnelorequipment.

AllsparepartsmustmeetorexceedOEMspecificationsinordertomaintainequipmentintegrity,especiallyprotectiveequipment.

DO NOT PERFORM MAINTENANCE UNTIL TUBULAR CONNECTION EQUIPMENT HAS BEEN COM-PLETELY ISOLATED FROM HYDRAULIC POWER

Yourequipmentusesmaterialsthatmaybeharmfultotheenvironmentifimproperlydisposedof(hydraulicfluid,grease,etc.).Disposeofallmaterialsaccordingtoyourcompany’sproscribedenvironmentalprotectionregulations.

B. CLEANINGClean tong thoroughlycleanedwithagoodpetroleum-basedcleaningagentaftereach job,prior tostorage.Farr® recommends thatthemotorandvalveassemblybeperiodicallyremoved,alongwiththetoptongplate,sothatguides,rollersandgearscanbeproperlycleaned(seeSection3.H,Overhaul).Ensurethatcleaningsolventsandchemicalsarecapturedtopreventenvironmentalcontamination,anddisposeofallmaterialsaccordingtoyourcompany’sproscribedenvironmentalprotectionregulations.

C. PREVENTIVE MAINTENANCE PRACTICESRegularmaintenanceprogramsarenecessary,andmustbeestablishedtoassuresafe,dependableoperationofyourHydraulicTubularConnectionSystemandtoavoidcostlybreakdownmaintenance.Thefollowingmaintenanceproceduresprovidesinformationrequiredtoproperlymaintainyourequipment.Yourequipmentmayrequiremore,orlessmaintenancedependinguponthefrequencyofuseandthefieldconditionsunderwhichyourequipmentoperates.Thesemaintenanceproceduresaredesignedforequipmentoperatingat10°Cto35°Cambienttemperaturefor10hoursperday.McCoyrecommendsthattheinspectionandmaintenanceproceduresinthissectionbeperformedasrecommendedinthemaintenancechecklists(seeAppendices),orinconjunctionwithyourmaintenanceforeman’sexperi-enceandbestestimateofwhenyourequipmentisdueforthismaintenance.

Manufacturersofpurchasedcomponentsincludedwithyourhydraulictubularconnectionequipment(forexample:motors,valves,etc.)mayspecifymaintenancetasksandintervalsoverandabovewhatMcCoyrecommendsaspartoftheirrecommendedprocedures.Usersofthisequipmentmaychoosetoperformorignoretheseadditionaltasksattheirdiscretion.

Filtrationofthehydraulicfluidmustbe10micronsorbetter.Prematurefoulingofparticulatefilterswithinyourprimemoverorancillaryhydraulicpowerunit requires immediatehydraulic fluid laboratoryanalysis topreventprematurewearofhydraulicsystemduetohighlevelsofwearmetalsinthefluid.

McCoy Drilling & Completions recommends tracking all maintenance activity including the lubrication schedule and replacement ofhydraulichoses.Thismaybeasimpleaskeepingapaperlog,orusingasoftware-basedmaintenancetrackingutility.Amaintenancelogisavaluabletoolthatcanbeusedforeasilyretrievingmaintenancehistoryoridentifyingtrendsthatrequirecorrection.



E. LUBRICATIONUseaqualitymultipurposebearinglubricantthatwillremainwithinitsviscosityrangeatexpectedoperatingtemperatures.Inaddition,Farrrecommendsthefollowinglubricationprocedureatthecompletionofeachjobpriortostorage.

McCoyrecommendsthataliberalcoatingofgreasebeappliedtothecamsurfaceoftherotarydrivegearpriortojawinstallation.Also,theclutchinspectionplateshouldperiodicallyberemoved,andaliberalcoatingofgreaseappliedtotheclutch,drivegearsandshiftingshaft.

Coatthejawpinsandrollerswithaliberalamountofanti-seizecompoundwheninstallingnewjawdiekits

1. Cage Plate Guide Rings / Cam FollowersKT1625Tongs(SeeIllustraton3.D.1)

Rotatetherotarygearoutofthecageplateassembly.Applygreasetothetopandbottomguiderings,andtothecageplateslotsoppositetherotarygear.

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

D. HYDRAULIC SYSTEM DE-PRESSURIZATIONMcCoyDrilling&Completionsrecommendsthatthehydraulicsystembede-pressurizedpriortomaintenanceonanyhydrauliccompo-nent.Performthefollowingstepstoensurethedangersposedbyhydraulicfluidunderpressureareminimized.

ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINA-TION FROM RESIDUAL HYDRAULIC FLUID

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

2) De-energizethepowerunit.

3) RepeatedlyactuatethetongmotorcontrolvalveleverINBOTHDIRECTIONStodissipateanyresidualpressureinthevalveandmotor.

4) RemovethehydraulicSUPPLYlinefromtheequipment.

5) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressureintheremainderofthehydrauliccontrolsystem.

7) DisconnectthehydraulicRETURNlinefromtheequipment.

8) Disconnectremaininghosessuchascasedrains,orlinesconnectedtotheturnscounter.

IllustratIon 3.e.1: Kt13625 guIde rIng luBrIcatIon

MAinTenAnce

Apply grease to top guide ring & bottom guide ring groove



Cage Plate Guide Rings / Cam Followers Continued:LW1625Tongs(SeeIllustration3.E.2)

Applygreasetothecamfollowersthroughthegreasefittingsrecessedinboththetopandbottomcageplates(22locationstotal).

IllustratIon 3.e.2: lw13625 caM Follower luBrIcatIon

2. Support Roller BearingsSupplygreasetothesebearingsthroughthegreasefittingsintheendsoftherotaryrollershafts,locatedonthetopofthetong(14locationstotal).

IllustratIon 3.e.3: support roller BearIng luBrIcatIon

MAinTenAnce



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3. Rotary Idler BearingsApplygreasetothesebearingsthroughthegreasefittingsintheendsoftherotaryidlershaftslocatedontheleftandrightsidesofthetong(2locationstotal).

4. Pinion Idler BearingsApplygreasetothesebearingsthroughthegreasefittingsintheendsoftheidlerhalfshafts,locatedonthetopfaceofthetong(2locationstotal).

IllustratIon 3.e.4: rotary Idler luBrIcatIon

IllustratIon 3.e.5: pInIon Idler luBrIcatIon



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IllustratIon 3.e.6: pInIon luBrIcatIon top plate

IllustratIon 3.e.7: pInIon luBrIcatIon BottoM plate

5. Pinion BearingsApplygreasetothesebearingsthroughthegreasefittingsinthepinionbearingcaps,whicharelocatedonthetopandbottomfaceofthetong(fourlocationstotal).



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6. Clutch ShaftApplygreasetothesebearingsthroughthethreegreasefittingsintheclutchbearingcap,whichislocatedatthebottomfaceofthetong.

IllustratIon 3.e.8: clutch shaFt luBrIcatIon

IllustratIon 3.e.9: shIFtIng shaFt luBrIcatIon

7. Shifting ShaftApplygreasetotheshiftingshaftandshiftingshaftbushings,whichmaybeaccessedthroughthecoverplateonthesideofthetong.

Accessshiftercomponentsthroughthispanel



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IllustratIon 3.e.10: Motor Mount luBrIcatIon

IllustratIon 3.e.11: door latch caM luBrIcatIon

8. Motor Mount HousingApplygreasetothegearsinthishousingthroughthegreasefittingonthetopofthemotormount.

9. Door Latch CamApplygreasetothedoorlatchcamthroughthegreasefittinginthetopofcamadjustmentboss.



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10. Door Spring Cylinders

Periodicallydisassemblethedoorstopcylindersandcoatthespringandcylinderwithageneralpurposelubricatingoil.

THE DOOR STOP CYLINDER SPRING MAY RETAIN ENERGY FROM BEING COMPRESSED. USE A CLAMP TO CONTAIN THE ENDS OF THE CYLINDER WHEN IT IS REMOVED, AND RELIEVE THE SPRING TENSION GRADUALLY.

IllustratIon 3.e.12: door stop sprIng luBrIcatIon

11. Backup Cage Plate Cam FollowersApplygreasetothebackupcamfollowersthroughthegreasefittingontopofeachcamadjustmentfollower(22locationstotal).

IllustratIon 3.e.13: Farr© BacKup caM rIng caM Follower luBrIcatIon



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IllustratIon 3.F.1: BraKe Band adjustMent

TOP AND BOTTOM BRAKE BANDS MUST BE ADJUSTED SIMULTANEOUSLY AND EQUALLY

F. ADJUSTMENTS1. Brake Band Adjustment:

Thetopandbottombrakebandsmustbeperiodicallyadjustedtocontinuetoprovidesmoothandefficient jawcamaction.If thecageplateturnswiththerotarygear,thejawswillnotcamproperlyand,therefore,willnotbiteonthetubingorcasing.Tighteningthebrakebandagainstthecageplateswillincreasefrictionalresistance,allowingjawstocamproperlyandgripthecasing.Adjustthebrakebandusingtheadjustmentnutandboltsetasshownintheillustrationbelow.Usecaution,asover-tighteningwillcauseexcessiveweartothebrakebands.

BRAKE BANDBRAKE BAND ADJUSTMENT BOLT AND NYLOCK NUT



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2. Door Latch AdjustmentNormaloperationofthetongmaycausewearofthedoorlatch,whichwillcausethedoortodevelopaloosefitatthelatch.Alatchcamplateislocatedatthetopfaceofthedoor.Thecamplatehaseightpositioningholeslocatedona360degreeboltcircle.Thelatchcamshaftextendsdown through thedoorand issecuredat the topbya3/8”hexheadbolt.Tomakeadjustments indooralignment,removethe3/8”boltandturnthecamwithawrench.Whenthedoorhasbeenadequatelyaligned,replacethe3/8”bolt.

THE DOOR IS AN IMPORTANT PART OF THE STRUCTURAL INTEGRITY OF THE TONG. IT IS IMPERATIVE TO KEEP A SECURE FIT AT THE DOOR IN ORDER TO MAINTAIN PROPER GEAR ALIGNMENT, AND TO MINIMIZE THE POSSIBILITY OF DAMAGE TO THE GEAR TRAIN WHEN OPERATING THE TONG AT SPECIFIED TORQUE. A CLOSED DOOR ALSO ENSURES SAFETY OF OPERATING PERSONNEL.

IllustratIon 3.F.2: door latch caM adjustMent

DOOR LATCHADJUSTMENT CAM



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3. Door AlignmentEachdoorweldmentisequippedwithtwosetscrews,alongwithjamnutstolockposition,toalignthedoorwhenitisintheclosedposition.

InItIal alIgnMent

Ensuretongdoorsareclosed,andinspecthowonedooralignswiththeotherat thepointatwhichtheymeet. Ifmisalignment isseen,chooseoneortheotherdoortoadjust.Useabox-endwrenchtoloosenthelocknutsontheinsidesofthedoorweldment-thenutsmaybeaccessedfromthesideofthedoorweldment.Useahexkeytoturnthehexheadsetscrewseitherclockwiseorcounter-clockwisetoadjustthedoor.Notethatthetopandbottomofthedoorweldmentmaynotneedtobeadjustedequally-eachsetscrewshouldbeadjustedindependentlyuntilthedoorsarealigned.

FInal alIgnMent

Rotatethecageplate,andstopitwhentheinsidecircumferenceofthedooriscompletelycovered.Performthreemeasurements(seeillustrationnextpage):

1) Fromtheinsidesoftheouteredgeofeachdoorweldmenttothecageplate(2measurementstotal).

2) Fromtheexactcentrepoint(wherethetwodoorsmeet)tothecageplate.

IllustratIon 3.F.3: door alIgnMent

Thethreemeasurementsshouldbeequal.Ifthecentremeasurementislessthanthetwooutsidemeasurements,loosenallfourlockingnutsonthesetscrews,andturnallfoursetscrewsEqUALLYclockwise,untilthecentremeasurementisequaltothetwooutermeasurements.Ifthecentremeasurementismorethanthetwooutsidemeasurements,loosenallfourlockingnutsonthesetscrews,andturnallfoursetscrewsEqUALLYcounter-clockwise,untilthecentremeasurementisequaltothetwooutermeasure-ments.Ensurethatthelockingnutsaretightenedwhenthisprocedureiscomplete.

Measurement1

Measurement1

Measurement2



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4. Shifter Detent Force Adjustment:Overtimeweartotheshiftingshaft,weartothedetentball,andlossofspringtensioninthedetentspringmayresultinalooseor“sloppy”fitwithinthetopshifterbushing.Thedetentpressuremaybeincreasedorotherwiseadjustedbylooseningthe7/16”UNFlockingjamnut,andturningthe7/16”UNFdetentbolt.Shouldadequatedetentactionnotbeachieved,theshiftingshaft,detentball,ordetentspring(orpossiblyallthree)mayneedtobereplaced(seePp.5.16-5.17).

IllustratIon 3.F.4: shIFter detent Force adjustMent

5. Safety Door Adjustment:Thesafetydoorsystemistheprimeprotectivemeasureseparatingtheoperatorfromtherotarygear,andmustbeinworkingcondi-tionwhenoperatingtong.Thesafetydoorswitchisdesignedtointerrupthydraulicpowertothemotorwhenthetongdoorisopened,orevenslightlyajar.Thisisacriticalsafetysystem,andproperadjustmentisnecessarytomaintaintheintendedfunction.

KEEP HANDS CLEAR OF SAFETY DOOR LATCH CLAWS (PAINTED YELLOW) WHEN CLOSING DOOR.

Iftherotarygeardoesnotstopimmediatelyandcompletelystoprotatingwhenthedoorisopened,removethetongfromserviceandperformthefollowingadjustments:

a. Performapreliminaryassessmenttoensurethesafetydoorswitchisfunctioning:

i. Connectthetongtohydraulicpowerinacontrolledenvironment.

ii. Attempttorotatethecageplate.Failureofthecageplatetorotatewiththedoorsclosedindicatesthatthesafetydoorsystemhasfailedcompletely,orsimplyrequiresadjustment.

iii. Openthetongdoorsandfullydepressthehydraulicswitchtosimulatethepositionoftheswitchwhenthedoorsareclosed

iv. Keephandsclearof thecageplateassembly,andattempt torotatecageplate. If thecageplatedoesnot rotate thesafetydoorsystemhasfailedandmustberepairedbeforeproceeding.Whenthecageplatebeginstorotatereleasethesafetydoorswitch.Thecageplatemustimmediatelyandcompletelystoprotating,indicatingthatthesafetydoorsystemisoperationalbutrequiresadjustment.

IfthesafetydoorsystemisconfirmedoperationalbutthecageplatedoesnotrotatewiththedoorsclosedtheadjustmentplatemustbemovedtowardtheRHdoorassembly,enablingthesafetydoorswitchtobe“made”whenthedoorsareclosed.

b. Disconnecthydraulicpowertothetong.Removethesafetydoorguard.Wireties(ifapplicable)requireremovalbeforethefastenerssecuringtheguardtothetopplateofthedoorcanbeextracted.



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IllustratIon 3.F.5: saFety door swItch plate adjustMent

d. Tightenthesocketheadcapscrewstosecuretheadjustmentplate.Usethefourshoulderboltstore-mountthefloatingplateandsafetydoorswitchtothemountingplateontheLHdoorassembly.

e. Test thesafetydoorsystem.Connecthydraulicpower to the tong.Ensure thedoor is closedandall personnelareclear.Attempttorotatethecageplate.Ifthecageplatedoesnotrotatefurtheradjustmentoftheswitchisrequired.Repeatstepsc,d,&e.

f. Whenthecageplaterotateswiththedoorclosedre-testthesystemtoensurepowertothemotorisinterruptedwhenthedoorisopen-thecageplateshouldimmediatelyandcompletelystopwhenthedoorsareopened.

g. Ifadjustmentlimitshavebeenreachedbeforesafetydoorfunctionhasbeenestablishedfurthertroubleshootingofthesafetydoorsystemisrequiredbeforethetongisplacedintoservice.Somecomponentsmaybewornpasttheiruseful lives,andreplacementofthosecomponentsisnecessarytorestorepropersafetydoorfunction.

G. RECOMMENDED PERIODIC CHECKS1. Door Stop Spring

Thespringinsidetheactuatorcylindermustbeofsufficientstrengthtoenablethedoorlatchmechanismtosnapclosedproperly.Doorstopspringfatiguewillresultinsluggishlatchoperation.Replacethelatchspringinsidethecylinderwhenthisoccurs.

2. Shifting ShaftTheshiftingyokeissecuredtotheshiftingshaftbyonehexjamnutandonelocknutonthebottomoftheyoke.Checkthesenutsaftereachjob.Dothisbyremovingtheclutchinspectionplateandensuringasnugfitpriortolubrication.

3. Backing PinPerformavisualinspectionofthebackingpinaftereachjob.Replacethepinifstresscracksorexcessivewearisfound,orifthepinappearsbent.

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

Safety Door Adjustment (continued): c. RemovethefourshoulderboltssecuringthefloatingplateandsafetydoorswitchtothemountingplateontheLHdoorassem-

bly.Performaninitialalignmentofthesafetydoormechanism.LoosenthefourhexsocketheadcapscrewsenoughtolightlytapthebottommountingplatetowardtheRHdoorassembly.Onlymovethebottommountingplateinverysmallincrementsatatime(aboutonemillimeterperadjustmentstep).SeeIllustration3.F.5.

Loosen three socket head cap screws.

Tap adjustment plate in the desired direction.



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H. OVERHAUL PROCEDURESThetongmaybeoverhauledfollowingthedisassembly instructions inthefollowingprocedure.Accesstothegeartrain ispossiblebyremovingthetopplateofthetong.

ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP. THE BOTTOM PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED.

REPLACEMENT FASTENERS (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT.FASTENERS USED FOR MAINTENANCE OR OVERHAUL OF LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, LEGS) MUST BE TIGHTENED TO THE PROPER TORQUE.

REMOVAL OF BACKUP1. Constructasupportthatwill,whenthetongandbackuparelowered,supportthebackupassemblyenoughtoremovetheweight

fromthefrontlegandrearbackupsupportsprings.

2. Liftthetongandbackupandlowerontostructureconstructedinstep1.

3. Freethefrontlegspringsbyremovingthe1/2”x4”boltsandbottomspringcapsfromthebottomsofthelegs.Disconnecttherearbackupsupportspringsfromtheeyehooksonthebottomofthetong.

4. Liftthetongandfrontandrearlegsupandawayfromthebackup.Usecautionnottolosethelegspringsandtopspringcaps,whichwillcomeloosewhenthetongislifted.

REMOVAL OF LEG ASSEMBLIES5. Setthetongandlegassemblyontoaflatsurface.Ensurethatthemajorityoftheweightremainssupportedbytherigidslingand

thecrane,andthatthereisenoughclearancetoremovethelegswhentheyarefreed.

6. Supporttherearlegweldment(weight=208lb/95kg)beforedisconnectingfromthebottomtongplate.Removethefour1-1/4”x8”heavyhexboltssecuringtherearlegweldment.Useacraneandatemporaryliftingslingtoremovetherearlegweldmenttoasecurespotawayfromthedisassemblylocation.

7. Removethe7/16”x3”boltsfromthefrontlegmountweldmentstoremovethefrontlegweldments.

8. Setthetongontoasturdy,flatworksurfacethatprovideadequatesupport,butstillallowsaccesstothebottomcageplateassem-bly.Apairofsturdymetalhorsesworkwellinthisapplication.

REMOVAL OF TOP PLATE9. Disconnectthehydraulicconnectionsfromthemotor.Undotherestraintssecuringtheinletandoutletlinesfromtheirsupports,and

useacraneandtemporaryliftingslingtohoistthehydraulicvalvesectionawayfromthetong.Removetheinletandoutletsupportpieces.

10. Supporttherigidslingwithacrane.Removethetwohitchpinsfromeachrigidslingpin,andremovetheridslingpins.Therigidslingmaynowbeliftedawayfromthetongandstoredinasecurelocation.Removebothrigidslinghangerbracketweldments.

Theheadsofthefastenerssecuringtherigidslinghangerbracketsaredrilled,andareconstrainedtothebracketsusingwireties.Wiretiesmustberemovedbeforeextractingthefastenersandremovingtherigidslinghangerbracket.

11. Removethetongdoorstopcylinders.Thedoorstopcylinderspringsmayretainenergyfrombeingcompressed.Useaclamptocontaintheendsofthecylinderswhentheyareremoved,andrelievethespringtensiongradually.

THE DOOR STOP CYLINDER SPRINGS MAY RETAIN ENERGY FROM BEING COMPRESSED. USE A CLAMP TO CONTAIN THE ENDS OF THE CYLINDERS WHEN THEY ARE REMOVED, AND RELIEVE THE SPRING TENSION GRADUALLY.

12. Remove each door assembly by removing the door roller shafts. Support each door assembly as the roller shaft is removed.Removethenutfromthebottomoftherollershaft,anduseasoftalloymaterial(e.g.brassrod,etc.)to lightlytaptheshaftupthroughthesupportrollerassemblyuntilitcomesfreeatthetop.Usecautionthatthethreadsontheendsofthesupportrollershaftsarenotdamaged.

NOTE:Thesafetydoorswitchcomponentsmayremaininplaceonthedoorassemblies.

13. Removethetwosocketheadcapscrewssecuringthetorquegaugemount,andliftthegaugemountoutofplace.

14. Removetheremainingtwosocketheadcapscrewssecuringthemotor,andliftthemotoroffthemotormount.Inspectthemotorgear, locatedat thebottomof themotorshaft, forgearclashingor toothdamage.Also,ensure that themotorgear issecurelyattachedtothemotorshaft.



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21. Removethejawpivotboltsandthejawassemblies.

22. Removethetwofrontcageplatebolts,andtherearcageplatebolt,andthecageplatespacers.Thecageplatesmaynowberemoved-usecautionnottodamagethebottomcageplatesupportringorcageplatecamfollowers.

23. Pullthetopbearingcapandspacerforthepiniondrivegearbyremovingthefour1/2"boltswhichsecurethebearingcap.Threadtwooftheremovedboltsintotheextraholesontopofthebearingcap,andusethemasliftinglugstoliftthebearingcapoutofplace.

24. Removethe1-1/2”nutsandpadsfortherotaryidlergears,andthe1-1/2”nuts,5/8”bolts,andhalf-moonpadsfromthepinionidlergears.

25. Removethebottomrollershaftnuts.

26. Carefullyremovetheremainingtwelvesupportrollershafts.Asoftalloymaterial(e.g.brassrod,etc.)mayberequiredtolightlytaptheshaftsupthroughthesupportrollerassemblyuntiltheycomefreeatthetop.Usecautionnottomisplacethebrakebandlugweldmentsorthetwohydraulicvalvemountingpoststhatwillcomefreewiththisstep.

27. Removethehexheadboltsaroundtheperimeterofthetongwhichsecurethetopplatetothegearcasehousing.

28. Removethecountersunksocketheadscrewsaroundtheperimeterofthetong.

29. Withalltheabovestepstaken,thetoptongplatecanbeliftedoffprovidingaccesstotheinsideofthegearcase.

THE CAGE PLATE BOLTS ARE THE ONLY ITEMS FASTENING THE BOTTOM CAGE PLATE TO THE TONG. SUPPORT THE BOTTOM CAGE PLATE FROM BELOW PRIOR TO REMOVING CAGE PLATE BOLTS IN ORDER TO PREVENT DAMAGE TO THE BOTTOM CAGE PLATE OR PERSONAL INJURY TO THE MECHANIC

IF THE BEARING REMAINS ATTACHED TO THE GEAR SHAFT AFTER THE BEARING CAP IS PULLED, MCCOY DRILLING & COMPLETIONS SERVICE PERSONNEL RECOMMENDS LEAVING IT IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED.

Removal of Top Plate (Continued):15. Removethemotormountbyremovingthefoursocketheadcapscrews.Themotormountcanbeliftedoutofplace.Takecarenot

tolosethetwopositiondowels-one,orboth,maycomeoffwiththemount.

16. Removethesnapringthatsecuresthetopclutchgear.Removethetopclutchgearandtopclutchbushing.Removethe#10x3/4”socketheadcapscrewssecuringthebearingretainertothetopplate,andremovethebearingretainer.

17. Removetheclevispinconnectingtheshiftingshafthandletotheshiftingshaft.Backofftheshifterpositiondetentspringandballassemblyasmuchaspossiblewithoutremovingthedetentassembly.

18. Removetheaccesspanelonthebodysideadjacenttoshifterassembly.Removethe5/8”finethreadnut,and5/8”finethreadjamnutfromtheshiftingshafttoloosentheshiftingfork.Theshiftingshaftmaynowbecarefullyrotatedandpulledoutofthetopshifterbushing.

19. Loosenthetopbrakeband(Seepage3.3)bybackingoffthebrakebandadjustmentboltsuntilthenutisflushwiththeendofthebolt.

20. Removethebackingpinassembly,butleavetherearcageplateboltinplace.



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ALL FASTENERS USED DURING REASSEMBLY OF LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS) MUST BE TIGHTENED TO THE CORRECT TORQUE. THREADED FAS-TENERS USED IN LOAD-BEARING DEVICES MUST BE SECURED WITH RED LOCTITE™.

I. ASSEMBLY PROCEDURESAssemblyofFarrHydraulicPowerTongsissimple,andcanbeaccomplishedwithouttheuseofspecialtools.Theinstructionsonthispagearepresentedasaguideonly,andaresimilartotheassemblysequenceourtechnicianwouldusewhileassemblingthetonginourplant.

NOTE ON INSTALLATION PRACTICES: Ensure all bearings are liberally greased before installing over a shaft or into gears or bearing caps. When inserting a shaft through a support roller assembly ensure shaft is greased. Also ensure all metal-to-metal contact in the gear train is adequately greased. When graphics are not used in the assembly process, please refer to the relevant exploded diagrams in Section 5.

TIGHTENING TORQUE GUIDESAE GRADE 8 - FINE THREAD

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SAE GRADE 8 - COARSE THREADSIzE CLAMPLOAD PLAIN PLATED

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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



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Assembly Procedure:

apply a thIn layer oF grease to the surFace oF each MovIng part durIng asseMBly to aId In the asseMBly process.1. Positionthetongbodygearcaseonasuitablestationarysupport,ensuringthatthebottombodyplateremainsaccessible.Aset

ofsturdymetalhorsesworkswellinthisapplication.

2. Presssupportrollerbearingsintothesupportrollercupsandsecurewithretainingrings(28total).

KT-13625Tongs

Pressrollerbearing(PN02-0014)intoasupportrollercup(997-D21-135)andsecurewithaninsideretainingring(02-0013).Repeatforallremainingrollercupassemblies.

LW-13625Tong

Pressballbearing(PN02-0101)intoasupportrollercup(997-D21-135)andsecurewithaninsideretainingring(02-0013).Repeatforallremainingrollercupassemblies.

3. UsetherollercupassembliestoassemblefivesupportrollerassembliesasshownonPp.5.4-5.5,butatthistimeuseonlyitemsB,D,E,F,G,&H(i.e.allthesupportrollercomponentsthatresidebetweenthetopandbottomplatesofthetong,plusthesupportrollershaft.

4. Installfivesupportrollerassembliesplusshaftsalongonesideofthebodycase.Insertshaftsthroughthebottomplate,butdonotinstallthebottomnylocknutsor,whereused,thenarrowflatwashers.

5. Installrotarygear(PN997-D1-B),makingsurethebackingpinslotsareonthesidefacingup.EnsureonesideissupportedbythesupportrollersinstalledinStep3,andhavetheopeningintherotarygearorientedasshowninthefollowingillustration.

IllustratIon 3.I.1: tong asseMBly - rotary gear InstallatIon

6. Installsupport rollerassemblies in the locationsexposedby theopening in therotarygear.Continue to rotate therotarygear,installingsupportrollerassembliesintherotarygearopeningasitisrotated.Finishwiththerotarygearalignedwiththeopeninginthebottomplate.Donotinstallthetwodoorpivotsupportrollerassembliesatthistime.

7. Presspinionbearing(PN1234-08-01B)intobottompinionbearingcap,andinstallbearingcapintobottomplateoftongusingfour1/2”UNCx1-1/4”hexboltsand1/2”lockwashers.

8. Presslowerclutchbearing(PN02-0014)intobottomclutchbearingcap,andinstallbearingcapintobottomplateoftongusingfour3/8”UNCx1-1/4”hexboltsand3/8”lockwashers.

9. Installaretainerclip(PN02-0009)intobothrotaryidlergears.Pressanidlerbearing(PN02-0075)intoeachgearandsecurewithasecondretainerclip.

10. Lightlygreasethelargercircumferenceofthetworotaryidlershaftsandslidethemthroughthebearingandgearsassemblies,centeringthegearontheshaft.

11. Slidetwobearingseals(PN02-0010)overeachendoftheidlershaftsandpressagainsttheretainerclips.



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24. Installhighpiniongear(shouldersideup).

25. Installhighclutchgear,followedbythetopclutchbearingspacer(PN101-3599).

Assembly Procedure Continued:12. Slideabearingspacer(PN997-D20-121)overeachendoftherotaryidlershafts.

13. Placeeachrotaryidlerassemblythroughthebottomplate,ensuringtheendsoftheshaftswiththethreadedholeforthegreasefittingarepointedupward.

14. Placeanidlerpad(PN997-D20-125)overthebottomsideofeachrotaryidlershaft,andsecureeachwitha1-1/2”UNFnylocknut.

15. Placelowpiniongearshouldersidedownoverthelowerbearingandbearingcap,centeringasbestasable.

16. Installpiniongearshaftintothesplineofthebottompiniongearandthelowerpinionbearing.

17. Slide2needlebearings(02-1404)overeachendoftheclutchshaft,andpressupagainstcentregear.Slidelowclutchgearoverthebottomendoftheclutchshaft,ontothetwoneedlebearings.Slidebottomclutchspacer(pn997-99)overlowerendofshaft,andplacelowerendofclutchshaftintothelowerclutchbearingthathasbeenpre-mountedinthelowerbodyplate.

18. Installshiftingcollarwhichwillslipoverclutchshaftandmeshwithloworhighclutchgear.

19. Installthelowershiftingbushing(PN101-0003)inthebottombodyplateusingfour3/8”UNCx1”hexboltsand3/8”lockwashers.

20. Slidetheshiftingfork(PN997-HT-72)overtheendoftheshiftingshaft(PN997-B1-71),andsecureforktoshaftwitha5/8”UNFhexnut.Lockthehexnuttotheshiftingforkwitha7/8”UNFhexjamnut.Meshtheshiftingforkwiththeshiftingcollarontheclutchshaft.

21. Installaretainerclip(PN02-0009)intobothpinionidlergears.Pressanidlerbearing(PN02-0075)intoeachgear,andsecurewithasecondretainerclip.

22. Slideeachpinionidlerhalf-shaftthroughpiniongearassemblies.Slideabearingseal(PN02-0010)overtheendsofeachhalf-shaft,andsecurewithashaftretainerclip(PN02-0008).

23. Placepinionidlerassemblies, lesstheidlerpadsandtopfasteners,ontopofthelowerpiniongearandplacethemasbestaspossible-theirpositionmayhavetobeadjustedslightlyasthetopplateisattached(seeIllustration3.I.2).

IllustratIon 3.I.2: tong asseMBly - gear asseMBly posItIonIng



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Assembly Procedure Continued:26. Carefullyremoveallsupportrollershafts,usingcautionnottoshiftthepositionoftheinstalledsupportrollerassembliesortodamage

thethreadsontheendoftheshafts.

27. Locatethethreeun-threadedholesinthesidebodyofthetong,oneintherearcentreandonejusttoeithersideofthefrontopening.Ifolddowelpinsareinplace,removethembeforeinstallationofthetopplate.IfthedowelpinsareinanywaydamagedordeformedMcCoyrecommendsreplacingthemwithnew3/8”x1-1/2”hardeneddowelpins.Ifnecessarycleanthedowelpinholes,anddonotinsertdowelpinsuntilafterthetopplatehasbeeninstalled.

28. Useatemporaryliftingslingandcranetomaneuverthetopplate(PN101-0025)intoposition,andplaceontothesidebody.Insertthethreepositioningdowelpins(PN09-0092)throughthetopplateintotheirrespectiveholesinthesidebody.Useahammertotapthedowelpinsuntiltheyareflushwiththetopplate.Securethetopplatewitheighteen3/8”UNCx1-1/2”hexboltsand3/8”lockwashers,andtwo3/8”UNCx1”hexsocketheadcapscrewsasshowninillustration3.H.3.Donotinstallfastenersattherigidslinghangerlocations,indicatedbytheredcircles,orthedoorcylindermountingluglocationsindicatedbythegreencircles.

29. Installhalf-moonidlerpads9PN997-D17-108)overtheendofeachpinionidlershaft,andsecureeachwiththree5/8”UNCx1-3/4”hexboltsand5/8”lockwashers,followedbya1-1/2”UNFnylocknut.

30. Slidetheremainingrotaryidlerpads(PN997-D20-125)overtheendofthetworotaryidlershaftsandsecureeachwith1-1/2”UNFnylocknuts.

31. Presstheremainingpinionbearing(PN1234-08-01B)intothetoppinionbearingcapandinstalloverthetopofthepiniongearshaft-securewithfour1/2”UNCx1-1/4”hexboltsand1/2”lockwashers.

32. Installtopclutchbearingretainer(PN997-HT-59)intotopplateandsecurewithtwo10-24x3/4”hexsocketheadcapscrews.Inserttopclutchbearing(PN02-1403)overtheclutchshaftintothebearingretainer,followedbytheclutchbearingbushing(PN997-HT-60).

33. Installclutchdrivegear(PN997-HT-61)ontotheclutchshaftandsecurewiththeretainingsnapring(PN1234-00-04).

IllustratIon 3.I.3: tong asseMBly - top plate Fasteners



Assembly Procedure Continued:34. Re-installsupportrollershafts:

a. Slidea7/8”narrowflatwasherontotwoshortersupportrollershafts(PN101-1266)andre-install inthelocationscircledingreeninIllustration3.I.4.Slidea7/8”narrowflatwasheroverthefourlongersupportrollershafts(PN101-1268),andinstallwherethesupportrollersarecoincidentalwiththefrontlegweldmentsasshowncircledinredinIllustration3.I.4.Securethebottomofthetwoshortersupportrollershaftswith3/4”narrowflatwashersand3/4”UNFthinnylocknuts.

IllustratIon 3.I.4: tong asseMBly - support roller InstallatIon 01

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34. Re-installsupportrollershaftscont’d:

c) Ensurethetwotopandtwobottombrakebandlugweldments(topleft/bottomright=PN101-0007,topright/bottomleft=PN101-0008)areinstalledwiththetwofrontsupportrollershaftsoneachsideasshowninIllustration3.I.6onthefollowingpage.Notethatnoflatwashersareusedwheretheshaftsarecoincidentalwiththebrakebandlugweldments.Securethebottomofthefourshaftswith3/4”UNFthinnylocknuts.

Assembly Procedure Continued: 34 Re-installsupportrollershaftscont’d:

b) Tworearhydraulicvalvemountweldments(PN101-0011)arecoincidentalwiththetworearsupportrollershaftsasshowninillustration3.I.5.ASSEMBLYNOTE:Donotuse7/8”narrowflatwashersonthetopsoftheshaftswheretheyarecoincidentalwiththebrakebandlugweldments.Securethebottomsoftheshaftswith7/8”narrowflatwashersand3/4”UNFthinnarrownylocknuts.


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Assembly Procedure Continued:

35. Coatthethreadsofthetopshifterbushing(PN101-0020)withredLoctite™.Threadthetopshifterbushingovertheshiftingshaftintothetopplateuntilsnug.Threadthedetenttube(PN101-0019)intothetopshifterbushingasshowninillustration3.I.7.

36. Threadthree5/8”UNCx5/8”hexsocketsetscrewsintotheremainingthreeportsinthebushingasshowninillustration3.I.7.Thesesetscrewsareintendedtobeusedascontaminationbarriersonly.Donotbottomoutthesetscrewsontheshiftingshaft,ortheshaftwillnotmove.



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Assembly Procedure Continued:

37. Inserttheshifterdetentball(PN02-0018)intothedetenttube,followedbythedetentspring(PN02-0040).Threada7/16”UNFhexjamnutontoa7/16”UNFx1-1/4”hexnut,thenthreadthe7/16”boltintothedetenttube.

38. Inserttwo5/16”x7/8”dowelpinsintotheun-threadedholesintherearofthetong,adjacenttotheclutchdrivegear.

39. Attachmotormount(PN997-150)totopplate,andsecurewithfour1/2”UNCx1-3/4”hexsocketheadcapscrews.

40. Bolttheshifterlugweldment(PN101-0016)ontothetopplatewithfour3/8”UNCx1-1/2”hexboltsand3/8”lockwashers.

41. Insertthe5/16”x5/16”x2”motorgearkeyintothekey-wayinthemotorshaft.Slidethemotorgear(PN997-A10-149)ontothetothehydraulicmotorshaftandsecurewithtwo3/8”UNCx3/8”hexsocketheadsetscrews.

42. Installthehydraulicmotorontothemotormount.SecuretheRHsideofthemotortothemotormountusingtwo1/2”UNCx1”hexsocketheadcapscrewsand1/2”lockwashers.Positionthetorquegaugeholderweldment(PN1500-09-04A)ontheLHsideofthemotor,andsecuretheweldmentandthemotortothemotormountusingtwo1/2”UNCx1-1/4”hexboltsand1/2”lockwashers.

43. Securetheshiftinghandleweldment(PN1037-D-20B)totheshiftinglugweldmentandtheshiftingshaftusingone5/16”x1”clevispin,andone5/16”x1-1/2”clevispin.Securetheclevispinswithsmall“R”hitchpinsorcotterpins.

44. Installthecageplates:

KT13625Tong:

a. Pre-greasethesupportringslotinthelowercageplate(997-HT-22).Installthelowersupportring(PN997-HT-23-BOT)inthelowercageplateusingeleven3/8”x1-3/4”socketheadcapscrews.

b. Pre-greasethesupportringslotintherotarygear.Installtheuppersupportring(PN997-HT-23-TOP)intherotarygearusingeleven3/8”x1-3/4”socketheadcapscrews.

c. Pre-greasethesupportringslotinthetopcageplate,andsettopcageplateinplace,matingthesupportringslotwiththesupportringattachedtotherotarygear.

d. Securethebottomcageplatetothetopcageplateusingtwo1/2”UNCx6”hexboltsatthefront,andtemporarilyinstalltwojawpivotbolts(PN997-D3-28)attherearofthecageplateassemblytoprovidesupport.

e. Slidea1/2”narrowflatwasherfollowedbythebackingpinspacer(PN101-4093)overa1/2”UNCx8”hexbolt.Slidethebackingpinretainer(PN101-4139)overthebackingpinspacer.

f. Insertthe1/2”x8”boltandspacerassemblyintherearofthecageplateassemblies,ensuringthebackingpinspacerremainsbetweentheheadoftheboltandthetopofthetopcageplate.ASSEMBLY NOTE:Donotneglecttoinstallacageplatespacer(PN997-38B)betweenthetwocageplateswheninstallingthisbolt(Seeexplodeddiagram,Pp.5.28-5.29).

IllustratIon 3.I.7: tong asseMBly - top shIFter BushIng InstallatIon



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Assembly Procedure Continued: 44. Installthecageplates(continued):

LW13625Tong:

a. Installelevencamfollowers(02-0016) inthelowercageplate(PN997-D2-22)using5/8”UNFhexjamnutsand5/8” lockwashers.

b. Installelevencamfollowersinthetopcageplate(PN997-D2-21)using5/8”UNFhexjamnutsand5/8”lockwashers.

c. Lightlygreasethetopandbottomslotsintherotarygear,andsettopcageplateinplace,matingthecamfollowersonthecageplatewiththeslotontherotarygear.

d. Slidea1/2”narrowflatwasherfollowedbythebackingpinspacer(PN101-4093)overa1/2”UNCx8”hexbolt.

e. Securethebottomcageplatetothetopcageplate.Usetwo1/2”NCx6”hexboltsatthefront,andthe1/2”x8”boltandspacerassemblyintherearensuringthebackingpinspacerremainsbetweentheheadoftheboltandthetopofthetopcageplate.ASSEMBLY NOTE:Donotneglecttoinstallthethreecageplatespacers(PN997-38B)betweenthetwocageplatesduringinstallation(SeeexplodeddiagramPp.5.30-5.31).

45. Installbackingpin:

a. Threadthe3/8UNCx1-1/2”threadedstud(PN101-4097)intothebackingpin(PN101-4042).

b. InsertthebackingpinandstudthroughthebottomofthebackingpinretainerinstalledinStep45(e).Slidetheshortbackingpinspacer(PN101-4096)overthetopofthestud,andthreadthebackingpinknob(PN02-0017)ontothetopofthethreadedstud.

c. Liftthebackingpinandinsertintooneofthetworeceptaclesintherearofthetopcageplate.

46. Installupperandlowerbrakebandweldments(PN997-D23-29).Securethebrakebandstothetopandbottomplateswithonebrakebandretainer(PN101-0140)perside-securebrakebandretainerswith3/8”NCx1”hexboltsand3/8”lockwashers.Installfrontadjustmentsprings,bolts,andnuts.

47. Ifnotalreadydoneinstallthedoorpivotsupportrollercomponentsthatfitwithinthebodyplates,i.e.everythingexceptthetwopivotrollershafts.

48. Installadoorpivotshoulderbushings(PN101-5110)inthetopplateofeachoftheRHdoorweldment(PN101-0034)andtheLHdoorweldment(PN101-0032).ASSEMBLY NOTE:Insertthesebushingsfromthebottomofthetopdoorplatesotheshoulderridesbetweenthedoorweldmentsandthetopplateofthetong.

49. Insertabottomdoorbushing(PN101-5111)intothebottomplateofeachdoorweldment.

50. Threada3/8”UNChexjamnutontoa3/8”UNCx1-1/2”hexbolt.ThreadtheboltintotheRHdoorweldmentandlockitinplacewiththejamnut.Thiswillserveasadoorpositionadjustment.

51. Positionthedoorlatchweldment(PN101-0038)infrontoftheRHdoorweldment,andinserttwodoorlatchsprings(PN997-16)betweenthetwoweldments.Insertthedoorlatchadjustmentcam(PN997-A11-14)throughthetopplateoftheRHdoorweldmentandthelatchweldment(thespringsmayneedtobelightlycompressedtofacilitatetheinstallationofthelatchcam),andthroughthebottomplateoftheRHdoorweldment.SecurethedoorlatchcamtothetopoftheRHdoorweldmentusinga3/8”UNCx1”hexboltand3/8”lockwasher.Coatthethreadsofa5/8”UNFjamnutwithredLoctite®andthreadontothebottomoftheadjustmentcamuntilthenutisflushwiththeendoftheadjustmentcam.SeePp.5.32-5.33foranexplodedillustrationofthedoorassembly.

52. Alignthedoorpivotholeswiththepivotholesinthetopandbottomplates.Slidea7/8”narrowflatwasherovertheendofbothdoorpivotrollershafts(PN101-0046)andinserttheshaftsfromthetop-theymayhavetobetappedlightlywithasoftmetalorrubberhammer.Usecautionwhenslidingtheshaftthroughthesupportrollercomponents.Oncetheshaftshavebeentappedallthewaythrough,secureeachwitha3/4”UNFthinnylocknutand7/8”narrowflatwasher.

53. Installtwomechanicaldoorstops(PN101-0014)ontheundersideofthetong,nearthedoors.Secureusingtwo3/8”UNCx1-3/4”boltsand3/8”lockwasherseach.

54. Installdoorcylindermountinglugs(1050-12-001)intothethreadedlocationsdirectlyadjacenttothebrakebandlugweldmentsonthetopplate.

55. Installthedoorspringstopcylinderassemblies(PN101-0069)usingtwo1/2”x1/2”UNCshoulderbolts.

Ensuretheguardsondoorspringcylindersextendoverthetopofthesupportrollersratherthantowardtheedgeofthetong.



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Assembly Procedure Continued: 56. Mountthefrontlegmountweldments.Thefrontlegmountweldmentsarecoincidentalwithtwolongersupportrollershafts,which

wereinstalledinstep34(a).Securethefrontlegmountweldmentstothesupportrollershaftsusingone3/4”UNFthinhexnylocknutpershaft.ASSEMBLYNOTE:Flatwashersarenotusedwherethesupportrollershaftsarecoincidentalwiththefrontlegmountweldments.

IllustratIon 3.I.8: tong asseMBly - Front leg Mount weldMent InstallatIon

57. Installthesafetydoorcomponents(seePp.5.34-5.35)usingthefollowingprocedure:

a. Attachsafetydoorlatchplate(PN101-0320)totheLHdoorweldmentusingthree3/8”UNCx1”hexsocketheadcapscrews.

b. Attachsafetydoorlatchblock,PN101-0319,totheRHdoorweldmentusingtwo3/8”UNCx1-1/2”socketheadcountersunkcapscrewsandone3/8”UNCx1-1/2”hexboltandlockwasher.

c. Attachsafetydoorlatchblock,PNAE13-301S,tosafetydoorlatchplate,PNAE13-311,usingthree3/8”NCx1”flatheadcountersunkcapscrews.

d. Attachtheassemblyfromstepiiitothesafetydoorlatchplate,PN101-0320,usingfour5/16”x3/4”shoulderbolts.

CE-markedtongsonly:attachassemblyfromStep56ctothesafetydoorlatchplate(PN101-0320)tusingfour5/16”x3/4”UNCwire-drilledshoulderbolts

e. Attachsafetydoorlatchblock,PNAE13-302Mtothesafetydoorlatchblock,PN101-0319,usingfour3/8”UNCx3/4”hexbolts.

CE-markedtongsonly:attachsafetydoorlatchblock,PNAE13-302Mtothesafetydoorlatchblock,PN101-0319,usingfour3/8”UNCx3/4”wire-drilledhexbolts

f. Insertloadplunger,PNAE12-306,intoLHsafetydoorlatchblock,PNAE13-301S.



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Assembly Procedure Continued:57. Installthesafetydoorcomponentscontinued:

g. Attachthree1/4”NPTJICelbowstotheDeltrolsafetydoorvalve,PN08-0337M.Positiona15/16”valvelocknutasshowninillustration3.I.9,andsecurethesafetydoorvalvetothesafetydoorlatchblockusingthevalvelocknut.

IllustratIon 3.I.9: tong asseMBly - saFety door valve InstallatIon

h. Attachthefrontsafetydoorguardplateweldment,PN101-0387,totheLHtongdoorweldmentusingtwo3/8”UNCx1”hexboltsandlockwashers.Attachtherearsafetydoorguardplateweldment,PN101-0386,tothesafetydoorlatchplate,PN101-0320,usingasingle3/8”UNCx1”hexboltand lockwasher.Secure thetopguardplate to the frontandrearplatesusingfour3/8”UNCx3/4”hexboltsandlockwashers.Notethatasafetydooradjustmentmaybenecessarytoobtainproperoperation(referto3.F.5).

CE-markedtongsonly:Attachthefrontsafetydoorguardplateweldment,PN101-0387,totheLHtongdoorweldmentusingtwo3/8”UNCx1”wire-drilledhexboltsandlockwashers.Attachtherearsafetydoorguardplateweldment,PN101-0386,tothesafetydoorlatchplate,PN101-0320,usingasingle3/8”UNCx1”wire-drilledhexboltandlockwasher.Securethetopguardplatetothefrontandrearplatesusingfour3/8”UNCx3/4”wire-drilledhexboltsandlockwashers.Notethatasafetydooradjustmentmaybeneces-sarytoobtainproperoperation(referto3.F.5).

58. InstalltheLH&RHrigidslingmountinglugs(LH=PN101-1361,RH=PN101-1364)usingtwo3/8”UNCx1-3/4”hexboltsand3/8”lockwashers,andtwo1/2”UNCx1-1/4”hexboltsandlockwashersperside.

CE-markedtongsonly:secureLH&RHrigidslingmountinglugstothetopplateusingtwo3/8”UNCx1-3/4”wire-drilledhexboltsand3/8”lockwashers,andtwo1/2”UNCx1-1/4”wire-drilledhexboltsandlockwashersperside.

59. Slidethemasterliftinglink(PN02-0516)overtheadjustmenthelix(PN1053-1-H),andinstalltheadjustmenthelixintherigidslingweldment(PN101-1360)usinga3/4”UNCx9”hexboltand3/4”UNCnylocknut.

CE-markedtongsonly:rigidslingweldmentforCE-markedtong=PN101-1360-CE

ALL FASTENERS USED DURING REASSEMBLY OF LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS) MUST BE SECURED WITH RED LOCTITE™.



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Assembly Procedure Continued:60. Useacranetohoisttherigidslingweldment.Connecttherigidslingweldmenttotherigidslingmountinglugswithrigidslingpins

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

61. Threada3/4”UNChexnutontoeachoffourrigidslinglevelingadjustmentweldments(PN1053-C-1L).Threadthelevelingadjust-mentweldmentsintoeachsideoftherigidslingweldmentmountingbrackets,roughlyadjustingthemsotherigidslingisapproxi-matelyperpendiculartothetopplateofthetong(seeillustration3.I.10).

IllustratIon 3.I.10: tong asseMBly - levelIng Bolt InstallatIon

62. Installhydraulicinletsupportbase(PN101-1138)tothetopplatebetweentheRHpinionidlerandRHrotaryidlerusingtwo3/8”UNCx1”hexboltsand3/8”lockwashers.Attachaadjustmentplate(PN101-0022)tothesupportbaseusingtwo3/8”UNCx1”hexbolts,3/8”narrowflatwashers,and3/8”UNChexnylocknuts.

63. Attachtheoutletcouplingsupportweldmentmount(PN101-0021)tothetopplatetotheRHsideofthemotormountusingfour3/8”UNCx1”hexsocketheadcapscrews.Attachtheoutletcouplingsupport(PN101-0023)totheweldmentmountusingtwo3/8”UNCx1”hexboltsand3/8”lockwashers.Attachasecondadjustmentplate(PN101-0022)tothesupportbaseusingtwo3/8”UNCx1”hexbolts,3/8”narrowflatwashers,and3/8”UNChexnylocknuts.



Assembly Procedure Continued:64. Useacraneandatemporaryliftingslingtotransportthehydraulicvalveassemblytothetopofthetong.Attachtothevalvemount

weldmentsusingtwo1/2”UNCx5”hexboltsand1/2”narrowflatwashers

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

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

67. Connectthesafetydoorswitchtothesafetydoorblockandhydraulicvalveassembly.Refertohydraulicschematic,orcallMcCoyDrilling&Completions|Farrengineeringdepartmentforassistance.

68. Installthetwofrontlegweldments(PN997-917-00B)inthefrontlegmountsandsecureeachwitha1/2”UNCx4-1/2”hexbolt,1/2”UNChexnut,andtwoflatwashers.

CE-markedtongsonly:Installthevalvehandleguardweldment(PNCE-HANDLE-3)overthevalvehandleswhilesecuringthevalvebanktothesupports(seeillustration3.I.11).

IllustratIon 3.I.11: tong asseMBly - valve handle guard InstallatIon (ce MarKed tongs)

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1/2” UNC x 5”

1/2” LockWasher

1/2” UNC x 4-1/2”

1/2” UNC x 5”

1/2” NarrowFlat Washer

1/2” UNC ThinNylock Nut



Assembly Procedure Continued:69. Placetherearlegweldment(PN997-915-00)onaflatsectionoftheflooradjacenttothetongassembly.Useacranetoliftthe

tongassemblyfromitsassemblybase,andlowerontothelegassemblyensuringalltheweightremainssuspendedbythecrane.Securewithfour1-1/4”NCx8”heavyhexboltsandnylocknuts.

70. Supportbackupassemblyaboutwaist-highofffloor,ensuringthebackupsupportsdonotobstructfrontlegandrearlegareas.

71. Lifttongandrearlegassembly,andlowerontobackupsothatthefrontlegslowerthroughopeningsinbackup.Asmallamountofmaneuveringmaybenecessarytopositiontheloadcellweldmentbetweenthetworearlegplatesasthetongisloweredoverthebackup.Continuetolowertongassemblysothatroughlyhalfthelengthsofthefrontlegsprotrudethroughthebottomofthebackup.

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

72. Slideatopspringcap,PN1302-905-03B,overeachleg,followedbythefrontlegsprings(PN997-906-02),andthebottomlegspringcaps(PN1302-905-03A).Secureinplacewitha1/2”NCx4-1/2”hexbolt,nut,andtwoflatwashers.Notethatthepositionoftheseboltassembliesandthebottomspringcapmayhavetobeadjustedwhenlevelingthebackup.

73. Attachtworearsupportsprings(PN1302-905-06)totherearsuspensionbracketonthebackup,andtheU-Boltspringholderlinksonthebottomplateoftherearleg.

74. Lifttongandbackupassemblyhighenoughsothatthebackupsupportscanberemoved.Lowerassemblyuntilitrestsonitslegs.

75. Installgreasefittings:

i. Installone1/4”straightthreadgreasefitting(PN02-0097)intothetopsideofeachsupportrollershaft,includingthedoorpivotrollers(14locationstotal).

ii. Installone1/4”straightthreadgreasefitting(PN02-0097)intothetopsideofthelatchadjustmentcam.

iii. Installone1/8”NPTgreasefitting(PN02-0005)intothetopofeachidlershaftorhalf-shaft(fourlocationstotal).

iv. Installone1/8”NPTgreasefitting(PN02-0005)intotheendoftheclutchshaft,inthecentreoftheclutchbearingcap.

v. Installtwo1/8”NPT90ogreasefittings(PN02-0093)ineachpinionbearingcap(fourlocationstotal).

vi. Installtwo1/8”NPT90ogreasefittings(PN02-0093)inclutchbearingcap(twolocationstotal).

vii. Installone1/8”NPT90ogreasefitting(PN02-0093)inthetopofthemotormount.

viii. LW13625 ONLY:Installone1/8”NPTgreasefitting(PN02-0005)intoeachcamfollowerinthetopandbottomcageplates(22locationstotal).

ix. Installone1/8”NPTgreasefitting(PN02-0005) intoeachcamfollower in the topandbottomcageplates in theFARR®backup(22locationstotal).

76. Installdesiredjawdiekitinthetongusingthejawpivotbolts(PN997-D3-28).

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

1. Rotatecageplate/rotarygearuntiltheopeningintherotarygearfacestowardstherearofthetong.

3. Performaninitialwashofthetonginordertoremovethemajorityofdirtandgreasebuild-up.Ensureadequatecontainmentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluidanddirtygrease.

4. Removetheaccesspanelonthesideofthetongdirectlyadjacenttotheshiftermechanism.

5.Useaflashlighttoperformavisualinspectionofthegeartrainthroughtheaccesspanelandtheopeningoftherotarygear.Ifgeardamageorchipsofmetalareseen,thetongshouldberemovedfromserviceandoverhauledtoavoidfurtherdamage.Replaceaccesspanelwheninspectioniscomplete.

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

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

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

9. Inspecttongforsignsofprematurewear,ormovingpartsthatarerubbing(baremetalwherethereusedtobepaintisagoodindicationofwear.

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

11.Inspecttopandbottombrakebandlinings-replaceifnecessary.Unequalwearofthebrakebandsindicatesthatthebrakebandtension isnotevenlyadjusted.Refer tothemaintenancesectionof themanual for instructionsonproperlyadjustingbrakebands.

12. Performavisualinspectionofallhydrauliclines.Replaceflexiblelinesiftheyappeartobecracked,fatigued,orhavevisiblesignsofwearfromcontactwitharigidobject.

DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CONNECT-ED TO ANY HYDRAULIC POWER SUPPLY. FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED, AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF. ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINATION FROM RESIDUAL HYDRAULIC FLUID.

2.

depressurIze hydraulIc systeM In preparatIon For MaIntenance:

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

2) De-energizethepowerunit.





8) Disconnectremaininghosessuchascasedrains.

HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INJURIES

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21. Whilerotatingthecageplate,ensurethatthejawsproperlycam.Ifthejawsdonotcamproperly,thebrakebandsneedtobetightened.IncrementallyadjustboththetopandbottombrakebandsEqUALLYuntilpropercamactionisachieved.

13. Performacompletegreasingofthetong-refertoMaintenancesectionofthetechnicalmanual

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

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

NEVER OPERATE YOUR EQUIPMENT WITH A BYPASSED OR MALFUNCTIONING SAFETY DOOR

15.Performavisualinspectionoftheloadcell.Ifusingatensionloadcell,replaceanycracked,broken,ordistortedcomponentsincludinglinksandchains.Ifusingacompressionloadcell,replaceanycomponentthathasbeencrushedorotherwisedistortedthroughcompression.Inspecthydraulicline,fittings,anddiaphragmsealsforfluidleaks.

16. Ifapplicable,inspecttheloadcellanchorpins(tensionloadcellonly).Replacetheanchorpinsifcrackingormetaldistortionisseen.

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

17. Ensurethatsupplypressureisatorabovethetong’sspecifiedoperatingpressure,andthatthereturnpressureislessthan350psi.

18. Performavisualinspectionofpressurizedhydrauliclines.Documentandcorrectanyhydraulicfluidleaks.

19. Performafullfunctionaltestofthetong(refertosection2.I.4).

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

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

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K. DAILY INSPECTION & MAINTENANCE CHECKLIST (BACKUPS)FarrCanadarecommendsthatthefollowinginspectionandmaintenanceproceduresbeperformedbeforeeachuse,andatleastonceperdaywhenthebackupisinsteadyuse,intheorderinwhichtheyarelisted.

Donotperformanymaintenancewhilethetongandbackupassemblyisconnectedtoanyhydraulicpowersupply.FarrCanadarecommendsthatallhydrauliclinesarefullydisconnected,andresidualhydraulicpressureisbledoff.Ensureadequatecontainmentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluid.

all unIts

1. Performaninitialwashofthebackupinordertoremovethemajorityofdirtandgreasebuild-up.

2. Performanexternalinspection.Checktoensuretherearenolooseormissingfasteners-replaceifnecessary.

3. Checktoseeifbackupisparalleltothetong-ifthebackupisrestingatanangle,oneofthefrontlegspringsislikelybrokenorfatiguedtothepointitmustbereplaced.

wedge BacKup only

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

5. Inspectlatchmechanismtoensurethedoorlatchplatecompletelyengagesthedoor.Adjustorreplaceifnecessary.

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

clIncher BacKup only

4.Useaflashlighttoperformavisualinspectionoftheinteriorofthebackup-removeonesidepanelifnecessary.Prematurewearwheretherearemovingparts(baremetalwherethereusedtobepaint,andmetalshavingsinthegreasearegoodindicators)mayshowwhereacomponentneedstobeadjusted,or ifnecessaryreplaced.Replaceanyremovedpanelswheninspectioniscomplete.

5. Greaseclinchercylinderguidesusingthegreasefittingsonthetopbodyplate.

6. Ensurethesplinesontheclinchercylinderfaces,andontherearofthediearecleanandfreeofdebrisbeforeinsertingclincherdie.Ifdiearealreadyinstalled,ensurefastenersinthedieretainersaretightlysecured.

7. Inspectrearspringhangerassembly.Ensurealleyebolts,shackles,andcotterpinsareinplaceandingoodcondition.

8. Inspectclinchercylindersforhydraulicfluidleaksoncethesystempressurehasbeenrestored.

Farr-style BacKup only

4. Inspectcamringgearforbrokenteeth.

5. Lubricatethecamfollowerarray.

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

7. Inspectfrontandrearcamcylindersupports.Repairorreplaceanypartsthatarebroken,cracked,orbent.

8. Inspectrearspringhangerassembly.Ensurealleyebolts,shackles,andcotterpinsareinplaceandingoodcondition.

9. Openthebackupdoorandinspecttheconditionofthelatch.Repairorreplacedamagedlatchcomponents.Iflatchap-pearstobeingoodcondition,closethedoor,thentugfirmlyonittoensurethedoorremainslatched.

all unIts (aFter startIng power unIt)

10. Performavisualinspectionofpressurizedhydrauliclines-documentandcorrectanyhydraulicfluidleaks.

11. Performafullfunctionaltestofthebackup.Documentandcorrecthydraulicleaksfromthehydraulicvalvebank,orfromanyhydrauliccylindersthatareinuseonthebackup.



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L. MONTHLY MAINTENANCE CHECKLIST - POWER TONGThefollowingmaintenancechecklistisintendedasaguidelineratherthanadefinitivemaintenanceschedule.Yourequipmentmayrequiremore,or less,maintenancedependinguponthefrequencyofuse,thepercentageofmaximumtorquethatyourequipment isroutinelysubjectedto,andthefieldconditionsunderwhichyourequipmentoperates.Farrrecommendsthatthefollowinginspectionandmainte-nanceproceduresbeperformedmonthly,orinconjunctionwithyourmaintenanceforeman’sexperienceandbestestimateofwhenyourequipmentisdueforthismaintenance.

1. Rotatecageplate/rotarygearuntiltheopeningintherotarygearfacestowardstherearofthetong.

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


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

6. Inspectallfastenersandfastenersafetywires(ifequipped).Replaceanymissingfasteners-useGrade8boltsonlyunlessotherwisespecified.Re-torqueallexternalfastenerstoSAEspecifications.

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

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

9. Inspecttongforsignsofprematurewear,ormovingpartsthatarerubbing(baremetalwherethereusedtobepaintisagoodindicationofwear.

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

11. Visuallyinspectallload-bearingwelds.Anyweldthatiscrackedorseparatingmustberepairedandrepaintedbeforereturningthetongtoservice.

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

DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CONNECT-ED TO ANY HYDRAULIC POWER SUPPLY. FARR RECOMMENDS THAT ALL HYDRAULIC LINES ARE FULLY DISCONNECTED, AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF. ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMINATION FROM RESIDUAL HYDRAULIC FLUID.

2.

depressurIze hydraulIc systeM In preparatIon For MaIntenance:1) De-energizethepowerunit.






HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE INJURIES



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


24. Performavisualinspectionofpressurizedhydrauliclines.Ifanyhydraulicfittingsorhosesareleakingtheymustberepairedorreplacedbeforeproceeding.

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

26. Energizepowerunit.Rotatetongforoneminuteinbothhighandlowgear.Stopthetongandreversethedirectionofrotationforanotherminuteinbothhighandlowgear,endingwiththeopeningoftherotarygearfacingthegeartrain.

27. De-energizethepowerunit,andperformathirdgenerouslubricationofthegeartrain,includingthegearhousing.

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

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


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

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

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


16.Inspecttopandbottombrakebandlinings-replaceifliningisfoundtobeflakingorismissingpiecesofmaterial.Unequalwearofthebrakebandsindicatesthatthebrakebandtensionisnotevenlyadjusted.Refertothemaintenancesectionofthemanualforinstructionsonproperlyadjustingbrakebands.

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

18.Inspectbackupsprings(ifapplicable).Therearextensionsprings(whereused)shouldbeequallyextended,andthefrontlegspringsshouldbeequallycompressed.Ensurethatneitheroftherearbackupspringshavebeenover-extendedandlacksufficienttensiontoadequatelysupportthebackup.Ensurethatneitherofthefrontlegsprings(or,wheninstalled,thesinglerearbackuplegspring)havebeenover-compressed,andstillretainenoughspringstrengthtosupportthefrontofthebackup.

19. Extendallhydrauliccylinders,andinspectcylinderrodsforsignsofmechanicaldamage,flaking,orrust.Farrrecommendsthatdamagedcylindersbereplacedpriortostorage.

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

21. Generouslyfillthegeartrainhousingwithgreasethroughtheaccesspanel,andalsothroughtheopeningintherotarygear.Performafulllubrication-refertoMaintenancesectionofmanualtodeterminelubricationpoints.

22. Ensuremainsupplyandreturnconnectionstothetongarefullymadeup.Re-connecttheremainderofthehydrauliclines.



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30.Install load cell. If using a tension load cell, performa visual inspection and replaceany cracked, broken, or distortedcomponentsincludinglinksandchains.Ifusingacompressionloadcell,replaceanycomponentthathasbeencrushedorotherwisedistortedthroughcompression.Inspectloadcellfordamageorsignsofstress.Checkoillevelinloadcellandfillifnecessary(refertotechnicalmanualSection7orSection8).


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

33.Whilerotatingthecageplate,ensurethatthejawsproperlycam.Ifthejawsdonotcamproperly,thebrakebandsneedtobetightened.IncrementallyadjustboththetopandbottombrakebandsEqUALLYuntilpropercamactionisachieved.Refertothemaintenancesectionofthemanualforinstructionsonproperlyadjustingbrakebands.

34.Performafullfunctionaltestofthetongincluding,ifapplicable,backupcomponents,liftcylinder,andfloatframecompo-nents(refertoSection2.I.4).Reportandcorrectanyhydraulicleaksfromthehydraulicvalvebank,orfromanyhydrauliccylindersthatareused.

35.Testsafetydoorfeature(ifequipped).Beginrotatingthetongatlowspeed,andopenthetongdoor(s).Ifrotationdoesnotimmediatelystop,thisisanindicationthatthesafetydoormechanismisnotoperatingcorrectlyandthetongmustbere-movedfromserviceuntilthemechanismisrepaired.Repeatthetestwhileoperatingthetongintheoppositedirection.Ifthesafetydoorisoperatingcorrectly,cageplaterotationwillnotbeinhibitedoncethedoorisclosedandlatched.


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

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



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M. TUBULAR CONNECTION EQUIPMENT DE-COMMISSIONING & SHIPPINGPerformthefollowingdecommissioningprocedureswhenremovingtubularconnectionequipmentfromservice,withtheintentofshorttolong-termstorage.Theseproceduresareessentialforensuringproperprotectionoftheequipmentfromenvironmentalattack,andtoaidinthequickturnaroundwhenreturningtheequipmenttoservice.

Storeallo-rings,seals,packings,gaskets,etc. instrongmoistureproof,airtightcontainers.Ensure that these itemsarenotcrushed,nicked,orotherwisedamaged.

Donotperformanyfurtheractionsormaintenancewhilethetongisconnectedtoanyhydraulicpowersupply.Farrrecommendsthatallhydraulic linesare fullydisconnected,andresidualhydraulicpressure isbledoff.Ensureadequatecontainment is inplace topreventenvironmentalcontaminationfromresidualhydraulicfluid.

1. Performaninitialwashofthetoolinordertoremovethemajorityofdirtandgreasebuild-up.Ensureadequatecontainmentisinplacetopreventenvironmentalcontaminationfromresidualhydraulicfluidanddirtygrease.


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

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

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


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

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

9. Performaliberallubricationoftheequipment-refertoMaintenancesectionofmanualtodeterminelubricationpoints.Gener-ouslyfillthegeartrainhousingwithgreasethroughtheaccesspanel,andalsothroughtheopeningintherotarygear.

10. Connecttheequipmenttoahydraulicpowerunit.Ensurealllinesarefullymadeuptopreventequipmentdamagefromexces-sivebackpressure.Donotneglecttoconnectthemotordrain.

11. Energizepowerunit.

HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIPMENT IS USED TO GUARD AGAINST PRESSURE-INDUCED INJURIES

depressurIzatIon procedure In preparatIon For storage:1) Rotatethetongsothattheopeningintherotarygearfacesthegeartrain(towardstherearofthetong).Ensuretongandbackup

doors(ifequipped)areclosed.Fullyextendtheliftcylinder(ifequipped).Ifmountedinaframe,retractthefloatcylinders(ifequipped).2) De-energizethepowerunit.3) RepeatedlyactuatethetongmotorcontrolvalveleverINBOTHDIRECTIONStodissipateanyresidualpressureinthevalveand

motor.4) RemovethehydraulicSUPPLYlinefromtheequipment.5) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressureintheremainderof

thehydrauliccontrolsystem.7) DisconnectthehydraulicRETURNlinefromtheequipment.8) Disconnectremaininghosessuchascasedrains,orlinesconnectedtotheturnscounter.

IN ORDER TO MAINTAIN THE INTEGRITY OF INSTALLED SEALS, MCCOY RECOMMENDS THAT THE MAXIMUM STORAGE INTERVAL NOT EXCEED ONE YEAR. AT LEAST ONCE PER YEAR ALL TUBULAR CONNECTION EQUIPMENT IN LONG-TERM STORAGE SHOULD BE RECOMMISSIONED AS PER SECTION 3.M. IF FURTHER STORAGE IS REQUIRED, THE EQUIPMENT SHOULD THEN BE PUT THROUGH ANOTHER DE-COMMISSIONING PROCEDURE.



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depressurIzatIon procedure For storage:1) Rotatethetongtothe“openthroat”position.2) Exerciseeachhydrauliccylinderseveraltimes-openthetongandbackupdoors(ifequipped),retractandextendthe

remotebackingpinramp(ifequipped),retractandextendthefloatcylinders.Leaveallcylindersexceptforthedoorcylin-dersintheirfullyretractedposition.Thegeneralideaistohaveaslittleofthechromecylinderrodsexposedaspossible.

3) De-energizethepowerunit.4) RepeatedlyactuatethetongmotorcontrolvalveleverINBOTHDIRECTIONStodissipateanyresidualpressureinthe

valveandmotor.

5) RemovethehydraulicSUPPLYlinefromtheequipment.6) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressureinthe

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

remaininghydraulicfluidfromthevalveassembly-thiswillallowforthermalexpansionofthehydraulicfluidiftheequip-mentisstoredortransportedinhighambienttemperatures.Failuretodothismayresultindamagedordestroyedsealsintheequipment.



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

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

14. De-energizethepowerunit,andperformathirdgenerouslubricationofthegeartrain,includingthegearhousing.

15. Energizepowerunit,androtatethetongforafinaltime,oneminuteinonedirection,stop,andreversethedirectionofrota-tionforanotherminute,thistimeendingwiththerotarygearinthe“openthroat”position.

16. Extendallhydrauliccylinders,andinspectcylinderrodsforsignsofmechanicaldamage,flaking,orrust.Farrrecommendsthatdamagedcylindersbereplacedpriortostorage.

17.

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

18. Ifanyhydraulicfittingsorhosesareleakingtheymustberepairedorreplacedbeforeproceeding.

19.Wipeallexcessgreasefromoutsideofequipment.Replacetheaccessdoorpanel.Useasolvent-basedcleaneronragstowipeallexternalsurfacestoremoveresidualgreaseorhydraulicfluid.Oncetheoutsidesurfaceshavebeende-greased,wipeallexternalsurfaceswithcleanwatertoremoveresidualsolvent.

20. Farrrecommendsthatchainslingsberemovedandstoredseparately.Rigidslingsandotherrigidsuspensiondevicesmayremaininplace.

21. Applygreaseorheavyoiltoallexposedcylinderrods.

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

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

23. Allowtheanti-corrosivecoatingampletimetodry-refertomanufacturerdatasheetsfordryingtimesatroomtemperature.

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

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



MAinTenAnce

calculatIon oF requIred desIccant

1) Calculatethetrappedairvolumebymeasuringtheoutsidedimensionsofthetooltobestored,andtreatthatasthevolumetobestored.Forexample,theexternaldimensionsofaKT2000020”powertongare80.25”x50.5”x28”,whichcalculatestoanapproxi-matevolumeof113500in3,or66ft3(1.87m3).

2) Multiplythecalculatedairvolume,incubicfeet,bytherecommendedamountofdesiccantpercubicfoot.Carryingforththeexampleusedinthepreviousstep,therequireddesiccantchargewouldbe3.5g.x66ft3,equaling231g.Severalmanufacturersoffersilicageldesiccantinpackagedquantitiesof125gramsperbag,sotwopackagesofdesiccantwouldberequired.Pleasekeepinmindthatthisisaguidelineonly-moreorlessdesiccantmayberequiredinextremeenvironmentalconditions.

Forbestcorrosionresistancetheequipmentshouldberemovedfromstorageandexercisedonaregularbasis,dependingonthestorageenvi-ronment.Farrrecommendsthatforequipmentstoredinasalt-watermaritimeorexposeddustyenvironment,repeatsteps9through24monthly.Forequipmentstoredinisolatedstorageinanon-maritimeenvironment,repeatsteps9through24quarterly.Replacedesiccantpacksatthistime-depleteddesiccantpacksmaybetreatedasregulardunnage.

shIppIng InstructIons

Thefollowingprocedureliststhestepstobefollowedtoprepareyourtongforshipping.

1. Ifnotalreadydoneremoveaccessories(tongjaws,loadcell,torquegauge,etc.)McCoyrecommendswrappingtheseitemsinprotec-tivewrapandplacinginaseparatewoodencrate.

2. Placetheequipmentonasturdypalletconstructedof4”x4”cross-membersand2”x4”flooring.McCoyrecommendsplacinga2”x6”boardacrossthewidthofthetongunderthelegs(seeIllustration3.M.1).Ensurethepalletislargeenoughtoaccommodatethewoodencratecontainingthetongaccessories.

IllustratIon 3.M.1: shIppIng InstructIons - pallet



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shIppIng InstructIons (contInued):3. Useacranetosupportthechainsling(ifequipped).Wrapthechainslingwithbubblewraporanothersimilarprotectivewrapping,

andsecurethewrappingwithtape.Lowerthewrappedchainslingsoitsitsinsidetheopeningofthetong.

IllustratIon 3.M.2: shIppIng InstructIons - wrappIng chaIn slIng

4. Donotallowthebackup(ifequipped)to“float”onitssupportspringsduringshipping.Buildasturdywoodensupportstructureunderthefrontandbackofthebackuptosupporttheweightofthebackupandreleasethecompressiononthesprings.Strapthebackuptothesupportblocksandpalletindependentofthetong,usingminimum3/4”x0.029”metalstrappinginatleasttwolocations.Placestrappingasclosetothebackupsupportsaspossible,andusecautionnottoentrapanyflexiblehydraulichosesbeneaththestrap-ping.Beforetighteningstrapping,placestrappingprotectorswhereverthemetalstrappingcomesintocontactwiththeequipment.

IllustratIon 3.M.3: shIppIng InstructIons - BacKup support



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shIppIng InstructIons (contInued):5. Securelystraptheequipmentinplaceusingmetalstrapping.Placestrappingasclosetothecross-membersundertheequipment

legsaspossible,andusecautionnottoentrapanyflexiblehydraulichosesbeneaththestrapping(guidestrappingthroughbeneaththehydraulichoses).Usethefollowingguidelinestodeterminethestrappingrequirements:

Assembliesweighing1000lbs.(454kg.)orless:

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

Assembliesweighingmorethan1000lbs.(454kg.)orless:

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

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

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

6. Usealargepolyethyleneshippingbag(sometimescalledapalletcover)tocompletelyenclosetheequipment.Sealpolyethylenebagtothepalletusing1milpolyethylenewrap.Usethewraptoconformtheplasticcovertothegeneralshapeoftheequipment,butdonotwrapsotightthatsharpedgesontheequipmentperforatethecover.

7. McCoyrecommendsenclosingtheequipmentinasturdyshippingcratewhichissecurelyfastenedtothepallet.

IllustratIon 3.M.4: shIppIng InstructIons - strappIng equIpMent to pallet



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N. TUBULAR CONNECTION EQUIPMENT RE-COMMISSIONING PROCEDUREPerformthefollowingrecommissioningprocedureswhenremovingtubularconnectionequipmentfromshortorlong-termstoragebackintoregularservice.Theseproceduresareessentialforensuringproperequipmentpreparationandoperation.ThefollowingproceduresalsoassumethatthedecommissioningandstorageproceduresrecommendedbyFarrhavebeenstrictlyobserved.

7. Energizepowerunit.


9. Performathoroughinspectionofpressurizedhydrauliclinesandfittings.Anyleakinghydraulicfluidlinesorfittingsmustbereplacedbeforetheequipmentisreturnedtoservice.

10. Performathoroughinspectionofallseals.Anysealthatisleakingor“weeping”mustbereplacedbeforetheequipmentisreturnedtoservice.

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

12. Inspectallflexiblehydrauliclinesforsignsofwear,blistering,oranyothersignsofpotentialfailure-replaceifsignsofpotentialfailureareidentified.

13. Inspectthegeartrainhousing.Iftheamountofgreaseisinadequate,liberallygreasethegeartrainthroughtheaccesspanel,andthroughtheopeningintherotarygear.

14.Inspecttopandbottombrakebandlinings-replaceifnecessary.Unequalwearofthebrakebandsindicatesthatthebrakebandtension isnotevenlyadjusted.Refer tothemaintenancesectionof themanual for instructionsonproperlyadjustingbrakebands.Ensurethatallgreaseiswipedfrombrakebandliningsandthepartsofthecageplatesthatcomeintocontactwiththebrakebandlinings

15. Re-installaccesspanel.Installasetofpre-inspectedjawsthatarethecorrectsizeforthepipeorcasingbeingrun.

16.Installloadcell.Ifusingatensionloadcell,performavisualinspectionandreplaceanycracked,broken,ordistortedcompo-nentsincludinglinksandchains.Ifusingacompressionloadcell,replaceanycomponentthathasbeencrushedorotherwisedistortedthroughcompression.


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

19. Re-energizepowerunit.


1. Removeallprotectiveplasticwrapping. If therearedesiccantpackswith theassembly, theymaybedisposedofwith theregulargarbage.


3. Wipeexcessgreaseorheavyoilfromexposedcylinderrods.

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

5. Performaliberallubricationoftheequipment-refertoMaintenancesectionofmanualtodeterminelubricationpoints.Gener-ouslyfillthegeartrainhousingwithgreasethroughtheaccesspanel,andalsothroughtheopeningintherotarygear.

6. Connecttheequipmenttoahydraulicpowerunit.Ensurealllinesarefullymadeuptopreventequipmentdamagefromexces-sivebackpressure.Donotneglecttoconnectthemotordrain.



20. Performafull functional testof theequipment including, ifapplicable,backupcomponentsandfloat framecomponents.Reportandcorrectanyhydraulicleaksfromthehydraulicvalvebank,orfromanyhydrauliccylindersthatareused.

21.Ifusingaframe-mountedtongandbackupsystem,raisethetongoffthebeamsthatitisrestingupon.Removethebeamsandprotectivecloths-inspectthepaintontopofthebackupandthebottomofthetongtoensureithasnotbeendamagedbythebeam.

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


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

24. Whenallofthepreviousstepsarecompleted,youmayreturnyourre-commissionedequipmenttoservice.

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Adequatemaintenanceandproperfluidselectionisessentialforminimizinghydraulic-relatedfailures.Alltroubleshootingmustbeperformedbyatechniciantrainedinhydraulicsystems,andfamiliarwiththeequipmentdesign,assemblyandoperation.

Thefollowingtroubleshootinginstructionsareintendedtobeguidelinesonly.Anyfaultsnotsolvedthroughtheuseofthisguideshouldbereferredtoourengineeringdepartmentfortheirevaluationandrecommendations.

A. TONG WILL NOT DEVELOP SUFFICIENT TORQUE

MCCOY DRILLING & COMPLETIONS GUARANTEES CALIBRATION OF A LOAD CELL/TORQUE GAUGE ASSEMBLY FOR A PERIOD OF ONE YEAR. MCCOY SUGGESTS THAT THE LOAD CELL/TORQUE GAUGE ASSEMBLY BE RETURNED TO THE FACTORY FOR RE-CALIBRATION ON A YEARLY BASIS.

POSSIBLE PROBLEM SOLUTION(S)1 Malfunctioningreliefvalveontonghydrauliccircuit SeeSection4.B,ReliefValveTroubleshooting

2 Directionalvalveisleaking Checkdirectionalvalve.Neutralpositionshouldreturnfluiddirectlytothereser-voir.Replaceorrepairvalvetoensurecorrectoperation

3 Powerunitisnotproducingadequatepressure Troubleshootpowerunit(seeuser’smanualforyourparticularunit)

4Poor hydraulic pressure at the tong despite ad-equate pressure at the power unit, or excessivebackpressureinthereturnline.

Restrictionsexistinlinebetweenpowerunitandtong.Inspectintegrityofself-seal-ingcouplingstoensuretheyareallowingfullfluidflow.Checktoensurenootherrestrictionsexist(contaminatedcatchscreensorfilters,forexample)

5 Fluidviscosity isnotappropriate(toohighor toolow)

EnsurehydraulicfluidbeingusedistheviscosityrecommendedbyMcCoyDrilling&Completions.Powerunitpumpmaynotprimeiffluidistooheavy,andthehydraulicsystemwilloverheatiffluidistoolight.Replacewithproperviscosityfluid

Hydraulicfluidviscosityisaffectedbyenvironmentalconditions.Ensurethefluidbe-ingusedissuitableforhighorlowtemperatures.Replacewithproperviscosityfluidfortheoperatingconditionsifnecessary

6 Wornordamagedtongmotorcausingslippage Replaceorrepairwornordamagedmotor

7 Damaged bearings or gears causing excessivedrag Replaceorrepairwornordamagedgearsorbearings

8 Jawsslippingonpipe Ensurejawdiesarenotworntothepointthattheycannotgrip.Ensurethecorrectsizedjawsareinuse

9 Torquegaugeisindicatingincorrectly

Incorrectgauge isbeingused.Ensuregauge is theproper range,andhasbeenproperlycalibratedforthearmlengthoftheequipmentinuse

Gaugehasbeendamaged.Checkgaugeoperationandcalibrationonindependentsystem

Gaugehasmistakenlybeenmarriedtoanincorrectloadcell

10 Loadcellismeasuringincorrectly

Incorrectloadcellisbeingused

Airistrappedintorquemeasuringcircuit(loadcell,hydraulicline,orgauge.RefertotorquemeasurementtroubleshootinginSection6ofthismanual

Loadcellhasbeendamaged.Replaceloadcell,orreturntoMcCoyforrepairandre-calibration

POSSIBLE PROBLEM SOLUTION(S)

11 Incorrectmotorspeedselected(appliesto2-speedmotorsonly)

Maximum torquecanonlybedevelopedwhenLOWmotorspeed (maximumhy-draulicdisplacement)isselected.

12 Incorrecttonggearselected MaximumtorquecanonlybedevelopedwhenLOWmotorgearisselected



TRouBLeShooTing

B. RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING

d. Re-establishhydraulicpowertoyourtong.Ensurethatnoequipmentfunctionsareactive.

e. Loosenthelockingnutonthepressurereliefvalve.

f. Openthetongdoortoactivatethesafetydoorsystemandinhibittongrotation.

g. Activatemotorcontrolvalve.Observethepressuredisplayedonthepressureindicator.Adjustthereliefvalveuntilthepressureindicatedisatthemaximumsystempressurespecifiedonthespecificationspage(maximumsystempressureisthepressureatwhichyourtongachievesitsspecifiedtorque).

DO NOT ADJUST PRESSURE RELIEF TO A SETTING THAT ALLOWS HIGHER THAN MAXIMUM SYSTEM PRESSURE. DOING SO CREATES A POTENTIAL FOR SERIOUS INJURY OR DEATH, AND MAY CAUSE CATASTROPHIC EQUIPMENT FAILURE.

h. Releasethemotorcontrolvalveandtightenthelockingnutonthepressurereliefvalve.

i. Isolateyourtongfromhydraulicpower,anddepressurizefollowingtheprocedureinsection3.D.

j. Closethetongdoor,andremovethetemporarypressureindicator.Restorethesafetydoorpressuresupplylinetofactoryspecifi-cations.Verifythatsafetydoorisoperatingcorrectly(seesection2.I.5.k).


IllustratIon 4.B.1: relIeF valve trouBleshootIng - teMporary gauge InstallatIon


1

Reliefpressureset too low, resulting in in-sufficienttongtorque

Adjustsetting(Seefollowingprocedure):Relief pressure set too high, resulting incrushedpipeorgeartrainfailure

a. Ifyourtongisequippedwithasystempressureindicatorproceedtostep“f”.Ifyourtongdoesnothaveasystempressureindicator,atemporary0-3000PSIindicatormustbeinstalledonthehydraulicinlet.

b. Isolateyourtongfromhydraulicpower,anddepressurizefollowingtheprocedureinsection3.D.

c. Teeinatemporaryindicatoratthesafetydoorsupplypressureport.Ensureallhydraulicconnectionsareperformedbyaqualifiedhydraulictechnician.

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



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PROCEDURE:

a. Isolateyourtongfromhydraulicpower,anddepressurizefollowingtheprocedureinsection3.D

b. Loosenthelockingnutonthepressurereliefvalve.

c. Usealargeflat-headscrewdrivertocompletelyun-threadthepoppetandspringfromthereliefassembly.

d. Inspectthereliefvalvespring,poppet,andvalveseat.

e. Ifnodebrisisfoundinreliefvalveandifseatandpoppetareundamaged,replacereliefvalvespring.

f. Reassemblereliefvalve.

g. Reliefvalvemustbere-settoallowmaximumsystempressure.FollowtheprocedureinStep1ofthissectiontoproperlyadjustreliefvalve.

h. Ifmaximumsystempressurestillcannotbereached,replacetheentirereliefvalveassembly.


2 Reliefcannotbeadjusted tomaximumsystempres-sure(highfluidbypassresultsinlowsystempressure

Debrisonvalveseat

Valvespringisbroken

Valvespringhaslostspringforceduetocontinuoustension

RELIEF VALVE IS INCORRECTLY SET OR NOT FUNCTIONING Cont’d:



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1 Safetydoorswitchrequiresadjustment. Adjustswitchaspersection3.F.5

2 Safetydoorswitchhasfailed Testsafetydoorswitchforproperfunctionandreplaceifnecessary

3 Contaminationinhydrauliclines Ensureallthreeflexiblehydrauliclinestosafetydoorswitcharefree-flowing

4 Pilot-to-open valve in safety door valve block ismalfunctioning.

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

C. SAFETY DOOR DOES NOT OPERATE OR IS MALFUNCTIONING



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1 Obstructionintonghydrauliccircuitpreventingad-equateflow

Inspectself-sealingcouplingstoensuretheyareproperlyengaged

Themainhydrauliclines(supplyanddischarge)tothetongareobstructed.Removeandcleanifrequired

2 Powerunitisnotproducingadequatefloworpres-sure Troubleshootpowerunit(seeuser’smanualforyourparticularunit)

3 Tongmotorisexcessivelywornandisleakinghy-draulicfluidpastthevanes Replacemotor,orrebuildasperSection7ofthismanual

4 Bearings ingear trainand rotarysectionareex-cessivelyworn Overhaultong.SeeSection3ofthismanualfortongoverhaulprocedures

5 Shifterhasmalfunctionedandthetongisnotshift-ingtohighgear Inspectandrepairshiftmechanismasnecessary

6 HydraulicfluidviscositytoohighEnsurehydraulicfluidmeetsMcCoyDrilling&Completionsspecifications

Ensurehydraulicfluidisappropriateforclimaticconditions,especiallyduringcold-weatheroperation

7 By-passvalvenotfunctioning Checkandrepair

D. TONG RUNNING TOO SLOWLY



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E. FAILURE OF JAWS TO GRIP PIPE

POSSIBLE PROBLEM SOLUTION(S)1 Dieshavebecometoodulltoprovideadequategrip Replacedies

2 Incorrectjawsarebeingused Double-check jaw size to ensure they are rated for the diameter of pipe orcasingbeingrun

3 Incorrectdiesarebeingused Ensurediesloadedinthejawsareappropriateforthetypeofpipeorcasingbeingrun

4 Brakeband(s)is(are)insufficientlyadjusted,notallow-ingjawstocamproperly Adjustbrakebandstogiveproperresistancetocageplates

5 Jawrollerbrokenorworn Removejawassemblyandinspect.Replacerollersthatarevisibly“flat-spot-ted”orotherwisedamaged



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POSSIBLE PROBLEM SOLUTION(S)1 Bentorbrokenshifterhandle Replaceshifterhandle

2 “Frozen”orhard-to-moveshifterhandle Greaseshiftershaft

3 Bentorbrokenshifteryoke Inspectcomponentsthroughinspectiondoor.Replaceshifteryokeifneces-sary.

4 Bentorbrokenshiftershaft Replace

5 Locking nuts on shifting shaft have loosened andpositionofyokehaschanged Repositionyokeandre-tightenlockingnuts

6 Shiftingyokehascomeloosefromshiftingshaft Inspectyokeandinspectfordamage.Iffreeofdamage,replaceonshaftandtightenlockingnuts

7 Tongpopsoutofgear Ensurethatdetentball&springassemblyhasbeencorrectlyset

F. FAILURE OR DIFFICULTY OF TONG TO SHIFT



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G. GENERAL COMMENTSThefollowingfactorsgenerallycontributetopoorhydraulicoperationandprematurewearofequipment:

1. Contaminatedhydraulicfluidduetooveruse,overheating,orinadequatefluidfiltration.

2. Unsuitablehydraulicfluid,especiallyinextremeclimaticconditions.

3. Defectivepackingorsealsincomponentsofthehydraulicsystem.

4. Poororincompletehydraulicsystemtraining.Usersmustbefullyqualifiedtooperatetheequipment,andhavecompleteunder-standingofthehydraulicsystem.

Ifyourhydraulictroubleshootingproceduresinvolveflowandpressuretestsatthepowerunit,McCoyCompletions&Drillingrecom-mendsconstructionofatestrigthatcaneasilybeconnectedtothemainsuctionanddischargeportsofthepowerunit.



Assemblies and Parts

Model 80-0935-4 Shown

Model 80-0935-4 (CE Marked) Shown



ITEMS ON THE CRITICAL SPARE PARTS LIST MARKED IN RED INDICATE ESSENTIAL HEALTH & SAFETY ITEMS. FAILURE TO REPLACE DAMAGED ESSENTIAL HEALTH & SAFETY ITEMS WILL PRESENT IMMEDIATE DANGER TO PERSONNEL OR EQUIPMENT. HAVE THESE ITEMS ON HAND AT ALL TIMES. STOP WORK AND QUARANTINE TONG UPON DISCOVERY OF DAMAGED OR DEFECTIVE HEALTH AND SAFETY COMPONENTS UNTIL PARTS CAN BE REPLACED.

MISC TONG & BACKUP PARTSDescription Part Number Qty. Required

MotorGear 997-A10-149 1

JawPivotBolt 997-D3-28 2

CagePlateSpacer 997-38B 3

BackingPin 101-4142 1

LinedBrakeBandWeldment 997-D23-29 1

RigidSlingPins 1053-C-1C 2

UpperGuideRing(KT13625) 997-HT-23-TOP 1

LowerGuideRing(KT13625) 997-HT-23-BOT 1

SafetyDoorLatchClaw-RH AE13-302M 1

SafetyDoorLatchClaw-LH AE13-301S 1

SafetyDoorLoadPlunger AE12-306 1

DoorSpringStopCylinder 101-0069 1

DoorLatchSpring 997-16 2

DumbbellRollerCup 997-D21-135 4

DumbbellRollerSleeve 997-D21-134 2

BEARINGS & BUSHINGSDescription Part Number Qty. Required

DumbbellRollerBearing 02-0014 4

BottomClutchRollerBearing 02-0014 1

CamFollower(LW13625) 02-0016 5

PinionBearing 1234-08-01B 2

FASTENERS & FITTINGSDescription Part Number Qty. Required

ExternalSnapRingClutchDriveGearRetainer 1234-00-04 2

MotorGearSetScrew 09-0106 1

MotorGearKey 01-0317 1

HexBolt1/2"UNCX7"(CagePlateBolt) 09-1194 3

5/8"LockWasher(CamFollowerFastener-LW13625) 09-5114 5

5/8"UNFJamNut(CamFollowerFastener-LW13625) 09-5514 5

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

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

5/32”x2-15/16”HitchPin 02-0981 4

BEARINGS & BUSHINGSDescription Part Number Qty. Required

DumbbellRollerBearing 02-0014 4

BottomClutchRollerBearing 02-0014 1



ThefollowingtablelistspartsthatMcCoyDrilling&Completions|FARRhasidentifiedascriticalsparepartsforthismodeloftong.McCoyrec-ommendsthatthespecifiedquantityofeachpartbeonhandatalltimes.

SpARe pARTS LiSTS



Inadditiontothecriticalsparepartsidentifiedearlier,McCoysuggestsstockingthefollowingspareparts.Eventhoughthesearenotcriticalspares,stockingthesecomponentsmaysignificantlydecreaserepairtimeintheeventoflongleadtimesfromthefactory.

MISC TONG PARTS

Description Part Number Qty. RecommendedBackingPinSpacer 101-4096 1

BackingPinStud 101-4097 1

BackingPinKnob 02-0017 1

ShiftingYoke 997-HT-72 1

ShiftingShaft 997-B1-71 1

DoorSpringCylinder 101-0069 1

BrakeBandRetainer 101-0140 2


BEARINGS & BUSHINGS

Description Part Number Qty. RecommendedDoorBushing(Top) 101-5110 2

DoorBushing(Bottom) 101-5111 2

FASTENERS & FITTINGS

Description Part Number Qty. Recommended

ShifterDetentForceSpring 997-0-64 1

ShifterDetentForceBall 02-0018 1

1/8”NPTGreaseFitting 02-0005 2

1/8”NPT90oGreaseFitting 02-0093 2

1/8”NPT45oGreaseFittings 02-0006 2

1/4”StraightThreadGreaseFitting 02-0097 5

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

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

Critical Spare Parts ContinuedHYDRAULIC COMPONENTS

Description Part Number Qty. RequiredReliefCartridge(DVA35) 10-0010R 1

ReliefCartridge(SafetyDoor) 08-1625 1

SafetyDoorSwitch 08-0337M 1

HydraulicHose-LiftCylinderSupply(Ifliftcylinderisinstalled) 02-0934H 1

High-VisibilityProtectiveWrap,LiftCylinderHose(Ifliftcylinderisinstalled) 02-E0203 1

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

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

High-VisibilityProtectiveWrap,BackupHydraulicHose 02-E0204 1

JAW COMPONENTSDescription Part Number Qty. Required

JawRoller 997-JR-2125 2

JawPin 101-1581 2

JawRoller(Appliesonlytosizes12-3/4”to13-5/8”) 997-JR-1000 2

JawRollerKeeper(Appliesonlytosizes12-3/4”to13-5/8”) 101-0491 2

3.875"FlatDieInsert 13-0008-314-0 48

WraparoundInsert(3-1/2”jawdiekitsonly) 12-2006 4

WraparoundInsert(4”jawdiekitsonly) 12-2007 4

WraparoundInsert(4-1/2”wraparoundjawdiekitsonly) 12-2009 4

SpARe pARTS LiSTS



Thefollowingtables listpartsMcCoyDrilling&Completionsrecommendsreplacingwhenperformingacompleteoverhaulofyourtongandbackupassembly.

MISC TONG PARTS

Description Part Number Qty. RequiredJawPivotBolt 997-D3-28 2

BackingPin 101-4142 1

BackingPinShortSpacer 101-4096 1

BackingPinLongSpacer 101-4093 1

BackingPinStud 101-4097 1

BackingPinKnob 02-0017 1

BackingPinRetainer 101-4139 1

CagePlateSpacer 997-38B 3


BrakeBandRetainers 101-0140 2

DoorSpringStopCylinder 101-0069 2

DoorCylinderPost 1050-12-001 2

DoorLatchSprings 997-16 2

SafetyDoorLatchClaw(RH) AE13-302M 1

SafetyDoorLatchClaw(LH) AE13-301S 1

SafetyDoorLoadPlunger AE12-306 1

ShiftingShaft 997-B1-71 1

ShiftingYoke 997-HT-72 1

TopShifterBushing 101-0020 1

DumbbellRollerCup 997-D21-135 28

DumbbellRollerSleeve 997-D21-134 14

RollerSpacer 997-D21-140 28

RollerShaft 101-1266 10

RollerShaft(Long) 101-1268 2

DoorPivotRollerShaft 101-0046 2

DriveGear(Clutch) 997-HT-61 1

ShiftingCollar 997-HT-62 1

HighClutchGear 997-HT-51B 1

SplinedClutchShaft 997-HT-50 1

LowClutchGear 997-HT-52 1

MotorGear 997-A10-149 1

BEARINGS & BUSHINGS

Description Part Number Qty. RequiredDumbbellRollerBearings 02-0014 28

IdlerBearing 02-0075 4


BallBearing(BottomClutchBearing) 02-0014 1

NeedleBearing(ClutchShaft) 02-1404 4

BallBearing(TopClutchBearing) 02-1403 1


DoorBushing(Top) 101-5110 2

DoorBushing(Bottom) 101-5111 2

oVeRhAuL pARTS LiST



ITEMS ON THE CRITICAL SPARE PARTS LIST MARKED IN RED INDICATE ESSENTIAL HEALTH & SAFETY ITEMS. FAILURE TO REPLACE DAMAGED ESSENTIAL HEALTH & SAFETY ITEMS WILL PRESENT IMMEDIATE DANGER TO PERSONNEL OR EQUIPMENT. HAVE THESE ITEMS ON HAND AT ALL TIMES. STOP WORK AND QUARANTINE TONG UPON DISCOVERY OF DAMAGED OR DEFECTIVE HEALTH AND SAFETY COMPONENTS UNTIL PARTS CAN BE REPLACED.

FASTENERS & FITTINGS

Description Part Number Qty. Required

IdlerSeal 02-0010 6

IdlerRetainer 02-0009 8

1/4”StraightThreadGreaseFitting 02-0097 16

1/8”NPTGreaseFitting 02-0005 5

1/8”NPT90oGreaseFitting 02-0093 7

SnapRing(ClutchShaft) 1234-00-04 1

MotorGearSetScrew 09-0106 2

MotorKey 01-0317 1

7/8”NarrowFlatWasher(SupportRollerWasher) 09-5123 18

7/8"UNFThinNylockNut(SupportRollerFastener) 09-5722 12

3/4"UNFThinNylockNut(DoorPivotSupportRollerFastener) 09-5718 2

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

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

5/8"LockWasher(CamFollowerFastener,LW13625) 09-5114 26

5/8"UNFJamNut(CamFollowerFastener,LW13625) 09-5514 26

ShifterDetentForceSpring 997-0-64 1

ShifterDetentForceBall 02-0018 1

HYDRAULIC COMPONENTS

Description Part Number Qty. RequiredSafetyDoorSwitch 08-0337M 1

DVA35SealKit 07-0004 1

ReliefCartridge(DVA35) 10-0010R 1

ReliefCartridge(SafetyDoor) 08-1625 2

RineerGA15SealKit 87-7110 1

HydraulicHose-LiftCylinderSupply(Ifliftcylinderisinstalled) 02-0934H 1

High-VisibilityProtectiveWrap,LiftCylinderHose(Ifliftcylinderisinstalled) 02-E0203 1

oVeRhAuL pARTS LiST



geAR TRAin LAyouT

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geAR TRAin LAyouT

Item Type Description Qty Part NumberA Part HydraulicMotor 1 87-0112

B Assembly ShiftingAssembly(SeePp.5.16-5.17) 1

C Assembly ClutchAssembly(Pp5.14-5.15) 1

D Assembly PinionIdlerAssembly(Pp.5.10-5.11) 2

E Assembly PinionAssembly(Pp5.12-5.13) 1

F Assembly RotaryIdlerAssembly(Pp5.8-5.9) 2

G Assembly SupportRollerAssembly,FrontLegCoincidental(Pp.5.4-5.5) 4

H Assembly SupportRollerAssembly(Pp.5.4-5.5) 8

J Assembly DoorDoorPivotRollerAssembly(Pp.5.6-5.7) 2

K Part RotaryGear 1 997-D1-B



SuppoRT RoLLeR

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SuppoRT RoLLeR

Item Type Description Qty Part NumberA Part 1/4-24UNFGreaseFitting 1 02-0097

B Part SupportRollerShaft(SeeNoteA) 1 101-1266/101-1268

C Part 7/8”NarrowWasher(SeeNoteB) 2 09-5123

D Part RollerCapSpacer 2 997-D21-140

E Part BS3673MetricB062MRetainingRing 2 02-0013

F Part CylindricalRollerBearing(KT13625Tongs) 2 02-0014

Part BallBearingRollerBearing(LW13625Tongs) 2 02-0101

G Part RollerCup 2 997-D21-135

H Part SupportRollerSleeve 1 997-D21-134

J Part 7/8”UNFThinHexNylockNut 1 09-5722

NOTEA: Wherethesupportrolleriscoincidentalwiththefrontlegassembly,shaftnumber101-1268isused (4occurrences).

NOTEB: Upperwashersarenotusedwherethesupportrollerassemblyiscoincidentalwiththebrakebandretainer lugweldmentsandthehydraulicvalvemountpostweldments(6occurrences). Lowerwashersarenotusedwherethesupportrollerassemblyiscoincidentalwiththebrakebandretainer lugweldmentsandthefrontlegassemblies(8occurrences-backupready,or6occurrences-stand-alone tong).



SuppoRT RoLLeR - DooR piVoT

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SuppoRT RoLLeR - DooR piVoT

Item Type Description Qty Part NumberA Part 1/4-24NFGreaseFitting 1 02-0097

B Part SupportRollerShaft 1 101-0046

C Part 7/8”NarrowWasher 2 09-5123

D Part RollerCapSpacer 2 997-D21-140

E Part MetricB062MInsideSnapRing 2 02-0013

F Part CylindricalRollerBearing(KT13625Tongs) 2 02-0014

Part BallBearingRollerBearing(LW13625Tongs) 2 02-0101

G Part RollerCup 2 997-D21-135

H Part DoorRollerSleeve 1 997-D21-134

J Part 3/4”UNFThinHexNylockNut 1 09-5718



RoTARy iDLeR ASSeMBLy

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Item Type Description Qty Part NumberA Part GreaseFitting,1/8”NPT 1 02-0005

B Part 1-1/2”UNFNylockNut 2 02-5740

C Part RotaryIdlerPad 2 997-D20-125

D Part IdlerGearBearingSpacer 2 997-D20-121

E Part RetainerClip 2 02-0009

F Part BearingSeal 2 02-0010

G Part RotaryIdlerShaft 1 997-D19-117

H Part CylindricalRollerBearing 1 02-0075

J Part RotaryIdlerGear 1 997-A2-119C

RoTARy iDLeR ASSeMBLy



pinion iDLeR ASSeMBLy

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pinion iDLeR ASSeMBLy

Item Type Description Qty Part NumberA Part GreaseFitting 1 02-0005

B Part 1-1/2”UNFNylockNut 1 09-5740

C Part 5/8”NCx1-3/4”HexBolt 3 09-1232

D Part 5/8”LockWasher 3 09-5114

E Part PinionIdlerPad 1 997-D17-109

F Part PinionIdlerHalfShaft 1 997-D17-105B

G Part RetainerClip 2 02-0009

H Part CylindricalRollerBearing 1 02-0075

J Part PinionIdlerGear 1 997-A2-119B

K Part IdlerBearingRetainer 1 02-0008

L Part BearingSeal 1 02-0010



pinion ASSeMBLy

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pinion ASSeMBLy

Item Type Description Qty Part NumberA Part 1/8”NPTGreaseFitting 4 02-0005

B Part 1/2”NCx1-1/4”HexBolts 8 09-1168

C Part 1/2”LockWashers 8 09-5110

D Part PinionBearingCap 2 997-D15-89

E Part CylindricalRollerBearing 2 1234-08-01B

F Part HighPinionGear 1 997-A4-87B

G Part PinionGearShaft 1 997-A7-86B

H Part LowPinionGear 1 997-A5-88



cLuTch ASSeMBLy

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cLuTch ASSeMBLy

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

B Part DriveGear 1 997-HT-61

C Part ClutchBearingBushing 1 997-HT-60

D Part #10-24x3/4”HexSocketHeadCapScrew 2 09-0001

E Part CylindricalRollerBearing 1 02-1403

F Part BearingRetainer 1 997-HT-59

G Part NeedleRollerBearing 4 02-1404

H Part ShiftingCollar 1 997-HT-62

J Part SplinedClutchShaft 1 997-HT-50

K Part LowClutchGear 1 997-HT-52

L Part ClutchSpacer 1 997-99

M Part CylindricalRollerBearing 1 02-0014

N Part ClutchBearingCap 1 997-HT-54

P Part 3/8”LockWasher 4 09-5106

q Part 3/8”NCx1-1/4”HexBolt 4 09-1048

R Part 1/8”NPTGreaseFitting 1 02-0005

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

T Part ClutchSpacer 1 101-3599

U Part HighClutchGear 1 997-HT-51B



ShiFTeR ASSeMBLy

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ShiFTeR ASSeMBLy

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

B Part 5/16”x1”ClevisPin 1 02-0020

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

D Part 3/8”NCx1-1/2”HexBolt 4 09-1553

E Part 3/8”LockWasher 8 09-5106

F Part HITCHPIN.0930X1.125,SpaenaurCP-83H 2

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

H Part 7/16”UNFHexJamNut 1 09-5508

J Part DetentSpring 1 01-0040

K Part DetentBall 1 02-0018

L Part 5/8”NCx5/8”HexSocketSetScrew-CupPoint 3

M Part ThreadedShifterBushing 1 101-0020

N Part ShifterLugWeldment(Bolted) 1 101-0016

P Part KnobCollarPipe 1 101-0019

q Part ShiftingShaft 1 997-B1-71

R Part ShiftingFork 1 997-HT-72

S Part 5/8”UNFHexJamNut 1 09-5915

T Part 5/8”UNFHexNut 1 09-5914

U Part LowerShiftingShaftBushing 1 101-0003

V Part 3/8”NCx1”HexBolt 4 09-1046



hyDRAuLic VALVe SySTeM SuppoRTS

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hyDRAuLic VALVe SySTeM SuppoRTS

Item Type Description Qty Part NumberA Assembly DVAValveAssembly 1 SeePp.2.10-2.14

B Part 3/8”UNCx1-1/2”HexBolt 2 09-1553

C Part 3/8”NarrowFlatWasher 4 09-5124

D Part 3/8”ThinNylockNut 4

E Part HydraulicOutletSupportBase 1 101-0023

F Part HydraulicSupportMountBlock 1 101-0021

G Weldment HydraulicInletSupportBase 1 101-1138

H Part 1/2”UNCx5”HexBolt 2 09-1186

J Part 1/2”LockWasher 2 09-5110

K Part AdjustableSupportPlate 2 101-0022

L Part 3/8”UNCx1”HexBolt 6 09-1046

M Part 3/8”LockWasher 6 09-5106

N Weldment HydraulicValveMounts 2 101-0011

P Part 1/2”UNCx4-1/2”HexBolt 1 09-1184

q Weldment ValveHandleGuardWeldment 1 CE-HANDLE-3

R Part 1/2”NarrowFlatWasher 1 09-5010

S Part 1/2”ThinNylockNut 1 09-5610S

G

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



BRAKe BAnD ASSeMBLy

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Item Type Description Qty Part NumberA Part 3/8”NCx1”HexBolt 2 09-1046

B Part 3/8”LockWasher 2 09-5106

C Part 3/8”NarrowWasher 2 09-5124

D Part BrakeBandRetainer 1 101-0140

E Part BrakeBandWeldmentWithLining 1 997-D23-29

F Part 3/8”UNFx1-3/4”HexBolt 2 19-1552

G Part BrakeBandLugWeldment(Left) 2 101-0007

Part BrakeBandLugWeldment(Right) 2 101-0008

H Part 3/8”UNFHexNut 09-5906

BRAKe BAnD ASSeMBLy



MoToR MounT ASSeMBLy

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MoToR MounT ASSeMBLy

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

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

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

D Part 1/2”LockWasher 4 09-5110

E Part HydraulicMotor(KT13625Tong) 1 87-0112

Part HydraulicMotor(LW13625Tong) 1 87-0110

F Part MotorGear 1 997-A10-149

G Part 3/8”UNCx3/8”HexSocketSetScrew 2 09-2011

H Part 1/2”UNCx1-3/4”HexSocketHeadCapScrew(MotorMount) 4 09-2172

J Part 1/8”NPT90oGreaseFitting 1 02-0093

K Part MotorMount 1 997-150

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

M Part 0.148”x2.938”HitchPin 1

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

Part O-Ring 1

Part #20(1-1/4”)SplitFlange 2

Part 7/16”LockWasher 4

Part 7/16”UNCx1-1/2”HexBolt 4

P Weldment TorqueGaugeHolderWeldment 1 1500-09-04A

q Part 5/16”x5/16”x2”SquareGearKey 1

Kit Sealkitforhydraulicmotor 87-7110



hyDRAuLic ASSeMBLy

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hyDRAuLic ASSeMBLy

Item Type Description Qty Part NumberA Part M-NPT/F-NPT90d1”Fitting 1 02-9221

B Part 1”LongNipple 1 101-0079

C Assembly M-ORB/F-NPT90d1”Fitting(Includesseals) 1 02-9206

D Part HydraulicInlet,DVA35-A880 1 10-9016

E Part Male1”quickCouplerFitting 1 02-9214

F Part 1”DustCap 1 02-9213

G Assembly 1”HydraulicConnectionHoseAssembly 2 08-1724

H Assembly M-ORB/JICLONG90d1”(Includesseals) 1 02-9210

J Assembly MotorDrainHoseAssembly 1 101-0072

K Part ORBHEXBUSHING 1 10-9001

L Assembly M-ORB/JIC90DEG3/8”Fitting(Includesseals) 2 02-9200

M Part 1-1/4”DustCap 1 02-9212

N Part Male1-1/4”quickCouplerFitting 1 02-9215

P Part 1-1/4”LongNipple 1 101-0070

q Assembly M-ORB/F-NPT90d11/4”Fitting(Includesseals) 1 02-9202

R Part M-NPT/F-NPT90d11/4”Fitting 1 02-9220

S Part HydraulicOutlet,DVA35-TR99 1 10-0086

Part HydraulicOutlet,DVA35-PB55(ClosedCentreTongsOnly) 1 08-1825

T Part DVA35-DA84WAYSAEPorts 1 10-9019

U Assembly HandleAssembly 3 01-0409

Part HydraulicValveHandle 1 01-0409-HANDLE

Part ValveHandleLink 2 01-0409-LINK

Part HydraulicHandlePin 2 01-0409-PIN1

Part HydraulicHandleAuxiliaryPin 1 01-0409-PIN2

Part ValveHandleC-Clip 2 01-0409-CIRCLIP

Part CotterPin 2 01-0409-COTTER

V Part DVA35-SA8Valve(1”ORBPORT) 1 10-9015

W Part DVA35-MA84-WayDirectionalValve,SAEPort 1 10-9014

X Assembly HydraulicReliefValve(includesseals) 1 10-0010R

Y Part 1”OrbPlugFitting(includeso-ring) 1 02-9222

SEALKIT SealkitforDVA35Valve 02-9133



cAge pLATe ASSeMBLy - KT13625 Tong

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cAge pLATe ASSeMBLy - KT13625 Tong

Item Type Description Qty Part NumberA Part 1/2”UNCx8”HexBolt 1 09-1198

B Part 1/2”NarrowFlatWasher 1 09-5119

C Part JawPivotBolt 2 997-D3-28

D Part 1/2”UNCx6”HexBolt 2 09-1190

E Part BackingPinSpacer,Long 1 101-4093

F Part 1/2”LockWasher 2 09-5110

G Part TopCagePlate 1 997-HT-21

H Part SupportRing(Top) 1 997-HT-23-TOP

J Part JawAssembly(13-5/8”shown) 2 SeePp.2.17

K Part CagePlateSpacer 3 997-38B

L Part RotaryGear 1 997-D1-B

M Part SupportRIng(Bottom) 1 997-HT-23-BOT

N Part BottomCagePlate 1 997-HT-22

P Part BackingPinKnob 1 02-0017

q Part 3/8”UNFx2”ThreadedStud 1 101-4097

R Part BackingPinSpacer,Short 1 101-4096

S Part BackingPinRetainer 1 101-4139

T Part BackingPin 1 101-4142

U Part 3/8”UNCx1-3/4”HexSocketHeadCapScrew 22 09-2052



cAge pLATe ASSeMBLy - LW13625 Tong

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cAge pLATe ASSeMBLy - LW13625 Tong


B Part JawPivotBolt 2 997-D3-28

C Part 1/2”UNCx6”HexBolt 2 09-1190

D Part 1/2”NarrowWasher 1 09-5119

E Part BackingPinSpacer,Long 1 101-4093

F Part 1/2”LockWasher 2 09-5110

G Part TopCagePlate 1 997-D2-21

H Part CagePlateSpacer 3 997-D3-38

J Part RotaryGear 1 997-D1-B

K Part 5/8”LockWasher 22 09-5114

L Part 5/8”UNFHexJamNut 22 09-5514

M Part 1/8”NPTGreaseFitting 22 02-0005

N Part BackingPinKnob 1 02-0017

P Part BackingPinSpacer,Short 1 101-4096

q Part BackingPinRetainer 1 101-4139

R Part 3/8”UNFx2”ThreadedStud 1 101-4097

S Part BackingPin 1 101-4142

T Part CagePlateCamFollower 22 02-0016

U Part BottomCagePlate 1 997-D2-22



Tong DooR ASSeMBLy

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BAV



Item Type Description Qty Part NumberA Part 1/2”NCx2”HexBolt 4 09-1174

B Part 1/2”NCHexJamNut 4 09-5810

C Weldment RHDoorWeldment 1 101-0034

D Part 3/8”NCx3/4”HexBolt 1 09-1044

E Part 3/8”CarbonSteelLockWasher 9 09-5106

F Part DoorLatchCam 1 997-A11-14

G Part GreaseFitting 1 02-0097

H Part 3/8”NCx1-1/4”HexBolt 2 09-1048

J Part 3/8”NarrowWasher 4 09-5124

K Part DoorStopSpacer 4 997-13B

L Assembly DoorCylinderAssembly 2 101-0069

M Weldment LeftHandDoorWeldment 1 101-0032

N Part 3/8”NCx1-1/2”HexBolt 2 09-1553

P Part DoorCylinderMountingLug 2 1050-12-001

q Part ShoulderBushing 4 101-0045

R Weldment DoorLatchWeldment 1 101-0038

S Part DoorLatchSpring 2 997-16

T Part 3/8”NCx1-3/4”HexBolt 1 09-1557

U Part 3/8”NCHexNut 1 09-5806

V Part 5/8”NCHexJamNut 1 09-9141

Tong DooR ASSeMBLy



SAFeTy DooR coMponenTS

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QR

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UB

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AB

rear swItch guard wall Is secured at the BottoM By one 3/8” unc x 1” hex Bolt, whIch threads Into part# 101-0320



SAFeTy DooR coMponenTS


B Part 3/8”CarbonSteelLockWasher 11 09-5106

C Part SwitchGuardPlate 1 101-0384

D Weldment RearSwitchGuardWallWeldment 1 101-0386

E Weldment FrontSwitchGuardWallWeldment 1 101-0387

F Part LoadPlunger 1 AE12-306

G Part 15/16”ValveLockNut 1 09-0278

H Part SafetyDoorLatchBlock 1 AE13-301S

J Part 1/4inchNPT-JIC90degreeElbow 3 08-0284

K Part DeltrolGaugeIsolatorValveGI21S 1 08-0337M

L Part 5/16’X3/4”UNCShoulderBolt 4 09-0227

M Part DoorLatchPlate 1 AE13-311

N Part 3/8”UNCx1”HexSHCS 3 09-1738

P Part SafetyDoorLatchPlate 1 101-0320

q Part 3/8”UNCx3/4”HexFHCS 3 09-4044

R Part 3/8”UNCx1-1/2”HexFHCS 2 09-4050

S Part 3/8”UNCx3/4”HexBolt 4 09-1044

T Part SafetyDoorLatchBlock 1 AE13-302M

U Part 3/8”UNCx1-1/2”HexBolt 1 09-1553

V Part SafetyDoorLatchBlock 1 101-0319

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

A Part 3/8”UNCx1”HexBolt,SSDrilled 5 09-1046SSD

L Part 5/16”x3/4”HexSocketShoulderBolt,UNC,Drilled 4 09-0227SSD

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

U Part 3/8”UNCx1-1/2”HexBolt,SSDrilled 1 09-1553SSD



RigiD SLing

Item Type Description Qty Part NumberA Part MasterLiftingLink 1 02-0516

B Part 3/4”UNCx9-1/2”HexBolt 1 09-1324

C Part 3/4”FlatWasher 1 09-5018

D Weldment RigidSlingWeldment 1 101-1360

E Part LevelingBolt 4 1053-C-1L

F Part 3/4”HexNut 4 09-5818

G Part 1/2”UNCx1-1/4”HexBolt 4 09-1168

H Part 1/2”LockWasher 4 09-5110

J Part AdjustingHelix 1 1095-220


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RigiD SLing

Item Type Description Qty Part NumberK Part 3/4”UNCHexNylockNut 1 1429-39-02

L Part HangerPin 1 1095-218

M Part R-ClipPin 4 02-0981

N Part 3/8”UNCx1-3/4”HexBolt 4 09-1557

P Part 3/8”LockWasher 4 09-5124

q Part RHBoltedHangerWeldment 1 101-1364

Part LHBoltedHangerWeldment 1 101-1361

The following parts apply to rigid slings on CE-Marked assemblies onlyR Weldment RigidSlingWeldment 1 101-1360

S Part 1/2”UNCx1-1/4”Wire-DrilledHexBolt 4 09-1168SSD

T Part Rivet 4 02-0557

U Part MassPlacard,KT13625+FBU 1 CE-MASS-KT13625FBU

V Part 3/8”UNCx1-3/4”Wire-DrilledHexBolt 4 09-1557SSD

R

V

U

T

S

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



Leg ASSeMBLieS

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Item Type Description Qty Part NumberA Part 1-1/4”UNCx8”HeavyHexBolt 4 09-0222

B Part RearLugSpacer 2 101-1546

C Part EyeBolt 2 101-2055

D Weldment RearLegWeldment 1 997-915-00

E Part 1-1/4”UNCNylockNut 4 09-1484

F Part RearLevelingSpring 2 1302-905-06

G Part 1/2”UNCx4-1/2”HexBolt 4 09-1184

H Part 1/2”FlatWasher 8 09-5010

J Part SupportRollerShaft(FrontLegMounts) 4 101-1268

K Weldment FrontLegMount 2 997-917-00A

L Part RubberGuard(CE-MarkedTongsOnly) 2 101-5733

M Part TopLegSpringCap 2 1302-905-03B

N Part FrontLegSpring 2 997-906-02

P Part BottomLegSpringCap 2 1302-905-03A

q Weldment FrontLegWeldment 2 997-917-00B

Weldment FrontLegWeldment(CE-MarkedTongsOnly) 2 101-5784

R Part 1/2”UNCNylockNut 4 09-5610

Leg ASSeMBLieS




FARR® BAcKup

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H

KJ

ELMN



Item Type Description Qty Part NumberA Part 3/4”UNCHexNylockNut 2 1429-39-02

B Part CamCylinder 1 1364-902

C Weldment BackupDoorWeldment 1 997-05-00

D Part 1”UNCNylockNut 1 09-5725

E Part 1”PlainNarrowWasher 2 09-5120

F Part 1”UNCx4”HeavyHexBolt 1 09-1422

G Part 1-1/4”UNCHeavyHexNut 2 09-5832

H Part RearLegSpringV-Bracket 1 1483-500-00-04

J Part 3/16”x1-1/4”ExtendedProngSquareCutCotterPin 2

K Part RearLegSpringRetainer 2 1483-500-00-04B

L Weldment BackupBodyWeldment 1 997-521B-00

M Part DoorCylinder 1 101-0069

N Part 3/8”UNCx1-1/2”HexBolt 2 09-1553

FARR® BAcKup



BAcKup RoTARy ASSeMBLy

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B Part 1/2”NarrowFlatWasher 1 09-5119

C Part BackingPinSpacer,Long 1 101-4093

D Part JawPivotBolt 2 997-D3-28

E Part 1/2”UNCx6”HexBolt 2 09-1190

F Weldment TopCagePlateWeldment 1 101-1241

G Part JawAssembly(13-5/8”shown) 2 SeePp.2.17

H Part 5/8”x1-1/2”HexSocketUNCShoulderScrew 9 09-0116

J Part BackupCamGear 1 997-500-01

K Part BottomCagePlate 1 997-D2-22

L Weldment BackupBodyPlateWeldment(shownforillustrationpurposesonly) 1

M Part 1/2”UNCThinNylockNut 9 09-5610S

N Part BackingPinKnob 1 02-0017

P Part 3/8”UNFx2”ThreadedStud 1 101-4097

q Part BackingPinSpacer,Short 1 101-4096

R Part BackingPinRetainer 1 101-4139

S Part BackingPin 1 101-4142

T Part 1/8”NPTGreaseFitting 22 02-0005

U Part 5/8”UNFHexJamNut 22 09-5514

V Part 5/8”CarbonSteelLockWasher 22 09-5114

W Part CamFollower 22 02-0016

X Part CagePlateSpacer 3 997-D3-38

BAcKup RoTARy ASSeMBLy




ToRque MeASuReMenT

A. BASIC TORQUE MEASUREMENT Basictorquemeasurementsareperformedusingasimplehydraulicmeasurementsystem.Ahydraulicloadcellconnectstoacalibratedtorquegaugethroughareinforcedflexiblehydraulichose.Thetorquegaugeisfactory-calibratedtodisplayaccuratetorquemeasurementsforatongortongandbackupassemblywithaparticulararmlength.Thearmlengthisameasurementfromthecentreofthepipeorcas-ingtothecentreoftheforcebeingappliedtotheloadcell.

Twoloadcelloptionsareavailable.Atensionloadcellistypicallyusedwithasuspendedstand-alonetong.Thisapplicationrequiresthattheloadcellbeattachedtotherearofthetongaspartoftherestraintlinethatopposestheforcegeneratedwhenthetongmakesuporbreaksoutajoint.Acompressionloadcellisusedinatongandbackupassembly,andistypicallylocatedontherearofthebackupbetweenthebackupandastationaryframe.Theloadcellmustbelocatedinthecentreofthecompressionforcevectorgeneratedbetweenthebackupandtheframe.

Hydraulicforcegeneratedbyaloadcellistransmittedtothetorquegaugeviaareinforcedflexiblehydraulicline.ThehydraulicforceisdisplayedastorqueinunitsofFt.-Lbs(or,optionally,newton-meters).Thetorquegaugehasared“peaktorque”indicatorthattrackswiththetorquegaugeneedletothepointofhighesttorque,andremainsatthepointofhighesttorqueuntilmanuallyreset.Notethateverymodeloftongandtongandbackupassemblyhasauniquearmlength,andthetorquegaugemustbecalibratedforthatarmlength.Torquegaugesthatarenotcalibratedforthearmlengthofthetoolinservicewillnotdisplaycorrecttorque.Toensurecorrecttorquemeasure-ment,ensurethearmlengthor“handle”asdisplayedonyourtorquegaugematchesthearmlengthofthetoolinserviceaslistedonthespecificationspageofthetechnicalmanual.

Theimagesonthispageareforillustrationpurposesonlyandmaynotaccuratelyrepresentthetorquegaugeandloadcellthathavebeensuppliedwithyourequipment.

THE IMAGES DISPLAYED ARE SUPPLIED FOR ILLUSTRATION PURPOSES ONLY

TORQUE GAUGES AND LOAD CELLS ARE FACTORY-SUPPLIED SUPPLIED AS MATCHED CALI-BRATED PAIRS. IF REPLACING EITHER COMPONENT THE LOAD CELL AND TORQUE GAUGE MUST BE RETURNED TO THE FACTORY FOR RE-CALIBRATION BEFORE PLACED INTO SERVICE.

Torquegaugesandloadcellsaresuppliedasamatchedcalibratedpair.Substitutingoneortheotherwillrenderthecalibrationinaccurateeveniftheactualmodelnumbersappeartobeidentical.Theserialnumbersofmatchingloadcellandtorquegaugesareclearlyidentifiedonthecalibrationcertificate.Shouldyoususpecttheaccuracyofyourtorquemeasurements,orwishtoreplaceeithercomponentthepairshouldbereturnedtothefactoryforre-calibrationbeforeplacingintoservice.

IllustratIon 6.a.1: torque gauge (For IllustratIon purposes only)

IllustratIon 6.a.3: coMpressIon load cell

IllustratIon 6.a.2: tensIon load cell



ToRque MeASuReMenT

THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE. THE PART NUMBERS LISTED IN THE FOLLOWING TABLE ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED.

BASIC TORQUE MEASUREMENT (Continued:)Theimagesontheprecedingpageareforillustrationpurposesonlyandmaynotaccuratelyrepresentthetorquegaugeandloadcellthathavebeensuppliedwithyourequipment.Pleasenotethatthepartslistedinthefollowingtablearecorrectforaccuratetorquemeasure-mentwhileusingtheequipmentforwhichthismanualissupplied.

Applies to KT13625 Tong & FARR® Backup Assemblies (Imperial)Item Type Description Qty Part Number

Assembly 32”-40,000Lbs-FtTorqueMeasurementAssembly 1 10-0071CA Part CompressionLoadCell 1 10-0008CB Part 40,000Lbs-Ft.Gauge,32”ArmLength(includesfollowing) 1 10-0071G

Part 1/4”FNPTTEE 1 60-0364Part 1/4”NPTStreetElbow 1 08-0023Part 1/4”NPTCap 1 08-0424

C Part 5Ft.HoseAssembly 1 02-0069

Applies to LW13625 Tong & FARR® Backup AssembliesItem Type Description Qty Part Number

Assembly 32”-30KTorqueMeasurementAssembly 1 10-0022CA Part CompressionLoadCell 1 10-0008CB Part 30,000Lbs.-Ft.Gauge,32”ArmLength(includesfollowing) 1 10-0022G


C Part 5Ft.HoseAssembly 1 02-0069

Applies to KT13625 Tong & FARR® Backup Assemblies (Metric)Item Type Description Qty Part Number

Assembly 32”-55000NmTorqueMeasurementAssembly 1 10-0071C-MA Part CompressionLoadCell 1 10-0008CB Part 55000NmGauge,32”ArmLength(includesfollowing) 1 10-0071G-M


C Part 1.5mHoseAssembly 1 02-0069



ToRque MeASuReMenT

IllustratIon 6.a.4: coMpressIon load cell exploded

This is the standard hydraulic compression load cell supplied by McCoy Drilling & Completions | Farr. Contact our sales department for information about optional application-specific compression load cells.

A

B

C

D

E

F

G

H

Compression Load Cell, 8 in2

Item Type Description Item Type Description

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

B Part Load Plate F Part Diaphragm Casing

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

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



ToRque MeASuReMenT

IllustratIon 6.a.5: turn counter encoder Mount exploded

2.74”2.75”

J

A

B

C

D

E

D

C

F

G

H

Item Type Description Qty Part Number

Assembly Standard Turn Counter Encoder Mount 1 60-0001

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

B Part Helical Flexible Encoder Shaft Coupling 1 60-0130N

C Part Internal Retainer Ring 2 1376-13

D Part Bearing 2 1376-05

E Part Encoder Housing 1 1392-104A

F Part Internal Retainer Ring 1 02-0436

G Part Encoder Shaft 1 1392-103A-01

H Part Encoder Gear 1 01-0320A-M

J Part 10-24 x 1-1/4” Hex Socket Head Set Screw 1



ToRque MeASuReMenT

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

1. Symptom: No indication on gauge.

PossibleProblem: Obstructioninhydraulichose. Solutions: Checkhydraulichoseforkinks. Replacehydraulichose.

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

PossibleProblem: Internalmechanismoftorquegaugeisdamaged. Solution: Replacegauge.

2. Symptom: Gauge indication unexpectedly high.

PossibleProblem: Excessivehydraulicfluid. Solutions: Completelydrainhydraulicfluidfromtorquegauge/loadcellsystem.Rechargefollowingthe procedureinSection6.C.

PossibleProblem: Internalmechanismofgaugeisdamaged. Solution: Replacegauge.

PossibleProblem: Incorrecttorquegaugeinuse(notpartoftheoriginaltorquegauge/loadcellpair). Solution: Replacegaugewithgaugeproperlycalibratedfortheloadcellinservice.

3. Symptom: Gauge indication unexpectedly low

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

PossibleProblem: Obstructioninhydraulichose. Solutions: Checkhydraulichoseforkinks. Replacehydraulichose.

PossibleProblem: Snublinenotatright-angletotonghandle. Solution: Checkangleofsnublineandcorrectifnecessary.


PossibleProblem: Incorrecttorquegaugeinuse(notpartoftheoriginaltorquegauge/loadcellpair). Solution: Replacegaugewithgaugeproperlycalibratedfortheloadcellinservice.

4. Symptom: Gauge indication is erratic or sluggish

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

PossibleProblem: Lossofdampingfluidintorquegauge. Solution: Topuporrefilldampingfluid(NOTE:Ensureleakagepointsingaugeareidentifiedandrepaired topreventfurtherlossofdampingfluid).

PossibleProblem: Airbubblesinhydraulicfluidinthetorquemeasurementsystem. Solution: Bleedairfromloadcellandtorquegaugeandtopupfluid(ifnecessary)asperSection6.C.


IFTROUBLESHOOTINGREVEALSTHATTHEREISINSUFFICIENTFLUIDINTHESYSTEM,BEFORERECHARGING,CHECKTHATALLSYSTEMCOMPONENTSAREFREEFROMDAMAGE.THISWILLENSURETHATFLUIDLOSSWILLNOTCONTINUEAFTERRELOADING



ToRque MeASuReMenT

C. PERIODIC INSPECTION AND MAINTENANCE

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

UN-CONTAINED SPILLAGE OF THE HYDRAULIC FLUID IN THIS SYSTEM MAY CONTRAVENE GOVERNMENTAL ENVIRONMENTAL REGULATIONS, OR THE ENVIRONMENTAL REGULA-TIONS AND POLICIES OF YOUR COMPANY. FARR CANADA CORP. HIGHLY RECOMMENDS PLACING YOUR LOAD CELL IN A CONTAINMENT BASIN BEFORE PROCEEDING WITH THE BLEEDING & REFILLING PROCESS.

d. FillhandpumpbowlwithW15/16hydraulicfluid.

e. Remove theventplugscrewandStat-O-Seal (ItemsCandDon Illustration6.A.4,or itemHon Illustration6.A.5) toallowtrappedairtoescape.

f. Pumpfluidintothesystemuntilnomoreairisseenescapingfromtheventport.

g. ReplacetheventplugscrewandStat-O-Sealandtightensecurely.

h. Removeloadcell fromcontainmentvesselandwipeclean.Reclaimthehydraulic fluid(if it isclean)ordisposeofallwastematerialsaccordingtogovernmentaloryourcompany’sproscribedenvironmentalprotectionregulations.

i. Disconnectthehandpumpfromthetorquegauge.

j. Replacethebrasscaponthetorquegaugecheckvalvefitting.

3. Reference Checking Your Torque Measurement SystemThefollowingstepsdefineaprocessfordeterminingifyourtorquemeasurementsystemiscorrectlymeasuringandindicatingwithinanexpectedrange.Thisprocedureisbestsuitedforperforminginashoporlocationremovedfromthedrillfloor,withinrangeofacrane.Thisisareferencecheckandnotacalibration.Calibrationsmustbeperformedatanauthorizedcalibrationfacility.

TensionLoadCell

a. Locateaknownweightintherangeofapproximately500to1000lbs(227to455kg),andmovetheweightnexttothetongandbackupassembly.

b. Removethetensionloadcellfromthetong,butdonotdisconnectfromthetorquegauge.

c. Suspendtheloadcell,pistonsideup,fromacranecapableofsupportingtheknownweightinStep3a.

d. Connecttherodsideoftheloadcelltotheknownweight,andusethecranetohoisttheweightfromthesurfacetobesus-pendedfreely.

e. Performasimplecalculationtodeterminetheexpected indicationonthetorquegaugebasedontheknownhoistedweight.Thisisacalculationthatmustbeperformedusingthearmlengthexpressedinimperialunits(feet).Thecalculationis:[KNOWNWEIGHT]x[ARMLENGTHASDISPLAYEDONTHETONGPLACARD(infeet)].Forexample,ifthearmlengthis32inchesandthehoistedweightis1000lbsthecalculationis:

1000x(32/12)=2667

Therefore,theexpectedindicationonthetorquegaugeshouldbe2667lbs-ft.

1. InspectionThetorquemeasurementsystemsuppliedwithyourequipment isdesignedandbuilt toprovideyearsoftrouble-freeservicewithminimummaintenance.Periodicinspectionsoftheloadcell,hydrauliclinesandfittingsarerecommendedinordertokeepthesystemintopoperatingcondition.Athoroughinspectionshouldbemadeateachrig-up.

2. Fluid RechargeRechargehydraulicsystemwithW15/16 fluid through thecheckvalveon the torque indicatinggauge.Rechargingmustonlybeperformedwhenthereisnoloadontheloadcell.Refertotheillustrationsonpages6.3&6.4forguidanceifrequired.

a. Placethetorqueindicatinggaugehigherthantheloadcell.Removethebrass1/4”capfromthefittingonthecheckvalveonthetopofthegauge.

b. Connectthehandpumptothecheckvalvefitting.

c. Elevatetheloadcellsoitishigherthanthetorquegaugeandhandpump.

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



Reference Checking Your Torque Measurement System (continued):TensionLoadCell(continued):

e. Performasimplecalculation(continued):

Calculationsforametrictorquemeasurementsystemusingtensionloadcellareasfollows:

[KNOWNWEIGHT(inkg)]x[2.2]x[ARMLENGTHINDICATEDONTONGPLACARD](infeet)]x[1.356].Forexample,ifthearmlengthis32inchesandthehoistedweightis500kgthecalculationis:

[500]x[2.2]x[(32/12)]x[1.356]=3977.6

Therefore,theexpectedindicationonthetorquegaugeshouldbeapproximately3980lbs-ft.

CompressionLoadCell

a. Locateaknownweight,andmovetheweightnexttothetongandbackupassembly.

b. Removethecompressionloadcellfromthetong,butdonotdisconnectfromthetorquegauge.

c. Placethecompressionloadcell,pistonsidedown,onasturdysurfacesuchasaconcreteshopfloor.

d. Useacranetohoisttheknownweightontotherodendofthecompressionloadcell.Thisisasmallarea,soanidealknownweightshouldberelativelysmallanddense.Ablockofsolidmetalorconcreteispreferred.Theweightmustbecenteredexactlyontherodendof the loadcell toensureevenandaccuratecompression.Donotuseatallunrestrainedknownweightthatcouldtopple.Donotdisconnecttheknownweightfromthecrane,butensurethecraneexertsnoupwardforceontheweight.Theattachedcranepreventsanun-centeredweightfromtoppling.

e. Performasimplecalculationtodeterminetheexpectedindicationonthetorquegaugebasedontheknownweightontheloadcell.This isacalculation thatmustbeperformedusingthearmlengthexpressed in imperialunits(feet).Thecalculation is:[KNOWNWEIGHT]x[ARMLENGTH(infeet)].Forexample,ifthearmlengthis32inchesandtheknownweightis500lbsthecalculationis:

[500]x[(32/12)]=1333.3

Therefore,theexpectedindicationonthetorquegaugeshouldbeapproximately1333lbs-ft.

Ifyouareusingametrictorquemeasuresystemcalculationsareasfollows:

[KNOWNWEIGHT(inkg)]x[2.2]x[ARMLENGTH(infeet)]x[1.356].Forexample,ifthearmlengthis32inchesandtheknownweightis250kgthecalculationis:

[250]x[2.2]x[(32/12)]x[1.356]=1988.8

Therefore,theexpectedindicationonthetorquegaugeshouldbeapproximately1990Nm.

4. Repair And CalibrationReturntheloadcellandindicatorgaugetotheauthorizedrepairfacilityforrepairsandcalibration.




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



Eight fixed displacement motorsranging from 6 in3 to 15 in3.Starting and stall torques equalto 90-94% of theoretical torque.Speed to 2,000 RPM continuous.Up to 75 HP continuous.Conforms to SAE 'C' mountingspecification.Weighs 43 lbs.

Features of the 15 Series Standard Motor:Standard Motor - 3000 PSI (Code 61)

MOTOR SELECTION GUIDE

POWER to be the Best!

CROSS SECTION

Made in USA PUBLICATION DS151005 8/03

HYDRAULICS, INC.HYDRAULICS, INC.

R

MA

NU

FA

CT

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OR

S



1.38

SAE 14T 12/24 PITCHFLAT ROOT SIDE FITINVOLUTE SPLINE

OPTIONAL SHAFT

6.81

3.41

4.51

5.70

9/16" DIA., 4 HOLES

17°

17°

CENTERLINECASEDRAIN

CENTERLINE

CASEDRAIN

5.91

5.69

7.17 2.18

5.87.24

.51 1.62EFF.KEY

1.0

5.0004.998

1.2501.248

.314

.3161/2-

13UNC

3/8" O-RING BOSSCASE DRAIN(2) PLACESSAE STD. 1.25

4-BOLT FLANGENEAR AND FAR

15 Series Standard Motor Envelope

A

B

6.82

3.41

4.50SQR.

5.70

17°

CENTERLINECASEDRAIN

17°

CENTER LINECASE DRAIN

PORT"B"

PORT"A"

5.91

9.0 2.18

5.80.24

.50 1.62EFF.KEY

1.0

5.0004.998

1.2501.248

.313

.315

7.80

PORT 'A'

5.40

1.3

OPTIONAL SHAFT

1.8 2.2

REAR VIEW

SAE 14T 12/24 PITCHFLAT ROOT SIDE FITINVOLUTE SPLINE

ALTERNATEPORT "A"1-1/4 O-RING BOSS

ALTERNATEPORT "B"

1-1/4 O-RING BOSS

1/2-13UNCx 1/2 DP.

3/8" O-RING BOSSCASE DRAIN(2) PLACES

SAE STD. 1.254-BOLT FLANGENEAR AND FAR

SAE 1/4 O-RING BOSS

1/4 O-RING BOSS

9/16" DIA., 4 HOLES

15 Series Two Speed EnvelopeTechnical Information - All Styles

VANE CROSSING VANEThe Rineer patented vane crossing vane design producesmuch higher volumetric and mechanical efficiencies than ispossible with a standard vane type design. This designprovides a sealing vane between cavities to improvemechanical and volumetric efficiencies.

STARTING AND STALL TORQUEThe Rineer motor produces torque curves which are virtuallyflat, with starting and stall torque equal to approximately 90-94% of theoretical torque.

MORE POWER STROKES PER REVOLUTIONThe 15 Series has four stator cavities and 10 rotor vanes.Each rotor vane works in each stator cavity once perrevolution, which results in 40 power strokes per revolution.This helps produce higher mechanical efficiency and flattertorque curves.

BEARING LOADINGThe bearings in the 15 Series can accept radial load per theradial capacity chart. Thrust load is not recommended undermost conditions. Consult with a Rineer Application Engineerfor optional bearing configurations to match your application.

SEALSBuna N seals are supplied as standard on the Rineer 15series motors. Viton seals may be ordered as an option.

ROTATING GROUP - 1S or 1HUnder most operating conditions, 1S (standard rotatinggroup parts) should be used. Under some high speedconditons 1H can be specified.

ROTATIONThe 15 Series Motor rotates equally well in either directionand smoothly throughout its entire pressure and speedrange. Looking into the end of the shaft, rotation is clockwisewhen oil is supplied to port "A".

HORSEPOWER LIMITATIONMaximum horsepower limitations may vary with differentapplications. When using the 15 Series Motor above 75HP, consult a Rineer Application Engineer.

FILTRATION25 micron minimum.

FLUIDWe suggest premium grade fluids containing high quality rust,oxidation and foam inhibitors, along with anti-wear additives.For best performance, minimum viscosity should bemaintained at 100 SSU or higher. Fluid temperature should notexceed 180O F. Elevated fluid temperature will adversely affectseal life while accelerating oxidation and fluid breakdown. Fireresistant fluids may be used with certain limitations. ContactRineer for additional information.

CASE DRAINThe 15 Series Motor is designed for either internal or externalcase drain. Two case drain ports are supplied. When usinginternal case drain, simply plug the two ports. When usingexternal case drain, use the port at the highest elevation. Werecommend case drain pressure of 35 PSI or less when usingthe standard seals.

CASE DRAIN CIRCULATIONFluid should be circulated through the case when atemperature differential exists between the motor and thesystem in excess of 50O F. Should this occur, contact aRineer Application Engineer.

MOUNTINGThe mounting position is unrestricted. The shafts, pilots, andmounting faces should be within .002 TIR.

INTERMITTENT CONDITIONSIntermittent conditions are to be less than 10% of every minute.

OTHER AVAILABLE MOTORSFor information on additional Rineer Motors, request one of thefollowing publications:

37 Series ..............................................Publication DS37100357 Series ..............................................Publication DS571003125 Series ............................................Publication DS1251003

Technical Information - Retractable Shaft Motor

RETRACTING THE SHAFTThe shaft is spring loaded into the engaged position. Pullingon the knob attached to the shaft at the rear of the motor willmove the shaft 1.25 inches into the motor.CAUTION: Retracting the shaft must be done when themotor and driven mechanism are not in operation andare unloaded.

RETAINING SHAFT IN RETRACTED POSITIONThe shaft is retained in the retracted position by inserting a2.0 inch wide spacer between the rear housing and the knobattached to the shaft. Depending on the application andmounting position of the motor, the spacer design may vary.Spacers are not supplied with the motor.

RE-ENGAGING THE SHAFTThis is accomplished by releasing the shaft, then rotating itclockwise until the splines of the shaft line up and engage thesplines of the driven mechanism.CAUTION: Re-engaging the shaft must be done when themotor and driven mechanism are not in operation and areunloaded.

BEARING LOADINGThe 15 series Retractable is not suitable for applications whichrequire radial or axial loading of the shaft.

MOUNTINGThe mounting position is unrestricted. CAUTION: The shaftextension and knob at the rear of the motor rotates whenthe motor is in operation.



hyDRAuLic coMponenT inFoRMATion

Performance Data - Selected Displacements

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

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

0102030405060708090

100110120130140150160170180190200

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0

10

20

30

40

50

60

70

POW

ER(H

P)

2000 RPM

100 RPM

2000 RPM

1200 RPM

400 RPM

100 RPM

800 RPM

1600 RPM

ACTUAL FLOW - 6 CID

0

5

10

15

20

25

30

35

40

45

50

55

60

65

0 500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

RPM800

1000

1200

1400

1600

1800

2000

200

400

600

100

9.5 C.I.D.

ACTUAL FLOW - 9.5 CID

0

5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

15001400

1200

1000

800

600

400

200100

1700

ACTUAL TORQUE AND POWER 9.5-CID

020406080

100120140160180200220240260280300320340360

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0102030405060708090100

POW

ER(H

P)

1700 RPM100 RPM

1700 RPM

900 RPM

300 RPM100 RPM

500 RPM

1300 RPM

RPM

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

0255075

100125150175200225250275300325350375400425450

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0102030405060708090100110120130

POW

ER(H

P)

1600 RPM

800 RPM

200 RPM100 RPM

400 RPM

1200 RPM

1600 RPM100 RPM

ACTUAL FLOW - 11.5 CID

0

10

20

30

40

50

60

70

80

90

100

0 500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

1600

400

600

800

1000

1200

1400

100

200

RPM

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

0255075

100125150175200225250275300325350375400425450475500525550575600

500 1000 1500 2000 2500 3000PRESSURE (psid)

TOR

QU

E(ft

-lbf)

0

25

50

75

100

125

150

POW

ER(H

P)

1500 RPM

100 RPM

1500 RPM

700 RPM

300 RPM100 RPM

500 RPM

1100 RPM

ACTUAL FLOW - 15 CID

0

10

20

30

40

50

60

70

80

90

100

110

500 1000 1500 2000 2500 3000PRESSURE (psid)

FLO

W(g

pm)

1500

1100

1300

500

700

900

100

300

RPM




For durable hydraulic motors that meet your demands, specify Rineer.For over 35 years, we have specialized in only one thing - engineering the right motor for your needs.Rineer delivers the performance you can count on.

Model CodeM015 - 61/62 -1S -015 -31 -B1 -TV -000

M015 - 61 = 015 Single SpeedM015 - 62 = 015 Two Speed

Options:62 = Two Speed Single Pilot

Open During Crossover63 = Two Speed Single Pilot

Closed During Crossover65 = Two Speed Double Pilot

Open During Crossover67 = Two Speed Double Pilot

Closed During Crossover1S = Std.1H = High Speed

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

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

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

Bearing Package Selection

Seal - Package Selection

Special Code Designator

331 Breesport San Antonio, Texas 78216

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

Applications

Rineer Hydraulics, Inc. warrants that, at the time of shipment toPurchaser, our product will be free of defects in the material andworkmanship. The above warranty is LIMITED to defectiveproducts returned by Purchaser to Rineer Hydraulics, Inc., freightprepaid within four hundred and fifty-five (455) days from date ofshipment, or one (1) year from date of first use, whichever expiresfirst. We will repair or replace any product or part thereof which isproved to be defective in workmanship or material. There is noother warranty, expressed or implied, and in no event shall RineerHydraulics, Inc. be liable for consequential or special damages.Dismantling the product, operation of the product beyond thepublished capabilities or for purposes other than that for which theproduct was designed, shall void this warranty.

Limited Warranty Policy




Standard Motor

Two Speed Motor

HYDRAULICS, INC.HYDRAULICS, INC.

R

MA

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RER OF HYDRAU

LIC

MO

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RS

15 Series

Repair Manual

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







WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.

1

2

3

4

5

6

7

8

5

1) Remove snap ring

WARNING: Use caution when removing snap ring. If released accidentally it can become an airborne hazard.

1) Pry out shaft seal plate with two screw drivers.2) Remove seal plate o-ring from groove in bearing bore.

1) Loosen and remove 8 each 10-32 bolts.2) Pry off seal plate with screw driver.

Loosen and remove 8 each 3/8" bolts with 5/16" socket head wrench.

1) Press shaft out of bearing box.2) Proceed to step 9, disregarding steps 11 & 12

1) Loosen clamp screw in lock nut.2) Unscrew lock nut and remove.

Lift up on the bearing box to remove from motor.

1) Two of the 3/8" bolt holes are provided with jack screw threads.2) Insert a piece of 1/4" round stock by 2-1/2" long into each jack screw hole3) Screw two 7/16-14 bolts into the jack screw threads until the bearing box is free of the motor.

REMOVAL OF SHAFT SEAL

REMOVAL OF WHEEL MOTOR SEALPLATE AND BEARING BOX

DISASSEMBLY OF WHEEL MOTORBEARING BOX





9

10

11

12

13

14

15

16

6

1) Remove front housing2) Note: Two 5/16" ball checks and one main body o-ring may be dislodged and fall free.

1) Mark one side of the motor for proper assembly, paying careful attention that the cartridge will not be installed upside down.2) Secure the motor prior to loosening the 5/8-11 bolts.

With the seal plate removed, press shaft and ball bearing out of front housing.

1) Remove snap ring from shaft.2) Press shaft out of bearing.

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

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

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

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

DISASSEMBLY OF FRONTHOUSING AND SHAFT

DISASSEMBLY OF ROTOR/STATORCARTRIDGE





17 21

22

23

24

18

19

20

7

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

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

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

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

Note: Measure the rotor and stator length to the fourth decimal point and supply measurement when ordering rotor, stator, or vanes.

STATOR: Normal wear results in polishing of cam form which does not impair motor performances.Noticeable wear may be apparent along the corner of one side of the staor vane slot. This does not necessarily require replacement of the stator, but may slightly affect volumetric efficiency.

ROTOR: Normal wear results in polishing of rotor faces which does not impair motor performance.Examine the rotor vane slots closely. Polishing down in the slots is normal, but if there is any indication of a "pocket" forming in the wall of the slot, the rotor should be replaced.

PLATES: Normal wear results in marking of timing plates which does not impair motor performance.Replacement of the timing plate is required if any smearing, galling, or heat cracks are present.

INSPECTION AND REPLACEMENTOF PARTS





25

26

27

28

29

30

31

32

8

1) Reverse the procedures in steps 17, 16, 15, and 142) NOTE: Make sure that the radiused edge of each stator vane points to the rotor and the radiused edge of each rotor vane points to the stator.3) NOTE: Make sure springs are seated in the bottom of the spring pocket in both the rotor and stator.

1) Press bearing onto shaft.2) Install snap ring.

Press shaft and bearing assembly into front housing by pressing on the outer race of bearing.

1) Place seal in seal plate.2) Place seal plate o-ring into groove in the front housing.3) Press seal plate into front housing.4) Install snap ring.5) Proceed to step 30.

1) Install main body o-ring into front housing.2) Install ball checks into front housing.3) Place a small amount of grease over ball checks and o-ring.4) Wipe off excess grease.

1) Place rotor/stator cartridge onto rear housing.2) NOTE: Make sure assembly marks from step 3 are lined up.

1) Install dowel pins into rear housing.2) Install ballchecks into rear housings.3) Install main body o-ring.

1) Reverse the procedures in steps 8 thru 3.2) Screw lock nut onto shaft until all threads are engaged.3) Tighten clamp screw until lock nut turns with a slight drag.4) Tighten lock nut until desired rolling drag of bearing is obtained - see procedure Page 9.5) Tighten clamp screw6) Tighten all seal plate bolts.

ASSEMBLY OF ROTOR/STATORCARTRIDGE

ASSEMBLY OF FRONT HOUSING

ASSEMBLY OF WHEEL MOTORFRONT HOUSING

ASSEMBLY OF MOTOR





33

34

35

36

B

A

9

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

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

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

NOTE: Spool should be oriented as shown for two speed motors with model codes 62, 63, 68, & 69.

NOTE: Slight design variations may exist in motors manufactured either before or after the printing of this manual.

SPOOL ASSEMBLY FOR THETWO SPEED MOTOR

1)� Clean ALL assembly parts w/ lacquer thinner.2)� Dip clampnut and clamping bolt separately in lacquer thinner. � (Steps 3 thru 10 must be conducted to completion ONE assembly at a time.)3)� Press bearing cups into bearing housing. Make sure they are pressed completely against bearing shoulders.4)� Coat inner race of large cone with #609 (green) Loctite and press cone onto the shaft. Make sure the cone is completely against the shoulder of the shaft.5)� Insert shaft and large cone into bearing housing.6)� Coat inner race of small cone with #609 (green) Loctite and press small cone onto shaft.7)� Apply #272 (red) Loctite to the clampnut threads of the shaft. Apply #242 (blue) Loctite to the threads of the clamping bolt and install in the clampnut.8)� Spin clampnut onto shaft with the "B" face towards bearings. After the nut threads are fully engaged, but prior to the nut contacting the bearings, �� tighten the clamping bolt until there is drag on the clamping nut (see note Fig. 1). Tighten the nut until a 20 to 30 inch pound rolling torque is achieved.9)� Tighten clamping bolt on clampnut to 70 inch pounds and recheck rolling torque. Apply inspectors lacquer to head of the bolt.10)� Allow a minimum of 24 hrs. to dry.

Figure 1

CUTAWAY

Note:The slit in the clampnut allows for loose assembly on the shaft. Once in position, the clampnut clamping bolt MUST be tightened to a slight drag in order to correctly engage the threads on the shaft to achieve the clamp force required.

FACE"A"

CLAMPING BOLT

FACE"A"

FACE"B"

WHEEL MOTOR SHAFT AND BEARING ASSEMBLY PROCEDURE




Information:Bolt Torque -� Main Bolts (5/8-11): 190 ft. lbs.� Seal Plate (3/8-16)� (Wheel Motor only): 45 ft. lbs.Grease used for bolt threadsand o-ring retention:� Pennzoil 707L REDShaft seal assembly lube:� Mobilgrease special� with Moly

Seal Kits:� Standard 15 series seal kit� � #0150940� Standard 15 two speed seal kit� � #0150940� Standard 15 wheel motor seal kit� � #0150936

331 Breesport San Antonio, Texas 78216

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

WHEEL MOTOR

STANDARD MOTOR

TWO SPEED MOTOR

















































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

Capacity:60 gpm (240 L/min.)

Functional Group:Products : Cartridges : Corrosion Resistant : Logic Element : Unbalanced Poppet,Pilot-to-open, Switching Element, Spring biased closed, External Pilot Port 3pilot source

Model:

LKHC

Product DescriptionThese unbalanced poppet, logic valves are 2-way switching elements that arespring-biased closed. Pressure at either work port 1 or 2 will further bias thevalve to the closed position while pressure at port 3 will tend to open it. Theforce generated at port 3 must be greater than the sum of the forces acting atport 1 and port 2 plus the spring force for the valve to open. NOTE: The pilotarea (port 3) is 1.8 times the area at port 1 and 2.25 times the area at port 2.

Technical Features Because these valves are unbalanced,

operation is pressure dependent.Opening and closing of the poppet arefunctions of the force balances on threeareas: 1) Port 1 = 100%, Port 2 = 80%,and Port 3 = 180%.

These valves are pressure responsiveat all three ports, therefore it isessential to consider all aspects ofsystem operation through a completecycle. Pressure changes at any oneport may cause a valve to switch from aclosed to an open position, or viceversa. All possible pressure changes inthe complete circuit must be consideredto assure a safe, functional systemdesign.




These valves have positive sealsbetween port 3 and port 2.

Stainless steel cartridge options P or Ware intended for use within corrosiveenvironments with all externalcomponents manufactured in stainlesssteel or titanium. Internal workingcomponents remain the same as thestandard valves.

Incorporates the Sun floating styleconstruction to eliminate the effects ofinternal parts binding due to excessiveinstallation torque and/orcavity/cartridge machining variations.

Technical DataU.S. Units Metric Units

Cavity T-17ACapacity 60 240 L/min.Area Ratio, A3 to A1 1.8:1Area Ratio, A3 to A2 2.25:1Maximum Operating Pressure 5000 350 barMaximum Valve Leakage at 110 SUS (24 cSt) 10 10 drops/min.@70 barPilot Volume Displacement .15 2,5 ccSeries (from Cavity) 3U.S. Patent # 4,795,129Valve Hex Size 1 1/4 31,8 mmValve Installation Torque 150 - 160 200 - 215 NmSeal Kits Buna: 990-017-007Seal Kits Viton: 990-017-006

Option Selection

LKHC-X D N

Preferred Options

External

Control Cracking Pressure Material/SealMaterial

Standard OptionsX Not Adjustable N Buna-N

V Viton

Customer specified setting stamped on hex +$1.10

Related Information : Explanation of Sun cartridge control options - US units. Explanation of Sun cartridge control options - metric units.

Copyright © 2003 Sun Hydraulics Corporation.All rights reserved.

Terms and Conditions - Statement of Privacy




Pilot operated, balanced piston relief valve Capacity:25 gpm (95 L/min.)

Functional Group:Products : Cartridges : Relief : 2 Port : Pilot Operated, Balanced Piston

Model:RPEC-LAN

Product DescriptionPilot-operated, balanced-piston relief cartridges are normally closed pressureregulating valves. When the pressure at the inlet (port 1) reaches the valve setting,the valve starts to open to tank (port 2), throttling flow to regulate the pressure.These valves are accurate, have low pressure rise vs. flow, they are smooth andquiet, and are moderately fast.

Download

Technical FeaturesWill accept maximum pressure at port 2; suitablefor use in cross port relief circuits. If used in crossport relief circuits, consider spool leakage.

Main stage orifice is protected by a 150 micronstainless steel screen.

Not suitable for use in load holding applicationsdue to spool leakage.

Back pressure on the tank port (port 2) is directlyadditive to the valve setting at a 1:1 ratio.

All 2-port relief cartridges (except pilot reliefs) arephysically and functionally interchangeable (sameflow path, same cavity for a given frame size).

Stainless steel cartridge options P or W areintended for use within corrosive environmentswith all external components manufactured instainless steel or titanium. Internal workingcomponents remain the same as the standardvalves.

Incorporates the Sun floating style construction tominimize the possibility of internal parts bindingdue to excessive installation torque and/orcavity/cartridge machining variations.

Technical DataU.S. Units Metric Units

Model Weight 0.30 lb. 0.14 kg.Cavity T-10ACapacity 25 gpm 95 L/min.Adjustment - Number of Clockwise Turns to Increase Setting 5Factory Pressure Settings Established at 4 gpm 15 L/min.Maximum Operating Pressure 5000 psi 350 bar




Maximum Valve Leakage at 110 SUS (24 cSt) 2 in³/min.@1000 psi 30 cc/min.@70 barResponse Time - Typical 10 msSeries (from Cavity) Series 1Valve Hex Size 7/8 in. 22,2 mmValve Installation Torque 30 - 35 lbf ft 45 - 50 NmAdjustment Screw Hex Socket Size 5/32 in. 4 mmAdjustment Nut Hex Size 9/16 in. 15 mmAdjustment Nut Torque 108 lbf in. 12 NmSeal Kits Buna: 990-010-007Seal Kits Viton: 990-010-006

RPEC-LAN

Control Adjustment Range External Material/SealMaterial

Preferred Options

L Standard Screw Adjustment A 100 - 3000 psi (7 - 210 bar),1000 psi (70 bar) StandardSetting

W 150 - 4500 psi (10,5 - 315bar), 1000 psi (70 bar)Standard Setting

N Buna-N

Standard Options

C* Tamper Resistant - FactorySet

F Hex Head Screw withLocknut

B 50 - 1500 psi (3,5 - 105 bar),1000 psi (70 bar) StandardSetting

C 150 - 6000 psi (10,5 - 420

P Stainless/Buna-N

V Viton

W Stainless/Viton

K Handknob

O Handknob with Panel Mount

bar), 1000 psi (70 bar)Standard Setting

N 60 - 800 psi (4 - 55 bar), 400psi (30 bar) Standard Setting

Q 60 - 400 psi (4 - 25 bar), 200psi (14 bar) Standard Setting

If the material/seal is P, the control must be L or CIf the material/seal is W, the control must be L or C

* Special Setting required, specify at time of order

Related ModelsRPEC8

Explanation of Sun cartridge control options - US units.Explanation of Sun cartridge control options - metric units.Two-piece, floating cartridge construction.

Copyright © 2006-2007 Sun Hydraulics Corporation. All rights reserved.

Maximum Valve Leakage at 110 SUS (24 cSt) 2 in³/min.@1000 psi 30 cc/min.@70 barResponse Time - Typical 10 msSeries (from Cavity) Series 1Valve Hex Size 7/8 in. 22,2 mmValve Installation Torque 30 - 35 lbf ft 45 - 50 NmAdjustment Screw Hex Socket Size 5/32 in. 4 mmAdjustment Nut Hex Size 9/16 in. 15 mmAdjustment Nut Torque 108 lbf in. 12 NmSeal Kits Buna: 990-010-007Seal Kits Viton: 990-010-006

RPEC-LAN

Control Adjustment Range External Material/SealMaterial

Preferred Options

L Standard Screw Adjustment A 100 - 3000 psi (7 - 210 bar),1000 psi (70 bar) StandardSetting

W 150 - 4500 psi (10,5 - 315bar), 1000 psi (70 bar)Standard Setting

N Buna-N

Standard Options

C* Tamper Resistant - FactorySet

F Hex Head Screw withLocknut

B 50 - 1500 psi (3,5 - 105 bar),1000 psi (70 bar) StandardSetting

C 150 - 6000 psi (10,5 - 420

P Stainless/Buna-N

V Viton

W Stainless/Viton

Documents

TECHNICAL MANUAL KT (LW)13625 - TIOT€¦ · KT(LW)13625 13-5/8” Tong & FARR® BAcKup TechnicAL MAnuAL SecTion conTenTS iii This technical manual covers the following models: oVeRALL