Farr 80-0420-16 Technical Manual Download

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Summary of Contents for 80-0420-16

Page 1: ...shed by McCoy Corporation Technical Publications Department 14755 121A Avenue Edmonton AB Canada T5L 2T2 mccoyglobal com Specifications Operation Maintenance Assembly Model 80 0422 Model 80 0421 3 KT5500 5 1 2 13 97cm 18 7K Lbs Ft Hydraulic Power Tong CLINCHER Backup ...

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Page 3: ...ell style CLINCHER backup Tong equipped with hydraulic motor control lift control backup control rigid sling and safety door system 80 0421 3 80 0420 3 85 0506 0 5 1 2 configured power tong tension load cell style CLINCHER backup Tong equipped with hydraulic motor control lift control backup control rigid sling and safety door system 80 0422 80 0420 3 85 0404 0 5 1 2 configured power tong compress...

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Page 5: ... 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 ...

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Page 7: ... 17 New cage plate assembly and B O M 5 5 24 5 25 Replaced motor motor mount assembly B O M 5 5 28 5 29 Replaced tong door assembly B O M 6 Complete revision of torque measurement section Copyright 2007 2011 McCoy Corporation including its wholly owned subsidiaries McCoy all rights reserved This document is the property of McCoy and is supplied as reference information for users of our products Th...

Page 8: ... Unit 3 26 Monthly Inspection Maintenance Checklist Power Tong 3 27 Tubular Connection Equipment De commissioning Procedures 3 28 Tubular Connection Equipment Re commissioning Procedures 3 31 Troubleshooting Section 4 Tong Will Not Develop Sufficient Torque 4 1 Failure Of Jaws To Grip Pipe 4 3 Tong Running Too Slowly 4 4 Failure Or Difficulty Of Tong To Shift 4 5 General Comments 4 6 Parts and Ass...

Page 9: ...evelop operating procedures that conform to all policies set forth by the operating authority ies A WARNING is represented by an exclamation point within an orange triangle and contains information that will alert per sonnel to a potential safety hazard that is not life threatening A WARNING may also serve to alert the user to information critical to the correct assembly or operation of the equipm...

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Page 11: ...the manual before installing and using your equipment Replace ment parts are readily available from McCoy Drilling Completions FARR in Edmonton Alberta Note that many parts are transferable between FARR tongs and backups Should you need replacement parts or should you experience any difficulty not covered in this manual please contact McCoy Drilling Completions FARR 14755 121A Avenue Edmonton Albe...

Page 12: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 1 2 Technical Manual Specifications 60 37 52 Model 80 0421 3 Shown ...

Page 13: ...nfiguration Centre line of pipe to centre line of anchor Weight Approximate without jaws 2050 lb 932 kg Recommended Spring Hanger 85 0106XXH Capacity 3500 lbs 1591 kg Casing Jaws Available inches See Pp 2 12 2 14 Torque Table Pressure High Gear Low Gear PSI MPa Lbs ft Nm Lbs ft Nm 1000 6 89 1530 2074 7650 10372 1400 9 66 2250 3050 11250 15253 1800 12 41 2970 4027 14845 20127 2250 15 513 3780 5125 ...

Page 14: ...st lbs ASTM D 2509 50 Low temperature torque N m ASTM D 4693 1 3 max 40 C 40 F LT 37 pumpability g min 360 7 60 F 0 F 16 C 18 C Copper corrosion ASTM D 4048 1B Oil viscosity 40 C 104 F cSt 151 100 C 212 F cSt 19 2 Flash point F C ASTM 92 450 232 Use a premium quality hydraulic fluid that meets or exceeds the following specifications Typical Density kg m3 878 Viscosity cSt 40 C 68 8 cSt 100 C 8 7 V...

Page 15: ...n for Slings 1910 184 ANSI ASME B30 9 SLINGS ANSI ASME B30 10 HOOKS and ANSI AMSE B30 26 RIGGING HARDWARE for additional information DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN DEACTIVATED OR ISOLATED A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG OPERATOR Adequate setup and proper hydraulic connections are...

Page 16: ...n links supplied is not be below the values listed Minimum Allowable Chain Link Thickness at Any Point Nominal Chain Size Minimum Thickness Inches 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 Stretched bent twisted or deform...

Page 17: ...VICE AND QUARANTINED UNTIL RECERTIFIED Written records of the most recent periodic inspection shall be maintained and shall include the condition of the sling 2 Proper Use Of Load Bearing Devices Whenever any load bearing device is used the following practices shall be observed Load bearing devices that are damaged or defective shall not be used Slings shall not be shortened with knots or bolts or...

Page 18: ...ual Setup Operation B MAJOR COMPONENT IDENTIFICATION Item Description 1 Front Leg Assembly 2 Rigid Sling 3 Power Tong 4 Rear Backup Spring Support Assembly 5 Rear Leg Assembly Tension Load Cell Configuration 6 CLINCHER Backup Tension Load Cell Configuration 5 4 6 3 2 1 ...

Page 19: ...n 7 Rigid Sling Leveling Device 8 Cage Plate Assembly 9 Safety Door Switch Guard 10 Safety Door Switch 11 Tong Door Latch 12 Torque Gauge Mounting Plate 13 Backing Pin Assembly 14 Tong Jaws with Die Inserts 15 Brake Band Adjustment 16 Tong Door Cylinder 17 Tong Door Weldment 7 8 9 12 13 10 11 14 15 16 17 ...

Page 20: ...ts 2 6 Technical Manual Setup Operation Item Description 18 Hydraulic Valve Bank Assembly 19 Manual Shift Assembly 20 Access Panel 21 CLINCHER Cylinder With Wraparound Insert 22 Hydraulic Motor 23 Motor Mount 24 Tension Load Cell 24 23 22 18 19 20 21 ...

Page 21: ...ER Backup Section Contents 2 7 Technical Manual Setup Operation Item Description 25 CLINCHER Backup Compression Load Cell Configuration 26 Rear Leg Assembly Compression Load Cell Configuration 27 Compression Load Cell 25 26 27 ...

Page 22: ... 4WAY SAE PORTS 10 9014 4 Backup Section DVA35 DA8 4WAY SAE PORTS 10 9019 5 Lift Section DVA SA8 1 ORB PORT 10 9015 6 Outlet Section DVA35 TR99 SAE PORT 10 0086 7 Flow Control Valve N800S not shown 08 9062 8 Pilot To Operate Cartridge Valve LKHC XDN 08 1625 9 Safety Door Valve Block 101 0727 10 Safety Door Switch 08 0337 11 Check Valve SH4600 87 0110 12 Rineer GA15 13 Hydraulic Motor 02 9022 13 Re...

Page 23: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 2 9 Technical Manual Setup Operation 7 1 2 6 5 12 3 4 11 9 8 ...

Page 24: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 2 10 Technical Manual Setup Operation 10 13 18 17 ...

Page 25: ...the power unit see illustration below Ancillary devices hydraulic motors hydraulic cylinders etc are connected through the valve block Perform any hydraulic connection when the power unit is not running or when the hydraulic pump is disengaged The possibility of error in inter changing the high pressure supply hose and the low pressure return hose has been eliminated because the supply side coupli...

Page 26: ...cialized applications Call our sales office for information on jaw and die systems designed for higher or lower grip or non marking applications The table lists standard contoured flat and wraparound die inserts that are available as spare parts However a wide variety of diamond tooth GRITFACE aluminium and wrap around fine tooth dies are available for specialized applications Please refer to our ...

Page 27: ...or use in 1064 WJK 550 12 2012 2 Jaw Jaw Die Removal The tong jaws will often require removal to change jaw size or replace worn jaw die inserts Support the jaw being removed from the bottom and use a wrench to loosen and remove the jaw pivot bolt Slide the jaw away from the rotary gear towards the centre of the cage plate assembly and lift clear of the tong Repeat for the other jaw Note that remo...

Page 28: ... Backup Aluminum Insert 12 6130 2 875 CLINCHER Backup Aluminum Insert 12 6113 4 125 CLINCHER Backup Insert 12 6046 2 875 CLINCHER Backup Insert Grit 12 6189 4 25 CLINCHER Backup Insert 12 6094 3 CLINCHER Backup Insert 12 6089 4 50 CLINCHER Backup Insert 12 6051 3 125 CLINCHER Backup Insert 12 6014 4 50 CLINCHER Backup Aluminum Insert 12 6115 3 25 CLINCHER Backup Insert 12 6019 4 75 CLINCHER Backup...

Page 29: ...ion i Extend CLINCHER cylinders enough so that the hex flat head cap screws securing the die retainer tabs are well exposed Turn off hydraulic power ii Remove the two hex flat head cap screws securing the die retainer tab on the top of the CLINCHER die iii Remove the top die retainer tabs iv Slide the die straight up and remove ...

Page 30: ...made up and imparts additional force to the suspension cable a single spring hanger typically applies 420 lbs 191 kg to the suspension line for every inch of thread made up a double spring hanger typically applies 840 lbs 382 kg to the suspension line for every inch of thread made up If you do not know which specific spring hanger is in use check the specification page in this manual for informati...

Page 31: ...ction of the snub line is the complete responsibility of the customer Snub lines must be securely connected to the rear of the tong and backup assembly and tied off to a suitable anchor 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 construct...

Page 32: ... Configuration The backup is directly coupled to the compression load cell via the backup body paddle The load cell hanger is simply hung on the paddle and secured through the top of the U by a bolt and washer set and in normal operation does not need to be adjusted or removed The assembly in the first of the following two illustrations has been configured in the make up configura tion to convert ...

Page 33: ...iguration make up to break out or visa versa simply remove the heavy duty bolts securing the load cell and restraint chains and switch to the opposite sides Reinstall the heavy duty bolts to secure the load cell and restraint chains in place For your reference the assembly in the following illustration has been configured to measure make up torque If measurement of break out torque is desired the ...

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Page 35: ...on of the equipment under the supervi sion of a trained equipment operator until a satisfactory level of competence is achieved Typical operator training should include Introduction to and general description of equipment Technical specifications and performance data Operating instructions Control systems and interlocks Operating hazards Checks and inspections 2 Initial Start up and Break in Proce...

Page 36: ... higher hydraulic output to the controlled device The following illustration demonstrates the type and effect of the hydraulic valves with which this tong is may be equipped TONG MOTOR This is a proportional valve Pushing the valve handle forward will cause the tong motor to rotate in a clockwise direction as seen from the top of the tong This is the desired direction of rotation for making up a j...

Page 37: ...ocknut is tightened once the desired detent pressure has been set To shift to the high speed gear move the shifting handle upward from neutral position To shift to the low speed gear move the shifting handle down through the neutral detent to its lowest position Note that the high clutch gear or the low clutch gear may not be exactly aligned when shifting so the operator may need to bump the motor...

Page 38: ... or high torque condition Although this method is very effective in breaking out joints the extremely high stress placed on the gear train frequently causes gear breakage G EXTREME COLD WEATHER OPERATION PROCEDURES 1 Consult the power unit engine operator s manual for all cold weather operating procedures and precautions 2 Select gear and bearing lubricants that are compatible with expected climat...

Page 39: ...may be harmful to the environment if improperly disposed of hydraulic fluid grease etc Dispose of all materials according to your company s proscribed environmental protection regulations B CLEANING Clean tong thoroughly cleaned with a good petroleum based cleaning agent after each job prior to storage Farr recommends that the motor and valve assembly be periodically removed along with the top ton...

Page 40: ...ure at the completion of each job prior to storage 1 Cage Plate Cam Followers Apply grease to the grease fittings recessed in both the top and bottom cage plates 26 locations total 13 top 13 bottom 2 Support Rollers Apply grease to the support roller bearings through the grease fittings recessed into the top of each support roller shaft NOTE the safety door cam assembly needs to be removed to acce...

Page 41: ...the rotary idler bearings through the grease fittings recessed into the top of each shaft on the top face of the tong two locations total 4 Pinion Idler Apply grease to the pinion idler bearing through the grease fitting recessed into the top of the half shaft located on the bottom face of the tong one location only ...

Page 42: ...ngs located on the bearing caps on the top and bottom faces of the tong two locations top two locations bottom 6 Clutch Bearings Apply grease to the clutch bearings through the two grease fittings located on the clutch bearing cap on the bottom face of the tong and the single grease fitting recessed into the end of the clutch shaft three locations total ...

Page 43: ...gear clutch drive gear through the grease fitting located on the top of the motor mount one location only 8 Shifting Shaft Apply grease to the shifting shaft and top shifting shaft bushing The shaft and shifting yoke can be accessed through the cover plate on the side of the tong Access shifter components through this panel ...

Page 44: ...ch Apply grease to the door latch through the grease fitting located in the top of the adjustment cam Maintenance 10 CLINCHER Cylinders Apply grease to the external surfaces of the clincher cylinders through the grease fittings in the top and bottom body plates eight locations total ...

Page 45: ...t D ADJUSTMENTS 1 Brake Band Tension Adjustment The top and bottom brake bands must be periodically adjusted to continue to provide smooth and efficient jaw cam action If the cage plate turns with the rotary gear the jaws will not cam properly and therefore will not bite on the tubing or casing Tightening the brake band against the cage plates will increase frictional resistance allowing jaws to c...

Page 46: ...HE 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 3 Shifter Detent Force Adjustment Over time wear to the shifting shaft wear t...

Page 47: ...2 Remove top brake band assembly leave adjustment lug weldments in place for now 13 Remove the tong door stop cylinder F RECOMMENDED PERIODIC CHECKS 1 Door Stop Spring The spring inside the actuator cylinder must be of sufficient strength to enable the door latch mechanism to snap closed prop erly and to hold the door in the open position when opened Door stop spring fatigue will result in sluggis...

Page 48: ... Pull the top bearing cap and spacer for the pinion drive gear by removing the four 1 2 bolts which secure the bearing cap Thread two of the removed bolts into the extra holes on top of the bearing cap and use them as lifting lugs to lift the bearing cap out of place 16 Remove the jaw pivot bolts and the jaw assemblies 17 Ensure the bottom cage plate is supported before beginning this step Remove ...

Page 49: ... 5 8 18 625 23 025 240 ft lbs 180 ft lbs 3 4 16 750 33 600 420 ft lbs 315 ft lbs 7 8 14 875 45 825 668 ft lbs 501 ft lbs 1 12 1 000 59 700 995 ft lbs 746 ft lbs 1 14 1 000 61 125 1019 ft lbs 764 ft lbs 1 1 8 12 1 125 77 025 1444 ft lbs 1083 ft lbs 1 1 4 12 1 125 96 600 2012 ft lbs 1509 ft lbs 1 3 8 12 1 375 118 350 2712 ft lbs 2034 ft lbs 1 1 2 12 1 500 142 275 3557 ft lbs 2668 ft lbs SAE GRADE 8 ...

Page 50: ...e 2 Assemble ten support roller dumbbell assemblies Insert an inner support roller spacer PN 1064 183 into each dumbbell support roller PN 1064 181 Press a support roller bearing PN 02 0099 into each end of the dumbbell rollers Slide a support roller bearing spacer PN 1064 182 over each support roller shaft 5 x PN 101 3942 4 x PN 101 3944 1 x PN 101 3943 Insert a support roller shaft through compl...

Page 51: ...nst centre gear 17 Slide high clutch gear PN 997 A1 51 over the bottom end of the clutch shaft and seat gear on the needle bearings ensuring the smaller diameter on the high clutch gear is oriented toward the center gear on the clutch shaft Place lower end of clutch shaft into the lower clutch bearing that has been pre mounted in the lower body plate and mesh the high clutch gear with the high pin...

Page 52: ...ng retainer Insert clutch bearing bushing PN 997 60 shoulder side up between bearing and clutch shaft 30 Secure clutch drive gear PN 997 A3 61 to the top of the clutch shaft with retaining snap ring PN 02 0001 31 Install rotary idler pads PN 997 D20 125 over the top of the rotary idler shafts and secure with 1 1 2 UNF hex nylock nuts 32 Press remaining pinion bearing into the top pinion bearing ca...

Page 53: ...nt PN 1500 09 04A is secured by the two LH motor screws position the torque gauge holder weldment in place and secure it and the LH side of the motor with two 1 2 UNC x 1 1 2 hex socket head cap screws and 1 2 lock washers 40 Attach the two 20 1 1 4 x JIC 1 flange elbows PN 02 9216 to the motor ports using two 20 split flange kits PN 02 9217 41 Attach the shifter lug weldment PN 101 0016 to the to...

Page 54: ...y gear ensuring the cam followers are nested within the groove in the rotary gear Place the top cage plate in position over the rotary gear ensuring the cam followers are nested within the groove in the rotary gear 48 Place cage plate spacers PN 1064 38 between the two cage plates at their connection points one in the rear centre and one each side just inside the rotary gear 49 Slide a 1 2 narrow ...

Page 55: ...tom plates and insert the door pivot roller shaft PN 101 3943 it may have to be tapped lightly with a soft metal or rubber hammer Use caution when sliding the shaft through the support roller components Once the shaft has been tapped all the way through secure the bottom of the shaft with a 7 8 UNF thin nylock nut and 7 8 narrow flat washer 58 If your tong is equipped with the safety door option i...

Page 56: ... PN 101 0112 using a 3 4 UNC x 8 hex bolt and 3 4 UNC nylock nut 66 Use a crane to hoist the rigid sling weldment Connect the rigid sling weldment to the rigid sling mounting lugs with rigid sling pins PN 1053 C 1C Secure each pin with two 0 148 x 2 938 hitch pins 67 Thread a 3 4 UNC hex nut on to each of two rigid sling leveling adjustment weldments PN 1053 C 1L Thread the leveling adjustment wel...

Page 57: ... leg tube with a 7 16 UNC x 4 hex bolt 7 16 narrow flat washer and a 7 16 UNC nylock nut Repeat for the other leg tube 77 Slide a leg spring PN 1391 905 02B over the bottom of each leg tube followed by a bottom spring cap PN 1302 905 03C Secure each leg spring and bottom spring cap to the leg tube using a 7 16 UNC x 3 hex bolt 7 16 narrow flat washer and a 7 16 UNC nylock nut 78 85 0604 and 85 060...

Page 58: ...ustment plate PN 101 0277 to the outlet support weldment using four 3 8 NC x 1 hex bolts 3 8 narrow flatwashers and 3 8 UNC hex nylock nuts 84 Coat the threads of the hydraulic valve mounting posts PN 101 0116 with Loctite and thread into the top plate just behind the brakeband on either side of the brakeband retainer 85 Mount the DVA35 hydraulic valve assembly on the mounting posts using two 1 2 ...

Page 59: ...ect all chains master links and turnbuckles again if any damage is noted replace the damaged part s before placing the tong in service 9 Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is a good indication of wear 10 Inspect backing pin s If cracked broken or bent it they must be replaced 11 Inspect top and bottom brake band linings...

Page 60: ...ve the tong s specified operating pressure and that the return pressure is less than 350 psi 17 Perform a visual inspection of pressurized hydraulic lines Document and correct any hydraulic fluid leaks 18 Perform a full functional test of the tong Report and correct any hydraulic leaks from the hydraulic valve bank or from any hydraulic cylinders that are used 19 Perform a visual inspection of the...

Page 61: ...on of all fasteners and protruding body pieces example hydraulic valve mounts inlet outlet line supports tong legs shifter handle pivot lugs Tighten or replace loose or missing fasteners Farr recommends that damaged or missing body parts be repaired or replaced as soon as possible 9 Inspect tong for signs of premature wear or moving parts that are rubbing bare metal where there used to be paint is...

Page 62: ...sual inspection of the gear train through the access panel and the opening of the rotary gear while the gear train is being rotated If gear damage or chips of metal are seen the tong should be removed from service and overhauled to avoid further damage Replace access panel when inspection is complete 14 Inspect all jaws and dies in use for the maintenance interval Inspect the jaw roller pins for s...

Page 63: ...re installing the beam liberally grease the anchor pin before reinserting into the load cell beam 34 Inspect load cell for damage or signs of stress Check oil level in load cell and fill if necessary refer to technical manual Section 7 or Section 8 35 While rotating the cage plate ensure that the jaws properly cam If the jaws do not cam properly the brake bands need to be tightened Incrementally a...

Page 64: ...isually inspect all electrical lines and visible connections If your unit is NOT explosion proof open the electrical en closure and VISUALLY inspect contacts and connections for signs of corrosion or arcing Do not open explosion proof enclosures 2 Visually inspect main electrical line between main power source and power unit All Units 5 Perform a visual inspection of all parts Check to ensure ther...

Page 65: ...ing parts bare metal where there used to be paint and metal shavings in the grease are good indicators may show where a component needs to be adjusted or if necessary replaced Replace any removed panels when inspection is complete 5 Grease clincher cylinder guides using the grease fittings on the top body plate 6 Ensure the splines on the clincher cylinder faces and on the rear of the die are clea...

Page 66: ...sure washer or an appropriate solvent based grease cutting cleaner such as Varsol Ensure adequate containment is in place to prevent environmental con tamination from residual hydraulic fluid dirty grease and cleaning agents Make a note if any metal shavings or metal pieces are flushed out of the gear train cavity if shavings or metal pieces are seen the tong must be overhauled before it is return...

Page 67: ...t cylinder rods for signs of mechanical damage flaking or rust Farr recom mends that damaged cylinders be replaced prior to storage 17 If you are using a frame mounted tool the tong must be lowered onto the backup in order to remove the risk of sudden and catastrophic movement when pressure is removed from the float cylinders Cover the top of the backup with protec tive cloth to protect the paint ...

Page 68: ...tiply the calculated air volume in cubic feet by the recommended amount of desiccant per cubic foot Carrying forth the example used in the previous step the required desiccant charge would be 3 5 g x 66 ft3 equaling 231 g Several manufacturers offer silica gel desiccant in packaged quantities of 125 grams per bag so two packages of desiccant would be required Please keep in mind that this is a gui...

Page 69: ...correct size for the pipe or casing being run 16 Install load cell If using a tension load cell perform a visual inspection and replace any cracked broken or distorted components including links and chains If using a compression load cell replace any component that has been crushed or otherwise distorted through compression 17 If applicable inspect the load cell anchor pins tension load cell only ...

Page 70: ...pen the tong door s and attempt to rotate the cage plate at low speed low gear in both directions makeup and breakout If cage plate begins rotating the safety door mechanism is not functional and the tong must be removed from service until the safety door mechanism can be repaired If the safety door is operating correctly cage plate rotation will not be inhibited once the door is closed and latche...

Page 71: ...s manual for your particular unit 4 POSSIBLE PROBLEM Poor hydraulic pressure at the tong despite adequate pressure at the power unit or excessive back pressure in the return line SOLUTION Restrictions exist in line between power unit and tong Inspect integrity of self sealing couplings to ensure they are allowing full fluid flow Check to ensure no other restrictions exist contaminated catch screen...

Page 72: ...d Replace load cell or return to McCoy for repair and re calibration 11 POSSIBLE PROBLEM Incorrect motor speed selected SOLUTION Maximum torque can only be developed when motor is in the lowest speed Ensure motor is in low speed 12 POSSIBLE PROBLEM Incorrect tong gear selected SOLUTION Maximum torque can only be developed when tong is in low gear Ensure tong is in low gear McCoy Drilling Completio...

Page 73: ...ted for the diameter of pipe or casing being run 3 POSSIBLE PROBLEM Incorrect dies are being used SOLUTION Ensure dies loaded in the jaws are appropriate for the type of pipe or casing being run 4 POSSIBLE PROBLEM Brake band s is are insufficiently adjusted not allowing jaws to cam properly SOLUTION Adjust brake bands to give proper resistance to cage plates 5 POSSIBLE PROBLEM Jaw roller broken or...

Page 74: ...OBLEM Bearings in gear train and rotary section are excessively worn SOLUTION Overhaul tong See Section 3 of this manual for tong overhaul procedures 5 POSSIBLE PROBLEM Shifter has malfunctioned and the tong is not shifting to high gear SOLUTION Inspect and repair shift mechanism as necessary 6 POSSIBLE PROBLEM Two speed hydraulic motor if equipped is not set to correct speed SOLUTION Check motor ...

Page 75: ...hifter handle SOLUTION Grease shifter shaft 4 POSSIBLE PROBLEM Bent or broken shifter shaft SOLUTION Replace 5 POSSIBLE PROBLEM Locking nuts on shifting shaft have loosened and position of yoke has changed SOLUTION Reposition yoke and re tighten locking nuts 6 POSSIBLE PROBLEM Shifting yoke has come loose from shifting shaft SOLUTION Inspect yoke and inspect for damage If free of damage replace on...

Page 76: ...c fluid especially in extreme climatic conditions 3 Defective packing or seals in components of the hydraulic system 4 Poor or incomplete hydraulic system training Users must be fully qualified to operate the equipment and have complete understanding of the hydraulic system If your hydraulic troubleshooting procedures involve flow and pressure tests at the power unit McCoy Completions Drilling rec...

Page 77: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 1 Technical Manual PARTS AND ASSEMBLIES Model 80 0422 Shown Model 80 0421 3 Shown ...

Page 78: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 2 Technical Manual Gear Train Layout J L A B C E F D G H K ...

Page 79: ... 5 14 5 15 1 D Assembly Rotary Idler Assembly Pp 5 8 5 9 2 E Assembly Support Roller Extended Shaft For Front Leg Mount Pp 5 4 5 5 4 F Assembly Support Roller Extended Shaft For Front Leg Mount Pp 5 4 5 5 5 G Assembly Shifter Shaft Assembly Pp 5 16 5 17 1 H Assembly Pinion Assembly Pp 5 12 5 13 1 J Assembly Pinion Idler Assembly Pp 5 10 5 11 1 K Assembly Door Pivot Support Roller Pp 5 6 5 7 1 L Pa...

Page 80: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 4 Technical Manual Support Roller A B C D E F G E D C H ...

Page 81: ...art Tapered Roller Bearing 2 02 0099 F Part Support Roller Shaft Spacer 1 1064 183 G Part Support Roller 1 1064 181 H Part 7 8 UNF Hex Thin Nylock Nut 1 09 5722 1 Backup ready tongs use 5x support roller shaft PN 101 3942 Use four long support roller shafts PN 101 3944 where coincidental with the front leg mount weldments The door pivot shaft remains PN 101 3943 2 Top and bottom flat washers are n...

Page 82: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 6 Technical Manual Rotary Idler Assembly A B C D E F G E F D C H J K ...

Page 83: ...umber A Part Grease Fitting 1 8 NPT 1 02 0005 B Part 1 1 2 UNF Nylock Nut 2 09 5740 C Part Rotary Idler Pad 2 997 D20 125 D Part Idler Bearing Spacer 2 997 D20 121 E Part Bearing Seal 2 02 0010 F Part Bearing Retainer Ring 2 02 0009 G Part Idler Shaft 1 997 D19 117 H Part Idler Bearing 1 02 0011 J Part Idler Gear 1 997 A2 119 ...

Page 84: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 8 Technical Manual Pinion Idler Assembly A B C D E C J H F G K L ...

Page 85: ... 0008 B Part Bearing Seal 1 02 0010 C Part Retainer Ring 2 02 0009 D Part Idler Gear 1 997 A2 119 E Part Idler Bearing 1 02 0011 F Part Idler Half Shaft 1 997 D17 105 G Part Pinion Idler Pad 1 1400 109 H Part 5 8 Carbon Steel Lock Washer 3 09 5114 J Part 5 8 UNC x 2 1 4 Hex Bolt 3 09 1235 K Part 1 1 2 UNF Nylock Nut 1 09 5740 L Part Grease Fitting 1 8 NPT 1 02 0005 ...

Page 86: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 10 Technical Manual Pinion Assembly A B C D E J H F G F E D C B A ...

Page 87: ...rease Fitting 1 8 NPT x 90 Degree 4 02 0093 B Part 1 2 UNC x 1 1 4 Hex Bolt 8 09 1168 C Part 1 2 Lock Washer 8 09 5110 D Part Pinion Bearing Cap 2 997 D15 89 E Part Pinion Bearing Spacer 2 1400 89A F Part Pinion Idler Bearing 2 02 0007 G Part Low Pinion Gear 1 997 A5 88 H Part Pinion Gear 1 997 A7 86 J Part High Pinion Gear 1 997 A4 87 ...

Page 88: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 12 Technical Manual Clutch Assembly A B C D E J J K L H F G N P Q R S T U M ...

Page 89: ...400 59A F Part Clutch Bearing Bushing 1 997 60 G Part Top Clutch Bearing 1 02 0002 H Part Low Clutch Gear 1 997 A1 52 J Part Needle Bearing 4 02 0003 K Part Clutch Shaft 1 997 A8 50 L Part Shifting Collar 1 997 A9 62 M Part High Clutch Gear 1 997 A1 51 N Part Bottom Clutch Bearing 1 02 0004 P Part Clutch Bearing Cap Spacer 1 1400 54A Q Part Clutch Bearing Cap 1 997 D11 54 R Part 3 8 Carbon Steel L...

Page 90: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 14 Technical Manual Shifter Assembly A B C D E J K M N L H F G P Q R S C ...

Page 91: ...t Tube 1 101 0019 F Part Shifter Detent Ball 1 02 0018 G Part Shifter Detent Spring 1 997 0 64 H Part 7 16 UNF Hex Nut 1 09 5908 J Part 7 16 UNF x 1 1 4 Hex Bolt 1 09 1608 K Part Shifting Yoke 1 997 D13 72 L Part 5 8 NF Hex Jam Nut 1 09 5915 M Part 5 8 NF Hex Nut 1 09 5914 N Part Bottom Shifter Bushing Typically welded to bottom plate 1 1064 B1 95 P Part 3 8 x 1 Hex Bolt 4 09 1170 Q Part 3 8 Carbo...

Page 92: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 16 Technical Manual Cageplate Assembly A B C D E J H F G K L M N P Q R S T U ...

Page 93: ...Top Cage Plate 1 1400 21 G Part Cage Plate Spacer 3 1064 38 H Assembly Jaw Assembly 5 1 2 shown see Pp 2 12 2 J Part Rotary Gear 1 1064 D1 K Part Bottom Cage Plate 1 1400 22 L Part 1 2 UNC Thin Nylock Nut 3 09 5610S M Part Backing Pin Knob 1 02 0017 N Part 3 8 UNC x 1 1 2 Threaded Dowel Pin 1 101 4097 P Part Backing Pin Spacer 1 101 4096 Q Part Backing Pin Retainer 1 101 4095 R Part Backing Pin 1 ...

Page 94: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 18 Technical Manual Tong Body Assembly A B C D E F G E J S B H K L D E E G N P Q R M ...

Page 95: ...1048 E Part 3 8 Carbon Steel Lockwasher 39 09 5106 F Part 3 8 Narrow Flat Washer 2 09 5124 G Part 3 8 NC x 1 1 2 Hex Bolt 29 09 1050 H Part Rigid Sling Pin 2 1053 C 1C J Weldment Rigid Sling Bracket 2 101 0151 K Assembly Rigid Sling See Pp 7 32 7 33 1 L Part Hitch Pin 1 4 x 5 4 09 9075 M Weldment Shifter Lug Weldment 1 101 0016 N Assembly Motor Motor Mount See Pp 7 26 7 27 1 P Part Top Plate 1 140...

Page 96: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 20 Technical Manual Brakeband Assembly A B C D E F G ...

Page 97: ...8 NC x 3 4 Hex Bolt 2 09 1044 B Part 3 8 Carbon Steel Lock Washer 2 09 5106 C Part Brake Band Retainer 1 101 0140 D Assembly Brake Band Lined 1 1064 D4 29 E Part 3 8 NF Hex Nut 2 09 5906 F Weldment LH Brake Band Lug Weldment 1 101 0134 Weldment RH Brake Band Lug Weldment 1 101 0132 G Part 3 8 NF x 1 1 2 Brake Band Adjustment Bolt 2 09 1553 ...

Page 98: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 22 Technical Manual Motor Mount Assembly A B C D E J F G K N M P Q H L ...

Page 99: ...3 6 5 Two Speed Hydraulic Motor Optional 1 87 0007 F Part Motor Gear 1 997 A10 149 G Part 3 8 NC x 3 8 Hex Socket Set Screw 2 09 0106 H Part 1 2 NC x 1 1 2 Hex Socket Head Cap Screw 4 09 2170 J Part 1 8 NPT 90 DEG Grease Fitting 1 02 0093 K Weldment Torque Gauge Holder Weldment 1 1500 09 04A L Part 20 1 1 4 Split Flange Kit 2 02 9217 Part O Ring 1 Part 20 1 1 4 Split Flange 2 Part 7 16 Lock Washer...

Page 100: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 24 Technical Manual Hydraulic Assembly C R S Q A V W D B F G L J K U N P T E M H X X ...

Page 101: ...ls 2 02 9200 M Part 1 1 4 Dust Cap 1 02 9212 N Part Male 1 1 4 Quick Coupler Fitting 1 02 9215 P Part 1 1 4 Long Nipple 1 101 0070 Q Assembly M ORB F NPT 90d 1 1 4 Fitting Includes seals 1 02 9202 R Part M NPT F NPT 90d 1 1 4 Fitting 1 02 9220 S Part Hydraulic Outlet DVA35 TR99 1 10 0086 T Part DVA35 DA8 4WAY SAE Ports 1 10 9019 U Assembly Handle Assembly 3 01 0409 Part Hydraulic Valve Handle 1 01...

Page 102: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 26 Technical Manual Tong Door Assembly A B C D E F G H J K L M N P Q P R ...

Page 103: ...stment Cam 1 1400 14 F Weldment Door Weldment 1 1400 10 G Part 3 8 UNC Hex Nut 2 09 5806 H Part 3 8 NC x 1 1 2 Hex Bolt 1 09 1553 J Part Latch Spring 2 997 16 K Weldment Door Latch Weldment 1 1064 C7 15 L Part Shoulder Bushing 1 101 5110 M Part Door Bushing Bottom 1 101 5111 N Part Door Pivot Roller 1 101 3943 P Part 7 8 Narrow Flat Washer 2 09 5123 Q Part Door Cylinder Mounting Lug 1 1050 12 001 ...

Page 104: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 28 Technical Manual Safety Door Assembly A B C A D H G E F J D L K D M N P Q R ...

Page 105: ...ock 1 101 1104 F Part 15 16 Valve Lock Nut 1 09 0278 G Part Safety Door Latch Block 1 101 1103 H Part Safety Door Latch Plate 1 101 1105 J Part 3 8 NC x 1 1 2 Hex Bolt 2 09 1553 K Part 3 8 NC x 1 1 2 Flat Head Countersunk Cap Screw 2 09 4050 L Part Safety Door Latch Block 1 101 0914 M Part Load Plunger 1 AE12 306 N Part 1 4 inch NPT JIC 90 degree elbow 3 08 0284 P Part Deltrol Gauge Isolator Valve...

Page 106: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 30 Technical Manual Leg Assemblies A B D E F H Q C L P M L P G N J K ...

Page 107: ...Top Spring Cap Front Leg Compression Load Cell Configuration 2 101 4489 L Part 1 2 NC x 3 Hex Bolt 4 09 1178 M Part Front Leg Spring Tension Load Cell Configuration 2 1391 905 02B Front Leg Spring Compression Load Cell Configuration 2 1302 905 08 N Part Bottom Spring Cap Front Leg 2 1302 905 03C P Part 1 2 NC Nylock Nut 4 09 5610 Q Part Rear Backup Suspension Spring Tension Load Cell Configuration...

Page 108: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 32 Technical Manual Leg Assemblies A Q O R S P T U M N J L W V K I B C H D E F G B ...

Page 109: ...Roller Shaft 4 101 3944 I Weldment 2 Load Cell Holder 1 01 9116D J Part 1 2 NC x 6 Hex Bolt 4 09 1190 K Weldment RH Front Leg Mount 1 101 0786 L Weldment Rear Backup Leg Spring Plate Top 1 101 4495 M Part 1 2 Hex Nut 4 09 9124 N Weldment Rear Backup Leg Spring Plate Bottom 1 101 4496 O Part Heavy Hex Bolt 1 101 0040 P Part 7 8 NC x 7 Hex Bolt 1 Q Part 0 148 x 2 938 Hitch Pin 2 R Part 1 1 4 Hex Nut...

Page 110: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 34 Technical Manual Backup Body Assembly Tension LC Config A B D E J K H C G L M B Q N P G F ...

Page 111: ...Hex Bolt 1 09 1050 G Part 3 8 Carbon Steel Lock Washer 21 09 5106 H Part 1 UNC x 8 1 2 Hex Bolt 4 09 0287 J Weldment Backup Body Weldment 1 1483 500 00 K Part Rear Jaw 1 1403 08 L Part Rear Side Cover Plate 2 1483 500 00 02 M Part 3 8 UNC x 3 4 Hex Bolt 20 09 1044 N Part Side Cover Plate 2 1483 500 00 01 P Assembly CLINCHER Cylinder Assembly 2 1403 00 00B Q Part 1 UNC Nylock Nut 4 09 5725 R Weldme...

Page 112: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 36 Technical Manual Backup Body Assembly Compression LC Config A B E F K L J C D H G R Q T M S N M P U V ...

Page 113: ...iner 2 1483 500 00 4B G Part 1 1 4 NC x 8 Threaded Rod 1 101 1993 H Part 1 4 NC x 3 4 Hex Bolt 2 09 1005 J Part 2 1 2 Face 0 3000 PSI 1 4 NPT Gauge 1 02 0246 K Weldment Gauge Protector Weldment 1 1483 500 18 L Part 3 8 NC x 1 1 2 Hex Bolt 1 09 1050 M Part 3 8 Carbon Steel Lockwasher 17 09 5106 N Part 1 NC x 8 1 2 Hex Bolt 4 P Part Rear Jaw 1 1403 08 Q Part Rear Side Cover Plate 2 1421 500 11B R Pa...

Page 114: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 38 Technical Manual Low Profile Backup Body Assembly Compression LC Config A I J B K E G H F C L M N D ...

Page 115: ...1839 D Part BCJ Body 1 08 1327 E Part Rear Cover Plate 1 101 4482 F Part 3 8 NC x 3 4 Hex Bolt 16 09 1044 G Part 3 8 Lock Washer 16 09 5106 H Part Front Cover Plate 2 1421 500 11 I Part 3 8 NC x 1 1 4 Hex Bolt 1 09 1048 J Part 1 NC x 9 Hex Bolt 4 09 0288 K Weldment Gauge Protector Weldment 1 1483 500 18 L Part CLINCHER Rear Jaw 1 1403 08 M Assembly CLINCHER Cylinder Assembly 2 1403 00 00B N Part R...

Page 116: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 40 Technical Manual CLINCHER Cylinders A K D G J L H C B P Q E F M N R S T ...

Page 117: ... 01 E Part Cylinder Rod 1 1401 04B G Part Cylinder Piston 1 1401 05B J Part 3 8 UNC x 1 Hex Bolt 4 09 1170 K Part 3 8 Carbon Steel Lock Washer 4 09 5106 L Part 3 8 Plain Narrow Washer 4 09 5124 M Part Backing Plate 1 1403 03 N Part 5 8 UNC x 1 1 4 Hex Socket Head Cap Screw 4 09 0240 P Part Cylinder Gland 1 1401 06B Kit CLINCHER Cylinder Seal Kit 1401 00 00 SK F Seal 2 231 O Ring 1 H Seal 37504750 ...

Page 118: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 5 42 Technical Manual Rigid Sling Assembly A F C B A G H J D K L E M N P Q J ...

Page 119: ...1 09 1322 E Weldment Rigid Sling Weldment 1 101 0656 F Weldment Leveling Bolt 2 1053 C 1L G Part Rigid Sling Pin 2 1053 C 1C H Part 3 8 NC x 1 Hex Bolt 4 09 1170 J Part 3 8 Carbon Steel Lockwasher 8 09 5106 K Weldment LH Rigid Sling Bracket 1 101 0150 Weldment RH Rigid Sling Bracket 1 101 0151 L Part Hitch Pin 1 4 x 5 4 09 9075 M Part 1 2 NC x 1 1 4 Hex Bolt 2 09 1168 N Part 1 2 NC Hex Jam Nut 2 0...

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Page 121: ...e point of highest torque and remains at the point of highest torque until manually reset Note that every model of tong and tong and backup assembly has a unique arm length and the torque gauge must be calibrated for that arm length Torque gauges that are not calibrated for the arm length of the tool in service will not display correct torque To ensure correct torque measurement ensure the arm len...

Page 122: ...2 Arm 1 10 0029G C Part Hydraulic Hose 1 02 0069 THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE RANGE OF THE EQUIPMENT IN USE THE PART NUMBERS LISTED IN THE FOLLOWING TABLEs ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH THIS MANUAL IS SUPPLIED Basic Torque Measurement Continued The images on the preceding page are for illustration purposes only ...

Page 123: ...ng 1 08 0596 G Part Load Cell Piston 1 LC99 101 H Part Load Cell End 1 LC99 003 J Part Flange Gasket 1 02 0073 K Part Load Cell Rod 1 LC99 002 L Part Wiper 1 08 1558 M Part 3 8 NC x 3 8 Cup Point Hex Set Screw 2 09 0106 Seal Kit Replacement Seal Kit 4 08 in2 Tension Load Cell 02 4578 This is the standard tension load cell sup plied by McCoy Drilling Completions Farr Contact our sales department fo...

Page 124: ...cket Head Cap Screw 6 09 2024 D Part Retainer Ring 1 E360 8 E Part Diaphragm 1 E358 2 F Part Diaphragm Casing 1 E360 C G Part Street Elbow 1 H Part 1 4 NPT Brass Plug 1 This is the standard hydraulic com pression load cell supplied by McCoy Drilling Completions Farr Contact our sales department for information about optional application specific compression load cells Electronic compression load c...

Page 125: ...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 Turn Counter Encoder Mount Exploded 2 74 2 75 A B C D E D C ...

Page 126: ...6 C NOTE Ensure any breaches in the hydraulic system between the load cell and torque gauge are repaired to prevent further fluid loss Possible Problem Obstruction in hydraulic hose Solutions Check hydraulic hose for kinks Replace hydraulic hose Possible Problem Snub line not at right angle to tong handle Solution Check angle of snub line and correct if necessary Possible Problem Internal mechanis...

Page 127: ...N THE HAND PUMP BOWL TO AVOID PUMPING AIR INTO THE SYSTEM DO NOT ALLOW THE LEVEL TO FALL BELOW ONE HALF FULL Un contained spillage of the hydraulic fluid in this system may contravene governmental environmental regulations or the environmental regulations and policies of your company McCoy Drilling Completions highly recommends placing your load cell in a containment basin before proceeding with t...

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Page 129: ...nt Information The manufacturer information contained in this section has been obtained from publicly available web sites and has been provided for information purposes only Farr Canada Corp does not guarantee the accuracy of the in formation contained in this section All original copyrights claimed by the manufacturer s apply ...

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Page 131: ...theoretical torque Speed to 2 000 RPM continuous Up to 75 HP continuous Conforms to SAE C mounting specification 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 M A N U F A C T U R E R OF HYDRA U L I C M O T O R S ...

Page 132: ... STD 1 25 4 BOLT FLANGE NEAR AND FAR 15 Series Standard Motor Envelope A B 6 82 3 41 4 50 SQR 5 70 17 CENTER LINE CASE DRAIN 17 CENTER LINE CASE DRAIN PORT B PORT A 5 91 9 0 2 18 5 80 24 50 1 62 EFF KEY 1 0 5 000 4 998 1 250 1 248 313 315 7 80 PORT A 5 40 1 3 OPTIONAL SHAFT 1 8 2 2 REAR VIEW SAE 14T 12 24 PITCH FLAT ROOT SIDE FIT INVOLUTE SPLINE ALTERNATE PORT A 1 1 4 O RING BOSS ALTERNATE PORT B ...

Page 133: ...erature will adversely affect seal life while accelerating oxidation and fluid breakdown Fire resistant fluids may be used with certain limitations Contact Rineer for additional information CASE DRAIN The 15 Series Motor is designed for either internal or external case drain Two case drain ports are supplied When using internal case drain simply plug the two ports When using external case drain us...

Page 134: ...UAL TORQUE AND POWER 9 5 CID 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 500 1000 1500 2000 2500 3000 PRESSURE psid TORQUE ft lbf 0 10 20 30 40 50 60 70 80 90 100 POWER HP 1700 RPM 100 RPM 1700 RPM 900 RPM 300 RPM 100 RPM 500 RPM 1300 RPM RPM 11 5 C I D ACTUAL TORQUE AND POWER 11 5 CID 0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 500 1000 1500 20...

Page 135: ...ouble Key 50 Retractable 53 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 sales rineer com Applications Rineer Hydraulics Inc warrants that at the time of shipment to Purchaser our product will be free of defects in the material and workmanship The above warranty is LIMITED to defective...

Page 136: ...7 8 Technical Manual Hydraulic Motor Information Standard Motor Two Speed Motor HYDRAULICS INC HYDRAULICS INC R M A N U F A C T U R E R OF HYDRA U L I C M O T O R S 15 Series Repair Manual 331 BREESPORT SAN ANTONIO TX 78216 210 341 6333 FAX 210 341 1231 ...

Page 137: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 9 Technical Manual Hydraulic Motor Information ...

Page 138: ... 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 p...

Page 139: ...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 car...

Page 140: ... 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 ...

Page 141: ... 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 I...

Page 142: ...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...

Page 143: ...5 ft lbs Grease used for bolt threads and o ring retention Pennzoil 707L RED Shaft 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 sales rineer com WHEEL MOTOR STANDARD MOTOR TWO SPEED MOTOR ...

Page 144: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 16 Technical Manual Hydraulic Valve Information ...

Page 145: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 17 Technical Manual Hydraulic Valve Information ...

Page 146: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 18 Technical Manual Hydraulic Valve Information ...

Page 147: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 19 Technical Manual Hydraulic Valve Information ...

Page 148: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 20 Technical Manual Hydraulic Valve Information ...

Page 149: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 21 Technical Manual Hydraulic Valve Information ...

Page 150: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 22 Technical Manual Hydraulic Valve Information ...

Page 151: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 23 Technical Manual Hydraulic Valve Information ...

Page 152: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 24 Technical Manual Hydraulic Valve Information ...

Page 153: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 25 Technical Manual Hydraulic Valve Information ...

Page 154: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 26 Technical Manual Hydraulic Valve Information ...

Page 155: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 27 Technical Manual Hydraulic Valve Information ...

Page 156: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 28 Technical Manual Hydraulic Valve Information ...

Page 157: ...KT5500 5 1 2 Tong CLINCHER Backup Section Contents 7 29 Technical Manual Hydraulic Valve Information ...

Page 158: ...n it The force generated at port 3 must be greater than the sum of the forces acting at port 1 and port 2 plus the spring force for the valve to open NOTE The pilot area 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 are functions of the force balances ...

Page 159: ...ns Technical Data U S Units Metric Units Cavity T 17A Capacity 60 240 L min Area Ratio A3 to A1 1 8 1 Area Ratio A3 to A2 2 25 1 Maximum Operating Pressure 5000 350 bar Maximum Valve Leakage at 110 SUS 24 cSt 10 10 drops min 70 bar Pilot Volume Displacement 15 2 5 cc Series from Cavity 3 U S Patent 4 795 129 Valve Hex Size 1 1 4 31 8 mm Valve Installation Torque 150 160 200 215 Nm Seal Kits Buna 9...

Page 160: ...use in cross port relief circuits If used in cross port relief circuits consider spool leakage Main stage orifice is protected by a 150 micron stainless steel screen Not suitable for use in load holding applications due to spool leakage Back pressure on the tank port port 2 is directly additive to the valve setting at a 1 1 ratio All 2 port relief cartridges except pilot reliefs are physically and...

Page 161: ...mum Operating Pressure 5000 psi 350 bar Maximum Valve Leakage at 110 SUS 24 cSt 3 in min 1000 psi 50 cc min 70 bar Response Time Typical 10 ms 10 ms Series from Cavity 2 Valve Hex Size 1 1 8 in 28 6 mm Valve Installation Torque 45 50 lbf ft 60 70 Nm Adjustment Screw Hex Socket Size 5 32 in 4 mm Adjustment Nut Hex Size 9 16 in 15 mm Adjustment Nut Torque 108 lbf in 12 Nm Model Weight 50 lb 0 25 kg ...

Page 162: ... bar 1000 psi 70 bar Standard Setting E 25 400 psi 1 7 28 bar 200 psi 14 bar Standard Setting D 25 800 psi 1 7 55 bar 400 psi 30 bar Standard Setting B 50 1500 psi 3 5 105 bar 1000 psi 70 bar Standard Setting Q 60 400 psi 4 25 bar 200 psi 14 bar Standard Setting N 60 800 psi 4 55 bar 400 psi 30 bar Standard Setting P Stainless Buna N W Stainless Viton V Viton Special Setting required specify at ti...

Page 163: ...he load pressure at port 1 Pressure at port 2 directly opposes pilot pressure Technical Features Provides hose break protection prevents loads from drifting and positively locks pressurized loads Standard unsealed pilot allows air trapped in the pilot line to be purged from the circuit Extremely low leakage The seat and poppet are heat treated for long life If the load drifts due to the valve the ...

Page 164: ... Sun floating style construction to eliminate the effects of internal parts binding due to excessive installation torque and or cavity cartridge machining variations Technical Data U S Units Metric Units Cavity T 2A Capacity 30 gpm 120 L min Pilot Ratio 3 1 3 1 Maximum Operating Pressure 5000 psi 350 bar Maximum Valve Leakage at 110 SUS 24 cSt 1 drops min 0 07 cc min Series from Cavity 2 Valve Hex...

Page 165: ... W Stainless 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 Option Selection CKEB X C N Preferred Options Control Cracking Pressure External Material Seal Mat...

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