Farr KT5500 User manual

TECHNICAL MANUAL
©2011 McCoy Corporation. All rights reserved.
Published by McCoy Corporation, Technical Publications Department
14755 - 121A Avenue • Edmonton, AB, Canada, T5L 2T2 mccoyglobal.com
•Specications
•Operation
•Maintenance
•Assembly
Model80-0422
Model80-0421-3
KT5500
5-1/2” (13.97cm) 18.7K Lbs.-Ft.
Hydraulic Power Tong & CLINCHER® Backup

KT5500 5-1/2” Tong & CLInCHER® BaCKup
SECTIon ConTEnTS iii TECHnICaL ManuaL
This manual covers the following models:
NOTE: Some illustrations used in this manual may not exactly match your model
of tong.
oVERaLL
MoDEL
Tong
MoDEL
BaCKup
MoDEL REV DESCRIpTIon
80-0420-16 80-0420-3 85-0408 0 5-1/2”configuredpowertong&low-profilecompressionloadcell-style
CLINCHER®backup.Tongequippedwithhydraulicmotorcontrol,lift
control,backupcontrol,rigidsling,&andsafetydoorsystem.
80-0421-3 80-0420-3 85-0506 0 5-1/2” configured power tong & tension load cell-style CLINCHER®
backup.Tongequippedwithhydraulicmotorcontrol,liftcontrol,backup
control,rigidsling,&andsafetydoorsystem.
80-0422 80-0420-3 85-0404 0 5-1/2”configuredpowertong&compressionloadcell-styleCLINCH-
ER®backup.Tongequippedwithhydraulicmotorcontrol,liftcontrol,
backupcontrol,rigidsling,&andsafetydoorsystem.

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KT5500 5-1/2” Tong & CLInCHER® BaCKup
SECTIon ConTEnTS v TECHnICaL ManuaL
WARNINGS
ANY REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED
DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT UNLESS OTHERWISE
SPECIFIED.
WHEN RE-ASSEMBLING LOAD-BEARING DEVICES (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS,
ETC.) NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE
SPECIFIED FOR THAT SIZE OF FASTENER (SEE SECTION 3 - OVERHAUL). ANY THREADED FASTENER
IN A LOAD-BEARING DEVICE MUST BE SECURED WITH RED OR BLUE LOCTITE™.
A “LOAD-BEARING DEVICE” IS A CHAIN SLING, RIGID SLING, SPREADER BAR ASSEMBLY, FRAME, OR
ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGHT OF THE EQUIPMENT FOR WHICH
THIS MANUAL HAS BEEN PRODUCED
THE LOAD-BEARING DEVICE SUPPLIED BY MCCOY DRILLING & COMPLETIONS IS DESIGNED TO SUP-
PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL. MCCOY DRILLING & COMPLETIONS WILL NOT
GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, ASSEM-
BLY OR COMBINATION OF PARTS AND ASSEMBLIES. MCCOY DRILLING & COMPLETIONS WILL NOT
GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE TO LIFT OR SUPPORT THE EQUIPMENT
DESCRIBED IN THIS MANUAL IF THERE ARE ANY MODIFICATIONS TO THE LOAD-BEARING DEVICE,
OR ANY ADDITIONS TO THE EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE
EQUIPMENT, UNLESS SUPPLIED BY MCCOY DRILLING & COMPLETIONS.

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KT5500 5-1/2” Tong & CLInCHER® BaCKup
SECTIon ConTEnTS vii TECHnICaL ManuaL
Summary Of Revisions
Date Section Page Description Of Revision
Sep2007 N/A N/A InitialRelease
APR2008
Intro iii Correctedtableofassembliescoveredbythismanual,addedcompressionLCstyle
backup
1 1.3 AddedarmlengthspecsforcompressionLCstylebackup
3 3.4 AddedimageryforpartsidentificationforcompressionLCstylebackup
7 7.38 Createdpartslistsforcompression-styleLCbackup
8 8.1 Addedcompressionloadcellinformation
8 8.4 Addeddetailedcompressionloadcellpartslist
APR2009 7 7.21 Correctedreferencetopagenumbershowingthejawavailability.
AUG2009 Intro iii Addedmodel80-0420-16(tongwithlow-profileCLINCHER®backup)
Sep2010 N/A N/A Updatedgraphicallayouttocurrentbrandingstandards,added85-0404-1tocovered
assemblies,addeddrawingsfor85-0408backupandmountingkit
Nov2011
2 2.8 Removedhydraulicschematicforassemblynotequippedwithsafetydoor.
2 2.8 CorrectedhydraulicschematicB.O.M.
2 2.16 RevisedSection2.F.1,TongRig-Up&Leveling(Suspension&Restraint)
2 2.18 AddedSection2.F.3,TongRig-Up&Leveling(LoadCellConfiguration)
2 2.19 InsertedSection2.G.1,OperatorTraining
3 3.1 RevisedSection3.A,GeneralMaintenanceSafetyPractices
3 3.1 RevisedSection3.B,Cleaning
3 3.1 InsertedSection3.C,PreventiveMaintenancePractices
3 3.6 Addedlubricationinstruction,CLINCHER®cylinders
3 3.7 Addedlubricationinstruction,compressionloadcell
3 3.11-3.20 RevisedSectionH,MechanicalAssemblyProcedures
3 3.21-3.32 Movedallmaintenanceproceduresfromappendicestomaintenancesection.
4 4.1-4.6 Revisedtroubleshootingsection
55.4-5.5 NewsupportrollerassemblyandB.O.M.Removeddoorpivotrollerpagesandincorpo-
ratedwithsupportrollerassembly.
55.7 CorrectedrotaryidlerB.O.M.
55.16-5.17 NewcageplateassemblyandB.O.M.
55.24-5.25 Replacedmotor&motormountassembly&B.O.M.
55.28-5.29 Replacedtongdoorassembly&B.O.M.
6 Completerevisionoftorquemeasurementsection
Copyright©2007-2011McCoyCorporation,includingitswhollyownedsubsidiaries,(“McCoy”),allrightsreserved.Thisdocumentisthe
propertyofMcCoyandissuppliedasreferenceinformationforusersofourproducts.Thisdocumentandthecontentswithinareconsid-
ered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informa-
tion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
equipmentintegrity.

KT5500 5-1/2” Tong & CLInCHER® BaCKup
SECTIon ConTEnTS
viii TECHnICaL ManuaL
Introduction................................................................................................................................................................. Section 1
 Introduction&ContactInformation....................................................................................................................... 1.1
EquipmentSpecications..................................................................................................................................... 1.2
 LubricantSpecications....................................................................................................................................... 1.4
Setup & Operation...................................................................................................................................................... Section 2
 Sling/Load-BearingDeviceSafety...................................................................................................................... 2.1
 MajorComponentIdentication............................................................................................................................ 2.4
 HydraulicSchematic/ComponentIdentication.................................................................................................. 2.8
 HydraulicConnections......................................................................................................................................... 2.11
 Tong&BackupJawAvailability&Installation...................................................................................................... 2.12
 TongRig-Up&Leveling....................................................................................................................................... 2.16
 TongOperation.................................................................................................................................................... 2.19
 ExtremeColdWeatherOperationProcedures..................................................................................................... 2.22
Maintenance................................................................................................................................................................ Section 3
 GeneralMaintenanceSafetyPractices................................................................................................................ 3.1
 Cleaning............................................................................................................................................................... 3.1
 PreventiveMaintenancePractices....................................................................................................................... 3.1
 Lubrication............................................................................................................................................................ 3.2
 Adjustments.......................................................................................................................................................... 3.7
 RecommendedPeriodicChecks.......................................................................................................................... 3.8
 OverhaulProcedures........................................................................................................................................... 3.9
 AssemblyProcedures.......................................................................................................................................... 3.11
 DailyInspection&MaintenanceChecklist(PowerTong)..................................................................................... 3.21
 DailyInspection&MaintenanceChecklist(Backup)............................................................................................ 3.23
 DailyInspection&MaintenanceChecklist(PowerUnit)...................................................................................... 3.26
 MonthlyInspection&MaintenanceChecklist(PowerTong)................................................................................ 3.27
 TubularConnectionEquipmentDe-commissioningProcedures.......................................................................... 3.28
 TubularConnectionEquipmentRe-commissioningProcedures.......................................................................... 3.31
Troubleshooting......................................................................................................................................................... Section 4
 TongWillNotDevelopSufficientTorque............................................................................................................ 4.1
 FailureOfJawsToGripPipe.............................................................................................................................. 4.3
 TongRunningTooSlowly.................................................................................................................................... 4.4
 FailureOrDifficultyOfTongToShift.................................................................................................................. 4.5
 GeneralComments.............................................................................................................................................. 4.6
Parts and Assemblies................................................................................................................................................ Section 5
 GearTrainLayout................................................................................................................................................ 5.2
 SupportRoller...................................................................................................................................................... 5.4
 RotaryIdler........................................................................................................................................................... 5.6
 PinionIdler.......................................................................................................................................................... 5.8
 PinionAssembly................................................................................................................................................... 5.10
 ClutchAssembly................................................................................................................................................... 5.12
 ShifterAssembly.................................................................................................................................................. 5.14
 CagePlateAssembly........................................................................................................................................... 5.16
 TongJaws............................................................................................................................................................ 5.18
 TongBodyAssembly........................................................................................................................................... 5.20
 BrakeBandAssembly.......................................................................................................................................... 5.22
 MotorMountAssembly......................................................................................................................................... 5.24
 HydraulicAssembly.............................................................................................................................................. 5.26
 TongDoorAssembly............................................................................................................................................ 5.28
 SafetyDoorAssembly.......................................................................................................................................... 5.30
 LegAssemblies.................................................................................................................................................... 5.32
 BackupBody(TensionLCConguration)............................................................................................................ 5.36
 BackupBody(CompressionLCConguration).................................................................................................... 5.38
 Low-ProleBackupBody(CompressionLCConguration)................................................................................. 5.40
CLINCHER®Cylinders........................................................................................................................................ 5.42
 RigidSlingAssembly............................................................................................................................................ 5.44
Torque Measurement................................................................................................................................................. Section 6
Hydraulic Section....................................................................................................................................................... Section 7
 HydraulicMotorInformation................................................................................................................................. 7.1
 HydraulicValveInformation................................................................................................................................. 7.14

KT5500 5-1/2” Tong & CLInCHER® BaCKup
SECTIon ConTEnTS ix TECHnICaL ManuaL
IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF
IMPORTANCE USED IN THIS INSTALLATION GUIDE
McCoyDrilling&Completionsusesthreeindicatorstodescribeitemsofthreedegreesofimportance.
AHAZARDtooperatorsorequipment is represented by an exclamationpoint within ared triangle and identifiesitems
ofthehighestimportance.FailuretoheedinformationidentifiedbyaHAZARDsymbolmayresultinbodilyinjury,death,
catastrophicequipmentdamage,oranycombinationofthese.AHAZARDmayalsoindicatethepotentialfordangerous
environmentalcontamination.
The information presented in this document will provide setup, operating, and maintenance instruc-
tions for your KT5500 tong & CLINCHER® backup. Due to the wide variety of operating conditions,
these instructions must be considered guidelines rather than absolute operating procedures. It is the
responsibility of the user to use these guidelines together with an experienced manager to develop
operating procedures that conform to all policies set forth by the operating authority (ies).
AWARNINGisrepresentedbyanexclamationpointwithinanorangetriangle,andcontainsinformationthatwillalertper-
sonneltoapotentialsafetyhazardthatisnotlife-threatening.AWARNINGmayalsoservetoalerttheusertoinformation
criticaltothecorrectassemblyoroperationoftheequipmentinuse.
This identies a HAZARD to operators or equipment
This identies a WARNING to users
ACAUTIONisrepresentedbyanexclamationpointwithinayellowtriangleandhighlightsinformationthatmayaidtheuser
duringassemblyoroperationofyourequipment.CAUTIONsarealsousedtoensurecommonerrorsarenotmadeduring
assemblyoroperationofyourequipment.
This identies a CAUTION to users
Observance of the following is the full responsibility of the user:
● all descriptions, information and instructions set out in this manual
● any regulation or requirement issued by an authority or agency which may influence operation,
safety or integrity of the equipment that overrules the content of this document.
● any legal or other mandatory regulation in force governing accident prevention or environmental
protection.

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