EP021 - BU3-1500 Operation Manual

E
EPP002211 -- C
Coou
uggaarr T
Tooo
oll B
BU Brreeaakko
U--11550000 B ouutt U
Unniitt
O
Oppeerraattiio
onnss M
Maan
nuuaall
MAY 2009
Cougar Tool BU3-1500 Breakout Unit Manual
Table of Contents
Introduction 2
Safe Practices and Procedures 3
Cougar Tool BU3-1500 Breakout Operation 4

I. Installation 4
a. Hydraulic Connections 4
b. Anchoring the Breakout Unit (with Optional Push/Pull Unit) 4
II. Breakout Unit Controls 6
III. Breakout Unit Operation 7
a. Positioning Tool in Breakout 7
b. Making/Breaking Joints 7
c. Spinner Operation (Optional) 8
d. Push/Pull Procedure (Optional) 9
I. Pulling Operations 9
II. Pushing Operations 9
e. Test Bed Procedure (Optional) 10
Maintenance and Troubleshooting 12

I. Weekly Maintenance 12
II. Monthly Maintenance 13
III. Annual Maintenance 13
IV. Troubleshooting Guide 14
Cougar Tool BU3-1500 Parts List 16
Assembly Drawings for Cougar Tool BU3-1500 23

I. Bed Assembly (BU3-1500-100) 23
II. Headstock Assembly (BU3-1500-200) 24
III. Tailstock Assembly (BU3-1500-300) 25
IV. Clamp Cylinder Assembly (BU3-1500-500) 26
V. Die Head Assembly (BU3-1500-600) 27
VI. Jack Head Assembly (BU3-1500-700) 28
Attachments 29
I. Setting Operation for HILTI HAD-P Anchors 29
II. HAD-P 20-M10x100/20 Technical Data 29
III. Calibration Certificates 30
Revision: 2 Approved By: -1-

Date: MAY 6 2009 T.GUST
MAY 6 2009
Introduction
The Cougar Tool BU3-1500 Breakout Unit is an extremely robust make/break

machine. The unit allows the operator to apply a torque to a connection
without applying a damaging side load. This guarantees torque and easy, fast
servicing of drilling tools. The BU3-1500 consists of a breakout bed with a
stand-alone console. Mounted on the bed is a fixed head with a power
traversing, chain-driven tailstock. The fixed head applies the torque while the
traversing tailstock allows the operator to precisely position the location of
the reactive torque.
The bed features enclosed traverse drives for added safety and less
maintenance and a full drip tray to contain harmful fluids. The clamping force
is uniformly applied and proportional to the diameter to ensure that delicate
components are not damaged during servicing. The control console houses
the electric drive motor and hydraulic pumps along with the required controls
and the hydraulic reservoir. The console requires the only electrical
connection to operate the breakout. The stand alone control console allows
maximum flexibility of unit placement for ease of use and safety.
General Specifications:
- 175,000 ft-lbs make-up torque

- 250,000 ft-lbs break torque
- 7,500 ft-lbs minimum torque
- Accommodates Ø3 ½” to Ø14” tools
- 15’ bed accommodates long tools
- Safe 3,000 PSI system pressure
- Extra heavy-duty construction to guarantee durability
- Leveling jacks on both headstock and tailstock
Electrical Specifications
- 30hp electric motor, 22kW

- Customer specified voltage and frequency
Options
- Tailstock spinner, 500 ft-lbs at 6 ½” O.D.

- Push/pull cylinder, 48” stroke at 47,700 lbs (push) and 26,500 lbs (pull)
- Test Bed Console incorporated into breakout console, if desired

MAY 6 2009
Safe Practices and Procedures
Appropriate personal protective equipment and clothing is to be worn when

operating the breakout unit.
Unsupervised operation of the breakout unit is recommended only if an

individual has successfully completed a safety training course and an
overhead crane and jib crane course.
Familiarization with the control panel above before using the breakout unit is
recommended. Refer to each section in this manual for specific control
functions.

MAY 6 2009
Cougar Tool BU3-1500 Breakout Operation
Section I: Installation
The BU3-1500 unit comes almost fully assembled for easy installation. The only
installation issues there may be include the anchoring of the unit, and the
connection of the hydraulic hoses.
Installing the hydraulic hoses
The only connections that need to be made are the hydraulic connections to
the control panel. For ease of installation, each hose has been labeled with the
port number stamped next the port in the back of the control panel.
Simply connect the corresponding hose to the port. Some connections may not
be labeled; these are known as EZ Fit connections, and they will only fit into
the proper connection. Connecting all labeled connections first will make it easy
to locate the remaining EZ Fit connections – remember that it is possible that
all connections are labeled and you will not need to worry about the EZ Fit
connections.
Anchoring the Breakout Unit (with Optional Push/Pull Unit)
It is important to anchor the BU3-1500 unit, and the push-pull unit(optional).

The layout below indicates the floor mounts that need anchoring. These are
MAY 6 2009
the only floor mounts that need anchoring. It is important to use HILTI HDA
Undercut Anchors: HDA-P M10X100/20. The base concrete should be a
minimum of 6 3/4 inches (170 mm) thick. (see Attachments for specs and
HILTI’s Installaton Instructions for the Anchors page 29)
ANCHOR
ANCHOR ANCHOR ANCHOR ANCHOR
ANCHOR
ANCHOR ANCHOR ANCHOR ANCHOR
Anchor in locations shown (both sides of unit).

Determine exact locations from equipment to be installed.
Note: The tailstock stopper bolts onto the top of the push/pull beam on the
bed.
If there is any doubt about installation, please call your Cougar representative
and they would be more than happy to accommodate your concerns.

MAY 6 2009
Section II: Breakout Unit Controls
System Pressure/Torque
Pressure Adjuster
Gauge
Headstock Jar Test Push/Pull Torque Tailstock

Clamp Lever Lever Cylinder Make/Break Clamp Lever
Lever Lever
Make Torque
Break Torque Control

Panel
Display
Clamping
Push/Pull
Jar Tester
Start/Stop
Switch
Tailstock Spinner Head Spinner Head Headstock Tailstock

Travel Lever Make/Break Clamp Lever Jack Lever Jack Lever
Lever

MAY 6 2009
Section III: Breakout Unit Operation
Positioning Tool in Breakout Unit
1. Press the green “start” button on the console to start the machine.
2. Using an overhead crane, position the connection to be made/broken within

the breakout bore so that the headstock will clamp on one side of the joint
and the tail stock on the other side. The distance between the traveling
tailstock and the headstock can be adjusted using the traverse/travel lever.
Making/Breaking Joints
1. Move the tailstock clamp lever to the clamp position until the clamping jaws
seat on the part, it may be necessary to leave the lever in the clamp
position to ensure that clamping force is not reduced when making/breaking
connection.
2. Support overhang from either end by raising the headstock/tailstock jacks,

just enough to help support the tool. Too much load on the jacks can
damage them or the tool.
3. Once the tool is properly supported in the breakout unit, unhook it from the
overhead crane and move the crane so that it will not interfere with the
breakout unit.
4. Rotate the headstock by pushing or pulling the “head rotate” lever until the
torque cylinders are at the extremes of their travel, as required for making
MAY 6 2009
or breaking. When rotating the headstock, ensure the headstock clamp

cylinders are withdrawn enough that the clamping dies do not drag along
the surface of the part.
5. Move the headstock clamp lever to the clamp position until the clamping
jaws seat on the part, it may be necessary to leave the lever in the clamp
position to ensure that clamping force is not reduced when making/breaking
connection.
6. Push or pull the “head rotate” lever in the direction required to make/break
the connection as needed.
7. Once the headstock stops rotating, repeat steps 4-6 until either no
movement is seen in the connection (make) or the connection has backed
off enough that it can be turned with chain tongs (break).
8. Once the connection is broken or made up to the correct value on the

torque gauge, support the parts with an overhead crane and completely
withdraw the clamp cylinders.
9. Lower the headstock and tailstock jacks.
10. Turn “pressure adjust” knob counterclockwise until all system pressure is
relieved, and shut down the machine by pressing the red “stop” button.
Spinner Operation (Optional) – See Section II for diagrams of the controls
1. Adjust the spinner head by pushing or pulling the spinner head lever until
the spinners are against the tool.
2. Rotate the spinners to make (pull) or break (push) the connection by

moving the lever in the appropriate direction.
MAY 6 2009
Push/Pull Procedure (Optional) – See Section II for diagrams of the controls
I. Pulling Operations
1. Clamp stator tube in breakout unit headstock.
2. Attach appropriate nubbin to rotor connection.
3. Use pins to secure the position of the push/pull assembly in the

appropriate location to pull the rotor; where ram extends the furthest.
4. Connect the rotor nubbin to the ram(in extended position).
5. Use the push/pull lever on the control panel to pull the rotor and stator
apart.
6. Repeat steps until rotor and stator are fully separated. It may be
necessary to adjust stator position in the headstock, and/or the
location of the push/pull assembly to fully separate the rotor and
stator.
II. Pushing Operations
1. Clamp stator tube in breakout unit headstock.
2. Attach appropriate nubbin to rotor connection.
3. Use pins to secure the position of the push/pull assembly in the

appropriate location to push the rotor; with ram retracted as far as
possible.
4. Connect the rotor nubbin to the ram(in retracted position).
5. Use push/pull lever on the control panel to push the rotor into the
stator.
CAUTION: Pushing with ram more then 16” (406mm) extended

could cause the ram to bend.
6. Repeat steps until rotor and stator are fully mated. It may be
necessary to adjust stator position in the headstock, and/or the
location of the push/pull assembly to fully mate the rotor and stator.
MAY 6 2009
Test Bed Procedure (Optional) – See Section II for diagrams of the controls
1. Use the overhead crane to pick up the tool and position it over the top of
the test bed.
2. Find the appropriate test nubbin connections and attach them to each end
of the tool.
3. Adjust the Trail (pinned slider) in order to make the tool fit in the test bed,
leaving enough room to push or pull tool’s stroke.
NOTE: Pins must be in before test or damage will occur
4. Lower the bottom end nubbin into the cup on the trail.
Revision: 2 Approved By: - 10 -

MAY 6 2009
5. Adjust the push pull hydraulic ram until the cup is under the top end of
the nubbin.
To do this:
a) Press the on (green) button on the Control Stand.
b) The jar test lever adjusts the position of the hydraulic ram.
c) The pressure/torque adjuster knob adjusts the force applied
by the hydraulic ram, as indicated on the display.
d) The pressure should be turned down before and after testing
the tool.
6. After adjusting the hydraulic ram, lower the top end nubbin into the cup
on the push/pull ram.
7. Using the proper test procedure and service report, testing may begin
once the serial number is written on the report. Senior service staff will
teach testing of tools.

MAY 6 2009
Maintenance and Troubleshooting
The breakout controls should be tested before operating with tools. This is
easily done by turning the breakout unit on, turning the “pressure adjusting”
knob clockwise 2 to 3 times to raise pressure in the system, and
pushing/pulling each lever slightly to verify that each control is working
properly.
The maintenance schedule below must be followed to improve the life and
functionality of the breakout unit. The warranty offered with the Cougar Tool
BU3-1500 will be void if the schedule below is not followed:
Section I: Weekly
1. Check the dies for wear. If the dies are worn or smooth they will not grip
against the tool properly – replace as necessary.
2. Check that the roller chain at the bottom of the bed is not loose. Also
ensure that the chain is not dislodged from the drive shaft and remove
dirt and grease from the chain and drive shaft. Grease the chain after
every cleaning.
3. Check all hydraulic hoses and hose connections – ensure there are no
leaks and that the area around each connection is clean.
MAY 6 2009
4. Clean the drip tray of oil and debris.
Section II: Monthly
1. Check the sight glass for the level of oil in the system. Best practice is to
keep the oil at ½ the height of the sight glass. Also, it is not
recommended that the unit be in continuous operation for more than an
hour, or when the temperature on the site glass reads above 60OC.
Oil Level
2. Grease all bearings. The arrows in the figures below indicate the location
of the grease fittings. They are located behind the front plate of the
headstock (4) and on the backside of the headstock (4).
Rotate headstock
to line up grease
fittings with holes
in front/back
plates.
3. Change the hydraulic filter on a monthly basis or when it is very dirty,

whichever comes first.
Section III: Annually
1. All gauges should be calibrated on a yearly basis by Cougar Tool Inc.

MAY 6 2009
Section IV: Troubleshooting Guide
Symptom: Unit will not turn on
Cause: The unit may not be connected to the power outlet
Remedy: Check that the unit is connect to the power outlet and try to turn the
unit on again
Cause: The “On/Off” switch may have malfunctioned
Remedy: Check the electrical connections on the switch. If the connections are
fine, the switch itself has malfunctioned and must be replaced.
Symptom: System is not responding to the “Pressure Adjust Knob”
Cause: Hose or hydraulic leaks
Remedy: The fittings may be loose, dirty or damaged. If the fittings are loose,
simply tightening them may resolve the problem. If not, the fitting is
damaged and must be replaced. Dirty fittings should also be replaced.
Symptom: Tong dies are slipping on the tool
Cause: Cylinders are not clamped tightly enough
Remedy: Slightly increase the pressure by turning the pressure knob clockwise
until the cylinders are tight enough to grip around the tool.
Cause: Dies are too worn to maintain a grip on the tool
Remedy: Replace the worn dies.
Symptom: No oil visible in sight glass
Cause: Not enough oil in the system
Remedy: Fill the unit with oil until the sight glass contains oil halfway

MAY 6 2009
Symptom: Noise coming from hydraulic pump
Cause: Hydraulic Filter is dirty
Remedy: Check the hydraulic filter for anything that may be clogging fluid flow or
if it is dirty. Clean the filter, reinstall and check again for noise. If the
noise continues, the hydraulic filter needs to be replaced.
Symptom: Tool deformed in clamp
Cause: The clamps are too tight for the tool
Remedy: Release the pressure from the clamps by adjusting the pressure knob
counterclockwise until the pressure reaches the rated make/breaking
torque.
Symptom: Travel Speed of headstock is slow or stuck
Cause: The rail on which the tailstock travels is dirty
Remedy: Keep the rail clean and free of debris
Cause: The roller chain is loose or stuck
Remedy: Ensure that the chain is not dislodged from the drive shaft and remove
dirt and grease from the chain and drive shaft. Grease the chain after
every cleaning.
Cause: The flow control valve for the drive motor is not adjusted properly
Remedy: The flow control valve can adjust the speed of the tailstock. There are 2
flow control valves on the drive motor (or hydraulic lines leading to the
valves located under the control panel), each controlling the speed in
one direction. Adjust the speed by turning the graduated knob on the
valve to control the speed of the direction the valve is controlling.

MAY 6 2009
Cougar Tool BU3-1500 Parts List
Breakout Unit Assembly (Drawing # BU3-1500-V1)

Description Qty. Drawing #
Bed Assembly 1 BU3-1500-100
Bed Weldment 1 BU3-1500-101
Drip Tray Bottom Plate 1 BU3-1500-113
Oil Pan Cap 2 BU3-1500-106
Bed End Plate 2 BU3-1500-123
Bed Base Plate 4 BU3-1500-124
Straight Support 5 BU3-1500-126
Bed Side Plate 2 BU3-1500-122
Bed Top Plate 1 BU3-1500-120
Bed Side Rails 2 BU3-1500-121
Angled Support 6 BU3-1500-127
Tailstock Weldment 1 BU3-1500-104
Tailstock Stopper 1 BU3-1500-109
Stopper Gusset 2 BU3-1500-110
Shaft Cover Weldment 2 BU3-1500-103A
Shaft Cover - 3/8" x 8" Dia. x 30" lg. 1 BU3-1500-107
Shaft Cover Bracket - 3/8" x 3" x 4" Plate 1 BU3-1500-108
Motor Base Plate - 4" x 1/2" x 7 1/8" lg. Flat Bar 1
Drive Shaft 1 BU3-1500-111
Idler Shaft 1 BU3-1500-112
Pillow Block Housing - RASE 1 INA 4
Split Taper Bushing Sprocket - H50H13 4
Drain - 1" NPT Coupling c/w Plug 1
Chain Guide w/ Bracket 4 BU3-1500-129
Chain Runner 1 BU3-1500-105
Chain Bracket 4 BU3-1500-128
Drive Motor - ADM150-4RO 1
Drive Motor Support Mount - FM-200 1
Martin Chain Coupling - 5016-1 1
7/16"-14 UNC - 1 1/2" lg. Hex Cap Screw 8
7/16" Flat Washer 8
1/2"-13 UNC - 1" lg. Hex Cap Screw 4
1/2"-13 UNC - 2" lg. Heavy Hex Bolt 2
1/2"-13 UNC - 1" lg. Hex Bolt 16

MAY 6 2009
1/2" Lock Washer 22

1/2" Hex Nut 16
Headstock Assembly 1 BU3-1500-200
Cylinder Port Assembly 1 BU3-1500-501
Header Frame Weldment 1 BU3-1500-201
Headstock Cylinder Block 1 BU3-1500-213
Stub For Rotating Headstock 2 BU3-1500-214
Outer Clevis Pin 2 BU3-1500-216
Inner Clevis Pin 2 BU3-1500-215
Clamp Cylinder Assembly 6 BU3-1500-500
Clamp Cylinder Body 1 BU3-1500-502
Clamp Cylinder Cap 1 BU3-1500-503
Clamp Cylinder Piston 1 BU3-1500-504
Clamp Cylinder Rod 1 BU3-1500-505
#266 O-Ring 1
#234 O-Ring 1
5/16"-18 UNC - 3/8" lg. Set Screw 1
C914-8000-375 Chemcast 1
2500-4000-562B Poly Pak 1
SHD-4000 Wiper 1
W2-8000-500 Wear Ring 2
W2-4250-500 Wear Ring 2
Die Head Assembly 6 BU3-1500-600
Die Head 1 BU3-1500-601
Die Key 1 BU3-1500-602
Die Holder 2 BU3-1500-603
1” x 1 1/4” x 3 7/8” Tong Die - CD1-1691 1
3/8"-16 UNC - 5/8" lg. Socket Head Cap Screw 1
3/8"-16 UNC - 7/8" lg. Socket Head Cap Screw 1
3/8"-16 UNC - 1" lg. Flat Countersunk Head Cap Screw 4
3/8"-16 UNC - 7/8" lg. Socket Set Screw - Cone Point 2
Front Bearing Support 1 BU3-1500-217
Back Bearing Support 1 BU3-1500-218
Back Plate Weldment 1 BU3-1500-203
Back Plate 1 BU3-1500-211
Back Plate Base 1 BU3-1500-224
Back Plate Gusset 1 BU3-1500-212
Front Plate Weldment 1 BU3-1500-701

MAY 6 2009
Front Plate Weldment 1 BU3-1500-202

Front Plate 1 BU3-1500-207
Right Gusset Plate 1 BU3-1500-210
Left Gusset Plate 1 BU3-1500-209
17” Support Plate 2 BU3-1500-221
Slewing Bearing - VSU 20 0544 2
2-385 O-Ring 2
2-387 O-Ring 2
5/8"-11 UNC - 3 1/2" lg. Socket Head Cap Screw 48
3/4"-10 UNC - 2 1/2" lg. Hex Head Cap Screw 24
1/2"-13 UNC - 2 1/2" lg. Hex Head Cap Screw 64
Mount Tab 1 BU3-1500-703
Internal Guide 2 BU3-1500-706
Flow Divider Support Bracket 1 BU3-1500-311
1/4" Thick Steel Plate 1 BU3-1500-312
1/4" Thick Steel Plate 1 BU3-1500-313
1/4" Thick Steel Plate 1 BU3-1500-314A
1/4" Thick Steel Plate 1 BU3-1500-314B
Hydraulic Torquing Cylinder - RHK MF00-343 2
Long Torque Cylinder Pin 4 BU3-1500-403
3000 psi Hydraulic Jack Cylinder - PMC-43008 1
Jack Head 1 BU3-1500-700
Jack Head Backing Plate 1 BU3-1500-710
Support Plate 2 BU3-1500-705
Nut 1 BU3-1500-709
Gusset 2 BU3-1500-704
Threaded Ring 2 BU3-1500-708
Mathews 101105 Ball Transfer - B4560 Ball Transfer 2
External Guide 2 BU3-1500-707
Flow Divider - 6 Sections - 31 Series
Torque Pin Weldment 4 Bu3-1500-400
Torque Cylinder Pin 1 BU3-1500-402
Cylinder Pin Plate 1 BU3-1500-401
5/8" Lock Washer 8

MAY 6 2009

7/16" Lock Washer 8
Spinner Mounting Assembly 1 SP1-1450-045
Tailstock Assembly 1 BU3-1500-300
Tailstock Weldment 1 BU3-1500-301
Tailstock Cylinder Block 1 BU3-1500-307
Tailstock Side Plate 2 BU3-1500-305
Tailstock Front Plate 1 BU3-1500-303
Tailstock Back Plate 1 BU3-1500-304
Clamp Cylinder Assembly (same as Headstock) 6 BU3-1500-500
Die Head Assembly (same as Headstock) 6 BU3-1500-600
Chain Anchor 4 BU3-1500-308
Jack Head Assembly (Tailstock) 1 BU3-1500-711
Square Tube Support 2 (Tailstock) 1 BU3-1500-715
Support Plates 2 BU3-1500-713
Nut 1 BU3-1500-712
Threaded Ring 2 BU3-1500-708
Mathews 101105 Ball Transfer - B4560 Ball Transfer 2
Square Tube Support (Tailstock) 1 BU3-1500-714
Base Plate (Tailstock) 1 BU3-1500-718
Side Support Plates (tailstock) 2 BU3-1500-720
2" x 2" x 1/4" thick Square Tubing - 8"lg. 1
Hydraulic Jack Cylinder (Tailstock) – Monarch Ind. 30TL08-125 1
Cam Follower - CF30 PP 38
3/4"-10 UNC Hex Nut 38
3/4" Lock Washer 38
3/8" Lock Washer 8
Spinner Assembly 1 SP1-1450-035
Traverse Beam 1 SP1-1450-018
Mounting Block 1 SP1-1450-020
Traverse Tube 1 SP1-1450-017
Traverse Plate 8 SP1-1450-042
Arms 1 SP1-1450-036A & B
Spinner Arm 2 SP1-1450-014
Arm Plate 1 SP1-1450-011
Arm Plate "B" 1 SP1-1450-012

MAY 6 2009
Cassette Mount Plate 1 SP1-1450-039

Spinner Brace 1 SP1-1450-040
Spinner Plate 1 SP1-1450-041
Cassette Assembly 2 SP1-1450-037
Cassette 1 SP1-1450-009
Cassette Mount 1 SP1-1450-013
Motor Plate 1 SP1-1450-007
Cassette End Plates 2 SP1-1450-032
Backing Plate 1 SP1-1450-008
Wheel 2 SP1-1450-001
Hub 2 SP1-1450-004
Bobbin 319010 Trelleborg 8
Outer Bearing Support 2 SP1-1450-006
Inner Bearing Support 2 SP1-1450-005
Bearing - SKF 6015-2RS1 4
Hydraulic Motor - Eaton 104-1003 2
3/8"-16 UNC - 1 1/4" lg. Cap Screw 16
3/8"-16 UNC - 1 1/4" lg. Low Profile Cap Screw 10
3/8"-16 UNC - 1" lg. Cap Screw 12
1/2"-13 UNC - 2" lg. Cap Screw 4
M12 x 1.75 Hex Nut 8
Cross Shaft Retainer 4 SP1-1450-015
Cross Shaft 2 SP1-1450-016
1/2"-13 UNC - 1 1/4" lg. Cap Screw 24
M12 x 1.75 Hex Nut 16
Swing Arm 1 SP1-1450-038
Swing Arm 1 SP1-1450-027
Swing Arm Plate 1 SP1-1450-026
Swing Arm Tab 1 SP1-1450-025A
Swing Arm Tab 1 SP1-1450-025B
Swing Arm End Plate 1 SP1-1450-033A
Swing Arm End Plate 1 SP1-1450-033B
Swing Arm End Plate 1 SP1-1450-033C
Rosta Bracket 2 SP1-1450-034
Adjuster 1 SP1-1450-031
Adjuster Plate 1 SP1-1450-029
Gusset 4 SP1-1450-028
Adjuster Collar 1 SP1-1450-030

MAY 6 2009
Rubber Suspension Unit - Rosta DK-A-1 50x300 1

Square Key 8mm x 300mm lg. 1
Rubber Suspension Unit - Rosta DO-A-1 50x200 2
Hanger 4 SP1-1450-021
M12 x 1.75 x 60 lg. Socket Head Cap Screw 8
M12 x 1.75 x 80 lg. Socket Head Cap Screw 32
1/2"-13 UNC - 2" lg. Socket Head Cap Screw 6
Break Out Mount 1 SP1-1450-024
Rib 2 SP1-1450-023
Mount Plate 1 SP1-1450-022
Mount Tube 2 SP1-1450-043
Hydraulic Cylinder - R6-20CT-14 1
3/4"-10 UNC - 4 1/2" lg. Set Screw - Flat Point 1
Spacer 2 SP1-1450-044
Push/Pull Assembly 1 PP1-017
Cylinder Strap 1 PP1-013
Push/Pull Frame 1 PP1-016
Pin Collar 2 PP1-010
Rear Tube 1 PP1-012
Brace 2 PP1-023
Front Tube 1 PP1-011
Cross Brace 1 PP1-015
Base Plate 2 PP1-008
Strut 4 PP1-007
Cylinder Mount Tab 2 PP1-014
Axle 2 PP1-001
Roller 2 PP1-002
Beam Guide 4 PP1-009
Cylinder Pin 1 PP1-018
Push/Pull Nubbin 1 PP1-021
Hydraulic Cylinder - R4506159 1
1/2"-13 UNC - 2" lg. Hex Bolt 8
3/8"-16 UNC - 1" lg. Hex Bolt 8
3/8" Flat Washer 8

MAY 6 2009
1 1/2" Flat Washer 2

1 1/4" Flat Washer 2
Push/Pull Beam 1 PP1-024
Push/Pull Beam 1 PP1-005
Module I-beam 1 TB2-002
VAS 8 TB1-30-001D
Floor Mount 3 PP1-006
Side Breakout Mount 1 PP1-004
Top Breakout Mount 1 PP1-003
Push/Pull Beam Extension 1 PP1-020
Floor Mount 3 PP1-006
Module I-beam 1 TB2-002
VAS 8 TB1-30-001D
Push/Pull Beam Flange 2 PP1-025
3/4"-10 UNC - 2 3/4" lg. Hex Bolt 6
3/4" Lock Washer 6
Chain Bolt 4 BU3-1500-315
Roller Chain (551 links) - #50-1R Ren 2
Trail Pin 2 TB1-30-004
Control Panel 1
1/2"-13 UNC - 2" lg. Hex Bolt 2
1/2" Lock Washer 2
5/8" Flat Washer 18
5/8" Lock Washer 18
Breakout Hydraulic Hose Kit 1

MAY 6 2009
Assembly Drawings For Cougar Tool BU3-1500
Bed Assembly
(From BU3-1500-100)
NOTCH SPLASH GUARD

TO FIT AROUND COUPLING
TAIL STOCK WELDMENT BOLTS

ONTO PP1-005 (NOT SHOWN)
FOR ASSEMBLY OF BU3-1500-V1
VIEW B-B
NOTE: SOME ITEMS REMOVED FOR CLARITY
VIEW A-A
SECTION A-A
DETAIL B
DETAIL A

MAY 6 2009
Headstock Assembly
(From BU3-1500-200)
NOTE: ASSEMBLE ENTIRE HEAD STOCK ASSEMBLY BEFORE BOLTING TO BREAK-OUT BED
FRONT VIEW BACK VIEW

MAY 6 2009
Tailstock Assembly
(From BU3-1500-300)
Ø15.000
36.137
Ø16.000
8.7
17.9
8.7
1.25

MAY 6 2009
Clamp Cylinder Assembly

(From BU3-1500-500)

MAY 6 2009
Die Head Assembly

(From BU3-1500-600)
6 2
BILL OF MATERIALS
ITEM QTY DRAWING/PART NUMBER DESCRIPTION
1 1 BU3-1500-601 DIE HEAD
2 1 BU3-1500-602 DIE KEY
3 2 BU3-1500-603 DIE HOLDER
4 1 1” x 1 1/4” x 3 7/8” TONG DIE CD1-1691
5 1 3/8 - 16 UNC - 5/8LG Hex Socket Head Cap Screw
6 1 3/8 - 16 UNC - 7/8LG Hex Socket Head Cap Screw
7 4 3/8-16 UNC x 1LG Hex Socket Flat C'sunk HCS
8 2 3/8-16 UNC x 7/8LG Hex Socket Set Screw - Cone Point

MAY 6 2009
Jack Head Assembly

(From BU3-1500-700)
3.50
(TYP)
15°
3.5
3.25 1.75
(TYP) (TYP)
6.5
11.0
(REF)
SECTION A-A
3.25

MAY 6 2009
Attachments
HDA-P 20-M10x100/20 Item No.: 00331544 Technical Data

The indicated load value applies to non-cracked concrete C20/25,
Additional Product Information
with no edge distance and spacing influence.
Anchor Length 150 mm
Standard Embedment Depth 100 mm
Max. thickness fastened in concrete 20 mm
Min. thickness fastened 10 mm
Hole depth 107 mm
Baseplate clearance hole 12 mm
Washer size 27.5 mm
Wrench size 17 mm
Drill bit diameter 20 mm
Length identification mark I
Material coating/plating/finish Galvanized min. 5 μm
Material composition Steel grade 8.8
Required torque 50 Nm
Min. thickness of base material 170 mm
Effective anchorage depth 100 mm
Approvals ETAG, DIBt, Shock BZS, Fire IBMB
Required setting tool TE-C-HAD-ST 20-M10
Package quantity 12
Recommended tension load general 21.9 kN

MAY 6 2009

EP021 - BU3-1500 Operation Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

EP021 - BU3-1500 Operation Manual

Uploaded by

Copyright:

Available Formats

E

Safe Practices and Procedures 3

Cougar Tool BU3-1500 Breakout Operation 4

Maintenance and Troubleshooting 12

Cougar Tool BU3-1500 Parts List 16

Assembly Drawings for Cougar Tool BU3-1500 23

Revision: 2 Approved By: -1-

The Cougar Tool BU3-1500 Breakout Unit is an extremely robust make/break

- 175,000 ft-lbs make-up torque

- 30hp electric motor, 22kW

- Tailstock spinner, 500 ft-lbs at 6 ½” O.D.

Revision: 2 Approved By: -2-

Safe Practices and Procedures

Appropriate personal protective equipment and clothing is to be worn when

Unsupervised operation of the breakout unit is recommended only if an

Revision: 2 Approved By: -3-

Cougar Tool BU3-1500 Breakout Operation

Installing the hydraulic hoses

Anchoring the Breakout Unit (with Optional Push/Pull Unit)

It is important to anchor the BU3-1500 unit, and the push-pull unit(optional).

Anchor in locations shown (both sides of unit).

Revision: 2 Approved By: -5-

Section II: Breakout Unit Controls

Headstock Jar Test Push/Pull Torque Tailstock

Break Torque Control

Tailstock Spinner Head Spinner Head Headstock Tailstock

Revision: 2 Approved By: -6-

Section III: Breakout Unit Operation

Positioning Tool in Breakout Unit

2. Using an overhead crane, position the connection to be made/broken within

2. Support overhang from either end by raising the headstock/tailstock jacks,

or breaking. When rotating the headstock, ensure the headstock clamp

8. Once the connection is broken or made up to the correct value on the

9. Lower the headstock and tailstock jacks.

Spinner Operation (Optional) – See Section II for diagrams of the controls

2. Rotate the spinners to make (pull) or break (push) the connection by

Push/Pull Procedure (Optional) – See Section II for diagrams of the controls

1. Clamp stator tube in breakout unit headstock.

2. Attach appropriate nubbin to rotor connection.

3. Use pins to secure the position of the push/pull assembly in the

4. Connect the rotor nubbin to the ram(in extended position).

II. Pushing Operations

1. Clamp stator tube in breakout unit headstock.

2. Attach appropriate nubbin to rotor connection.

3. Use pins to secure the position of the push/pull assembly in the

4. Connect the rotor nubbin to the ram(in retracted position).

CAUTION: Pushing with ram more then 16” (406mm) extended

Revision: 2 Approved By: - 10 -

Revision: 2 Approved By: - 11 -

Maintenance and Troubleshooting

4. Clean the drip tray of oil and debris.

Section II: Monthly

3. Change the hydraulic filter on a monthly basis or when it is very dirty,

Section III: Annually

1. All gauges should be calibrated on a yearly basis by Cougar Tool Inc.

Section IV: Troubleshooting Guide

Symptom: Unit will not turn on

Cause: The unit may not be connected to the power outlet

Cause: The “On/Off” switch may have malfunctioned

Symptom: System is not responding to the “Pressure Adjust Knob”

Cause: Hose or hydraulic leaks

Symptom: Tong dies are slipping on the tool

Cause: Cylinders are not clamped tightly enough

Cause: Dies are too worn to maintain a grip on the tool