Farr Hd8625 User manual

HD8625

8-5/8” (22cm) 35K

Hydraulic Power Tong

•Specications

•Operation

•Maintenance

•Assembly

Published by McCoy Corporation, Technical Publications Department

14755 - 121A Avenue • Edmonton, AB, Canada, T5L 2T2 mccoyglobal.com

TECHNICAL MANUAL

Technical Manual

hD8625 8-5/8” 35K Tong

iii

This manual covers the following models:

NOTE: Some illustrations used in this manual may not exactly match

your model of tong.

PATENTED & PATENTS PENDING

TONG

MODEL

REV DESCRIPTION

80-0605-6 1Tongisequippedwithatwo-speedhydraulicmotor,motorvalve,liftcylindervalve,rigidsling,

andsafetydoor.

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Technical Manual

hD8625 8-5/8” 35K Tong

WARNINGS

ANY REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED

DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE

SPECIFIED.

WHEN RE-ASSEMBLING LOAD-BEARING DEVICES (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS,

ETC.) NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE

SPECIFIED FOR THAT SIZE OF FASTENER (SEE SECTION 3 - OVERHAUL). ANY THREADED FASTENER

IN A LOAD-BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE™.

A “LOAD-BEARING DEVICE” IS A CHAIN SLING, RIGID SLING, SPREADER BAR ASSEMBLY, FRAME, OR

ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH

THIS MANUAL HAS BEEN PRODUCED

THE LOAD-BEARING DEVICE SUPPLIED BY MCCOY DRILLING & COMPLETIONS IS DESIGNED TO SUP-

PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL. MCCOY DRILLING & COMPLETIONS WILL NOT

GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, ASSEM-

BLY OR COMBINATION OF PARTS AND ASSEMBLIES. MCCOY DRILLING & COMPLETIONS WILL NOT

GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT

DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD-BEARING DEVICE,

OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE

EQUIPMENT, UNLESS SUPPLIED BY MCCOY DRILLING & COMPLETIONS.

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Technical Manual

hD8625 8-5/8” 35K Tong

vii

Summary Of Revisions

Date Section Page Description Of Revision Approved

June2011 Initialrelease S.Hargreaves

Sep2012

2.7 ReplacedhydraulicschematicandB.O.M.toreflectchangestohydrauliccir-

cuit.

M.Gerwing

2.9 ReplacedIllustration2.C.4toreflectchangestohydrauliccomponents

2.10 Updatedpartnumberforstandardflatdie

3.9 RevisedSection3.G,“OverhaulProcedures-Disassembly”

3.11-3.21 RevisedSection3.H,“AssemblyProcedures”

3.22-3.23 RevisedSection3.I,“DailyInspection&MaintenanceChecklist”

3.24-3.26 RevisedSection3.J,“MonthlyInspection&MaintenanceChecklist”

RemovedSection,“DailyInspection&Maintenance-PowerUnit”

3.27-3.30

Revisedsection3.K,“TubularEquipmentDecommissioning”,addedpack-

agingandshippinginstructionsandretitled“TubularConnectionEquip-

mentDe-Commissioning&Shipping”.

4.1 Revisedsection4.A,Troubleshooting-TongWillNotDevelopSufcient

Torque

4.2 Insertednewsection4.B,Troubleshooting-ReliefValve

4.4 Insertednewsection4.C,Troubleshooting-SafetyDoor

4.5 Renumberedsection4.D,Troubleshooting-TongRunningTooSlowly

4.6 Renumberedsection4.E,Troubleshooting-FailureofJawstoGripPipe

4.7 Renumberedsection4.F,Troubleshooting-Shifting

5.15 UpdatedB.O.M.,ClutchAssembly

5.17 UpdatedB.O.M.,ManualShifter

5.28-5.29 Replacedillustration&updatedB.O.M.,TongDoorAssembly

5.30-5.31 Replacedillustration&updatedB.O.M.,TongSafetyDoorComponents

Removedillustration,CompressionLoadCellExploded

6.6 Insertednewsubsection6.C.3,“ReferenceCheckingTorqueMeasurement

System”

Copyright © 2011 - 2012 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.Thisdocumentandthecontentswithinareconsidered

confidentialinformation,nottobedisclosed,copied,transmitted,transcribedinanyform,orstoredonanytypeofdatastoragemediawithout

theexpresswrittenconsentofMcCoy.

McCoyhasmadeeveryefforttoensuretheinformationcontainedinthisdocumentisaccurateandcurrent.Thismanualisintendedtoprovide

equipmentoperationandsafetyinstructionsforyourequipment.However,McCoydoesnotwarrantorguaranteethattheinformationiseither

completeoraccurateineveryrespectandtheuserofthemanualshouldconsultwithitsMcCoysalesrepresentativeforanyclarificationsand

updates.

Theuserofthemanualshallprotect,indemnify,andholdharmlessMcCoyanditsdirectors,officers,employees,andagentsfromandagainst

allliabilityforpersonalinjury,death,orpropertydamageresultingdirectlyorindirectlyfromtheuseoftheinformationcontainedinthismanual.

Observanceofalldescriptions,informationandinstructionssetoutinthismanualisthefullresponsibilityoftheuser.Thismanualisintended

forguidanceandinformationalpurposesandmustbeusedinassociationwithadequatetrainingandon-the-jobsupervisiontoprovidesafeand

effectiveequipmentuse.

Itistheresponsibilityoftheusertoconformtoallregulationsandrequirementsissuedbyanauthorityoragencywhichmayaffecttheoperation,

safetyorequipmentintegrity,thatmayoverrulethecontentofthisdocumentation.

Theuserwillacknowledgeandobeyanygenerallegalorothermandatoryregulationinforcerelatingtoaccidentprevention,safety,andequip-

mentintegrity.

viii

hD8625 8-5/8” 35K Tong

Technical Manual

Table ofconTenTs

SECTION ONE: INTRODUCTION

 Introduction&ContactInformation................................................................................................................................... 1.1

 EquipmentSpecications................................................................................................................................................. 1.2

 LubricantSpecications................................................................................................................................................... 1.6

SECTION TWO: SETUP & OPERATION

A. SLING/LOADBEARINGDEVICESAFETY........................................................................................................... 2.1

1. InspectionOfSlings......................................................................................................................................... 2.2

2. ProperUseOfLoad-BearingDevices............................................................................................................. 2.3

3. StorageOfLoad-BearingDevices................................................................................................................... 2.3

B. MAJORCOMPONENTIDENTIFICATION............................................................................................................... 2.4

C. HYDRAULICSCHEMATICS&VALVEIDENTIFICATION....................................................................................... 2.7

D. HYDRAULICCONNECTIONS.................................................................................................................................  2.9

E. TONG/BACKUPJAWAVAILABILITY&INSTALLATION

1. Availability........................................................................................................................................................ 2.10

2. Jaw&DieRemoval.......................................................................................................................................... 2.11

F. TONGRIG-UP&LEVELING

1. Suspension&Restraint................................................................................................................................... 2.11

2. TongLeveling...................................................................................................................................................  2.13

G. TONGOPERATION

1. InitialStart-upandBreak-inProcedure............................................................................................................ 2.14

2. ValveOperation............................................................................................................................................... 2.15

3. ShiftingGears.................................................................................................................................................. 2.17

4. GeneralComments.......................................................................................................................................... 2.17

H. MAKINGANDBREAKINGCONNECTIONS

1. MakingAConnection....................................................................................................................................... 2.18

2. BreakingAConnection..................................................................................................................................... 2.23

I. EXTREMECOLDWEATHEROPERATIONPROCEDURES................................................................................. 2.25

SECTION THREE: MAINTENANCE

A. GENERALMAINTENANCESAFETYPRACTICES................................................................................................ 3.1

B. CLEANING............................................................................................................................................................... 3.1

C. PREVENTIVEMAINTENANCEPRACTICES.......................................................................................................... 3.1

D. LUBRICATION......................................................................................................................................................... 3.2

E. ADJUSTMENTS

1. BRAKEBANDADJUSTMENT:................................................................................................................................ 3.7

2. DOORLATCHADJUSTMENT................................................................................................................................. 3.7

3. SHIFTERDETENTFORCEADJUSTMENT:........................................................................................................... 3.8

F. RECOMMENDEDPERIODICCHECKS

1. DoorStopSpring............................................................................................................................................. 3.9

2. ShiftingShaft.................................................................................................................................................... 3.9

3. BackingPin...................................................................................................................................................... 3.9

4. TorqueGaugeAssembly.................................................................................................................................. 3.9

G. OVERHAULPROCEDURES-DISASSEMBLY....................................................................................................... 3.9

H. ASSEMBLYPROCEDURES.................................................................................................................................... 3.11

I. DAILYINSPECTION&MAINTENANCECHECKLIST(POWERTONG)................................................................ 3.22

J. MONTHLYMAINTENANCECHECKLIST-POWERTONG................................................................................... 3.24

K. TUBULARCONNECTIONEQUIPMENTDE-COMMISSIONING&SHIPPINGPROCEDURE.............................. 3.27

L. TUBULARCONNECTIONEQUIPMENTRE-COMMISSIONINGPROCEDURE................................................... 3.31

SECTION FOUR: TROUBLESHOOTING

A. TONGWILLNOTDEVELOPSUFFICIENTTORQUE............................................................................................ 4.1

B. RELIEFVALVEISINCORRECTLYSETORNOTFUNCTIONING........................................................................ 4.2

C. SAFETYDOORDOESNOTOPERATEORISMALFUNCTIONING..................................................................... 4.4

D. TONGRUNNINGTOOSLOWLY............................................................................................................................. 4.5

E. FAILUREOFJAWSTOGRIPPIPE........................................................................................................................ 4.6

F. FAILUREORDIFFICULTYOFTONGTOSHIFT................................................................................................... 4.7

G. GENERALCOMMENTS.......................................................................................................................................... 4.8

SECTION FIVE: PARTS AND ASSEMBLIES

GearTrainLayout............................................................................................................................................................ 5.2

SupportRoller.................................................................................................................................................................. 5.4

SupportRoller-DoorPivot.............................................................................................................................................. 5.6

RotaryIdler....................................................................................................................................................................... 5.8

PinionIdler...................................................................................................................................................................... 5.10

PinionAssembly............................................................................................................................................................... 5.12

ClutchAssembly............................................................................................................................................................... 5.14

ShiftingAssembly............................................................................................................................................................. 5.16

Rotary(CagePlate)Assembly......................................................................................................................................... 5.18

Continued on next page ...

Technical Manual

hD8625 8-5/8” 35K Tong

SECTION FIVE: PARTS AND ASSEMBLIES (Continued):

LegWeldments............................................................................................................................................................ 5.20

HydraulicSupports....................................................................................................................................................... 5.22

Motor&MotorMountAssembly................................................................................................................................... 5.24

BrakeBandAssembly.................................................................................................................................................. 5.26

TongDoorAssembly.................................................................................................................................................... 5.28

SafetyDoorComponents............................................................................................................................................. 5.30

RigidSlingAssembly.................................................................................................................................................... 5.32

SECTION SIX: TORQUE MEASUREMENT

A. BASICTORQUEMEASUREMENT........................................................................................................................ 6.1

B. TROUBLESHOOTING............................................................................................................................................. 6.5

C. PERIODICINSPECTIONANDMAINTENANCE

1. Inspection......................................................................................................................................................... 6.6

2. FluidRecharge................................................................................................................................................. 6.6

3. ReferenceCheckingTheTorqueMeasurementSystem................................................................................. 6.6

4. RepairAndCalibration..................................................................................................................................... 6.7

SECTION SEVEN: HYDRAULIC COMPONENT INFORMATION

Table ofconTenTs

hD8625 8-5/8” 35K Tong

Technical Manual

Table ofillusTraTions

Illustration1.A.1:HD8625Tong................................................................................................................................................ 1.1

Illustration1.A.2:HD8625PowerTongDimensions................................................................................................................. 1.2

Illustration2.A.1:SlingAngle.................................................................................................................................................... 2.1

Illustration2.B.1:MajorComponentIdentication01............................................................................................................... 2.4

Illustration2.B.2:MajorComponentIdentication02............................................................................................................... 2.5

Illustration2.B.3:MajorComponentIdentication03............................................................................................................... 2.6

Illustration2.C.1:HydraulicSchematic..................................................................................................................................... 2.7

Illustration2.C.2:HydraulicComponentIdentication01......................................................................................................... 2.8

Illustration2.C.3:HydraulicComponentIdentication02......................................................................................................... 2.8

Illustration2.C.4:HydraulicComponentIdentication03......................................................................................................... 2.9

Illustration2.D.1:HydraulicConnections01............................................................................................................................. 2.9

Illustration2.D.2:HydraulicConnections02............................................................................................................................. 2.10

Illustration2.E.1:JawRemoval................................................................................................................................................ 2.11

Illustration2.F.1:TongSuspensionRelativeToAxialCentre................................................................................................... 2.12

Illustration2.F.2:TongSuspensionRelativeToVerticalCentre............................................................................................... 2.13

Illustration2.F.3:TongLeveling(Side-To-Side......................................................................................................................... 2.13

Illustration2.F.4:TongLeveling(Front-To-Rear....................................................................................................................... 2.14

Illustration2.G.1:TongRotationControlValve......................................................................................................................... 2.15

Illustration2.G.2:TongLiftCylinderControlValve................................................................................................................... 2.16

Illustration2.G.3:TongMotorSpeedControlValve................................................................................................................. 2.16

Illustration2.G.4:TongManualShiftControl............................................................................................................................ 2.17

Illustration2.H.1:MasterLiftingLink........................................................................................................................................ 2.18

Illustration2.H.2:BackingPinSetTo“Make-up”Position........................................................................................................ 2.19

Illustration2.H.3:LiftCylinderControl-Raise.......................................................................................................................... 2.19

Illustration2.H.4:OpeningTongDoor...................................................................................................................................... 2.20

Illustration2.H.5:MotorControl-Make-up............................................................................................................................... 2.21

Illustration2.H.6:MotorControl-ReleasingJaws................................................................................................................... 2.21

Illustration2.H.7:LiftCylinderControl-Lower......................................................................................................................... 2.22

Illustration2.H.8:SettingBackingPinTo“Break-Out”Position................................................................................................ 2.23

Illustration2.H.9:RotationControl-Break-out......................................................................................................................... 2.24

Illustration2.H.10:UsingMotorControlToReleaseTongJawsFollowingBreak-out&Un-threading.................................... 2.24

Illustration2.H.11:LoweringTongUsingLiftCylinderControl.................................................................................................. 2.25

Illustration3.D.1:CamFollowerLubrication............................................................................................................................. 3.2

Illustration3.D.2:SupportRollerLubrication............................................................................................................................ 3.2

Illustration3.D.3:RotaryIdlerLubrication................................................................................................................................ 3.3

Illustration3.D.4:PinionIdlerLubricationPoint........................................................................................................................ 3.3

Illustration3.D.5:PinionLubricationPoints.............................................................................................................................. 3.4

Illustration3.D.6:ClutchLubricationPoints.............................................................................................................................. 3.5

Illustration3.D.7:MotorMountLubricationPoint...................................................................................................................... 3.5

Illustration3.D.8:ShifterShaftLubrication............................................................................................................................... 3.6

Illustration3.D.9:TongDoorLubricationPoints....................................................................................................................... 3.6

Illustration3.D.10:DoorCylinder.............................................................................................................................................. 3.7

Illustration3.E.1:BrakeBandAdjustment................................................................................................................................ 3.7

Illustration3.E.2:TongDoorLatchAdjustment........................................................................................................................ 3.8

Illustration3.E.3:ShifterDetentForceAdjustment................................................................................................................... 3.8

Illustration3.H.1:TongAssembly-RotaryGearInstallation.................................................................................................... 3.12

Illustration3.H.2:TongAssembly-GearAssemblyPositioning............................................................................................... 3.13

Illustration3.H.3:TongAssembly-TopFastenerLocations..................................................................................................... 3.14

Illustration3.H.4:TongAssembly-SupportRollers(SecuringLegMounts............................................................................. 3.15

Illustration3.H.5:TongAssembly-FrontLegInstallation........................................................................................................ 3.15

Illustration3.H.6:TongAssembly-SupportRollers(BrakebandWeldments.......................................................................... 3.16

Illustration3.H.7:TongAssembly-TopShifterBushingAssembly.......................................................................................... 3.17

Illustration3.H.8:TongAssembly-FrontCagePlateSpacers................................................................................................. 3.18

Illustration3.H.9:TongAssembly-SafetyDoorValveInstallation........................................................................................... 3.19

Illustration3.H.10:TongAssembly-RigidSlingAdjustmentBoltInstallation........................................................................... 3.20

Illustration3.L.1:ShippingInstructions-Pallet......................................................................................................................... 3.29

Illustration3.L.2:ShippingInstructions-WrappingChainSling&StrappingToPallet............................................................ 3.30

Illustration4.B.1:ReliefValveTroubleshooting-TemporaryGaugeInstallation...................................................................... 4.2

Illustration6.A.1:TorqueGauge............................................................................................................................................... 6.1

Illustration6.A.2:TensionLoadCell......................................................................................................................................... 6.1

Illustration6.A.3:CompressionLoadCell................................................................................................................................ 6.1

Illustration6.A.4:TensionLoadCellExploded......................................................................................................................... 6.3

Illustration6.A.5:TurnCounterEncoderMountExploded....................................................................................................... 6.4