Mccoy Farr sl-4500 User manual

SL-4500

4-1/2” (11.43cm) 8K Lbs.-Ft. “Slim”

Hydraulic Power Tong & Backup

•Specications

•Operation

•Maintenance

•Assembly

TECHNICAL MANUAL

Published by McCoy Corporation, Technical Publications Department

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

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This manual covers the following models:

NOTE: CE Marking available for all models except 80-2001-10. Some illustrations

used in this manual may not exactly match your model of tong.

moDeL ReV DeScRiPTion

80-2001-6 04-1/2”6500lb.-ft.“Slim”Tongwithintegratedbackup&supportstructure,standard2-armsling,motor

valve,backupvalve,&safetydoor.

80-2001-8 04-1/2”8000lb.-ft.“Slim”Tongwithintegratedbackup&supportstructure,standard2-armsling,motor

valve,backupvalve,liftvalve,&safetydoor.

80-2001-10 04-1/2”8000lb.-ft.“Slim”Tongwithintegratedbackup&supportstructure,short2-armsling,motorvalve,

backupvalve,liftvalve,&safetydoor.

80-2001-13 04-1/2”8000lb.-ft.“Slim”Tongwithintegratedbackup&supportstructure,standard2-armsling,motor

valve,backupvalve,liftvalve,safetydoor,&dumpvalve

PATENTED & PATENTS PENDING

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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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SL4500 4-1/2” “SLim”Tong

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Summary Of Revisions

Date Section Page Description Of Revision

May2009 N/A N/A InitialRelease

Sep2009 Intro 1.2&1.3 Correcteddimensionsonthespecificationpages

May2010 Varies Varies Updatedillustrationsthroughouttorepresentupdatedjawretentionmechanism,

updatedlogosandbranding

June2010 Varies Varies UpdatedmanualtocomplywithCEmarking

September2010 Appendixes Varies Revisedappendixes

December2011

All All Addedtableofillustrations

22.13 Revisedsubsection2.F.1,“TongRig-Up&Leveling,Suspension&Restraint”

22.17 Insertedsubsection2.G.1,“TongOperation,OperatorTraining”

22.21 RemovedSections2.J&2.K,“MakingUpAJoint”and“BreakingOutAJoint”,

insertedsection2.I,“Making&BreakingAConnection”.

3 3.1 RevisedSection3.A,“GeneralMaintenanceSafetyPractices”.

3 3.1 InsertedSection3.C,“PreventiveMaintenancePractices”.

3 3.6 InsertedSubsection3.E.2,“SafetyDoorSwitchAdjustment”.

3 3.16 Moved“DailyPowerTongInspection&MaintenanceChecklist”toMaintenance

section.

3 3.18 Moved“MonthlyPowerTongInspection&MaintenanceChecklist”toMaintenance

section.

3 3.21 Moved“DailyBackupInspection&MaintenanceChecklist”toMaintenancesec-

tion.

3 3.22 Moved“DailyPowerUnitInspection&MaintenanceChecklist”toMaintenance

section.

3 3.23 Moved“TubularConnectionEquipmentDe-commissioningChecklist”toMainte-

nancesection.

3 3.26 Moved“TubularConnectionEquipmentRe-commissioningChecklist”toMainte-

nancesection.

44.1-4.6 Revised“Troubleshooting”section.

6 ALL Completerevisionoftorquemeasurementsection

Copyright©2009-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.

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Introduction & Specifications.................................................................................................................................... Section One

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

 EquipmentSpecifications..................................................................................................................................... 1.2

 LubricationSpecifications..................................................................................................................................... 1.4

Setup & Operation...................................................................................................................................................... Section Two

 Sling/LoadBearingDeviceSafety...................................................................................................................... 2.1

 MajorComponentIdentification............................................................................................................................ 2.4

 HydraulicSchematic/HydraulicValveIdentification........................................................................................... 2.8

 HydraulicConnections......................................................................................................................................... 2.11

 Tong/BackupJawAvailability&Installation....................................................................................................... 2.12

 TongRig-Up&Leveling....................................................................................................................................... 2.13

 TongOperation.................................................................................................................................................... 2.17

 ExtremeColdWeatherOperationProcedures..................................................................................................... 2.20

 Making&BreakingConnections.......................................................................................................................... 2.21

Maintenance................................................................................................................................................................ Section Three

 GeneralMaintenanceSafetyPractices................................................................................................................ 3.1

 Cleaning............................................................................................................................................................... 3.1

 PreventiveMaintenance....................................................................................................................................... 3.1

 Lubrication............................................................................................................................................................ 3.2

 Adjustments.......................................................................................................................................................... 3.5

 RecommendedPeriodicChecks.......................................................................................................................... 3.7

 Disassembly&OverhaulProcedures................................................................................................................... 3.8

 AssemblyInstructions.......................................................................................................................................... 3.9

 DailyInspection&MaintenanceChecklist(PowerTong)..................................................................................... 3.16

 MonthlyInspection&MaintenanceChecklist(PowerTong)................................................................................ 3.18

 DailyInspection&MaintenanceChecklist(Backup)............................................................................................ 3.21

 DailyInspection&MaintenanceChecklist(PowerUnit)...................................................................................... 3.22

 TubularConnectionEquipmentDe-commissioningProcedures.......................................................................... 3.23

 TubularConnectionEquipmentRe-commissioningProcedures.......................................................................... 3.26

Troubleshooting ......................................................................................................................................................... Section Four

 TongWillNotDevelopSufficientTorque............................................................................................................. 4.1

 FailureOfJawsToGripPipe............................................................................................................................... 4.3

 TongRunningTooSlowly.................................................................................................................................... 4.4

 GeneralComments.............................................................................................................................................. 4.5

Assemblies And Parts ............................................................................................................................................... Section Five

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

 IdlerAssemblies................................................................................................................................................... 5.4

 ReductionGearAssembly(Small)....................................................................................................................... 5.6

 ReductionGearAssembly(Large)....................................................................................................................... 5.8

 RotaryAssembly.................................................................................................................................................. 5.10

 RotaryGearAssembly......................................................................................................................................... 5.12

 TongBodyAssembly........................................................................................................................................... 5.14

 HydraulicAssembly.............................................................................................................................................. 5.16

 MotorAssembly.................................................................................................................................................... 5.18

 BrakeBands......................................................................................................................................................... 5.20

 DoorAssembly..................................................................................................................................................... 5.22

 RigidSlingAssembly............................................................................................................................................ 5.24

 BackupAssembly................................................................................................................................................. 5.26

 RearLegAssembly.............................................................................................................................................. 5.28

 FrontLegAssemblies........................................................................................................................................... 5.30

Torque Measurement ................................................................................................................................................. Section Six

Hydraulic Component Information ........................................................................................................................... Section Seven

TabLe of conTenTS

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Illustration1.A.1:SL4500Tong&Backup....................................................................................................................................  1.1

Illustration1.A.2:SL4500Dimensions.......................................................................................................................................... 1.2

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

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

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

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

Illustration2.B.4:ComponentIdentication04............................................................................................................................. 2.6

Illustration2.B.5:ComponentIdentication05............................................................................................................................. 2.7

Illustration2.C.1:HydraulicSchematic01....................................................................................................................................  2.8

Illustration2.C.2:HydraulicComponentIdentication01.............................................................................................................  2.9

Illustration2.C.3:HydraulicComponentIdentication02.............................................................................................................  2.9

Illustration2.C.4:HydraulicComponentIdentication03.............................................................................................................  2.10

Illustration2.D.1:HydraulicConnections01................................................................................................................................. 2.11

Illustration2.D.2:HydraulicConnections02................................................................................................................................. 2.11

Illustration2.E.1:TongJawRemoval........................................................................................................................................... 2.12

Illustration2.E.2:TongJawDieReplacement.............................................................................................................................. 2.13

Illustration2.F.1:MasterLink.......................................................................................................................................................  2.14

Illustration2.F.2:TongLeveling...................................................................................................................................................  2.15

Illustration2.F.3:LoadCellConguration....................................................................................................................................  2.16

Illustration2.G.1:TongMotorControl..........................................................................................................................................  2.18

Illustration2.G.2:LiftCylinderControl..........................................................................................................................................  2.18

Illustration2.G.3:BackupClampControl.....................................................................................................................................  2.19

Illustration2.G.4:MotorSpeedControl........................................................................................................................................ 2.19

Illustration2.I.1:TongSuspension-MasterLink.........................................................................................................................  2.21

Illustration2.I.2:SettingBackingPinto“Make-up”....................................................................................................................... 2.22

Illustration2.I.3:BackupControl................................................................................................................................................... 2.22

Illustration2.I.4:CLAMPPressureGaugeonGaugePanel......................................................................................................... 2.23

Illustration2.I.5:BackupPressureControlValve......................................................................................................................... 2.23

Illustration2.I.6:Unlatching&OpeningDoor...............................................................................................................................  2.24

Illustration2.I.7:LiftCylinderControl............................................................................................................................................ 2.25

Illustration2.I.8:BackupControl................................................................................................................................................... 2.26

Illustration2.I.9:MotorSpeedControl.......................................................................................................................................... 2.26

Illustration2.I.10:RotationControl-Makeup............................................................................................................................... 2.27

Illustration2.I.11:Torque&SystemPressureGaugesonGaugePanel.....................................................................................  2.27

Illustration2.I.12:SwitchingMotorspeedSwitchToLOWSPEED.............................................................................................. 2.28

Illustration2.I.13:ReversingRotationToFreeTongJaws........................................................................................................... 2.28

Illustration2.I.14:Un-clampingBackupJaws...............................................................................................................................  2.29

Illustration2.I.15:LoweringAssemblyUsingLiftCylinderControl............................................................................................... 2.29

Illustration2.I.16:SettingBackingPinTo“Break-out”Mode........................................................................................................  2.30

Illustration2.I.17:RotationControl-Break-out............................................................................................................................  2.31

Illustration2.I.18:SwitchingMotorSpeedControlToHIGHSPEED........................................................................................... 2.32

Illustration2.I.19:ReleasingTongJawsFollowingBreakOut&Un-threading............................................................................ 2.32

Illustration2.I.20:Un-clampingBackupJaws...............................................................................................................................  2.33

Illustration2.I.21:LoweringAssemblyUsingLiftCylinderControl............................................................................................... 2.33

Illustration3.D.1:CagePlateRollerLubrication...........................................................................................................................  3.2

Illustration3.D.2:IdlerShaftBearingLubrication......................................................................................................................... 3.2

Illustration3.D.3:ReductionGearBearingLubrication................................................................................................................  3.3

Illustration3.D.4:DoorPivotShaftLubrication.............................................................................................................................  3.3

Illustration3.D.5:DoorLatch&PostLubrication..........................................................................................................................  3.4

Illustration3.D.6:JawAssemblyLubrication................................................................................................................................ 3.4

Illustration3.D.7:LoadCellLubrication........................................................................................................................................  3.5

Illustration3.E.1:BrakeBandAdjustment.................................................................................................................................... 3.5

Illustration3.E.2:SafetyDoorPlungerAdjustment01.................................................................................................................  3.6

Illustration3.E.3:SafetyDoorPlungerAdjustment02.................................................................................................................  3.6

Illustration3.E.4:SafetyDoorPlungerAdjustment03.................................................................................................................  3.7

Illustration3.H.1:GearboxCoverInstallation............................................................................................................................... 3.10

Illustration3.H.2:IdlerGearInstallation.......................................................................................................................................  3.11

Illustration3.H.3:RotaryGearAssembly.....................................................................................................................................  3.11

Illustration3.H.4:“ButtonGuide”Installation................................................................................................................................ 3.12

Illustration3.H.5:MainBodyFastenerPlacement.......................................................................................................................  3.12

Illustration3.H.6:DoorLatchWeldmentInstallation..................................................................................................................... 3.13

Illustration3.H.7:DoorDetentInstallation.................................................................................................................................... 3.14

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

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

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

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

Illustration6.A.5:CompressionLoadCellExploded....................................................................................................................  6.4

Illustration6.A.6:TurnCounterEncoderMountExploded........................................................................................................... 6.5

LiST of iLLuSTRaTionS

SL4500 4-1/2” “SLim”Tong

SecTion conTenTS

xTechnicaL manuaL

IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF

IMPORTANCE USED IN THIS INSTALLATION GUIDE

FarrCanadaCorp.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instructionsforyour

SL4500tong.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op-

erating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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