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    Service - Anda Hydraulics Asia Pte Ltd
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    814 OPERATION SERVICE MANUAL Rev. 7-10-08 (1) (1)

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    814 OPERATION SERVICE MANUAL Rev. 7-10-08

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    Service - Anda Hydraulics Asia Pte Ltd

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    © All Rights Reserved
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    MODEL 814 BUCKING UNIT OPERATION AND SERVICE MANUAL INSTRUCTION MANUAL MODEL 814 BUCKING UNIT NOTICE "The information contained in this document is subject to change without notice. NATIONAL OILWELL, PRODUCT AND TECHNOLOGY SHALL NOT BE LIABLE VOR TECIINICAL OR EDITORIAL, ERRORS OR OMISSIONS CONTAINED HEREIN, NOR FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. RESULTING FROM THE FURNISHING, PERFORMANCE, OR USE OF THIS MATERIAL, National Oilwell Product and Technology Product nanies mentioned herein may be wademarks and/or registered trad narks of their respective companies, ©2001 National Oilwell Product and Technology All rights reserved, Printed in the U.S.A. MODEL 814 BUCKING UNIT Document Part Number (204415/010) MODEL 814 BUCKING UNIT OPERATION AND SERVICE MANUAL f ped-O-matic see BOWEN ToOLs, INC. TABLE OF CONTENTS | 2 SECTION 1 - GENERAL PAGE ‘ Briel description . at ace . we Preparation of new equipment ior operation... : 1 _ SECTION 2 - INSTALLATION Placement of the bucking unit .. 7 Peta Seed Connection of the hydraulic and air lines between the power unit and the tong skid. Connection of the air supply to the bucking unit SECTION 3 - OPERATION General . 7 Adjustment of the bucking unit height Reversing the tong jaws Changing the tong jaws and inserts Reversing the rotary back-up assembly jaws. Changing the jaws and inserts for the rotary back-up assembly 212.12) Operation of the bucking unit ..........22++ 7 Make-up Breakout 2 SECTION 4- PREVENTATIVE MAINTENANCE General Cleaning and greasing the tong jaws, drag ring and pins Adjustment of the drag ring plugs «2+... Replacement of the tong jaw inserts : fl 4. Changins the jaws and inserts for the rotary back-up assembh © Draining oil from the ease : ae Replacing oil in the case «1.2 ‘Cleaning and greasing rotary backcup assembiy Cleaning the back-up assembly air cylinder rod Cleaning the suction strainers of the power unit Replacing the power unit hydraulic fluid line fiter elements Cleaning the air liter ‘Adding lubricant to the mist lubricator Replacing the replenishing pump hydraulic fluid filter element “Replacing the high pressure hydraulic fluid filter element . 5 __ SECTION § - TROUBLESHOOTING covet SI Troubleshooting chart ... [SECTION 6- SERVICE List of tools required for service . Hydraulic and pneumatic schemati {Final drive gear front oil seal {Final drive gear rear oil seal . | Drive train bearings | Front quide bell wear ring .- (Rear guide bell wear ring and drag ring bushing . 4 Hydraulic motor manifold seals Hydraulic motor .. Rotary backup air eyinder ‘seals SECTION 7 - HYDRAULIC MOTOR ~TONG SECTION 8 - HIGH PRESSURE PUMP —POWER UNIT LECTION 9 - HIGH PRESSURE HYDRAULIC FLUID FILTER ~POWER UNIT SECTION 10 - REPLENISHING PUMP HYDRAULIC FLUID FILTER—POWER UNIT SECTION 11 - PARTS Parts List ....... Wwi-3 INDEX Sheet 17.1 WWH-3 Sheet 12a8b WWW-3 Sheet 46 WWW-3 Sheet 70 WwW-3 Sheet 72 WHW-3 Sheet 5 WHW-3 Sheet 59 SECTION 1 GENERAL [ Diese. PoweRED TRAILER MOUNTED BUCKING UNIT FIGURE 11 i mopeL 14 BUCKING UNIT + BRIEF DESCRIPTION The Peck © Matic Model 814 bucking unit is hydraulically powered equipment for making up and breaking out pipe couplings (Figure 1-1) The mode! 81 4will work 4 1/2:inch through 21 inch pipe. I is available skid or trailer mounted, ‘The hydraulic power unit can be electrically or diesel owered. The electrically powered units operate on 130/460 volt, 50/60 hertz, three phase alternating current electricity. For 230 volt ‘service, the unit requires @ 240 ampere circuit and for a 460 volt service a 120 ampere LI Gitcuit. The bucking unt’ powered by a single hydraulic ! motor and requires no clutches or transmissions. Male up «can be performed in as little as 15 seconds per joint for 13, 3/8:inch couplings and break-out in as litle as 20 seconds per joint for 13 3/8.inch couplings. The model §1 4produces torque from 1,500t0 18,000ft-Ibs at 40rpmin the high speed range and from 3,350 1044 ,000ft-Ibs at 20 ¢pm in the low ; speed range. The model @4 torque curveis shown in Figure 12, ACCESSORIES 1, The Model 814 can be equipped with control valves, andior a hydraulic pump for operating accessory equipment such as hydraulic pipe racks 2. The bucking unit can be supplied with a hydraulic load cell, and torque gauge opposed ta the standard torque ‘gauge operating fram the hydraulic system pressure 3. A high speed model is also avaliable with speeds to 80 pm in high range and 40 rpm in low range, with torques of 10,000 ft-lbs and 23,000 ft-lbs, respectively. 4, The unit can also be supplied witha high speed computer to control torque and turns. The computer contains aCRT display of torque both graphically and digitally andis housed ina free standing operator's console. (Figure 1-3) 5. The bucking unit can be equipped with an electric elevator system with a maximum travel of twelve inches. ‘The four elevators, each on acorner of the tong skid, canbe controlled by one Switch mounted on the control console. (Figure 1-3) 6. The Model 814 can be equipped with an electronic load cell, chart recorder, and digital gauge all contained within one operators console. (Figure 1-4) 7. The Model 314 bucking unit can also be equipped with a ampere fuse for 230 volt service or a 120 ampere fuse for follow the wiring schematic on the motor name plate FIGURE 14 CHART RECORDER AND DIGITAL GAUGE OPERATORS CONSOLE (CRT COMPUTER ~~ prguRe. 13 CRT COMPUTER CONSOLE AND ELECTRIC ELEVATOR SYSTEM 1 DIRECTION OF ROTATION FOR HIGH PRESSURE PUMP) FIGURE 15 * PREPARATION OF NEW EQUIPMENT FOR OPERATION i 1. Upon receipt of the bucking unit, inspect thoroughly to. | make sure it has not been damaged during shipment. 2. For electrically powered bucking units, a 100hp motor ; | starter and power disconnect, ampere fuse for 250 volts #°° volt service should be vice or s 120 ampere fuse for: ised, d,s wired for 440 volt alternating the motor for 220 volt service, : 14 box must be installed. A240 | j {Tolow the wiring “Schematic | marked low voltage, | 4. The high pressure pump must rotate clockwise when [facing the shaft end of the pump. If the pump rotates | counterclockwise, the motor phases must be rewired at the the motor name plate | motor starter. The direction of the motor rotation can be changed by reversing any two of the three wires going to the ! motor starter. (Figure 1-5) Caution: Rotation of the high {pressure pump in the counterclockwise direction for ‘more than 15 seconds may cause damage to the pump. f SECTION 2 INSTALLATION ‘APPROXIMATELY 2 TO § FEET © PLACEMENT OF THE BUCKING UNIT 17 Postion the tong skid, or trailer, i s0 that the coupling end of the pipe is assembly side of the unit to 5 feet between the pipe rack and the buckingunit to ‘easy access to the back-up assembly. the! fed into the bac ck-up ‘There should be approximately 2 allow a. 2. Make sure the tong is perpendicular to the centerline of; the pipe on the pipe rack. (Figure 2-1) Note: The tong ; jnust operate perpedicular to the pipe, which allows the jaws to evenly bite the coupling. unit to the left side of the tong skid. ines supplied with the bucking unit ‘the power unit and thetona skid. ; 3.Position the power The hydraulic and air allow up to 3 feet between HIGH PRESSURE PUMP SWASH PLATE FiGune 22 CONNECTING THE HYDRAULIC AND AIR Fi ©. ew i pinecrion we SEE FIGURE 67 FOR ACTUAL HOSE LOCATION LINES BETWEEN THE POWER UNIT AND THE TONG SKID CONNECTION OF THE HYDRUALIC AND AIR LINES BETWEEN THE POWER UNIT AND THE. TONG SKID 1. The hydraulic and air ines between the power unit and the tong skid (Figure 2-2) perforrn the following functio Line Hi - Linch 6,000 psi rated motor hydraulic fluid pressure line ‘Line H2 - 1inch 6,000 psi rated motor hydraulic uid pressure line Line H3 -3/4inch 500 psi rated motor case hydraulic fluid return line Line H4 - 1/4inch 6,000 psi rated hydraulic Muid high 22 pressure torque line Line H5 - 1/4.inch 2,000 psi rated shifter hydraulic uid pressure line Line Al 1/4.inch air cylinder air line Line A2 - 1/4:inch air cylinder air line 2. Connect the air and hydraulic lines to the power unit and the tong skid. (Figure 2-2) f the distance between the power unit and the tong skid is greater than 3 feet, the hoses supplied with the bucking unit must be lengthened. Caution: If the hoses are lengthened or replaced, make sure that the new hoses are the same pressv rating as the hoses originally supplied with t.. bucking unit. CONNECTION OF THE AIR SUPPLY TO THE BUCKING UNIT 1, The bucking unit requires a dry, oil free compressed air supply of at least 20 CFM’s at 60 psi. 2. Connect the ait supply, using the quick disconnect coupling, to the air fiter. (Figure 2-3) 3. Set the air pressure, read on the pressure gauge mounted on the air regulator, to 60 psi. To adjust the air pressure, loosen the lock nut on the pressure regulator with a 9/16. inch wrench. Turn the knob on the regulator clockwise to increase the pressure and counterclockwise to decrease the pressure. When the correct pressure is read on the pressure gauge, tighten the lock nut on the pressure regulator. (Figure 2:3) PRESSURE REGULATOR PRESSURE GAUGE = \ AIR LUBRICATOR AK FILTER» ‘FicRe 25 ~ CONNECTING THE AIR SUPPLY AND ADJUSTING THE PRESSURE REGULATOR 23 SECTION 3 OPERATION GENERAL 1. Before operating the bucking unit. remove the oil fill plug to cheek the tong case oil level. The level n the case should be to the middle of the elbow, (2 US gallons). I the oillevel is low or the oil is discolored, change the oil as structed in Section 4 “Preventative Maintenance’ 2. Verify that the power unit hydraulic fluid reservoir is tull ‘by looking at the sight glass, Ifthe hydraulic uid levels low, remove the breather cap and add hydraulic fluid, (Arco Tuflo 150 is recommended), until the fuid level shown on the sight glass is at the full mark, (Figure 3.1) Caution: If you are using a hydraulic fluid other than the fluid recommended by the manufacturer, (Arco Tuflo 150), add only the same type of fluid as is presently in the reservoir. Mixing hydraulic fluids may cause fluid deterioration and damage the power unit and equipment. 3. Verify that the hydraulic fuid temperature before ‘operating is between 10 and 100 degrees Fahrenheit by tooking at the thermometer found in the sight glass on the reservoir (Figure 3-1) Note: If the temperature always ‘exceeds 180 degrees Fahrenheit while operating, the addition of an oil cooler is recommended. 4. Determine the torque value for the size and grade of pipe being worked. When its available, use the recommended values specified by the manufacturer. A chart of the torque valves for common size and grades of pipe is shown 220 in Figure 3.2. Its torque values are based upon the following and should be used as a guide: Data relating to API and X connections complied by Continental Oil from joints giving good performance on Loomis testing ‘over an eight month peroid, May thre December, 1955. Others are manufactures’ recommendations. , ADJUSTMENT OF THE BUCKING UNIT HEIGHT * -The height of the bucking unit must be adjusted so that the centerline of the tong and the centerline of the pipe HYDRIL, (FOOT-POUNDS) | He \ HER CAP, SIGHT GLASS FIGURE 31 (CHECKING THE POWER UNIT HYDRAULIC FLUID RESERVOIR FLUID LEVEL — coincide. (Figure 3-3) Note: This adjustment must be made each time the diameter of the pipe being worked is changed. 2. To adjust the height of the tong skid, unscrew the four lock bolts on each jack leg, using a 15/16 inch wrench.To raise the legs, turn the valve on all four jacks clockwise. Insert the jack handle in one of the jacks and raise the unit Place the handle in the next jack and raise to the same height as the first leg. Continue raising each leg in this manner, sequentially, until the correct height is achieved. To lower the legs, tum the valve on all jacks | counterclockwise until the legs lower to the correct height ; land then turn the valves clockwise. Tighten the four lock j bolts on each leg. (Figure 3-4) ‘API 8RD THREAD. Tenative 2500 - 3000 53000 «3500, 3500 «000, ~ FIGURE 32 CHART OF TORQUE VALUES CENTERLINE OF THE TONG k (CENTERLINE OF THE PIPE, {es BOLTS(I6) aif SSS JACKS (3) FIGURE 34 ADJUSTING THE BUCKING UNIT HEIGHT 32 FIGURE 93 c BUCKING UNIT HEIGHT REVERSING THE TONG JAWS 1. The tong jaws must be reversed when changing from make-up to break-out or from break-out to make-up. 2. Remove the latch pin which secures the front guide bell, Open the front guide bell and remove the cover plate. Slip the jaws off the drag ring pins, (Figure 35) 3. The jaws are marked on each end with either “M” for “make-up” or “B” for “break-out”. After removing the jaws, turn them over and reinsert them on the drag ring pins so that the applicable letter, “M” or “B”, is visible, 4. Check to make sure that the teeth on the jaws are equidistant from the inside diameter of the final drive gear. Figure 3-6) 5. Replace the cover plate, close the front guide bell, and replace the latch pin. CHANGING THE TONG JAWS AND INSERTS 1, The tong jaws and/or inserts must be changed for different diameters of pipe. Figure 3-7 is a table of the jaw and inserts sizes for the various diameters of pipe. LATCH Pine GUIDE BELL FIGURE 35 REVERSING THE TONG JAWS, FIGURE 36 INSTALLING JAWS EQUIDISTANT FROM DRIVE GEAR. 2. To change the tongjaws and inserts, remove the latch pin which secures the front guide bell. Open the front guide bell, and remove the cover plate. Slip the jaws off the drag ring pins, (Figure 3-5) Eee eee 3. To change the jaw insert, use a 3/B.inch Allen wrench to tnscrew the Allen head capscrew, which attaches the two! parts. Remove the insert from the jaw, add the new size ! insert, and replace the Allen head capscrew. (Figure 39) | 4. The jaws are marked on each end with either “M” for 5 “make-up” or “B" for “break-out”, Place the new size jaws ‘on the dragring pins so that the applicable letter, “M” or “B” is visible, ‘5. Check to make sure that the teeth on all the jaws are equidistant from the inside diameter of the final drive gear. Figure 36) £6. Replace the caver plate, close the front guide bell and 5 replace the latch pin, REVERSING THE ROTARY BACK-UP ASSEMBLY JAWS 1, The rotary back-up assembly jaws must be reversed when changing from makeup to break-out or from break-out to make-up, 2. Remove all the back-up jaw pins by removing the saftey clips. Hold the jaws so they will not fall, then pull the pins through the back-up plates. (Figure 3-10) i 43. The jaws are marked on each end with either “M” for | “make-up” or “B” for “break-out”. Note: This will not apply for the rotary back-up assembly. The jaws in the | rotary back-up assembly must be set in the opposite | direction of those in the tong. After removing the jaws, stroke the back-up air cylinder in the opposite direction of they vious operation, Turn the jaws over and reinsert the, ato the rotary back-up assembly in the, other direction. 4, Reinsert the pins into each jaw as itis inserted into the back-up assembly, check to make sure that all the jaws are equidistant from the inside diameter of the back-up ring gear, Figure 3-6) 5, Replace th Sty ins ‘CHANGING THE JAWS AND INSERTS FOR THE ROTARY BACK-UP ASSEMBLY 1, The rotary back-up assembly jaws and/or inserts must be changed for different diameters of pipe. Figure 3-8is atable of jaw and insert sizes for various diameters of 2. To change the rotary back-up jaws ai all the back-up jaw pins by removing the saltey pins. Hold the jaws so they will not fall, then pull the pins through the es. (Figure 3-10) ° : 3, To change the jaw inserts, use 2 3/8 inch Allen wrench to unscrew the Allen head capscrew which attaches the two parts. Remove the insert from the jaw, add the new size rsert, and replace the Allen head capscrew,or ifnecessary, ‘change the jaw assembly. (Figure 3.9) 4. The jaws are marked on each end with either “M" for “mnake up” or "B” for “break-out”. Note: This will not apply for the rotary back-up assembly. The jawsin the rotary back-up assembly must be set in the opposite direction of the jaws in the tongReinsert the new size , back-up assembly. ‘5. Check to make sure that all the jaws are equi the inside diameter of the backup ring gear. (Figure 2-6) 4 Replace the saftey pins. SAFETY PINS. SE Bee eee oa » FIGURE 3.10 REMOVING AND REVERSING THE ROTARY BACK UP ASSEMBLY JAWS OPERATION OF THE BUCKING UNIT TORQUE GAUGE 1. For diesel powered bucking units, fil the diesel fuel tank with diesel fuel and start the engine by turning the key to the a “on” position and depressing the start button. aia » | 2 For electrically powered bucking units, connect the ‘electrical cable to the electrical supply and start the unit by depressing the start button on the motor starter. 3, While throttle valve handle is in the neutral position, | Figure 3-11) also verily that the tong head is not rotating It the head does rotate, adjust the high pressure pump swash | plate. (Faure 22) The swash late is adusted by | unscrewing the lock nut on the end of the air eylinder rod, | using an 11/16inchwrench. (Figure 3-12) Adwst the length | "of the stroke of the rodby turningit with a 2/1sinchwrench | uniil the (ong rotation stops and tighten the lock nut THROTTLE VALUE 4, The throttle valve controls the direction of rotation and | up vate rpm of the tong for make-up and break-out (Figure 311) | oy t 7 setae et 5° ee center position, the throttle valve handle is.in the “pune Ti | CONTROL CONSOLE | 36 nur Qn fH © CYLINDER, oO AIR CYLINDER ROD FIGURE 312 ADJUSTING THE HIGH PRESSURE PUMP SWASH PLATE 6. For make-up, or clockwise rotation, the handles pushed forward in the “make” direction.’ For break-out, or “counterclockwise rotation, the handle is pulled backwardin the “break” direction. The further the handle is moved toward the “make” or “break” direction, the faster the tong rotates. (Figure 3-11) 7. The low speed range is engaged by pushing the shifter valve handle down in the “low” direction and upward for the “high” speed range. MAKE-UP 1. Verily that the correct tong jaws and inserts are in the tong and are set in the correct position for make-up. Also verily that the correct jaws and inserts arein therotary type back-up assembly. i 2. Use only the high speed rangeif the torque value required for making up the pipe is 19,500 ft-lbs or less. Ifthe torque requirements are greater than 19,500 ft-lbs, use the high | speed range to maximum capacity, then shift to the low * speed range, ' 3. Hand tighten the coupling onto the pipe. 4, Run the joint of pipe through thé Backup assembly and tong until the tong jawsrip the coupling and the back-up jaws will grip the pipe. (Figure 3-13) 5. To engage the rotary type back-up assembly on thepipe, "| move the back-up valve handle to the “engage” position. After the coupling has been made up, move the handle to: ; the “disengaged” position to disengage the back-up assembly.(Figure 3-11) 37 | BREAK-OUT. 6. Unscrew the torque relief valve lock nut by turning it counterclockwise. Turn the relief valve knob counterclockwise until tension is released (Figure 3:11) 7. Set the torque value on the tong by operating in the high speed range with the coupling in the tong and the pipe held by the back-up. Slowiy turn tha torque relief valve knob clockwise to increase the torque until the proper value is read on the torque gauge. (Figure 3-11) Read the high speed range, or inside scale marked on the console around the torque gauge if the torque value to be set is 18,000 lbs or less, Read the low speed range, oroutside scaleif the torque value is greater than 18,000 Cbs. Note: When setting the torque relief value for the low speed range, operate the tong in high speed range, but read the low speed range scale on the torque gauge. 8. When the correct torque value is reached, the tong will hydraulically stall and stop rotating. Tun the relief value lock nut clockwise until itis tight 9. Ifthe torque value is 18,000 f-1bs or less, thejoint is made up with the tong operating in the high speed range and the proper torque value is reached when the tong sialls 10. i the torque value is greater than 18,000 ft Lbs, the joint is made up with the tong operatingin bothspeed ranges; the high speed range until it stalls, then the low speed range until it stalls again at the preset torque value, When the tong stalls in low range, the proper torque value has been achieved. LL. After the-proper torque value has been achieved, reverse the tong operating direction to remove the tong jaws from the pipe. Caution: Reverse the tong operating direction only after the tong stops rotating. Otherwise, hydraulic pressure spike will damage the hydraulic motor. 12, Il you have a hydraulic system gauge, check the reading ‘on the torque gauge every four hours to verify that the tong still stalls at the proper torque value, This is necessary because changing hydraulic fluid viscosity due to temperature variations slightly alters the torque value. 1. Verify that the correct tong jaws and inserts are inthe - tong and are set in the correct position for break-out. Also verify that the correct jaws and inserts are in the rotary back-up assembly. 2, Run the joint of pipe through the back-up assembly and tong until the tongijawsiwill grip the coupling and the back up Jaws will grip the pipe. Set the torque relief value by ‘screwing the knob in as far as it will go and lock will lock nut. (Figure 3-13) 7 7 ae. fail FIGURE 3.13, POSITIONING THE PIPE IN THE BUCKING UNIT 3. To engage the rotary type back-up assembly on the pipe, move the back-up vaive handle to the “engage” position. When the coupling is broken out, move the handle ta the “disengage” position to disengage the back-up assernbly. (Figure 3-11) 4. Operate the tongin the low speed range, once the tension onthe joint has been removed by making one or two § revolutions, shift to the high speed range to finish : unscrewing the coupling. Caution: Starting break-out in the high speed range causes excess wear of the tong - jaw inserts. 5..After the coupling is unscrewed, reverse the tong operating direction to remove the tong jaws from the coupling. Caution: Reverse the tong. oper: | direction only after the fong stops rotating Otherwise, hydraulic pressure spike will damage the | | hydraulic motor. 38 ( SECTION 4 PREVENTATIVE MAINTENANCE ACTIVITY Clean tong jaws eee Adjust drag ring plugs eae Replace drag ring plugs and springs... i Ee Replace tong jaw inserts cio Replace rotary type back-up inserts. Replace oil in the case... Clean and grease back-up assembly... Clean power unit suction strainers - Replace power unit hydraulic return line filter elements : Repl + unit replenishing pump hydraulic uid fiter element Replace power unit high pressure hydraulic fluid liter elements Replace power unit hydraulic fluid oh : Clean air filter cadet ‘Add lubricant to the mist lubricator Clean back-up assembly air cylinder rod FIGURE 41 MAINTENANCE SCHEDULE GENERAL 1. Preventative maintenance of the bucking unit includes greasing, adjusting and replacing the drag ring plugs, replacing the tong jaw inserts, replacing the bacicup jaw inserts, replacing the case ol, replacing the power unit hydraulic filter elements and hydraulic fluid, cleaning the power unit suction strainers, cleaning the air filter and adding lubricant to the mist lubricator. 2. Preventative maintenance should be jperformed: in accordance with the frequency outlined in the maintenance FREQUENCY + -Daily When jaw slips around the collar [When worn [When worn When worn Monthly or when appearance indicates Weekly Yearly When dirt indicator tums red Yearly When dict indicator turns red Tl Yeariy Every sie months When lubricant level drops below 1/4 “| Daily schedule. (Figure 4-1) ADJUSTMENT OF THE DRAG RING PLUGS 1. After reinserting the drag ring into the tong, use a gjieinch Allen wrench to tighten the Allen head set screw that is al the bottom of the drag ring untilitis tush with the inside diameter of the drog ring. (Figure 43) Tighten the remaining Allen head set screws by skipping every other serew until siight, equal tension is felt on all the spings. This procedure assures that the drag ring is centered in the drag fing bushing a 2,-4ll the jaws should easily slide on and off the drag ring Mer Ine dg ng ha been sated mot, resus tow crag ring plugs and move the drag ring away from the FIGURE 43 ADJUSTING THE DRAG RING PLUGS side where the jaws will not slide on easily. Caution: Too much tension on the drag ring plugs will cause excessive wear on the bushing. REPLACEMENT OF THE TONG Jaw INSERTS irag ring plugs, springs and 1. Remove the latch pin which secures the front quide bell Open the front guide bell and remove the cover plate. Slip the jaws off the drag ring pins. (Figure 4-4) Note: Jaws to operate 4 1/2-inch through 9 5/S-inch diameter pipe have replaceable inserts. For larger diameter pipe, z FIGURE 44 i REMOVING THE TONG JAWS, a2 2 constuction. 2, Using» 3/8inch Allon wrench, unscrew the Allen head 4. The jows org mares Oa ast end with either “MO for aon iemoue the insert from the jaw (Figure 45) + make-up" or for “breakout”. Note: This will not apply for the rotary baclcup assembly. The jaws inthe aor, back-up assembly must be set in the opposite a jaws into the rotary back-up assembiy. en i oe Beis isle. Make sure that the fh Check to make sure that all the jaws are equidistant from applicable letter, “M’” oF "8 aie ae the ineide diameter of the back-up ring gear. (Figure 3-6) Peek on all the ows are equidistant trom the inside ~ diameter of the final drive gear. : cotta ee 6. Replace the saftey pins. '5. Replace the cover plate, close the front quide bell and __ replace the latch pit. DRAINING OIL FROM THE CASE 1. Place a container which wil hold at least 2US gallons of Oil under the case of drain plua ‘ALLEN HEAD. CAPSCREWS 12. Remove the oil fil plug with a 1 1/4inch wrench toaallow air to enter the case. i 3. Using a 9/16 inch wrench, unscrew the oil drain plug. { Ficccall of the olf to drain from the case. (Figure 46) FIGURE 45 REPLACING THE JAW INSERTS CHANGING THE JAWS AND INSERTS FOR THE ROTARY BACK-UP ASSEMBLY 1. The rotary back-up assembly jaws and/or inserts must be Changed for different diameters of pipe. Figure 38is atable Of jaw and inserts sizes for various diameters of pipe. Ot DRAIN PLUG 2. To change the rotary back-up jaws and inserts, remove All the backcup jaw pins by removing the saftey pins. Hold «the jaus so they will not fall, then pull the pins through the | back-up plates. (Figure 3-10) ! 3, yTo change the jaw inserts, use a 3/Binch Allen wrench to ; Gaserew the Allen head capscrew which attaches the two; parts. Remove the insert from the jaw, add the new size Frsert and replace the Allen head capscrew or if necessary, | change the jaw assembly. (Figure 45) 4 43 REPLACING OIL IN THE CASE 1. Usinga 1 1/4:inch wrench, remove the case oil fill plug. Fill ‘case with 2 US gallons of Varsol or diesel fuel and erate the tong in high speed range for two minutes to flush out any dirt or sediment. Drain the Varsolor diesel fuel from the case. 2. Replace the oil drain plug and fill the case with 2 US gallons of SAE 90 weight motor oil. Replace the oil fill plug, Figure 4-6) CLEANING AND GREASING ROTARY BACK-UP ASSEMBLY 1 The rotary backup assembly only requires greasingonce aweek, The grease zert fitting is located on the bottom of the back-up assembly. (Figure 48) This allows the back-up ring gear to be greased. While applying grease, activate the back-up assembly to allow even distribution of the grease. 2. The backup ring gear should be cleaned every time the jaws are removed. Wipe all the debris from the teeth of the back-up ring gear and back-up jaw pins with clean cloths and Varsol or diesel fuel. Wipe all traces of Varsal or diesel fuel from the back-up assembly before replacing the jaws. lote: If debris accumulates in the teeth of the back-up 43 gear, jaws will not operate properly. CLEANING THE BACK-UP ASSEMBLY AIR CYLINDER ROD i 1. Move the back-up assembly valve handle to the “disengage” position and hold until the air cylinder rod is fully extended. 2. Wipe the air cylinder rod with clean rags to remove any foreign matter on the rod DRAINING “THE POWER UNIT HYDRAULIC FLUID RESERVOIR 1. Either elevate the power unit so that a container which will hold at least 200 US gallons of oil can be placed under the drain plug, or use an oil pump to drain the reservoir. 2. If the oil is drained from the drain hole, use a 5/Binch wrench to unscrew the drain piug and allow all of the oil to drain from the reservoir. (Figure 4-7) OW DRAIN PLUG FIGURES . POWER UNIT HYDRAUUC FLUID RESERVOIR’ ¢ "CLEANING THE SUCTION STRAINERS OF THE | POWER UNIT - Ey Titer the hydraulic fluid reservoir has been drained, open, € the reservoir lid by turning the two latches 1/4 turn and | lifting. (Figure 4-9) FIGURE 47 2° GREASING THE ROTARY BACK-UP t SUCTION STRAINER FIGURE 49 CLEANING THE POWER UNIT SUCTION STRAINERS 2, Use a pipe wrench to unscrew the suction strainer. Clean the strainer with Varsol or diesel fuel, Inspect the strainer for damage. Repiace ifdamaged or cannot be cleaned. Place the strainer back into the reservoir. (Figure 49) 3. Close the lid and fasten the two latches. REPLACING THE POWER UNIT HYDRAULIC FLUID c 1. To replace the hydraulic fluid in the power unit hydra fluid reservoir, open the lid of the reservoir by turning the two latches 1/4 turn and lifting, (Figure 4-9) 2, Using rags soaked in Varsol or diesel fuel, clean the inside of the reservoir, Remove the reservoir drain plug to drain the Varsol or diesel fuel. Wipe the inside of the reservoir ‘with clean rags to remove all traces of Varsol or diesel fuel. Caution: I Varsol or diesel fuel i left in the reservoir, {will explode when compressed in the pump. FIGURE 410 REPLACING THE POWER UNIT HYDRAULIC RETURN LINE FILTER ELEMENTS, 3. Replace the reservoir drain plug, Fill the reservoir with hydraulic uid, (Arco Tullo 150is recommended), by adding | hudraulicfuid to the reservoir through theapenlid until the ! fluid level is midway between the low and igh marks on the sight glass. (Figure 4-9) Caution: If you are using a hydraulic fluid other than the fluid recommended by the manufacturer, (Arco Tuflo 150), add only the same type fluid as is presently in the reservoir. Mixing hydraulic fluids may cause deterioration and damage to the power unit and other components. REPLACING THE HYDRAULIC RETURN LINE - FILTER ELEMENTS 1, The hydraulic return line filter element should be changed when the color of the dit indicator turns from yellow to red. (Figure 4-10) * eee 2, Remove the hydraulic return line filter element with an oil fiter removal wrench, (Figure 4-10) 3. Apply a light film of hydraulic fluid on the gasket of the ! new filter element and install the filter element. “G, Turn the power unit on and verify that the dirt indicator color has changed back to yellow. If the color is still ed, check the hydraulic circuit for back pressure. 45 ~ -otary back up unit ‘ CLEANING THE AIR FILTER 1. The air fier system is located on the tong skid below the FILL PLUG BAFFLE ‘WING NUT a FIGURE 411 FIGURE 412 ee ADDING LUBRICANT TO THE MIST LUBRICATOR 2. Unscrew the bowl, unscrew the wing nut and slip the ita P REPLACING THE HIGH PRESSURE HYDRAULIC baffle and filter element off. (Figure 4.11) FLUID FILTER ELEMENT » Clean the internal parts, bowl and filter element with mild : ; Soap and water. Caution: Do not use cleaning agents _See Section 9, “High Pressure Hydraulic Fluid Filter’, for tsuch as acetone, benzene, carbon tetrachloride, the procedure to follow. The high pressure fiters (2) are gasoline, tolulene, etc., as they are damaging to located on the power unit rim in front of the high pressure plastic. pump. “4. The filter element should be replaced if the pressure 1 differential across the air filter is excessive after the filter is cleaned. Excessive pressure differential across the air filter will be indicated by a loss of air pressure at the tong console, '5-Reassemble the filter element, baffle, wing nut and bowl ADDING LUBRICANT TO THE MIST LUBRICATOR 1. Remove the fil plug from the top of the mist lubricator. ' "2. Fill the lubricator with SAE 10 weight oil until the bowl is completely full, and replace the fil plug. (Figure 4-12) REPLACING THE REPLENISHING PUMP HYDRAULIC FLUID FILTER ELEMENT |°~ See Section T0. Replenishing Pump Hivéraulc Fluid Filter", | ; Tthe procedure to follow. The replenishing pump fiter is : C cated on the power unit next fo the high pressure pump 46 ie SECTION 5 TROUBLESHOOTING TROUBLESHOOTING CHART PROBLEM Too much oil m the tong case ‘CAUSE T, The motor case pressures inexcess ‘of 20 psi causing hydraulic fluid to be pumped past the motor shaft seal. 2. The motor shaft seal is damaged. SOLUTION 1. Reset the motor case pressure to 30 psi when the throttle is in the neutral position. 2. Replace the motor shaft seal "The tong head rotates when the throt tle is in the neutral position. The back-up assembly jaws are not gripping the pipe evenly. The tong jaws do not bite the pipe. ‘The tong euns slow in both directions, Hrhe hydraulic motor does not shit irom high speed range to low speed range. The air cylinder rod length, which post- tions the high pressure pump swash plate, is not properly adjusted. 1, The jaws are not timed properly. 2. The tong and back-up assembly are misaligned to the pipe, T. The tension in the drag ring plugs not sufficient or the plugs are worn. 2. The teeth on the tong jaws are not equidistant from the inside diameter of the final drive gear 3. The jaw inserts are filled with metal, Shavings or other foreign matter. 4, The jaw inserts are worn, 5. The tong is not perpendicular with the pipe rack. 6. The pipe is not centered in the tong, T, More than 2 US gallons of oilin the case 2. Low hydraulic pressure. 3. The hydraulic motor is damaged or 4, The air pressure is less than 60 psi ‘ands insufficient to fully operate the air cylinder which positions the high pres: sure pump swash plate, 1. The shifting valve is loosing pressure. 2. The shifting valve handle és not fully in the “high” or “low” position. “Adjust the air cylinder rodlength on the high pressure pump. 1. Retime the back-up jaws. 2. Realign the tong and back-up 1. Adjust the tension or replace the plugs. 2. Reposition the tong jaws, +3, Clean the inserts 4, Replace the inserts 5. Reposition the tong 6. Measure from the pipe OD to the tong head ID in four places to deter ‘mine if the pipe is centered. If the pipe s pot centered, raise or ower the tong to Center the pipe. 1. Drain the oil in the case and replace with 2 US gallons of oil 2. Increase the hydraulic pressure of the power unit by readjusting the tong torque relief valve on the control console. 3, Repair the hydraulic motor. 4. Increase the air pressure to 60 psi by adjusting the air regulator on the tong skid. 1. Replace the shilting valve. 2, Place the shifting valve handle fully in the “high” or “low” position. 3. The shifting pump is not producing} sufficient hydraulic pressure. 4, The hydraulic motor is damaged, 51 3. Repair the shifting pump. 4, Repair or replace the hydraulic moter. PROBLEM CAUSE SOLUTION 1, Increase the hydraulic pressure ol The tong does not produce the re- “torque value. [Oil is leaking from the tong head. T. Low hydrauhe fluid pressure from the power unit 2. The hydraulic motor is damaged or 3. The hydrauke pump is damaged or 4. Air cylinder is not stroking the pump. 5. Torque reliel valve isnot functioning properly. 7 oe The oil seal is damaged. the power unit by readiusting the tong} torque relief valve located on the} the control console. 2. Repair the hydraulic motor. 3. Replace or repair pump. 4, Check and clean air system and| ‘components. 'S. Replace or repair torque relief valve. Replace the seal. Ifthe seal is not dam aged, remove the spring from the seal and disconnect the spring. Shorten its length and reconnect the spring. Re- place the spring and seal 52 SECTION 6 \_ SERVICE | Hct: Low ] te as —al LS" CONTROLLER CYLINDER eH teed f : « | HYDRAULIC SCHEMATIC — / PNEUMATIC SCHEMATIC é "FIGURE 61 . _ HYDRAULIC AND PNEUMATIC SCHEMATICS 5/16inch wrench 9/16inch wrench a 3/Minch Allen wench 10mm Allen wrench 12mm Allen wrench Ibinch crescent wrench putty gun and silicone tubes “HYDRAULIC AND PNEUMATIC SCHEMATICS _ ‘A schematic of the hydraulic and pneumatic systems is| ‘shown in Figure 6-1. t oT OF TOOLS REQUIRED FOR SERVICE >) | gpa OP ier driver The following tools are required for servicing theModel 821 | Spanner wrench bucking unit: 1 [Needle nose piers 1 mei | Oi fitter removal wrencl : 7/AGinch wrench : 9/3Ginch wrench PPutty ie : 1 5/Binch wrench {Rubber hammer 1 11/16.inch wrench {1 Sledge hammer 3/Minch wrench : ({ Ranch . : i | 19/isinch wrench + It Pry! ar | F1/4.inch wren : i | 1 Elfsinch wrench {Mee 1 FINAL DRIVE GEAR FRONT OIL SEAL 1. Remove the oil fil plug with a 1-1/4.inch wrench to allow aic to enter the case. 2. Use a 9/16 inchwrench to unscrew the oii drain plug from the bottom of the case. Allow all of tie oil to drain. 3. Remove the latch pin which secures the front guide bell + and open the guide bell. Using a_ straight slotted screwdriver, remove the front oil seal (Figure 62) 4, Inspect the front oil seal for damage and replace if damaged, 5.1 thesealis not damaged, remove the spring from the seal + and disconnect by unscrewing at the junction. Shorten the length from the female end and reconnect the spring, Reinstall the spring in the seal : 6.Using arabber haminer, tap the front oil seal into the case lid with the spring side towards the final drive gear, being careful not to pinch the seal. Use a straight slotted «screwdriver to insert the seal lip around the final drive + gear.Note: Start tapping the seal into the case lid at } the bottom of the tongso that any crimp in the seal will } occur at the top of the tong above the oil level. Close front guide bell, replace the latch pin and oil drain plug. j_ 7. Refill the case with approximately 2US gallons of SAE 90 motor oil and replace the oil plus. FIGURE 62 REMOVING THE FRONT OIL SEAL FROM THE TONG FINAL DRIVE GEAR REAR OIL SEAL 41. Remove the oil fil pag with a 1 1/4.wrench to allow air to center the case. 2, Use 29/16inchwrench to unscrew the il drain plug from the bottom of the case. Allow all of the oil to drain, 3, Remove the latch pin which secures the front guide bel ‘Open the front guide bell and remove the cover plate. Slip the jaws off the drag ring pins 4, Using a 9/16.inch Allen wrench, loosen the five Allen head set screws inside the drag ring. Lift the dragringout of the tong. 5. Using a 3/4inch wrench, remove rear quide bell by unscrewing the six bolts. Using a straight slotted screwdriver remove the rear oil seal from the case.(Figure 63) 6. Inspect the rear oil seal for damage and replace if damaged 7. Ifthe sealis not damaged, remove the spring from the seal and disconnect by unscrewing at the junction. Shorten the length from the female end and reconnect the spring, Reinstall the spring in the seal 8, Using a rubber hammer, tap the rear oil seal into the case with the spring side towards the final drive gear, being careful not to pinch the seal. Use a straight ‘slotted screwdriver to insert the seal lip around the final drivegear. Note: Start tapping the seal into the case at the( bottom of the tong so that any crimp in the seal will ‘occur at the top of the tong above the oillevel. Replace the rear guide bell and six bolts. 1 9. Replace the drag ring in the tong. Using a 9/16-inch Allen wrench, tighten the Allen head set screw that is on bottom: | Since ants hnhaattneleldechameteratine drag ring. Tighten the remaining Allen head set screws by. ee ee err equal teceee tier the springs, which assures that the drag ring is centered in the drag ring bushing, 10. All the jaws should easily slide on and off the drag ring pins after the drag ring has been adjusted. If not, readjust 1g ring by movingit away from the side where the jaws wor |. Caution: Too much tension on the drag ring plugs will cause excessive wear on the | drag ring plugs, springs and bushing. 11. Reinsert the jaws on the drag ring pins so that the applicable letter, “M” or “B”, is visible. Make sure that the teeth onall the jaws are equidistant from the inside diameter of the final drive gear. 1-12. Replace the cover plate, close the front guide bell, ! replace the latch pin and oil drain plug. ( 13. Refil the case with approximately 2 US gallons of SAE ; 90 weight motor cil and replace the oil fill plus. 62, 7 BOLTS 1 REAR GUIDE BELL FIGURE 63 ! REMOVING THE REAM Ol SEAL FROM THE TONG DRIVE TRAIN BEARINGS Fe 4. Using a 9/16inch Allen wrench, loosen the five Allen head set screws inside the dragring andiift the dragringout , of the tong (Figure 64) : 1. Remove the oi fil plug with a 11/4inchwrenchtoallow 5. Using a 3/4inch wrench, remove the rear guide bell by | air to enter the case. Unscrewing the six bolts. Lit off the rear guide bell (Figure : 64) i 6. Disconnect the shuttle valve fluid pressure lines, H9 and | Hi0, fuid return hose, H-11, the shifter hydraulic fuid line, | H2, the motor case hydraulic fuid return line, HS, the motor | oa . oe \ © 2.Usea9/i6inchwrench to unscrew the oildrain plug from | | case hydraulic fluid pressure line, H6, and the motor | the case, Allow all of the oil to drain. Use a 1 1/4-inch wrench to unscrew the pipe plug from the back of the case. = hydraulic fluid pressure lines, H7 andH8, from the hydraulic 3, Remove the latch pin which secures the front guide bell.’ | motor with a IGinch cresent wrench. As the lines are | (Open the front guide bell and remove the cover plate. Sip ._disconnected, tag them with their Ine numbers to assure the jaws off the drag ring pins.(Figure 6-4) they are reconnected properly.(Figure 65) : 63 PIPE PLUG, BOLTS (5 REAR GUIDE, FRONT GUIDE BELL BELL DRAG RING, LATCH PIN, ’ WL. DRAIN PLUG. FIGURE 64 REMOVING THE DRAG KING AND REAR GUIDE BELL FROM THE TONG. 7. Attach the ends of a chain sling to the two handles at the top of the tong and attach the sling to one fork of afork lift. Wrap a chain around the motor adapter and attach the other end of the chain to the other fork of the fork lit. (Figure 6-6) 8. Unscrew the twelve bolts with a 15/16-inchwrench which attach the tong to the skid.(Figure 67) 9. Raise the tong from the skid with the fork lit, the tong is not balanced, adjust the length of the chain wrapped around the motor adapter one link at a time untilitis balanced. Lay the tong on its back. Note: If the tong is not removed from the skid, the final drive gear will fall out of the tong when the case lid is removed and the chain is unfastened. 10. Use a 3/4.inch Allen wrench to unscrew thetwelve Allen head capscrews which secure the hydraulic motor. Install the eye bolt in the hole provided on top of the hydraulic ‘motor. Place a chain in the eye bolt and lift the motor from the tong. 11. Use a 15/16 inch wrench to unscrew the forty-one bolts which secure the case lid. 12. Place the forks of the forklift on either side of the motor adapter and lift the fd from the case by raising the forks of the fork lift, Use a brass bar and hammer to remove the bearing and primary drive sprocket out of the motor adapter as the fork lft raises the case lid and motor adapter from the tong. Use a rubber hammer to remove the front oll DISCONNECTING THC HYDRAULIC HOSES Fost seal from the inside ofthe case Fd so that damage does not ‘THE HYDRAULIC MOTOR occur to the seal. - 64 caw FiGure ATTACHING LIFTINC 13. Using needle nose pliers, remove the cotter pin from the offset link of the chain, Turn the final drive gear untilthe pin of the offset link lines up with the hole in the back of the case where the pipe plug was removed. Push the pin out of the offset link through the hole in the case. Slip thechain off the teeth of the finai drive gear and the primary drive sprocket. 14, Install two eye bolts in the two threaded holes on top of the final drive gear. Place a chain in the eye bolts, and using “ apry bar to assist, lit the final drive gear and bearings from the case.(Figure 69) 15, Inspect the radial thrust bearings on either side of the ! final drive gear for damage or wear and replace any damaged or worn bearings. To replace the radial thrust bearings, use a chisel and ball peen hammer to obtain sufficient space to insert apry bar between the bearings and | + the final drive gear. Use appry bar to pry the bearingsoffthe | final drive gear. Place the new bearings on the final drive gear so that the side with the widest race lips isfacingouton ° both sides of the final drive gear. (Figure 6-10) Tap the new , bearings onto the final drive gear witha punch andballpeen hammer, making sure the bearings are properly seated on the final drive gear. Lower final drive gear into its original * Position, using aforklit, and assure tis properly seated soit | tests level. Caution: Hit the radial thrust bearings on ! the race only with the punch when installing t0 ! prevent damage to the bearings. 65 E65 HAINS TO, 16, Using a pry bar, remove the primary drive sprocket an bearings trom the Case. If the rear bearing remains in th rear bearing cap when the sprocket is removed from th case, it can be tapped out by removing the twol/¢ine! plugs from the rear bearing cap. Insert a punch in the hole inthe cap where the plugs were removed and use a ball pees hammer to tap the bearing from the cap. (Figure 69) 17. Inspect the primary drive sprocket beatings for damag. ‘or wear and replace any that are damaged or worn, replace the bearings, usea pry bar toremove ther from th sprocket. Tap the new rear bearing into the rear bearing cap, after replacing cap with a rubber hammer. Tap the primary drive sprocket into the rear bearing using a rubs hammer. Tap the front bearing onto the sprocket wit punch and ball peen hammer, making sure the bearings ar properly seated on the sprocket. Caution: Hit the front bearing on the bearing race only with the punch when installing to prevent damage to the bearing, 18. Replace the chain and insert the pin through the ofiset link. Replace the cotter pin in the pin “19. Use a putty knife to remove all races ofthe old silicone “sealant, which is used as gasket material between the case lid and case, from the edge of the case and the ease lid. Place .3/8.inch wide bead of silicone sealant (clear Devcon Silite is recommended) around the edge of the case. FIGURE 67 REMOVING THE TONG FROM THE SKID 20. Replace the case lid on the case and use abrass bar and + hammer to drive the motor adapter onto the primary drive * sprocket front bearing, BI Replace the forty-one bolts and lock washers which ‘secure the lid on the case. Use a putty knife to scrape the ‘excess silicone sealant from the edge of the case and lid ‘while the sealant is still wet. 22, Using a rubber hammer, tap the front and rear oil seals, into the case lid and case respectively with the spring side towards the final drive gear, being careful not to pinch the als. Use a straight slotted screwdriver to insert the seal 98 around the final drive gear. Note: Start tapping the zal into the case lid and case at the bottom of the tong so that any crimp in the seal will occur at the top of the tong above the oil level. Replace the rear guide bell | and six bolts. Replace the hydraulic motor and twelve Allen « head capscrews, 24, Place the tong on the skid, and replace the twelve bolts which secure the tong to the skid. Reconnect the eight hydraulic lines to the hydraulic motor. Caution: Make sure all hydraulic lines are connected to the correct fittings on the hydraulic motor or damage to the motor may result. 25. Replace the drag ring in the tong. Using a 9/16inch * * Allen wrench, tighten the Allen head set screw on bottom of the drag ring until itis flush with the inside diameter of the 66 drag ring. Tighten the remaining Allen head set screws by skipping every other screw until equal tensionis felt inallthe | springs, which assures that the drag ring is centered inthe ; drag ring bushing 2. Clean the grease from the wear ring with Varsolor diesel RADIAL THRUST t oe BEARING. a VE ae = 3. Inspect the wea wear and replace if worn, 4.To replace the wear ring, remove the safety pin and hinge pin which attach the front guide bell fo the tong. Lift the front guide bell fom the tong 5. Use a straight slotted screwdriver to unscrew the six brass screws and remove the wear ring. Position the new wear ring and replace the six brass screws. (Figure 611) 6. Replace the front guide bell hinge pin, safety pin, and door latch pin. |] o RADIAL THRUST =~ BEARING ~ AGURE 6:10 INSTALLING BEARINGS ON THE FINAL DRIVE GEAR. 26. All the jaws should easily slide on and off the drag ring pins, after the drag ring has been adjusted, If not, readjust the drag ring by moving it away from the side where the jaws ‘would not slide on easily. Caution: Too much tension on 7 the drag ring plugs will cause excessive wear on the drag ring plugs, springs and bushings. tATCH Pa 27. Reinsert the jaws on the drag ring pins so that the oe applicable letter, “M” or “B", is visible. Make sure that the = eet teeth ofall the jaws are equidistant from the inside diameter FIGURE 611 of the final drive gear. REPLACING THE FRONT GUIDE BELL WEAR RING 29, Rell the case with approximately 2 US gallons of SAE 90 weight motor oil and replace the ol fl plug "FRONT GUIDE BELL WEAR RING 1. Remove the latch pin which secures the front guide bell. Gpen the front guide bel HYDRAULIC MOTOR MANIFOLD SEALS 1. Disconnect the motor case hydraulic Muid return line, H5, and unscrew the hydraulic fitting from the hydraulic motor with a 16-inch crescent wrench, Remove the seal washer, “spect for damage, and repiace if damaged. Place the seal vasher on thehydraulic motor, replace the hydraulic fitting, and reconnect the hydraulic line. Note: Label the - hydraulic lines before disconnection to assure that they are reconnected correctly. (Figure 6-13) 2. Disconnect the motor case hydraulic fuid pressure line, H6, and the fluid return line, H11, and unscrew the hydraulic motor witha iéinch cresent wrench. Remove the “O" ring, inspect for damage, and replace if necessary, Place the “O” ring on the hydraulic motor, replace the hydraulic fitting, and reconnect the hydraulic lines. Figure 6113) Caution: Do not interchange the fittings for lines HG and H6as pressure willincrease and damage to the hydraulic motor will result. 3. Disconnect the motor hydraulic fluid pressure lines, H7 ‘and H8, the shuttle vale fluid pressure lines H9 and Hi0, and the shifter hydrautic fluid line, H2, from the motor manifold. (Figure 6 13) 4, Using a 10 mm Allen wrench, unscrew the eight Alien head capscrews and remove the split flanges which attach ' the hydraulic fittings to the manifold. Remove the hydraulic fittings and “O" rings. Inspect the “O” rings for damage and ‘place if damaged. Place the "O” rings in the manifold, ! place the hydraulic fittings, spit flanges, and Allen head | capscrews. (Figure 614) i o SEAL WASHER FIGURE 613 REPLACING THE MOTOR CASE HYDRAULIC FLUID PRESSURE "AND RETURN LINE SEALS 5, Usinga 12mm Allen wrench, unscrew the four Allen head capscrews which attach the manifold to the hydraulic motor. Rernove the manifold and three “O” rings from the hydraulic motor. Inspect the “O" rings for damage and replace if damaged. Clean area on motor of contaminants. Place the "O" rings on the hydraulic motor, replace the ‘manifold, and four Allen head capscrews. (Figure 614) 6. Reconnect the five hydraulic lines to the manifold. Caution: Make sure ail the hydraulic hoses are connected to the correct fittings on the hydraulic motor or damage to the motor may result, HYDRAULIC MOTOR L Use a I6iinch crescent wrench to disconnect the eight hydraulic lines from the motor. Note: Label the hydra lines before disconnecting to assure that they are reconnected correctly. ~ 9 BD 5, oN BY COR & > i \seanes 9S ~ 70" RING & HEAD CAPSCREWIS | 2. Use a 3/t-inch Allen wrench to unscrew the twelve Allen head capcrews which secure the hydraulic motor. 3. Install one eye bolt in the hole provided on top of the hnyxiraulic motor. Place a chain in the eye bolt and lift the motor from the tong. (Figure 615) ALLEN HEAD CAPSCREWS (13) « y “Hydraulic Motor", for the procedure to the moter. e 1 "FIGURE 615 i: an (REMOVING THE HYDRAULIC MOTOR FROM THE TONG 61 END car, TIE ROD CYLINDER BARREL gh ore ™ <8 pencens Pre a PISTON ROD GLAND’ SEAL, FIGURE 616 DISASSEMBLING THE AIR CYLINDER ROTARY’ BACK-UP AIR CYLINDER SEALS 1. Disconnect the two 1/4”.inch air lines from the air cylinder by using the air couplings provided, Remove the Bin and saftey clips from the cylinder rod eye and remove ' 1 the two back up cover plates. Using a'1 I/B-inch wrerehe » Temove the four 3/4”.inch nuts and studs that secure the front and rear retainer rings to the back up ring gear,and remove the two retainer rings. As the retainer rings are removed, the air cylinder can be lifted from its mounting Position. 2. Unscrew the rod eye from the end of the aircylinder rod, 7 | _ and, using 7/16~inch wrench, remove the fourboltswhich | i Secure the rod gland to the éylinder. Using a 9/16".inch wrench, unscrew the four nuts and tie rods that hold the ait cylinder assembly together. Slide the tie rods from the two ait cylinder end caps and remove the end plates. Slide the rod gland from the air eylinder rod, and remove the rodand | ito fom the cylinder barrel. Inspectallofthe packing or, the rod gland and piston, and replace the necessary parts. Reverse the disassembly procedure to reassemble the ait cylinder. When replacing and tightening the tie rods, skip every other tie rod to assure even make up of air eylinder end caps. 814 GENERAL ASSEMBLY 204415/010 Bon ~ Houston company = 120 Pos. component Deseription Component Type Revi- Length Width No. of Net Quantity Un. Extra sion find Cin} units Info then + ouansyaie 4014 conan ASS. 440/60, 080, ow gaits tam Reviaton « oa co 27784, 9/30 1 204641/006 DRIVE UNIT ASSY.C11-110) SCN E-Itom 1.00 A 2 204660/003 2O"BACK-UP ASSY.C12-116) SCH E-Itom 1.00 Ea 53 206835/005 SKID ASSEMBLY Sch E-Ten 1.00 ER 4% 204437/016 100 He POULUNIT 782/814 & x 1.00 e2 5 217957/007 CONTROL CONSOLE ASSY F/16. SCN E-Iem 1.00 eR 6 202720/006 ELECTRIC LOAD CELL ASSY E-tten 1 1.00 EA 7 205204 /006 LEVELING JACK ASSEMBLY F/81 SCN E-Iton cece 100 ste 75 5/8 REF APPROX 44.25 REF 55 13/16 REF 73 13/16 REF 75 3/16 REF 82 1/4 REF ma 24 REF pe 83 1/2 REF POWER UNIT P/N 204437/016 (REF) CONTROL CONSOLE P/N 217957/007 (REF, 72 3/8 REF NOTES: 88 3/8 REF 1, TOTAL ESTIMATED WEIGHT: 10,000 LBS (NO OIL) 82 REF DCPE 20441 a DOWNHOLE TOOLS DMSION Jance 41/2" BOX 3186 HOUSTON, TEXAS / lecrnens ano euets 1/32 R Rass Sa at pT ea EAD AMS O01 TLR. GRCULAR GENERAL ASSEMBLY -_——— Ey ee SURFACE FINISH ana ne ow er OOO | OF ren RENTON Ba ae een MATERIAL, ‘SEE BOM DES APP =p wate 49 = PART NO. =— omen 2307- wc P— 204415/010 [ox 32 GENES FACETS OWG_NO. 814 DRIVE UNIT ASSEMBLY 204641/006 owen ~ Houston company Pos. component Description component Type Revi- Length Width Wo, of Net duantity Uns Extra sion fin} Gin Units Info soviaton 2 wo 17641, cat /a9 1 610/005 SOC HO CAP SCR V4 172 SOW E-Ten p00 tn 2 2o%400/005 GASKET, DOOR (S0BI- 119) elton - 1.00 eA 5 206152/005 To one eHeST-T07 Eten 100 ee 1 oc131/005 SDE 0cER (231-106) Se Eten 7 1.00 es 5 204592/005——GSKI-RMME PLATECSOB1-11B Etten - 2.00 ex 6 2063607005 FOP FBLA. MAME PLATE > E-iton : 1.00 eA 7 239067005 S/BHCAP SURE FA8.AL x Etta - 1.0 8 rart9/005 1-1/4" IPE PUUE.B.A.> F-ttea - 1.00 x 9 568/005 1 176990 st ett 1508 Eten 1.00 10 5791/08 FILLER PLUG (F889 x Eten ° 100 11 210125/005 VARIABLE O15. HoTOR x ectten ° 1.008 12 26785/008 17k senewcrn2s/01¢F8A) SOM E-Iton ° on ea 15 21er22/005—_eanaox x etten . 100 a 1 2039877005 eAR CAP CMAT-129 ete A naga 15 p1eiz1/o0s 25 TOOT SPROCKET Pe rtem a 4.00 ex 15 214641/008 CASE F/ BIG BUCKING UNIT SON E-Itom 1.00 Ex 17 25908/005 AP SOREN FORT/018) FER Etta 8.00 x 18 205309/003 BEARING (BOIT- 116), x ett c 1.00 eA 19 212756/008 HEX EAD BDL Ett 8.00 eA 20 2060107005 CHAIN «REFRI71/108) N etree a 1.00 Es 2 -207197/005 OPTICAL EACODER ADRPTER Fetten we 100 et 22 203310/005 BEARING, KAYOONTBOTT-115)WE-Ttem 2 2.00 eA 25 20u871/005 OL SEAL *ANDIE Eten a 2.00 Fr 2% 28560/005——SCKT.HD.CAP SCHEW.5*TSNC Eten - 2.00 EA 25 218120/005 ——_GEARAOH ADAPTER N esteem sos non x 2% 205701/005 —_mbduER GROMMET ¥ Esteem ° 1.00 x 77 2048421005 ——S/BMF.AT SREWCFEZS 005 E-tten 4.00 €n 2 11144/005 ‘u2Ne10 seaey (OA) se este we 00 eA 29 203556/005 FINAL ORIVE GEARGGON2-O5 SIN E-Item eet 1.00 eA 430 203885/005LOMER GUIDE AELLEMIST-122 SIN E-Ltem coo v.00 eA 51 203885/005 ER GUIDE BELLMST-120 SC E-Ten & 1.00 55 2041957005 EAR aig

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