Farr Mccoy-Kt5500
Farr Mccoy-Kt5500
Farr Mccoy-Kt5500
KT-5500
5-1/2” (14 cm) 18.7K Lbs.-Ft.
Hydraulic Power Tong
• Specifications
• Operation
• Maintenance
• Assembly
mccoyglobal.com
Copyright © 2007 - 2012 McCoy Corporation. All rights reserved.
Published by McCoy Corporation, Technical Publications Department
14755 - 121A Avenue • Edmonton, AB, Canada, T5L 2T2
KT5500 5-1/2” 18.7K Tong
NOTE: Some illustrations used in this manual may not exactly match
your model of tong.
WARNINGS
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
ANY REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.)
USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT unless
otherwise specified.
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.
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.
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.
25-1/2”
33-1/4”
52”
ALL REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.)
USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT unless
otherwise specified.
** These are ideal values. Actual achieved torque is highly dependant upon tong efficiency, final posi-
tion of rotary gear when full torque load is reached, and the motor with which the tong is equipped.
Maximum Hydraulic Requirements:
60 US GPM (227.1 LPM) (Required to achieve maximum rated speed)
2500 PSI (17.2 KPa) (Required to achieve maximum rated torque)
Note: Maximum torque is only available in low gear at full motor
displacement
Length (Doors Closed): 52” inches / 132.1 cm
Height: 33-1/4” / 84.5 cm
Width: 25-1/2” inches / 64.8 cm
Weight (Approximate): 1250 lb. / 568.2 kg.
Space Required on Pipe: 6-3/4” / 17.1 cm
Maximum Elevator Diameter: N/A
Torque Arm Length: 36 inches / 91.4 cm (Centre line of pipe to centre line of anchor)
Casing Jaws Available (inches): See Pg. 2.12
Recommended Spring Hanger: 85-0106
Use a premium quality hydraulic fluid that meets or exceeds the following specifications:
Typical Density (kg/m3) 878
Viscosity - cSt @ 40 °C 68.8
- cSt @ 100 °C 8.7
Viscosity Index 97
Pour Point °F [°C] -22 [-30]
Flash Point °F [°C] 432 [222]
Colour, ASTM 1.5
Neutralization Number 0.40
Rust Protection - Distilled Water No Rust
- Sea Water No Rust
Hydrolytic Stability - Cu Mass Loss, mg/cm2 0.04
Copper Corrosion Test 1A
Filterability: Denison - Wet & Dry Pass
Afnor - Wet & Dry Pass
Cincinatti Milacron Spec Approved P69
Denison HF-0: Approved
Denison P-46 Piston Pump: Pass
Denison T6C Vane Pump: Pass
Vickers 35VQ25 Vane Pump Test: Pass
Vane pump test total ring and vane wear, mg. <10
Oxidation Stability:
Turbine Oil Stability Test Life, hours 2500+
Rotary Bomb Oxidation Test, minutes 325
FZG Spur Gear Test, Failure Load Stage (FLS) 12
DO NOT ACCESS ROTATING COMPONENTS UNLESS HYDRAULIC POWER SUPPLY HAS BEEN
DEACTIVATED OR ISOLATED.
A CLEARLY IDENTIFIED REMOTE POWER PACK EMERGENCY STOP MUST BE INSTALLED IN
THE IMMEDIATE VICINITY OF THE TONG OPERATOR.
A. SLING / LOAD BEARING DEVICE SAFETY
The supplied Load-Bearing device (chain sling, rigid sling, spreader bar assem-
bly, frame, or any other device that bears the partial or total weight of the
equipment described in this manual) has been specified or designed to support
the equipment described in this DOCUMENT. Farr will not guarantee the ability
of the load-bearing device to support any other part, assembly or combina-
tion of parts and assemblies, or any additions to the equipment described
in this manual that add weight to the equipment, unless supplied by McCoy
Drilling & Completions.
McCoy Drilling & Completions DOES not guarantee the INTEGRITY of MODIFIED OR
DAMAGED load-bearing deviceS, UNLESS THOSE MODIFICATIONS ARE PERFORMED BY
McCoy Drilling & Completions.
McCoy Drilling & Completions recommends following an industry-accepted standard such as OSHA, ASME B30.9-2006, or manu-
facturer’s guidelines when performing any rigging and overhead lifting. Use by untrained persons is hazardous. Improper use will
result in serious injury or death. Do not exceed rated capacity. Slings will fail if damaged, abused, misused, overused, or improperly
maintained.
●● Only grade 80 or grade 100 alloy chain should be used for overhead lifting applications.
●● Working Load Limit (WLL) is the maximum allowable load in pounds which may be applied to the load-bearing device, when the
device is new or in “as new” condition, and when the load is uniformly and directly applied. The WLL must never be exceeded.
●● Working Load Limit (WLL) is the maximum working load for a specific minimum sling angle, measured from the horizontal plane.
The Working Load Limit is identified on the sling.
●● The Working Load Limit or Design factor may be affected by wear, misuse, overloading, corrosion, deformation, intentional al-
terations, sharp corner cutting action and other use conditions.
●● Shock loading and extraordinary conditions must be taken into account when selecting alloy chain slings.
●● See OSHA Regulation for Slings 1910.184, ANSI/ASME B30.9-”SLINGS”, ANSI/ASME B30.10-”HOOKS” and ANSI/AMSE
B30.26 “RIGGING HARDWARE” for additional information.
THE MINIMUM SLING ANGLE (THE ANGLE OF THE LEG OF THE SLING MEASURED
FROM THE HORIZONTAL) MUST NEVER FALL LOWER THAN THE ANGLE SPECIFIED
FOR THE SLING IN USE
Sling Angle
Test / Examination
Non -Destructive Thorough Suffix To Be Marked
E xamination (NDE) Visual On Plate Attached
Time / Interval Lifting Tests1 of Lifting Points E xamination To Unit
Initial Certification By
YES YES YES T
Farr / Superior
Interval Not Exceeding At the discretion of At the discretion of
YES T or VN3
12 Months inspection body inspection body
Interval Not Exceeding At the discretion of
YES YES T or VN
60 Months inspection body
Following Substantial
YES YES YES T
Repair or Alteration4
1. Lifting test as per S 7.3 BS EN 12079 or DNV 2.7-1 May 1995
2. T = Proof Test, non-destructive examination; VN = non destructive examination and visual examination;
V = visual examination.
3. Dependant upon whether non-destructive examination has been carried out.
4. For the purposes of this standard, a substantial repair or modification is defined as any repair and/or
modification that has been carried out which may, in the opinion of the inspection body, affect the load-
bearing elements of the container or lifting device, or elements that contribute directly to its structural
integrity.
Written records of the most recent periodic inspection shall be maintained, and shall include the condition of the sling.
2. Proper Use Of Load-Bearing Devices
Whenever any load-bearing device is used, the following practices shall be observed.
• Load-bearing devices that are damaged or defective shall not be used.
• Slings shall not be shortened with knots or bolts or other makeshift devices.
• Sling legs shall not be kinked.
• Load-bearing devices shall not be loaded in excess of their rated capacities.
• Slings shall be securely attached to their load.
• Load-bearing devices shall be protected from snagging, and shall not be further obstructed by any object.
• Suspended loads shall be kept clear of all obstruction.
• All employees shall be kept clear of loads about to be lifted and of suspended loads.
• Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load.
• Shock loading is prohibited.
• Do not stand directly under a load during lifting.
3. Storage Of Load-Bearing Devices
Proper storage of out-of-service load bearing devices is important to ensure full integrity of the device once it is returned to
service. Farr recommends observing the following practices.
• Wipe off all excess grease. Use a solvent-based cleaner on rags to wipe all external surfaces to remove residual grease
or hydraulic fluid. Once the outside surfaces have been de-greased, wipe all external surfaces with clean water to remove
residual solvent.
• Farr recommends that an anti-corrosive agent such as Tectyl ® 506 be applied to all external surfaces. Refer to manufac-
turer data sheets for proper application and safety information. Allow the anti-corrosive coating ample time to dry - refer to
manufacturer data sheets for drying times at room temperature.
• Store in a clean, dry location. When returning to service, note that a full inspection of the device must be performed.
7
4
10
11
5
Item Description
1 Master Lifting Link
2 Rigid Sling
3 Tong Leveling Adjustment
4 Safety Door Switch & Guard Assembly
5 Tong Door Latch
6 Torque Gauge Mounting Plate
7 Manual Shift Assembly
8 Backing Pin Assembly
9 Cage Plate Assembly
10 Tong Door Cylinder
11 Tong Door
12 15
13
16
14
Item Description
12 Hydraulic Valve Bank Assembly
13 Hydraulic Motor
14 Motor Mount
15 Hydraulic Inlet
16 Hydraulic Outlet
19
17
20
21
18
Item Description
17 Brake Band Adjustment
18 Tong Jaws with Die Inserts
19 Safety Door Valve Block
20 Access Panel
21 Brake Band
T
Single Speed / Two Speed Motor (Optional)
6
7
LIFT
OPTIONAL
Dump Valve (Optional)
Hydraulic Schematic:
Backup Ready Tong
5
BACKUP
OPTIONAL
4
TONG MOTOR
(OPTIONAL TWO
SPEED SHOWN)
13
8
MAKE
UP
DUMP VALVE
3
(OPTIONAL)
11 12
14
15
T
4
2
G
2
10
9
1
MOTOR SPEED SWITCH
WITH 2-SPEED MOTOR)
(OPTIONAL - USED
16
9 2 4
14 2 MAKE
13
1 3 UP
KT5500 5-1/2” 18.7K Tong
16
15 1
Section Contents
P T
10 G LIFT
7
11 12 BACKUP
Technical Manual
T
1 2 3 4 5 6A
OPTIONAL OPTIONAL
Setup & Operation
Setup & Operation KT5500 5-1/2” 18.7K Tong
Item Description Part Number
1 Inlet Valve DVA35-A880 w/2500 TO 3500 DVG35 HMRV CARTRIDGE 10-9016
2 Relief Valve, DVA35-MRV-1 10-0010R
3 Motor Section, DVA35-MA8, 4WAY SAE PORTS 10-9014
4 Lift Section, DVA-SA8, 1” ORB PORT (Optional) 10-9015
5 Backup Section, DVA35-DA8 4WAY SAE PORTS (Optional) 10-9019
6 Outlet Section, DVA35-TR99, SAE PORT 10-0086
6A Outlet Section - Closed Centre, DVA35-PB90, SAE PORT (Optional) 08-1825
7 Flow Control Valve, N800S (not shown) 08-9062
8 Single-Speed Hydraulic Motor 87-0112
Two-Speed Hydraulic Motor (Optional) 87-0007
9 Motor Speed Valve (Optional) 10-9024
10 Safety Door Switch 08-0337
11 Pilot-To-Operate Cartridge Valve 08-1625
12 Safety Door Valve Block 101-0727
13 Check Valve (Optional) 02-9022
14 Dump Valve (Optional) 08-9284
15 Dump Valve Body (Optional) 08-9283
16 3000 PSI Pressure Gauge 02-0245
1 2 3 4 5 6 8
10
12
11
These hose couplings are self-sealing, and care should be taken to ensure complete engagement to prevent partial closure of the
check valve in the coupling. Ensure that the nut (female) side is completely made up onto the male connector - there is a line on the
male fitting that indicates complete make-up. Snug the female fitting right up to the line.
90o
90o
ii. Place a level lengthwise (front to back) along the tong, ensuring that it is parallel with the surface of the tong. Loosen the
3/4” jam nuts on the adjusting bolts on rigid sling brackets. Completely loosen the adjusting bolts. Turn each adjusting
bolt equally until tong hangs level front-to-back. Lock adjusting bolts in place with the jam nuts.
YOUR EQUIPMENT HAS BEEN THOROUGHLY TESTED AND INSPECTED AT THE FACTORY.
HOWEVER, WE ADVISE INSPECTION AND TESTING OF YOUR NEW TONG AFTER TAKING
POSSESSION IN ORDER TO ELIMINATE THE POSSIBILITY OF SHIPPING DAMAGE.
McCoy Completions & Drilling recommends that the following pre-operating tests be performed after receipt from the factory or
after extended storage, prior to releasing the tong to operations:
●● Perform a complete inspection of all fasteners to ensure none have loosened during transport.
●● Connect the tong to the power unit, and apply full hydraulic pressure. Inspect and correct any leaks.
●● Operate the tong at full speed and in high gear for a duration of one-half hour. Hot bearing caps may indicate impending
bearing failure.
●● Switch to low gear and operate for an additional one-half hour at full speed.
●● Run the backup through several clamp/un-clamp sequences to ensure functionality.
●● Inspect all components and hydraulic fittings for possible defects following completion of the tests. All FARR Tongs have
been thoroughly tested at the factory prior to shipping, but shipping damage must be identified before running the tong in
an operational environment.
●● Carefully inspect the safety door components, and test to ensure that the safety device on each door is operating correctly
before releasing the tong to the operating environment.
TONG DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE THE POWER UNIT IS ener-
gized IN ORDER TO ASSURE THE SAFETY OF OPERATING PERSONNEL
Ensure adequate lube oil and hydraulic oil levels before starting engine. Use start up procedures as recommended by the power
unit engine operator’s manual. Open the Bypass Valve on the hydraulic system, and inspect all pressure and return line hose
connections to ensure correct and secure installation.
IMPROPERLY SECURED HYDRAULIC CONNECTIONS WILL INTERRUPT HYDRAULIC FLUID FLOW, AND COULD
RESULT IN THE FOLLOWING FAILURES:
●● A restriction in the pressure supply hose will result in high pressure within the power unit hydraulic system, which will
activate the hydraulic governor and increase the engine speed to as high as maximum RPM.
●● A restriction in the return line will result in high pressure within the power unit and the tong hydraulic system, causing
engine speeds as high as maximum RPM, and possible failure of the motor seal.
Following inspection of the hoses, energize the hydraulic power unit and allow it to idle until warm. Allow hydraulic fluid to cir-
culate for approximately 10 minutes, then slowly close the Bypass Valve to allow hydraulic fluid to circulate through the hoses
and to the tong (circulating pressure should not exceed 200 psi). Place the tong gear shifter in low gear and rotate the tong
slowly forward and then reverse with the throttle valve control lever. Once this has been done and the proper size jaws have
been installed, the tong is then ready to run pipe.
2. Valve Operation
4-way proportional valves control operation of hydraulic devices on the tong assembly such as hydraulic motors and cylinders.
When any one valve is “centered” or in the detent position, there is no hydraulic output from the valve. When the valve is pushed
forward there is an effect, and when the valve is pulled back, there is an opposite effect. These valves feature proportional con-
trol, which means that further extension of the valve handle (thereby further opening the valve orifice) results in proportionally
higher hydraulic output to the controlled device.
The illustrations on the next two pages list the type and effect of the hydraulic valves this tong may be equipped with.
3. Shifting Gears
The shifting shaft has three “detent” positions identifying the low speed/high torque position, the “neutral” or free-spinning posi-
tion, and the high speed/low torque position. The detent strength may be adjusted by releasing the locknut on the detent tube
and increasing or relaxing pressure on the detent spring. Ensure the locknut is tightened once the desired detent pressure has
been set.
To shift to the high-speed gear, move the shifting handle upward from neutral position. To shift to the low-speed gear, move
the shifting handle down through the neutral detent to its lowest position. Note that the high clutch gear or the low clutch gear
may not be exactly aligned when shifting, so the operator may need to “bump” the motor control handle slightly to turn the main
clutch gear shaft and shifting collar into alignment. This is most effective when applying a small amount of pressure on the gear
shift lever in the direction you want to shift the tong, ensuring the shifting collar will “catch” when the main clutch gear aligns
with either the high or low clutch gear.
SEE ILLUSTRATION NEXT PAGE
SHIFTING TONG WHILE ROTATING THE MOTOR AND CAGE PLATE MAY RESULT IN
CATASTROPHIC GEAR TRAIN FAILURE
2. Support Rollers
Apply grease to the support roller bearings through the grease fittings recessed into the top and bottom of each support roller
shaft. NOTE: the safety door cam assembly needs to be removed to access the grease fitting in the top of the door pivot roller
shaft (ten locations top, ten locations bottom).
4. Pinion Idler
Apply grease to the pinion idler bearing through the grease fitting recessed into the top of the half-shaft, located on the bottom
face of the tong (one location only).
6. Clutch Bearings
Apply grease to the clutch bearings through the two grease fittings located on the clutch bearing cap on the bottom face of the
tong, and the single grease fitting recessed into the end of the clutch shaft. (three locations total).
8. Shifting Shaft
Apply grease to the shifting shaft and top shifting shaft bushing. The shaft and shifting yoke can be accessed through the cover
plate on the side of the tong.
Brake Band
Adjustment
Mechanism
top and bottom brake bands must be adjusted simultaneously and equally
ALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP. THE BOTTOM
PLATE OF THE TONG IS TYPICALLY WELDED TO THE SIDE BODY AND CANNOT BE REMOVED.
REPLACEMENT FASTENERs (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC.) USED
DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT.
FASTENERs USED for MAINTENANCE OR OVERHAUL of load-bearing components
(chain slings, rigid slings, legs) MUST BE tightened to the proper torque.
REMOVAL OF TOP PLATE
1. Remove the rigid sling assembly by disconnecting the leveling devices from the hanger brackets.
2. Remove the two rigid sling hanger brackets.
3. Disconnect the three hydraulic connections from the motor. Undo the restraints securing the inlet and outlet lines from their
supports, and lift the hydraulic valve section away from the tong. Remove the inlet and outlet support pieces.
4. Remove top brake band assembly (leave adjustment lug weldments in place for now).
5. Remove the tong door stop cylinder.
6. Remove door assembly by removing the door roller shaft. Support door assembly as the roller shaft is removed. Remove the
nut from the top of the roller shaft, and use a soft alloy material (e.g. brass rod, etc.) to lightly tap the shaft down through the
support roller assembly until it comes free at the bottom. Use caution that the threads on the ends of the support roller shafts
are not damaged. Do not lose the door shoulder bushings.
7. Remove the hitch pin securing the torque gauge holder to the torque gauge mount weldment, and remove the mount.
8. Remove the four hex socket head cap screws securing the motor and the torque gauge mount weldment. Remove the torque
gauge mount weldment, then lift the motor up and away from the motor mount. Inspect the motor gear, located at the bottom of
the motor shaft, for gear clashing or tooth damage. Also, ensure that the motor gear is securely attached to the motor shaft.
9. Remove the cotter pin and clevis pin connecting the shifter handle to the shifter shaft (it is not necessary to disconnect the handle
from the pivot lug weldment).
10. Unbolt the pivot lug weldment from the top plate, and remove the pivot lug and handle assembly.
11. Remove the four hex socket head cap screws securing the motor mount to the top plate. Use care not to dislodge and lose the
two positioning dowels.
12. Remove the snap ring securing the drive gear to the top of the clutch shaft. Carefully remove the drive gear from the clutch shaft.
13. Remove the two 10-24 x 3/4” hex socket head cap screws securing the top clutch bearing retainer to the top plate.
IF THE BEARING REMAINS ATTACHED TO THE GEAR SHAFT AFTER THE BEARING CAP IS
PULLED, McCoy Drilling & Completions SERVICE PERSONNEL RECOMMENDS LEAVING IT
IN PLACE UNTIL THE TOP TONG PLATE IS REMOVED.
16. Remove the jaw pivot bolts and the jaw assemblies.
17. Ensure the bottom cage plate is supported before beginning this step. Remove the two front cage plate bolt and nut sets.
Remove the backing pin assembly and the rear cage plate bolt, and the cage plate spacers. The top and bottom cage plates
may now be removed - Note that the cam followers are fastened to the top and bottom cage plates, so use caution not to dam-
age them.
THE CAGE PLATE BOLTS ARE THE ONLY ITEMS FASTENING THE BOTTOM CAGE PLATE TO THE
TONG. SUPPORT THE BOTTOM CAGE PLATE FROM BELOW PRIOR TO REMOVING CAGE PLATE
BOLTS IN ORDER TO PREVENT DAMAGE TO THE BOTTOM CAGE PLATE OR PERSONAL INJURY
TO THE MECHANIC
18. Remove the top nuts and pads for the rotary idler gears.
19. Remove the remaining top roller shaft nuts. Note that the top brake band adjustment lug weldments are removed at this point.
20. Loosen, but do not remove the detent bolt on the top shifter lug weldment. Once the force from the detent ball has been removed
from the shifter shaft, the top shifter bushing can be un-threaded from the top plate. Take care not to lose the detent ball when
the bushing comes free of the shaft.
21. Remove the hex head bolts and hex flat head cap screws around the perimeter of the tong that secure the top plate.
22. With all the above steps taken, the top tong plate can be lifted off providing access to the inside of the gear case.
lift the top plate straight up to avoid snapping the dowel pins. a snapped, bent,
or otherwise damaged dowel pin can be extremely difficult to remove.
4. Install rotary gear (PN 1064-D1), making sure the backing pin slots are on the side facing up. Ensure one side is sup-
ported by the support rollers installed in Step 3, and the opening in the rotary gear is oriented toward an open support
roller space as shown in the following illustration.
ensure the top plate remains parallel to the side body to avoid binding on the
dowel pins.
27. Use a rubber or wooden mallet to evenly tap the circumference of the top plate until it is flush with the side body.
28. Slide the clutch bearing retainer spacer (PN 1400-59A) over the bottom of the top clutch bearing retainer (PN 997-D11-59), and
mount top clutch bearing retainer and spacer to the top plate with two #10-24 x 3/4” hex socket head cap screws.
29. Press top clutch bearing (PN 02-0002) into top clutch bearing retainer. Insert clutch bearing bushing (PN 997-60) shoulder side
up between bearing and clutch shaft.
30. Secure clutch drive gear (PN 997-A3-61) to the top of the clutch shaft with retaining snap ring (PN 02-0001).
31. Install rotary idler pads (PN 997-D20-125) over the top of the rotary idler shafts and secure with 1-1/2” UNF hex nylock nuts.
32. Press remaining pinion bearing into the top pinion bearing cap (PN 997-D15-89) and secure over the top of the pinion gear shaft
with four 1/2” UNC x 1-1/4” hex bolts and 1/2” lock washers.
33. Slide the top shifter bushing (PN 101-0020) over the shifting shaft and thread in to the top plate until snug.
34. Thread the detent tube (PN 101-0019) into the top shifter bushing as shown. Thread three 5/8” NC x 5/8” hex socket set screws
into the remaining three ports in the top shifter bushing - do not bottom out the set screws on the shifting shaft, or the shaft will
not move.
vii. Attach the safety door switch guard plate, PN 101-1480, to the safety door switch guard weldment using three 3/8” NC
x 3/4” hex bolts and lock washers.
59. Thread door cylinder mounting post (PN 1050-12-001) into top plate, just adjacent to the top LH brake band lug weldment.
60. Install door cylinder (PN 101-0069) - secure onto posts with 1/2” NC x 1/2” hex socket head shoulder bolts (UNC).
1. Rotate cage plate/rotary gear until the opening in the rotary gear faces towards the rear of the tong.
Do not perform any further actions or maintenance while the tong is con-
nected to any hydraulic power supply. Farr recommends that all hydraulic
lines are fully disconnected, and residual hydraulic pressure is bled off.
Ensure adequate containment is in place to prevent environmental contami-
nation from residual hydraulic fluid.
1) Rotate the tong to the “open throat” position. Ensure tong and backup doors (if equipped) are closed. Fully extend
the lift cylinder
2) De-energize the power unit.
3) Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure
2. in the valve and motor.
4) Remove the hydraulic SUPPLY line from the equipment.
5) Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure
in the remainder of the hydraulic control system.
7) Disconnect the hydraulic RETURN line from the equipment.
8) Disconnect remaining hoses such as case drains, or lines connected to the turns counter.
Perform an initial wash of the tong in order to remove the majority of dirt and grease build-up. Ensure adequate contain-
3. ment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease.
4. Remove the access panel on the side of the tong directly adjacent to the shifter mechanism.
Use a flashlight to perform a visual inspection of the gear train through the access panel and the opening of the rotary
5. gear. If gear damage or chips of metal are seen, the tong should be removed from service and overhauled to avoid further
damage. Replace access panel when inspection is complete.
Perform a visual inspection of all fasteners and protruding body pieces (example: hydraulic valve mounts, inlet & outlet
6. line supports, tong legs, shifter handle pivot lugs). Tighten or replace loose or missing fasteners. Farr recommends that
damaged or missing body parts be repaired or replaced as soon as possible.
Inspect the jaws and dies. Inspect the jaw roller pins for signs of damage - replace pins if necessary. If the pins are welded
7. in place, replace the entire jaw assembly. Ensure dies are secure in the jaw - replace worn dies if necessary. Ensure that
the jaw rollers rotate freely. Check to ensure the size of the loaded jaws match the size of casing or pipe you are running.
Perform a visual inspection of all lifting points - if visible damage is seen, including cracks, broken lugs, distorted metal,
8. etc. replace damaged part(s) before placing tong in service. Also inspect all chains, master links, and turnbuckles - again,
if any damage is noted replace the damaged part(s) before placing the tong in service.
Inspect tong for signs of premature wear, or moving parts that are rubbing (bare metal where there used to be paint is a
9. good indication of wear.
10. Inspect backing pin(s). If cracked, broken, or bent it (they) must be replaced.
Inspect top and bottom brake band linings - replace if necessary. Unequal wear of the brake bands indicates that the
11. brake band tension is not evenly adjusted. Refer to the maintenance section of the manual for instructions on properly
adjusting brake bands.
Perform a visual inspection of all hydraulic lines. Replace flexible lines if they appear to be cracked, fatigued, or have
12. visible signs of wear from contact with a rigid object.
14. Perform a complete greasing of the tong - refer to Maintenance section of the technical manual
Ensure main supply and return connections to the tong are fully made up. Re-connect the remainder of the hydraulic
15. lines, and, if applicable, the electrical line to the turns counter.
Failure to ensure that the self-sealing supply and return lines are fully
made up may result in catastrophic equipment failure.
If using a stand-alone power unit, start it now - refer to the power unit technical manual for startup procedures. Listen to power unit for
a moment to see if there are any unusual mechanical sounds (rubbing, grinding, excessive pump noise). If using a diesel unit, allow
sufficient time for the engine to reach operating temperature before increasing engine RPM. Once engine is warm, gradually increase
engine RPM until operating speed is reached.
Ensure that supply pressure is at or above the tong’s specified operating pressure, and that the return pressure is less
16. than 350 psi.
17. Perform a visual inspection of pressurized hydraulic lines. Document and correct any hydraulic fluid leaks.
Perform a full functional test of the tong. Report and correct any hydraulic leaks from the hydraulic valve bank, or from
18. any hydraulic cylinders that are used.
Perform a visual inspection of the load cell. If using a tension load cell, replace any cracked, broken, or distorted com-
19. ponents including links and chains. If using a compression load cell, replace any component that has been crushed or
otherwise distorted through compression.
If applicable, inspect the load cell anchor pins (tension load cell only). Replace the anchor pins if cracking or metal
20. distortion is seen.
If applicable, the weld securing the single load cell anchor to the bridge bar main plate must be inspected (compression
load cell only). If the integrity of the weld has been compromised, the tong must be removed from service until the weld
21. is repaired. The load cell beam will need to be disconnected and removed so the weld is visible. Before re-installing the
beam, liberally grease the anchor pin before reinserting into the load cell beam.
Test safety door feature (if equipped). Open the tong door(s), and attempt to rotate the cage plate at low speed (low
gear) in both directions (makeup and breakout). If cage plate begins rotating, the safety door mechanism is not func-
22. tional, and the tong must be removed from service until the safety door mechanism can be repaired. If the safety door
is operating correctly, cage plate rotation will not be inhibited once the door is closed and latched.
While rotating the cage plate, ensure that the jaws properly cam. If the jaws do not cam properly, the brake bands
23. need to be tightened. Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action
is achieved.
1. Rotate cage plate/rotary gear until the opening in the rotary gear faces towards the rear of the tong.
Do not perform any further actions or maintenance while the tong is con-
nected to any hydraulic power supply. Farr recommends that all hydraulic
lines are fully disconnected, and residual hydraulic pressure is bled off.
Ensure adequate containment is in place to prevent environmental contami-
nation from residual hydraulic fluid.
1) Rotate the tong to the “open throat” position. Ensure tong and backup doors (if equipped) are closed. Fully extend
the lift cylinder
2) De-energize the power unit.
3) Repeatedly actuate the tong motor control valve lever IN BOTH DIRECTIONS to dissipate any residual pressure
2. in the valve and motor.
4) Remove the hydraulic SUPPLY line from the equipment.
5) Repeatedly actuate the remaining control valve levers IN BOTH DIRECTIONS to dissipate any residual pressure
in the remainder of the hydraulic control system.
7) Disconnect the hydraulic RETURN line from the equipment.
8) Disconnect remaining hoses such as case drains, or lines connected to the turns counter.
Clean the exterior of the tool thoroughly, using either water (if using a pressure washer ensure a low-pressure wash wand
3. is used), or an appropriate solvent-based grease-cutting cleaner such as Varsol. Ensure adequate containment is in place
to prevent environmental contamination from residual hydraulic fluid, dirty grease, and cleaning agents.
4. Remove the access panel on the side of the tong directly adjacent to the shifter mechanism.
Clean the interior of the tong thoroughly, using either water (do not use a pressure washer), or an appropriate solvent-
based grease-cutting cleaner such as Varsol. Ensure adequate containment is in place to prevent environmental con-
5. tamination from residual hydraulic fluid, dirty grease, and cleaning agents. Make a note if any metal shavings or metal
pieces are flushed out of the gear train cavity - if shavings or metal pieces are seen the tong must be overhauled before
it is returned to service.
Inspect all fasteners and fastener safety wires (if equipped). Replace any missing fasteners - use Grade 8 bolts only un-
6. less otherwise specified. Re-torque all external fasteners to SAE specifications.
Repair or replace any damaged or missing external body parts, such as torque gauge mounts, hydraulic supports, safety
7. door protectors, etc.
Perform a visual inspection of all fasteners and protruding body pieces (example: hydraulic valve mounts, inlet & outlet
8. line supports, tong legs, shifter handle pivot lugs). Tighten or replace loose or missing fasteners. Farr recommends that
damaged or missing body parts be repaired or replaced as soon as possible.
Inspect tong for signs of premature wear, or moving parts that are rubbing (bare metal where there used to be paint is a
9. good indication of wear.
Inspect all paint - locations in which the paint has been damaged must be repaired prior to the tong being returned to
service. Prepare areas to be painted to ensure they are free of grease, dirt, or solvent. Touch up using a solvent-based
10. acrylic paint - “McCoy Grey” is paint color number RAL7015 (contact Farr sales for paint number for custom paint applica-
tions). Allow sufficient time for paint to dry before proceeding.
Inspect all external welds. Any weld that is cracked or separating must be repaired and repainted before returning the
11. tong to service.
Rotate the gear train by hand, and use a flashlight to perform a visual inspection of the gear train through the access
panel and the opening of the rotary gear while the gear train is being rotated. If gear damage or chips of metal are
13. seen, the tong should be removed from service and overhauled to avoid further damage. Replace access panel when
inspection is complete.
Inspect all jaws and dies in use for the maintenance interval. Inspect the jaw roller pins for signs of damage - replace
14. pins if necessary. If the pins are welded in place, remove and quarantine the jaw until the weld is repaired. Ensure dies
are secure in the jaw - replace worn dies if necessary. Ensure that the jaw rollers rotate freely.
15. Inspect backing pin(s). If cracked, broken, or bent it (they) must be replaced.
Inspect top and bottom brake band linings - replace if necessary. Unequal wear of the brake bands indicates that the
16. brake band tension is not evenly adjusted. Refer to the maintenance section of the manual for instructions on properly
adjusting brake bands.
Inspect door springs. Ensure the springs retain sufficient strength to be able to assist the opening of the door, and to
17. keep the door open. The springs should also help to “snap” the door shut.
Inspect backup springs (if applicable). The rear extension springs should be equally extended, and the front leg springs
should be equally compressed. Ensure that neither of the rear backup springs have been over-extended and lack
18. sufficient tension to adequately support the backup. Ensure that neither of the front leg springs have been over-com-
pressed, and still retain enough spring strength to support the front of the backup.
Extend all hydraulic cylinders, and inspect cylinder rods for signs of mechanical damage, flaking, or rust. Farr recom-
19. mends that damaged cylinders be replaced prior to storage.
Perform a visual inspection of all hydraulic lines. Replace flexible lines if they appear to be cracked, fatigued, or have
20. visible signs of wear from contact with a rigid object. If your tong is equipped with rigid hydraulic lines, replace any line
that is dented or appears to be stressed or cracked.
Generously fill the gear train housing with grease through the access panel, and also through the opening in the rotary
21. gear. Perform a full lubrication - refer to Maintenance section of manual to determine lubrication points.
Ensure main supply and return connections to the tong are fully made up. Re-connect the remainder of the hydraulic
22. lines, and, if applicable, the electrical line to the turns counter.
Failure to ensure that the self-sealing supply and return lines are fully
made up may result in catastrophic equipment failure.
If using a stand-alone power unit, start it now - refer to the power unit technical manual for startup procedures. Listen to power unit for
a moment to see if there are any unusual mechanical sounds (rubbing, grinding, excessive pump noise). If using a diesel unit, allow
sufficient time for the engine to reach operating temperature before increasing engine RPM. Once engine is warm, gradually increase
engine RPM until operating speed is reached.
Ensure that supply pressure is at or above the tong’s specified operating pressure, and that the return pressure is less
23. than 350 psi.
Perform a visual inspection of pressurized hydraulic lines. If any hydraulic fittings or hoses are leaking they must be
24. repaired or replaced before proceeding.
Rotate tong for one minute, stop, and reverse the direction of rotation for another minute, ending with the opening of
25. the rotary gear facing the gear train. De-energize the power unit, and perform another generous lubrication of the gear
train, including the gear housing.
Energize power unit. Rotate tong for one minute, stop, and reverse the direction of rotation for another minute, ending
26. with the opening of the rotary gear facing the gear train.
27. De-energize the power unit, and perform a third generous lubrication of the gear train, including the gear housing.
Farr recommends that an anti-corrosive agent such as Tectyl® 506 be applied to all external unpainted surfaces
38. (and chain slings) EXCEPT cylinder rods, jaw rollers, and rotary gear camming surfaces. Refer to manufacturer data
sheets for proper application and safety information.
Once all of the above maintenance checklist items have been satisfactorily completed the tool may
be returned to service.
Do not perform any maintenance while the power unit is energized (electric) or if the engine is running (diesel). Ensure the electri-
cal supply is locked out, or, if using a diesel power supply, ensure that the engine is locked out or the starting mechanism otherwise
disabled.
Diesel Only
Activate mechanical shut-off device - ensure that shut-off switch on engine is engaging when manual shut-off switch
4. is actuated.
Electric Only
Visually inspect all electrical lines and visible connections. If your unit is NOT explosion proof, open the electrical en-
1. closure and VISUALLY inspect contacts and connections for signs of corrosion or arcing. Do not open explosion-proof
enclosures.
Never place hands inside an electrical enclosure unless you have confirmed
that the power has been disconnected and locked out
2. Visually inspect main electrical line between main power source and power unit.
All Units
5. Perform a visual inspection of all parts. Check to ensure there are no loose or missing fasteners.
Check hydraulic fluid level - ensure cold level is approximately half-way up the sight glass on the hydraulic fluid res-
6. ervoir.
7. Perform a visual inspection to ensure there are no hydraulic fluid leaks - correct if necessary.
8. Check that the main supply and return lines on the hydraulic fluid reservoir are both fully open.
Apply grease to any grease fittings that your power unit may have. Apply grease to each fitting until grease is visibly
9. displaced from bearing, or as recommended by your power unit manual.
10. Ensure supply and return connections at the power unit and at the equipment in use are fully made up.
Failure to ensure that the self-sealing supply and return lines are fully
made up may result in catastrophic equipment failure.
Check hydraulic fluid filter back pressure (must be done while fluid is circulating). If needle on indicator gauge is in
11. the red zone, the filter should be changed the next time the unit is shut down
Perform an initial wash of the tool in order to remove the majority of dirt and grease build-up. Ensure adequate contain-
1. ment is in place to prevent environmental contamination from residual hydraulic fluid and dirty grease.
2. Remove the access panel on the side of the tong directly adjacent to the shifter mechanism.
Clean the interior of the tong thoroughly, using either water (do not use a pressure washer), or an appropriate solvent-
based grease-cutting cleaner such as Varsol. Ensure adequate containment is in place to prevent environmental con-
3. tamination from residual hydraulic fluid, dirty grease, and cleaning agents. Make a note if any metal shavings or metal
pieces are flushed out of the gear train cavity - if shavings or metal pieces are seen the tong must be overhauled before
it is returned to service.
Clean the exterior of the tool thoroughly, using either water (do not use a pressure washer), or an appropriate solvent-
4. based grease-cutting cleaner such as Varsol. Ensure adequate containment is in place to prevent environmental contami-
nation from residual hydraulic fluid, dirty grease, and cleaning agents.
Inspect all fasteners and fastener safety wires. Replace any missing fasteners - use Grade 8 bolts only. Re-torque all
5. external fasteners to SAE specifications.
Repair or replace any damaged or missing external body parts, such as torque gauge mounts, hydraulic supports, safety
7. door protectors, etc.
Inspect all paint - locations in which the paint has been damaged must be repaired prior to storage. Prepare areas to be
8. painted to ensure they are free of grease, dirt, or solvent. Touch up using a solvent-based acrylic paint - “McCoy Grey” is
paint number RAL7015. Allow sufficient time for paint to dry before proceeding.
Perform a liberal lubrication of the equipment - refer to Maintenance section of manual to determine lubrication points.
9. Generously fill the gear train housing with grease through the access panel, and also through the opening in the rotary
gear.
Connect the equipment to a hydraulic power unit. Ensure all lines are fully made up to prevent equipment damage from
10. excessive back pressure. Do not neglect to connect the motor drain.
Rotate tong for one minute, stop, and reverse the direction of rotation for another minute, ending with the opening of the
12. rotary gear facing the gear train. De-energize the power unit, and perform another generous lubrication of the gear train,
including the gear housing.
14. De-energize the power unit, and perform a third generous lubrication of the gear train, including the gear housing.
Energize power unit, and rotate the tong for a final time, one minute in one direction, stop, and reverse the direction of
15. rotation for another minute, this time ending with the rotary gear in the “open throat” position.
Extend all hydraulic cylinders, and inspect cylinder rods for signs of mechanical damage, flaking, or rust. Farr recom-
16. mends that damaged cylinders be replaced prior to storage.
If you are using a frame-mounted tool, the tong must be lowered onto the backup in order to remove the risk of sudden
and catastrophic movement when pressure is removed from the float cylinders. Cover the top of the backup with protec-
tive cloth to protect the paint on the backup. Place two wooden beams across the top of the tong, ensuring that the beams
17. have a minimum size of 4” x 4” x the width of the tong. Cover the tops of the wooden beams with more protective cloth to
prevent paint damage to the tong. When lowering the tong onto the beams, ensure that the beams come into flat contact
with the bottom of the tong, away from bearing caps, brake bands, or other protrusions on the bottom of the tong. Ensure
that the tong hanger chains are loose, but not dangling into contact with the hangers or top plate of the tong.
18. If any hydraulic fittings or hoses are leaking they must be repaired or replaced before proceeding.
Wipe all excess grease from outside of equipment. Replace the access door panel. Use a solvent-based cleaner on
19. rags to wipe all external surfaces to remove residual grease or hydraulic fluid. Once the outside surfaces have been de-
greased, wipe all external surfaces with clean water to remove residual solvent.
Farr recommends that chain slings be removed and stored separately. Rigid slings and other rigid suspension devices
20. may remain in place.
Farr recommends that an anti-corrosive agent such as Tectyl® 506 be applied to all external surfaces EXCEPT cylinder
22. rods (including chain slings). Refer to manufacturer data sheets for proper application and safety information.
Allow the anti-corrosive coating ample time to dry - refer to manufacturer data sheets for drying times at room tempera-
23. ture.
Wrap entire assembly in 100 gauge (1 mil) corrosion-inhibiting wrap, at least 3 layers thick. Attempt to ensure that the tool
24. is well-sealed within the wrapping, including the bottom.
Remove all protective plastic wrapping. If there are desiccant packs with the assembly, they may be disposed of with the
1. regular garbage.
2. Remove the access panel on the side of the tong directly adjacent to the shifter mechanism.
If applicable, re-connect chain sling to lifting lugs. Perform a visual inspection of all lifting points - if visible damage is seen,
including cracks, broken lugs, distorted metal, etc. replace damaged part(s) before placing tong in service. Also inspect
4. all chains, master links, and turnbuckles - again, if any damage is noted replace the damaged part(s) before placing the
tong in service. If your company requires yearly certification of lifting equipment, ensure that the most recent test date falls
within the past year. Perform recertification if necessary.
Perform a liberal lubrication of the equipment - refer to Maintenance section of manual to determine lubrication points.
5. Generously fill the gear train housing with grease through the access panel, and also through the opening in the rotary
gear.
Connect the equipment to a hydraulic power unit. Ensure all lines are fully made up to prevent equipment damage from
6. excessive back pressure. Do not neglect to connect the motor drain.
Failure to ensure that the self-sealing supply and return lines are fully
made up may result in catastrophic equipment failure.
Ensure that supply pressure is at or above the tong’s specified operating pressure, and that the return pressure is less
8. than 350 psi.
Perform a thorough inspection of pressurized hydraulic lines and fittings. Any leaking hydraulic fluid lines or fittings must
9. be replaced before the equipment is returned to service.
Perform a thorough inspection of all seals. Any seal that is leaking or “weeping” must be replaced before the equipment
10. is returned to service.
Rotate tong in low gear for 5 minutes while monitoring pressurized seals and hydraulic lines. If a seal, line, or fitting begins
11. to leak while tong is rotating, it must be replaced before the equipment is returned to service. Finish this step with the
rotary gear opening facing the gear train. De-energize the power unit.
Inspect all flexible hydraulic lines for signs of wear, blistering, or any other signs of potential failure - replace if signs of
12. potential failure are identified.
Inspect the gear train housing. If the amount of grease is inadequate, liberally grease the gear train through the access
13. panel, and through the opening in the rotary gear.
Inspect top and bottom brake band linings - replace if necessary. Unequal wear of the brake bands indicates that the
brake band tension is not evenly adjusted. Refer to the maintenance section of the manual for instructions on properly
14. adjusting brake bands. Ensure that all grease is wiped from brake band linings and the parts of the cage plates that come
into contact with the brake band linings
15. Re-install access panel. Install a set of pre-inspected jaws that are the correct size for the pipe or casing being run.
Install load cell. If using a tension load cell, perform a visual inspection and replace any cracked, broken, or distorted
16. components including links and chains. If using a compression load cell, replace any component that has been crushed
or otherwise distorted through compression.
If applicable, inspect the load cell anchor pins (tension load cell only). Replace the anchor pins if cracking or metal distor-
17. tion is seen.
If applicable, the weld securing the single load cell anchor to the bridge bar main plate must be inspected (compression
load cell only). If the integrity of the weld has been compromised, the tong must be removed from service until the weld
18. is repaired. The load cell beam will need to be disconnected and removed so the weld is visible. Before re-installing the
beam, liberally grease the anchor pin before reinserting into the load cell beam.
While rotating the cage plate, ensure that the jaws properly cam. If the jaws do not cam properly, the brake bands
23. need to be tightened. Incrementally adjust both the top and bottom brake bands EQUALLY until proper cam action is
achieved.
24. When all of the previous steps are completed, you may return your re-commissioned equipment to service.
4. POSSIBLE PROBLEM: Poor hydraulic pressure at the tong despite adequate pressure at the power unit, or excessive back
pressure in the return line.
SOLUTION: Restrictions exist in line between power unit and tong. Inspect integrity of self-sealing couplings to ensure they
are allowing full fluid flow. Check to ensure no other restrictions exist (contaminated catch screens or filters, for example).
5. POSSIBLE PROBLEM: Fluid viscosity is not appropriate (too high or too low).
SOLUTION: Ensure hydraulic fluid being used is the viscosity recommended by McCoy Drilling & Completions. Power unit pump
may not prime if fluid is too heavy, and the hydraulic system will overheat if fluid is too light. Replace with proper viscosity fluid.
SOLUTION: Hydraulic fluid viscosity is affected by environmental conditions. Ensure the fluid being used is suitable for high or
low temperatures. Replace with proper viscosity fluid for the operating conditions if necessary.
1. POSSIBLE PROBLEM: Dies have become too dull to provide adequate grip.
SOLUTION: Replace dies.
4. POSSIBLE PROBLEM: Brake band(s) is (are) insufficiently adjusted, not allowing jaws to cam properly.
SOLUTION: Adjust brake bands to give proper resistance to cage plates.
3. POSSIBLE PROBLEM: Tong motor is excessively worn and is leaking hydraulic fluid past the vanes.
SOLUTION: Replace motor, or rebuild as per Section 7 of this manual.
4. POSSIBLE PROBLEM: Bearings in gear train and rotary section are excessively worn.
SOLUTION: Overhaul tong. See Section 3 of this manual for tong overhaul procedures.
5. POSSIBLE PROBLEM: Shifter has malfunctioned and the tong is not shifting to high gear.
SOLUTION: Inspect and repair shift mechanism as necessary.
6. POSSIBLE PROBLEM: Two-speed hydraulic motor (if equipped) is not set to correct speed.
SOLUTION: Check motor, and set to the correct speed if required.
7. POSSIBLE PROBLEM: Safety door system is not properly adjusted - hydraulic fluid leak past Deltrol valve.
SOLUTION: Check and adjust safety door system.
5. POSSIBLE PROBLEM: Locking nuts on shifting shaft have loosened and position of yoke has changed.
SOLUTION: Reposition yoke and re-tighten locking nuts.
6. POSSIBLE PROBLEM: Shifting yoke has come loose from shifting shaft
SOLUTION: Inspect yoke and inspect for damage. If free of damage, replace on shaft and tighten locking nuts.
B G
J
E
(1) “Stand-alone” tongs use 11x support roller shaft PN 101-3942, & 1x door pivot shaft PN 101-3944.
(2) “Backup-ready” tongs use 7x support roller shaft PN 101-3942. Use four “long” support roller shafts (PN 101-
3943) where coincidental with the front leg mount weldments. The door pivot shaft remains PN 101-3944.
(3) Top and bottom flat washers are not used where the support roller shaft is coincidental with the brake band lug
weldments. Bottom flat washers are not used where the support roller shaft is coincidental with the front leg
mount weldments.
A
B
C
D
F
G
H
R
S
C
B
Q
C
E
F
G
S
H
J
A
M
B
C N
D
P
E Q
R
F S
A B C D G H J K L D M
E E E
F
N
P
E
B S G
D E F
E F G
B
C
K
L
F
G
H
J
J L
K
M
N
G P
H Q
E F R
S
T
A B C
D
U
V
W
X
B
C
E N
F Q
G
H
J
L
K M
P
D D
E
F M
N
D Q
K R
L
A B C D
E
F L
A M
G N
H
J P
K J
torque gauges and load cells are factory-supplied supplied as matched cali-
brated pairs. if replacing either component the load cell and torque gauge
must be returned to the factory for re-calibration before placed into service.
THE TORQUE GAUGE USED IS FULLY DEPENDANT UPON THE ARM LENGTH AND TORQUE
RANGE OF THE EQUIPMENT IN USE. THE PART NUMBERS LISTED IN THE FOLLOWING TABLE
ARE CORRECT FOR ACCURATELY MEASURING TORQUE USING THE EQUIPMENT FOR WHICH
THIS MANUAL IS SUPPLIED.
A
B
L
C
D
M
H
D
E
2.75”
C
2.74”
D
Item Type Description Qty Part Number
Assembly Standard Turn Counter Encoder Mount 1 60-0001 C
A Part 6-32 x 3/8” Hex Socket Head Set Screw 4
B Part Helical Flexible Encoder Shaft Coupling 1 60-0130N F
C Part Internal Retainer Ring 2 1376-13
D Part Bearing 2 1376-05
E Part Encoder Housing 1 1392-104A
F Part Internal Retainer Ring 1 02-0436
G Part Encoder Shaft 1 1392-103A-01
H Part Encoder Gear 1 01-0320A-M
J Part 10-24 x 1-1/4” Hex Socket Head Set Screw 1
G
MAINTAIN GREATER-THAN HALF FULL FLUID LEVEL IN THE HAND PUMP BOWL TO AVOID
PUMPING AIR INTO THE SYSTEM. DO NOT ALLOW THE LEVEL TO FALL BELOW ONE-HALF FULL
e. Remove the vent plug screw and Stat-O-Seal (Items C and D on Illustration 6.A.4, or item H on Illustration 6.A.5) to allow
trapped air to escape.
f. Pump fluid into the system until no more air is seen escaping from the vent port.
g. Replace the vent plug screw and Stat-O-Seal and tighten securely.
h. Remove load cell from containment vessel and wipe clean. Reclaim the hydraulic fluid (if it is clean) or dispose of all
waste materials according to governmental or your company’s proscribed environmental protection regulations.
i. Disconnect the hand pump from the torque gauge.
j. Replace the brass cap on the torque gauge check valve fitting.
OF HYDR
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HYDRAULICS, INC.
MOTOR SELECTION GUIDE
CROSS SECTION
15Cross
Series Retractable
Section - Two Speed Motor
Weight = 61 lbs.
5.69 5.000
4.998
4.51 17°
1.250
1.248
5.91 5.70 17°
.314
.316
1/2-
13UNC
CENTER
LINE
3/8" O-RING BOSS CASE
1.0 CASE DRAIN 9/16" DIA., 4 HOLES DRAIN
SAE STD. 1.25 (2) PLACES 1.38
4-BOLT FLANGE
NEAR AND FAR
9.0 2.18
7.80
1/4 O-RING
BOSS .24
6.82
5.80 CENTER
.50 LINE 3.41
1.62 CASE
EFF. DRAIN
KEY
5.000
4.998
4.50
PORT
SQR. 17° "B"
1.250
5.40 1.248
5.91 5.70
PORT 17°
.313
.315 "A"
1/2-13UNC
PORT 'A' x 1/2 DP.
3/8" O-RING
SAE STD. 1.25
1.0 BOSS 9/16" DIA., 4 HOLES
4-BOLT FLANGE CASE DRAIN CENTER LINE
NEAR AND FAR (2) PLACES CASE DRAIN
SAE 1/4 O-RING ALTERNATE 1.8 2.2 ALTERNATE
BOSS PORT "B" PORT "A"
1-1/4 O-RING 1-1/4 O-RING
BOSS BOSS
1.3
REAR VIEW
7.4
attached to the shaft. Depending on the application and
Section
mounting position Contents
of the motor, the spacerTdesign
echnical Manual
may vary. MOUNTING
Spacers are not supplied with the motor. The mounting position is unrestricted. CAUTION: The shaft
extension and knob at the rear of the motor rotates when
the motor is in operation.
Hydraulic Motor Information KT5500 5-1/2” 18.7K Tong
TORQUE (ft-lbf)
120 220
70
TORQUE (ft-lbf)
POWER (HP)
80
POWER (HP)
140 1300 RPM 70
70 1200 RPM 40 120 60
60
100 900 RPM 50
50 30
800 RPM 80 40
40
30 20 60 500 RPM 30
20 400 RPM 40 20
10 300 RPM
10 20 10
100 RPM 100 RPM
0 0 0 0
500 1000 1500 2000 2500 3000 500 1000 1500 2000 2500 3000
PRESSURE (psid) PRESSURE (psid)
35 1000
40
800
RPM
30
RPM
800 35
25 30
600 600
20 25
400
20 400
15
200 15
10 100 200
10
100
5 5
0 0
0 500 1000 1500 2000 2500 3000 500 1000 1500 2000 2500 3000
PRESSURE (psid) PRESSURE (psid)
275 350
250 325
130 300 150
225
120 275 1500 RPM
200 1600 RPM 110 250 125
175 100 225
1200 RPM 90 200 1100 RPM 100
POWER (HP)
150 80 175
POWER (HP)
125 70 150 75
100 800 RPM 60 125 700 RPM
50
75
100 500 RPM 50
40 75
50 400 RPM 30 50 300 RPM 25
25 200 RPM 20 25 100 RPM
100 RPM 10 0 0
0 0 500 1000 1500 2000 2500 3000
500 1000 1500 2000 2500 3000
PRESSURE (psid)
PRESSURE (psid)
ACTUAL FLOW - 15 CID
ACTUAL FLOW - 11.5 CID 110
100
1500
100
90 1600
1300
90
80 1400
80 1100
70 1200
70
900
60
FLOW (gpm)
1000
FLOW (gpm)
60
RPM
50
800 50 700
RPM
40
600 40 500
30 30
400
300
20 20
200
10 10 100
100
0 0
0 500 1000 1500 2000 2500 3000 500 1000 1500 2000 2500 3000
PRESSURE (psid) PRESSURE (psid)
The above performance data was obtained at 140OF with ISO 46(DTE 25). These values must be maintained to
obtain the performance indicated. Contact Rineer Hydraulics, Inc. for additional displacements.
Model Code
M015 - 61/62 -1S -015 -31 -B1 -TV -000
Special Code Designator
M015 - 61 = 015 Single Speed
M015 - 62 = 015 Two Speed
Seal - Package Selection
Options:
62 = Two Speed Single Pilot Bearing Package Selection
Open During Crossover 30 = Keyed Shaft
63 = Two Speed Single Pilot 31 = Splined Shaft
Closed During Crossover 32 = Wheel Motor
65 = Two Speed Double Pilot 006 = 6 in3 (98cc)/rev. 010 = 10.5 in3 (172cc)/rev. 34 = Double Key
Open During Crossover 007 = 7 in3 (115cc)/rev. 011 = 11.5 in3 (189cc)/rev. 50 = Retractable
67 = Two Speed Double Pilot 1S = Std. 008 = 8 in3 (131cc)/rev. 013 = 13 in3 (213cc)/rev. 53 = API Thread
Closed During Crossover 1H = High Speed 009 = 9.5 in3 (156cc)/rev. 015 = 15 in3 (246cc)/rev.
Applications
For durable hydraulic motors that meet your demands, specify Rineer.
For over 35 years, we have specialized in only one thing - engineering the right motor for your needs.
Rineer delivers the performance you can count on.
Technical Manual
210-341-6333 Fax: 210-341-1231 e-mail: [email protected]
Section Contents 7.7
KT5500 5-1/2” 18.7K Tong Hydraulic Motor Information
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Repair Manual
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15 Series
MO
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HYDRAULICS, INC.
Standard Motor
331 BREESPORT * SAN ANTONIO, TX 78216 * (210) 341-6333 FAX (210) 341-1231
WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
5
Technical Manual Section Contents 7.11
KT5500 5-1/2” 18.7K Tong Hydraulic Motor Information
WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
6
7.12 Section Contents Technical Manual
Hydraulic Motor Information KT5500 5-1/2” 18.7K Tong
WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
7
Technical Manual Section Contents 7.13
KT5500 5-1/2” 18.7K Tong Hydraulic Motor Information
WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
8
7.14 Section Contents Technical Manual
Hydraulic Motor Information KT5500 5-1/2” 18.7K Tong
WARNING: RINEER RECOMMENDS FOLLOWING ALL STANDARD SHOP SAFETY PRACTICES SPECIFICALLY INCLUDING WEARING OF EYE PROTECTION.
Information:
Bolt Torque - Seal Kits:
Main Bolts (5/8-11): 190 ft. lbs. Standard 15 series seal kit
Seal Plate (3/8-16) #0150940
(Wheel Motor only): 45 ft. lbs. Standard 15 two speed seal kit
Grease used for bolt threads #0150940
and o-ring retention: Standard 15 wheel motor seal kit
Pennzoil 707L RED #0150936
Shaft seal assembly lube:
Mobilgrease special
with Moly
OR OR
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