FARR Wlliddld TECHNICAL MANUAL d) 4-1/2” (11.43cm) 8K ft-lbs “Slim” Hydraulically Powered Tong & Backup * Specifications * Operation + Maintenance + Assembly fo) £ mccoyglobal.comwave ‘avwm20s AONB WWEOTS ONKAON, IdNOD 2 ONITINIGMOWING GLOBAL ENERGY FORWARD FARR. This manual covers the following models: ‘OVERALL MODEL | TONG MODEL | BACKUP MODEL | REV DESCRIPTION FATE" 8000 BR, “Sim* Tong with Rigor 2-spa mo- SOO eases a 1 | tor, standard 2-arm sing, motor vale, & safety door “A72" 8000 Taf. “Sim” Tong with integrated back 80-2001-2 | 80-2001-3 | 85-2000 | 1 | up & support stucture, standard 2arm sing, moter valve, backup valve, & safety door. 172" 6500 I-A, “Sim” Tong with Rinwer 2-spd mo 80-2001-4 | 80-2001-4 “a 0 | tors stander 2-arm sing, mor valve, & sefety door. “172 6500 Ioft Sim’ Tong with integrated back 80-2001-6 | 80-2001-5 | 85-2000 | 0 | up & support structure, standard 2-arm sing, motor valve, backup valve, & safety doe. “€172" 8000 I6-A. “Sim Tong with integrated back: 80-2001-8 80-2001-7 85-2000 0 | up & support structure, standard 2-arm sting, motor ave, backup valve ft vaive, &safoty door. 80-2001-10 4-1/2" 8000 Ib.-fi. “Slim” Tong with integrated backup qworcurrenrty| 80-2001-9 | 85-2000 | 0 | & suppor stuctire, short 2-arm sing, motor vale, GE MARKED) bootup va, valve & safety door. 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. PATENTED & PATENTS PENDING Technical ManualThis page intentionally left blank Z\ iv ET ectnicot monvai COMPLETIONS Fare DRILLING & -COY |GY FORWARD MOVING GLOBAL B¥ FARR WARNINGS ITHE LOAD-BEARING DEVICE SUPPLIED BY FARR, A DIVISION OF MCCO ICORPORATION (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 DESCRIBED IN THIS MANUAL} HAS BEEN DESIGNED TO SUPPORT THE EQUIPMENT DESCRIBED IN THIS MAN. IUAL. FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEARING DEVICE} TO SUPPORT ANY OTHER PART, ASSEMBLY OR COMBINATION OF PARTS AND] |SSEMBLIES. FARR WILL NOT GUARANTEE THE ABILITY OF THE LOAD-BEAR- ING DEVICE TO LIFT THE EQUIPMENT DESCRIBED IN THIS MANUAL IF THERE| \RE 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 FARR. IWHEN 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 4 - OVERHAUL). Technical Monvol (RE cee NY REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE| SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE} 8 OR EQUIVALENT UNLESS OTHERWISE SPECIFIED.This page intentionally left blank Z\ vi Buc | Section Contents | Technical Manual SNS OMPLI FARR. DRILLING &ea wae mae (© Copyright 2009 Farr (A Division OF McCoy Corporation, all ights reserved. This document is the property of Farr and is ‘supplied as reference information for users of our products. Tis document and the contens within are considered confidential information, not o be disciosed, copied, ransmitted, transcribed in any form, or storod on any type of data storage media without the express writen consent of Far. While comioually striving ta maintain accuracy, Farr hereby stale thatthe information contained inthis technical documentation fs subject 10 change without notice. If you fal this document does not meet your needs, please cantact our sales office forthe ‘most current avaiable documentation for your product ‘Summary Of Revisions Date Section | Page Description Of Revision May 2008 WA WA__| Intel Release ‘Sep 2009) ino | 1.2813 | Corrected dimensions onthe spectication pages May 2010 Varies Varies | Updated itsirations throughout to represent updated jaw retention _mechanism, updated logos and branding ane 2070 Varies Varies | Updated manual te comply with CE marking ‘September 2070 | Appenanes | Varies | Revised appendixes ETIONS. OMPL DRILLING & FARR COY | - Techie Maal viIntroduction & Specifications. . Dimensionals. Equipment Specifications Lubrication Specifications ‘Setup & Operation .. ‘Sing /Load Bearing Device Safety - ‘Major Component Identifcation .... Hydraulic Schematic / Hydraulic Valve Identification . Hydraulic Connections Tong / Backup Jaw Availabilty & instalation Tong Rig-Up & Leveling Tong Operation. : Extreme Cold Weather Operation Procedures ‘Making Up Joints. Breaking Out Joins, Maintenance General Maintenance Safety Practices. Cleaning Lubrication. Adjustments, Recommended Periodic Checks. Disassembly & Overhaul Procedures ‘Assembly Instuctions Troubleshooting. ‘Pump Makes Excessive Noise . Hydraulic System Overheating . Excessive Wear Of Moving Parts Tong Running Too Slow. Tong Will Not Develop Sufiiont Torque Failure Of Jaws To Grip Pipe Failure Or Diffcully Of Tong To Shift General Comments. Assombllos And Parts Geartrain laler Assemblios Reduction Gear Assemby (Smal). Reduction Gear Assemby (Large) Rotary Assembly. Rotary Gear Assembly Tong Body Assembly Hydraulic Assembly. Motor Assombly Brakebands Door Assembly Rigid Sting Assembly Backup Assembly Rear Log Assembly. Front Leg Assembles Torque Gaugs Hydraulic Component Information... Daily Inspection & Maintenance Checklist (Power Tong) « Daily Inspection & Maintenance Checklist (Backup) c Daily Inspection & Maintenance Checklist (Power Unit)... ‘Monthly Inspection & Maintenance Checklist (Power Tong). Tubular Connection Equipment De-commissioning Procedures .. Tubular Connection Equipment Re-commissioning Procedures . Table Of Contents Section One 42 13 14 Section Two 24 24 29 212 213 244 amr 2.20 221 222 ‘Section Three 34 at 3 35 35 36 38 Section Four 41 42 43 44 45 46 47 48 ‘Section Five 52 54 56 58 5:10 512 514 5.16 518 5.20 5.22 524 5.26 5.28 5.30 Section Six Section Seven Appendix One Appendix Two ‘Appendix Throe Appendix Four Appendix Five Appendix Six FARRFARR Paes Cee IDENTIFICATION OF OF WARNINGS AND OTHER NOMENCLATURE OF IMPORTANCE USED IN THIS MANUAL Farr uses three subsets fo describe items in three degrees of importance, The highest lovel of urgency is called a CRITICAL WARNING, and is identified with an exclamation point, is red in color, and is surrounded by a double black box. A CRITICAL WARNING donotes an item of extreme importance, ‘and failure to heed a warning may result in bodily injury, death, severe equipment damage, or any combination of these. ‘A STANDARD WARNING is identifiod with an asterisk, and contains information critical to the correct assembly fr operation of the unit. A STANDARD WARNING may also serve to alert the user to a potential low-level injury hazard, A STANDARD WARNING is also surrounded by a double black box, but is amber in colour. ‘An ALERT is identified by black fext within a double black box. An alert contains specific information of note that pertains to the correct assembly or operation ofthe unit. WARNING CAUTION I ALERT Technical Manual ixThis page intentionally left blank /\ ONS MPLETIC FARR DRILLIN 1 FORWARD = g 8 g x HES echnical ManvalIntroduction Congratulations on the purchase of your new FARR 4-1/2" SL. (Sli) tong. This unt wil provide you with years of outstanding performance. Simple maintonance and care wil extend ils ife and ensure a continuing level of txcollnt performance and rlibity This manuel wil assist you in giving your equipment the care it requires. Please read the manual and follow tne enclosed maintenance instructions. Replacement parts are readily avaiable {rom FARR Ld. n Edmonton Alberta, However, most ofthe parts that are subject to wear or damago are standard items key f be found Supply stores or parts depots. Many parts ar transferable between FARR tongs and backups. Should you need replacement pars, or should you experience any dificulty not covered in this manual. please contact McCoy Driling & Completions - FARR Sales & Engineering 14755 121A Avenve Edmonton, Alberta Canad T5L 272 Phone: 780.453.3277 Fan: 780.495.2432 Email Sales: salosFar@mecoyolobal com Emal Engineering: engrar@mecoyolobal com Website: htp:/inw.mecoyolobalcom > | Bea | | Technical Manval 11eee PLEASE NOTE: AREAS SHOWN HIGHLIGHTED ARE POTENTIAL PINCH/HAZARD AREAS. EXER- GISE CAUTION AROUND THESE AREAS DURING | TONG OPERATION. 1.2 ESTE technical Marval 8 FARRSetup & Operation ma ‘Adequate setup and proper hydraule connections are essential n ensuring reliable operation of your tong. For best results and ‘ong term relabilty, read and bey the slar-up instructions inthis section. ANY INTERVENTION REQUIRING PERSONNEL TO ACCESS ANY POWERED ROTATING] :LEMENTS, DIES, ETC. SHOULD BE PERFORMED WHEN THERE IS NO ACTIVE POWER, SOURCE PRESENT. E.G., HYDRAULIC POWER SUPPLY SHOULD BE SWITCHED OFF ISOLATED, IN ADDITION, THERE MUST BE A CLEARLY IDENTIFIED REMOTE POWER PACK SMERGENCY STOP INSTALLED IN THE IMMEDIATE VICINITY OF THE TONG| A. SLING/LOAD BEARING DEVICE SAFETY lA “LOAD-BEARING DEVICE” IS A CHAIN SLING, RIGID SLING, SPREADER BAR ASSEW. lay, FRAME, OR ANY OTHER DEVICE THAT BEARS THE PARTIAL OR TOTAL WEIGH) JOF THE EQUIPMENT DESCRIBED IN THIS MANUAL. ITHE SUPPLIED LOAD-BEARING DEVICE HAS BEEN SPECIFIED OR DESIGNED TO SUP. \PORT THE EQUIPMENT DESCRIBED IN THIS MANUAL. FARR WILL NOT GUARANTE THE ABILITY OF THE LOAD-BEARING DEVICE TO SUPPORT ANY OTHER PART, AS: |SEmBLY OR COMBINATION OF PARTS AND ASSEMBLIES, OR ANY ADDITIONS TO THE| EQUIPMENT DESCRIBED IN THIS MANUAL THAT ADD WEIGHT TO THE EQUIPMENT, JUNLESS SUPPLIED BY FARR. |FARR WILL NOT GUARANTEE THE INTEGRITY OF MODIFIED OR DAMAGED LOAD: |BEARING DEVICES, UNLESS THOSE MODIFICATIONS ARE PERFORMED BY FARR. Fare recommends following an industry-acepted standard such as OSHA, ASME 830,9-2000, or manufacturer's guidelines tnien performing any raging and overhead iting, Use by untrained persons Is hazardous. Improper use will result serious Injury or death, Do not exceed rated capacity. Sings wil fail damaged, abused, misused, overused, or improperly main tained, COnly grede 80 or grade 100 alloy chain should be used for overhead iting applications. Working Load Linn (WAL) isthe maximum allowable loadin pounds which may be applied tothe load-bearing device, shen the device's new or in “as new" condition, and when the load is unifermly and directly applied. The WL must over be exceeded. + Working Load Limit (WL) isthe maximum working load for a specific minimum sing angle, measured from the hor'= zontal plane, The Working Load Limit i identified onthe sing. The Working Load Limit or Design factor may be affected by wear, misuse, overloading, corosion, deformation, Intentional ateratons, sharp comer cutting action and other use condions. + Shook loading and extraordinary conditions must be taken into account when selecting alloy chain sings. + See OSHA Regulation fr Sings 1910. 18s, ANSVASME 830 9."SLINGS", ANSVASME B30 10--HOOKS" and ANSI ‘AMSE 820.26 "RIGGING HARDWARE" for adalional information, [THE MINIMUM SLING ANGLE (THE ANGLE OF THE LEG OF THE SLING MEASURED ROM THE HORIZONTAL) MUST NEVER FALL LOWER THAN THE ANGLE SPECIFIED FOR THE SLING IN USE Technical Manual Pen oe 21Setup & Operation 1 Ingpeetion OF Sings Farr strongly recommends the following practices ‘A.complete inspection of new load-bearing devices and attachments shall be performed by a quaifed, designated person rir 1 nil use. Each lnk end component shal be examined invidually, aking care to expose and examine af surfaces ‘eluding the nner Ink surface. The sing shall be examined for condtions such as those sted i the removal eiteria below. In adalton, daly nspection of sings, fastenings and attachments shal be performed by a designated person. If damage or Gofects ae found at either inspection, the damaged or defective component shal be quarantined ram service unt con be properly repaired or replaced. Removal Cetera: ‘A load-bearing device shal be removed from service if conlions such as the following are present: + Missing o legible sling identitcaton. + Cracks or breaks 2 Evence of tampering is seen - sing tag has been modified or obscured, or tamper-proof nuts are missing ‘Signs of impact on load-bearing components, inluding spreader bars, lifing lugs, rigid sings & ngid sing weld. ments, and gs & leg mounts. + Broken or damaged welds. {Excessive wear nicks, or gouges. Refer othe char below fo ensure minimum thickness on chain links supplied Fg not be below the values liste “Minimum Allowable Chain Link Thickness at Any Point ‘Nominal Chain Size ‘Minimum Thickness Tches 7 aches Mi 72, 55 0.789, 4.80 aa, Z 0.239 607 wi6 é 0273 695 we 70 0382, 500 we 3 0449) 1126 8. 6 O56 13.87 v4 20 0.687 17.45 78. 22 0.750 79.05 7 25 0.887 22.59 114 22 1.097 2r74 Refer ToASMEBI0.9 ‘tretahed, bent, twisted, or deformed chain inks or components. Evidence of heal damage. Excessive pling or corosion Lack of abit of chain or components 1 hinge (articulate) freely. Weld spatter. Fr hooks, removal criteria as stated in ASME 830.10 ‘Other conditions, including visible damage, that cause doubt as fo the continued use of the sling. Inspect al lugs and fixing points for signs of elongation analer bending, or for material buic-yp around the hole. Repai or replace components that appear distorted, Ensure all hardware is ight and in good condition. Replace missing hardware #¥ nocessary. AI hardware must be fre of rust and corrosion. ‘Adivonal inspections shall be performed! curing sing use where service candions warrant, Periodic inspection intervals ‘hall not exceed one year. The frequency af periodic Inspections should be based on: Frequency of use ofthe load-bearing device Saveriy of service conditions Nature of fits being made Experience gained on the servic ite of load-bearing devices used in similar circumstances, Guidelines for the interval ar: + Normal Service - yeary + Severe Service - monthly to quarterly ‘Special Service - as recommended by a quaifed person 2.2 Technical Manual IS ETION DRILLING & 8 o COY | ENERGY FORWARD Moving Gtoval(G GLOBAL ENERGY FORWARD Mow Fare Specifications Torque Table (Low Torque) *= Pressure (PSI) | Hi Speed (lbs) | Lo Speed (ibs) 1000 650 2300, 7500 7060 3700, 2000) 1485, 5200 72500 7885 6500 ‘MAXIMUM RATED TORQUE: 6500 LBS.-FT. ‘Speed Table (Low Torque) ** iow (US GPM) | Lo Speed (RPM) | _HiSpeed (RPM) 0 é 2 20 16 5 20 a eo 40 ze a Torque Table (High Torque) ** Prossure (PSI)_| Hi Speed (bse) | Lo Speed (ibs -t) 7000 1400 2800 1500 2300, 4600) 2000) 3180, 300 2500, 4000. 3000) ‘MAXIMUM RATED TORQUE: 8000 LBS.-FT. ‘Speed Table (High Torque) * Flow (US GPM) | Lo Speed (RPM) | Hi Speed (RPM) 10 6 8 20 3 2 0 26 a 0 2 of These are idea! values. Actual achieved torque is highly dependant upon tong efficiency and final positon of rotary gear when ful torque load is reached. Hydraulic Requirements: Max Hydraulic Fluid Temp: Operating Temperature: Length: (Overat! Wicth: Height: Torque arm length: Weight (Approximate) Jaw Range: Jaws available (inches): ‘Max Sound Level: ANY REPLACEMENT FASTENER (BOLTS, NUTS, CAP SCREWS, MACHINE SCREWS, ETC) USED 40.GPM @ 2000 psi/ 151 LPM @ 13.8 MPa aro 20°C 0 M0"C 39:78"/ 101.36 20°/50.8. em 48412"/ 123.200 22 inches / 55.9 cm (Tong only) 18 inches / 48.7 om (Tong & Backup) Center Line of Pipe Genter Line of Anchor Hane 600.273 kg. (Tong Only) 950 10. / 409 kg. (Tong & Backup) 1.90" (48,25mm) - 5.00" (127mm) Diameter Pipe See Pp. 2.13 97 084 @ tm 96.086 @ tm DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT. Technical Monel 7Thickener LG! consistency grade LG! performance grade Penetration - ASTM D 217 (25°C [77°F] (0.1 mm) worked 60 strokes Dropping point, "F{"G} - ASTM 02265, ‘igh temperature Ifo, hours - ASTM D 3527 ‘Oxidation stabil, psi - ASTM D o42 Water washout, prcent - ASTM D 1264 Rust and corrosion - ASTM D 1743 it separation, percent loss - ASTM D 1742 (24 hours, 25°C [77°F] Leakage, glost- ASTM D 4290 Four ball wear test, mm scar - ASTM D 2266 Freting wear, ma - ASTM D 4170 Four ball EP. Kot ASTM D 2596 Weld point Load wear index Timken OK toad test, Ibs - ASTM D 2509 Low temperature torque, Nm - ASTM D 4693 (40°C [-40°F) LF-37 pumpabilty, grin (60°H0"F[16°C/-18°C) Copper corrosion - ASTM D 4048 ise brake whee! bearing specifications Ford ESA-MIC 1988 (Chrysler MS-3708 it viscosity: 40°C [104°F}, cSt 100°O [212°F}, est Flash point, °F°C]~ ASTM 92 Typical Density (kgm) Viscosity -oSt@ 40 °C ~ cSt @ 100°C Viscosity Index Pour Point (°C) Flash Point °F (°C) Colour, ASTM Neutralization Number ‘Rust Protection - Distiled Water Sea Water Hydroiyle Stabilty - Cu Mass Loss, mg/em2 Copper Corrosion Test Fiterabity: Denison - Wet & Dry ‘Afnor = Wet & Dry Cincinatti Milacron Spec Approved ‘Denison HFC: Denison P-46 Piston Pump: Denison T6C Vane Pu: Viekers 35V025 Vane Pump Test 104/105C Vane Pump Test Vane pump tes ota ring and vane wear, mg, ‘Oxidation Statilty Turbine Oil Stability Test Life, Pours Rotary Bomb Oxidation Test, minutos 2G Spur Geor Test, Failure Load Stage (FLS) LUse an EP synthetic groae hat meets or exceeds the following specifications: Lithium Complex 2 Go-16 265-295 minimum £50 (288) minimum 160 minimum (100 hv/300 re) 073 18max pass 9 max 1.0 max 0.40 max 34 max 4400 minimum ‘50 minimum 50 1.3 max 60/7 8 Yes Yes 151 19.2 450(232) Use a promium quality hydraulic fluid that meets or exceeds the following specifications oe 68.8 87 97 22 (20) 432 (222) 15 040 No Rust No Rust 0.04 a Pass Pass Poo ‘Approved Pass Pass Pass No Data Available <10 2500+ 25 2 14 Technical Manual IONS DRILLING & MPLET| MOVING GLOBAL ENERGY FORWARD FARR.Setup & Operation Eee Units designed and manufactured in accardance with EN 12079 and DNV 2.7-1 should be tested and examined in accor. ance with the folowing schedule of examination and test. The user of the load-bearing device shal place a permanent placard or plate upon which the type and dae ofthe las est shal be recorded. To avoid confusion, te plate shal not carry {he date ofthe next lst or examination, only the most recent. TTest/ Examination ‘Now Desraucrve | Tworovew | Suir To Be Meaxao Exasmarow (NDE) or | Vieux” | Ow Puare Arracnes Tine (rene Lrrae Tests! Ler Powre | Exauwaron To Us Thal Cerfication By ops ves YES ves r Interval Not Exceeding | Althe discretion of | Arthe oscretion of 7 12 Months inspection body _| inspection body ves eae Interval Nor Exceeding | At the discretion of 160 Months inspection body = a eae Following Substantial = = = . Repair or Alteration" 7. iting test as por S 7.3 BS EN 12079 or DNV 2.77 May 1905 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 cared out {4 For the purposas of this standard, 9 substantial repair or modtcation is defined as any repair andor ‘modification that has beon caried ut which may, i the opinin ofthe inspection body, affect the load bearing elements ofthe container or iting device, cr elements that contribute directly tots structural integrity. iF MECHANICAL DAMAGE IS SEEN OR SUSPECTED ON A LOAD-BEARING DEVICE, OR IF THE LOAD-BEARING DEVICE HAS BEEN OVERLOADED, IT MUS: BE REMOVED FROM SERVICE AND QUARANTINED UNTIL RECERTIFIED \Writlen records of the most recent periodic inspection shal be maintained, and shal include the condiion of the sing. 2. Proper Use Of Loed.Bearing Devices Whenever any load-bearing devi is used, the following practices shal be observed. Loadtbearing devices that are damaged or defective shall not be used. Sigs shall not be shortened with ots or bolts or other makeshift devices Sling egs shail ot be kinked. LLoad:bearing devices shall not be loaded in excess oftheir rated capacives. Slings shall be securely attached to ther led. Load:bearing devices shall be protecied from snagging, and shall nol be further obstructed by any object. Suspended loads shal be kept clear of al obstruction ‘Al employees shall be kept clear offoads about to belted and of suspended toads Hands or fingers shal not be placed between the sing and its load while the sing is being tightened around the oad. ‘Shock loading is prohibited. + Dosnot stand drecty under a load during iting. Teal Rone 23Ae ic Setup & Operation 3 Storage OF Loed:-Bearing Devices Proper storage of outotservce load bearing devices is important lo ensure ful ntegiy ofthe device once it Tetumed to serve, Far recommends observing the folowing practices. + Wipe offal excess grease. Use 2 solvent-based cleaner on rags 10 wipe all extemal surfaces 10 remove residual (reace or hydraulic fui. Once the outside surfaces have been de-greased, wipe all external surfaces with clear) ‘water fo remove residual solvent. + Farr recommends that an ant-corosive agent such 9s Tecty!® 606 be applied fo al extemal surfoces. Refer fo ‘nanufscture data sheets for proper appleation and safely information. Alow the anti-corrosive coating ample lime to ary = refer to manufacturer data sheots for crying tmes at room temperature + Store in clean, ry location. When returning f service, note that a ful inspection of the device must be per formed. 8. MAJOR COMPONENT IDENTIFICATION im Desert Pane 1 Rigid Sling 25 | 2 ‘Hydraulic Valve Assembly & Mounting Plate 25 | a Tons 25 | Rear eg Ren 2s 3 25 | 6 25 7 Backing Pin Assembly 26 | @ | cave Paw Asser 76 | 9 | Tog dws wih Dis 26 10 | ono Lewing Austen 26 11] Sef Doe Purge & Guard 26 | Tang oer Ze 13 ‘Tong Door Latch : 26 14 | Sete Bor Vane 27 15] Herel Mtr 27 16 | rater Adicinent 27 77 | Bock Jows ies 2a 18 | Compression Load Call ~ 2.8 [19 [toes Cr Spcer - [amize 20_| Rear Backup Flost Spring Assembly 28 | MOWING GLOBAL ENERGY FORWARD FarrRee eee Setup & Operation ae 7 oe : etc None E25Setup & Operation — Real aete eco LU ——— 26 Technical ManvalSetup & Operation Reece Ia Technicol Monvel EO =| 2.7ee ae ae Setup & Operation 2.8 ETS strict toniSetup & Operation C. HYDRAULIC SCHEMATIC & VALVE IDENTIFICATION The following hydraulic schematic iustrates the hydraulle controls of a fully equipped tong and backup assembly. Your specie equipment may or may not have all hyoraulic controls as stated. TONG MOTOR OPTIONAL © optional TOLIFT ® BACKUP OO @ i: @ ' ® '@ OPTIONAL OPTIONAL tem Description Part Number| Page 1__| let Valve ow safety door cariidge vorav7a_| 210 2_|_ Relief Vaive (type varies with mode) 2.10 | Pilot-To-Opan Valvo, Sun LXHC-XON 06-1625 ait | Motor Section, DVASS-MAB, 4-WAY SAE PORTS 10.9014 | 210 | Backup Section, DVAIS:DA8, SAE PORTS 70.9010 210 | 6 _| _Lif.Gylinder Section, DVA35-SAB, (1° ORB PORT) 10-0015 210 7_| Outlet Section, DVA35-TRO9, SAE PORT _ | re-0086 210 @_| Flow Control Valve, Parker NB00S (Not Shown) 08-9062 Not Shown 2 | Satety Door Switch 08.09a7__| 2.17 10_| Motor Shit Valve, Bay ED Series 220-906 10.9035 | 11 | Check Vaive [ae 9022 2a 12_| Ringer GAt5-13/6.5 Hydraulic Motor (High Torque Version) 187-0008 am Rinoor GAI5-10.5 Hycraulc Motor (Low Torque Version) {87-0010 an 13_| VAIS Transtion Plate 7079905 | 210 74_| 3000 p8i Prossure Gauge 02.0246 ‘Not Shown 15_| VaWe Body 08-1307 an 16 | Pilet-To-Open Check Valve, Sun CKEBXGN 08.0487 2H 47_| Relief Valve, Sun RPGC KAN 08.1749 Not Shown 18_| Relief Valve Block, Sun AAI 08.1750 Not Shown | 19_| Backup Clamp Gylindr (inside Backup) worasa | 210 | — Technical Monval (Ree ce 29Ee eee ied Setup & Operation 2.10 Technical Manual_ Setup & Operation J Technical Manual a Cue 211Ceol Setup & Operation D. HYDRAULIC CONNECTIONS ‘A pair of hydraulic lines - a 1” supply line and a 1-14" return Ine - connect the tong fo the power unt (see istration below) Anetlary devices (hycraute motors, hydraulic cylinders, etc) are connected through the valve block FPerorm any hydraulic connection wien the power unit isnot running, or when the hydrauile pump is disengaged. The [possibilty of error in infer changing the high pressure supply hase and the low pressure run hose has been eliminated, because the supply side coupling is smalier than the retura side ANTI-WHIPLASH LANYARDS MUST BE ATTACHED TO THE INLET AND OUTLE' HYDRAULIC HOSES FROM THE TONG TO THE INCOMING HOSE. 1” Hydraulic Inlet 1-1/4” Hydraulic oe ‘Outlet ‘Toso hose couplings ar so sealng, and care should be taken to ensure complete engagement o prevent partial closure of he check valve in the coupling. Ensure thatthe nut (female) sido is completely made up onto the male connector - there [Sa line onthe male fiting that incites complete make-up. Snug the fomatefiting right up tothe line. Make up female fitting to Marked point on male fitting 2.12 Ruka Technical Manual ERGY FORWARD (GLOBAL EN 3 FARRSetup & Operation 2 CEE IAr ace E TONG/ BACKUP JAW AVAILABILITY & INSTALLATION 4, AVAILABLE TONG JAWS ‘Te following table ist al jaw die kits that are avaiable as standard sizes for this model of tang. f your desired size |e no stad, Farr ean engineer custom jaw sizes ~ contact sales for further information. Description Part Number Description Part Number 1a daw Die Ki SLA500IDK- 1900 Te Wrap Around Jan Die Kit_| SL4500-WIDK-1000 2.063" Jaw Die Kt__|_SL4500uDK-2068 2.8/8" Wrap Around Jaw Dio Kt | SLA500-WADK-2375 2.3/8" Jaw bie Kt__ | SL4800J0K-2375 2.7/8" Wrap Around Jaw Die Kit | SL4500-WADK-2875 2.716 Jaw Die Kit | SL4S00.IDK-2675 F Wap Around Jew Die Kt | SL4500.4DK-2000 3 Jaw Die Kit ‘SLA500 Wraparound Style Jaw BACKUP JAWS The jaw oie hts used inthe Far backup are Identical o those used in the “sin tong (see previous page). Follow the seme removal and installation insructions a8 forthe tong aw dle Ks TONG HANDLES Tong handles may be supplied as an accessory with this tong. They may be removed for operational needs and requirements F. TONG RIG-UP & LEVELING Suspension The fong should be suspended by wire cable of sufficient strength lo suspend the enti weight of the tong (950 Ibs. / 422 kg forthe long & backup) with a minimum 10% safely margin, and rom a locaton i the derrick high enough to ‘assure easy handing and maneuvering ofthe tong. The hang line shoud be placed in @ postion as near the canter Of the rotary as possible without mfertering withthe movement ofthe hoisting equipment. This line may either be extended over a pulley and Balanced by a counterweight equal the weight ofthe fong (approximately 990 Ibs) oF ‘Simply tod of in the derrick fo form 2 dead ine, In cases wiere tho dead line arrangement is used, it's necessary to Use 8 FARR spring hanger ascembiy. Tie soring hanger allows the fang to compensate forthe downward movement lof the casing as the thread is made-up, Tong Leveling ‘The tong mus be leveled side-to-side and ront-fo-rear before placing into service, The folowing guidelines wil assist you when favaling your tong, Lift the ong by the main iting ink. Place @ level axel (side to so) across the tong, ensuring that iis para fel win the surface ofthe tong. Ifthe fong isnot hanging level, move the main lnk fo an adjacent notch on the hhanger to move the tong closer tothe level positon. 4 Technical Manval FarrMPI COY | rare Setup & Operation Master Link Piece a leve lengthwise (hont to Beck) along the tang, ensuring that it is parallel with the surface ofthe fong {Leosen the 1/2 locking nuts an the adjusting bots on gid sing brackets. Completlylocsen the adjusting bol. Tum each adjusting bot equally undl tong hangs love! Fontto-back. Lock adusting bots in place with he lack “Tate Mone 2sFE ae a Setup & Operation 3. LOAD CELL CONFIGURATION ‘The backup is drecty coupled fo the compression load cl via the backup body paddle. The ad cel hangers simply hung in its slot on the paddle, and in normal operation does not need 10 be adjusted or removed. The assembly in the fest ofthe flowing two ilustations has been configured inthe "make-up" configuration; to convert the assembly {o the “break-out” configuration simply it the load cell holder / spacer assembly off the pad, rotate it 180", end ‘replace ~ no tools are require for this operation. Load Cell - Makeup Configuration Load Cell - Breakout Configuration 976 EETEENININ cic onoctSetup & Operation ONS MPLI DRILL! CON FARR atta TONG OPERATION 1. INITIAL START UP & BREAKIN PROCEDURE ALTHOUGH YOUR NEW EQUIPMENT HAS BEEN TESTED AND INSPECTED AT THE] “ARR FACTORY PRIOR TO SHIPPING, WE ADVISE THOROUGH TESTING OF YOUR NE\ TONG AFTER YOU TAKEN POSESSION IN ORDER TO ELIMINATE THE POSSIBILITY OF} ‘SHIPPING DAMAGE. ‘Far recommends thatthe following pre-operatig tests be performed prior to releasing he fang assembly to a oper tional environment: (Operate the tong at full speed and in high gear for a duration of one-half hour. ‘Switch to low gear and operate for an edsitional one-half hour at fil speed. ‘Rum the backup though several lamp/unclamp sequences to ensure functionality. + Inspect all components and hydraulic fitings for possible defects folowing completion ofthe tests. All FARR Tangs have been throughly tested at th factory prior fo shipping, but shipping damage must be identiied before running the tong i an operational environment Carefully inspect the safety door components, and test fo ensure thatthe safety device on each door s operating correctly Before releasing the tong fo the operating environment, |DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE THE} |POWER UNIT IS STARTED IN ORDER TO ASSURE THE SAFETY OF} OPERATING PERSONNEL Ensure adequote lube oi and hysrautc ol lovels 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 tine hose connections fo ensure Correct and secure instalation. IMPROPERLY SECURED HYDRAULIC CONNECTIONS WILL INTERRUPT HYDRAULIC FLUID FLOW, AND COULD RESULT IN THE FOLLOWING FAILURES: + Arestriction in the pressure supply hose will result in high pressure within the power unit hydrauliq system, which will activate the hydraulic governor and increase the engine speed to as high ad ‘maximum RPM, A restriction in the retum line will result in high pressure within the power unit and the tong hydrau- lie system, causing engine speeds as high as maximum RPM, and possible failure of the moto seal, MOVING GLOBAL ENERGY FORWARD Folowing inspection ofthe hoses. start the engine and allow itt ale unt warm. Allow hydraulic fd to oreult for ‘anproximatly 10 minutes, hen siowly close the Bypass Valve to allow hydraulic fuid to circulate through the hoses ‘and to the fong (culating pressure should not exceed 200 ps). Place the fong gear she in low gear and rotate the tong slowly forward and ten reverse with the throie valve contra lever. Once ths has been done and the proper '5ze jas have been installed, the long is then ready to run pipe. 2. VALVE OPERATION Proportional valves contol operation of hydrauile devices onthe fong assembly, such as hydraulic motors and eiin- rs When any one valve is “centered or inthe detent postion, thre is no hydraulic output from the valve. When the valve is pushed forward there isan effect, and when the valve is pulled back, there isan opposite effect. These ‘valves feaure proportional cana, which means that futher extension ofthe vaive handle (thereby further opening the valve orice) results in proportionally higher hydraulic output tothe controled device. Technical Manval 217Setup & Operation les with which this fong fs may be nstrates the type and effect ofthe hydraulic The foiowing Mustration don equipped. TONG MOTOR This fsa proportional valve, Pushing the valve handle forward will cause the fong motor to rotate in @ clockwise Girecton fas seen from the top ofthe tong). This i the desired direction of rotation for making up ain, Puling the Valve handle in the opposite arecion rasults in caunter clockwise rtation, which isthe desred direction of rotation LIFT CYLINDER This is 0 drect-acting valve, Pushing the valve handle forward wil cause the Itt eyinder to Wf the tong vertical Paling the volve handle in the opposite dracon will cause the Jf cylinder fo lower the fongor tot Setup & Operation BACKUP This i @ two-way direct acting valve, without proportional contr. Pushing the valve handle forward wil cause the backup to engage. Puling backward, fowards the operator, reverses the operation. TONG SPEED The motor speed valve offers safe and smooth adustment ofthe fong speed without the need to manipulate gears in @ geartrain. Simply rotate the spead valve to change the speed ofthe motor. The simplicity of his systam is particularly tseful when making up oF breaking outa joint. al Renee! 2.19Setup & Operation 4. GENERAL COMMENTS 4) Position rotary gear in contact with both idler gears when breaking out joints or colar where high forques are required. DOOR MUST BE CLOSED AND SECURELY LATCHED BEFORE THE| IPOWER UNIT IS STARTED IN ORDER TO ASSURE THE SAFETY OF| OPERATING PERSONNEL 1) When meking-up integra (shouldered) joins, tie essentia 10 make up the lat tur ofthe threads in low gear. This reduces the fendenay of an instant stop or @ sudden Increase In torque, which induces extremely high “stresses on the gear rain. 00 NOT employ the ‘snap break” method of breaking-out joints when pulling a string. By definition, the “snap break” method is a procedure used by some operators te break out connections, accomplished by leaving slack inthe Jaw-ppe" engagement, and then quicly pling the throttle valve central fever allowing the tong {0 snap Into ts loaded er high ergue condition Although this method is very effective i breaking out jis, the extremely high stress placad on the gear train Frequently causes gear breakaae. THE “SNAP-BREAK"” METHOD IS HAZARDOUS TO RIG PERSONNEL 1H. EXTREME COLD WEATHER OPERATION PROCEDURES 1) Consut the power unit engine operator's manual for al cold weather operating procedures and precautions. 2) Select gear and bearing lubricants that are compatible wih expected climatic conditions, 3) Select hysraulic Rul that is compatible with expected climatic condtions. 4) Allow hycaule fluid to circulate for approximately 20 minutos aftr starting the power unit, prior to activating the bypass valve fo alow fuid to circulate to tong. Ifthe power unt is equipped wih an ol lemperature gauge, ensure that he fuld has reached operating temperature as specified by hyéraulc fui data sheet 8) Allow for adequate drying of moisture (erior 0 luticating) when clearing tong pats in cold weather. schnical Manual MOVING GLOBAL ENERGY FORWARD FARRSetup & Operation i SUE atmos J. "MAKE-UP" CASING USE THE FOLLOWING PROCEDURE TO PROPERLY MAKE UP A CASING JOINT: 1. POSITION TONG ASSEMBLY OVER CASING. (Open tong and backup doors, and move assembly into place over the protruding casing (the “stump'). Engage the clamping jaw of he back-up using the back-up clamp contol on the operate contol panel Note: Ensure clamping pressure is set within the range proscribed by the ppe size and wall thickness by adjusting the relief valve onthe side ofthe back-up. 2._ENGAGE CASING WITH TONG. JONLY THE OPERATOR IN DIRECT CHARGE OF THE EQUIPMENT CONTROLS IS} PERMITTED TO ACTUATE THE BACKING PIN. [oad fresh casing plece, and close fang doar. Ensure backing pn is corecty oot for making up a joint. Raise tong to the top ofthe float by puling down on Tong Vertical positon. Set tong rotation speed to te high range, and engage fong via the tong rotation contr 3. MAKEUP JOINT Rum tong at high speed until ont bogs fo ightan (torque wil begin to rapidly increase) ‘Stop tong rotation by centering the Tong Rotation Joystick, svtch to low gear, and push the tong rotation joystick up to make-up" Continue lo make-up casing to desired torque NOTE: Your tong wil be equipped with either a torque gauge or @ Wincott torque measurement sys tem. Stop apalyng torque when the facque measurement reaches the pre-determined value, or witen the Wineatt system actuates the pressure dump valve 4. DISENGAGE JAWS Rotate the rotary gear in the opposite direction uni the jaws have disengaged from the pipeleasng, andthe opening ‘ofthe rotary gear aligns with the door opening. Disengage the back-up clamping jaw from pipe. 5. OPEN DOORS Te tong can now be cleared trom the ploe by opening both doors. FARRCeol art ec “BREAK QUT" OF CASING USE THE FOLLOWING PROCEDURE TO PROPERLY BREAK OUT A CASING JOINT: 2 A 2.22 ETSY technical Monvat POSITION TONG ASSEMBLY OVER CASING. ‘Open tong and backyp doors, and move assembly int place over the protruding casing (the stump"). Engage the ‘Gomping aw ofthe backup using the back-up clamp contol en the operator control pan. Note: Ensure clamping pressure is set within the range proscribed by the poe size and wal thickness by adjusting the relief valve on the 60 of the back-up. ENGAGE CASING WITH TONG. THE BACKING PIN MUST ONLY BE ENGAGED / DISENGAGED OR OTHERWISE] CHANGED BY THE TONG OPERATOR. ‘Ensure fong ish low gear. Lower tang to clase proximity fo back-up before engaging ppe inorder to ensure the fong hhas enough rave to completely unthread connection. Close tong door and push the tong backing pn joystick up unt, the cams engage the jaws. Pll the tong rotation jystick down fo the "break out poston, which wi rotate the casing causing the threads fo begin to unthread. RELEASE THE THROTTLE. [Now that the connection has been Broken, stop applying torque by centering the tong ration joystick TONG SPEED. Sot the tong retatonal speed to high, and push the tong rotation joystick down to “break out’. Continue to rotate the casing unt fre. DISENGAGE JAWS, NOTE: Ensure that roe section of ppe/easing is supported or otherwise restrained before diser-gaging jaws. Rotate the rotary gear in the oppositedrecton unt the jaws have disengaged and the rotary gear algns with the door open: ng OPEN DOORS, The tong can now be cleared fram the pipe by opening the doors. Setup & Operation FARRFARR Maintenance REA wea Regular maintonance programs are necessary, and must be established fo assure dependable and lengthy operation of your FFARR Hydraulic Tubular Connection System. Use the folowing mainlenance recommendations fe enhance the ife expectancy ofthe system and assure safety of operating personnel A. GENERAL MAINTENANCE SAFETY PRACTICES ‘All maintenance must be performed by (rained and authorized personnel. Wear approved eyewear, and folow al of your ‘Company's safety guidelines ‘Farr recommends thet disconnection of hydraulic connectors be performed withthe power unit off and the hycroulic cut depressurized B CLEANING Clean tong thoroughly cleaned with a good petroleum-based cleaning agent aftr each jb, prior to storage. Farr recom: Imends thatthe motor and valve assembly be peradicaly removed, along with the top fang pate, so that guides, rollers ‘and gears can be properly cleaned. © LUBRICATION Use a quoity multipurpose bearing lubricant that wil romain within is viscosity range at expected operating temperatures. In adction, Farr recommends the following lubrication procedure atthe completion of each ob pricy fo storage. 4. CAGE PLATE ROLLERS Te cageplate cam folowers are sealed units, and do not require lubrication. However, the cageplate and rotary gear {grooves in which the cam followers rie should be hghty greased. When the cageplae is rotated as aun, the cam Followers are exposed, and can be greased. Continue rotating the cageplate assembly unt ll cam followers, top and bottom, aro greased (See first ilustation below) : Technical Manual 3.1Maintenance 2, IDLER SHAFT BEARINGS ‘Aoply grease fo these bearings Urough the grease fitings inthe ends ofthe idler shafts, lacated‘on the fop of the fong fo the side of each rigid sing weldment (3 locations ft) 3. REDUCTION GEAR BEARINGS Apply grease to these bearings though the grease fitings in tho ends ofthe reduction gear shafts, located on the fap ofthe tong arecly under the main hycraulsuppert, and Behind the motor (2 locations tot) Peas chnical Manual ON: IG ETI4500 Pan Maintenance 4. TONG DOOR PIVOT SHAFT ‘Apply grease tothe tong door pivot shat through the grease fiting i the end of the shat Farr 3.3 Technical Manual5. TONG DOOR LATCH ‘Aaply a thin layer of grease to the tong door latch claws, and the top and bottom ofthe door latch post to enable smooth latching action. 6. JAW ASSEMBLIES ‘Apply 2 thin layer of grease to the metal-to-metal contac! surfaces ofthe fong and backup jaws to enable them fo ‘side smoothly. 6, BACKUP/LOAD CELL Grease must be added to both sides ofthe interface of the load col and the rear log of the backup. 34 EERIE chia ener FARRelem Maintenance D. ADJUSTMENTS 4. BRAKE BAND ADJUSTMENT (See illustration below): The brake bands must be periodically adjusted fo continue fo provide smooth and efficent jaw cam action. i the cage plate turns with the rotary goar, the jaws will not cam propery and, therefore, wil nt bite on the tubing or casing. Tightening the brake band against the cage plates wil increase fictional resistance, alowing jaws to cam property ‘and grip the casing. Adust the brake band using the alustment nut and Bolt sot as shown in the istration below. Do not over tighten, as this causes excessive wear fo the brake bands. excessive tightening is required for tong operation, remove the brake band and inspect for wear or foreign debris! lexcessive grease. Cleaning may be required to restore the brake lining. Replace the brake band if the thicknoss is less than 10" (2.5mm) at any effective portion ofthe brake fining. 2a COMI DRI FAR BRAKEBAND ADJUSTMENT BRAKEBAND ‘BOLT AND NUT RECOMMENDED PERIODIC CHECKS 1. BACKING PIN Perform ¢ visual inspection ofthe backing pin after each job. Replace the pin if stress cracks or excessive wear is found, o iether pin is bort ‘CCOY | ¢ mn MOVING GLOBAL ENERGY FORWARD. 2. TORQUE GAUGE ASSEMBLY Periodic cabration ofthe torque gauge is recommended fo assure accurate torque readings. When having the forque ‘gauge serviced and calibrated, itis crical note the arm length ofthe tong, as indicated in the “Specifications” sec- iton. Farr recommends that he torque gauge assembly be callbrated yearly. Technical Manval Pe 35Maintenance F. OVERHAUL PROCEDURES ‘The ong may be overhauled flowing the dsassembly instructions inthe following procedure, Access fo the gear train is possible by romoving the top plate of the tong. JALL MAINTENANCE AND OVERHAUL SHOULD BE PERFORMED FROM THE TOP. THEREFORE, THE BOTTOM PLATE OF THE TONG SHOULD NEVER BE REMOVED FROM THE GEAR CASE HOUSING. ‘ANY REPLACEMENT FASTENER (BOL TS, NUTS, CAP SCREWS, MACHINE, SCREWS, ETC.) USED DURING MAINTENANCE OR OVERHAUL MUST BE GRADE 8 OR EQUIVALENT. TIGHTENING TORQUE GUIDE ‘SAE GRADE 8 FINE THREAD SE (CLAMP LOAD PLAIN, PLATED WA 28 (250) 3265, 74 Ros 10h os 16. 24 (3125) 8n3 2A bs. 20 bs, ‘¥8-24 (379) 7876 Bh bs 37 os TA6- 20.4375) 70,660) TER bs. 36 os W220 500) 14,400, 120 8s, 20 bs B16 16 (5625) 78,300) TR bs, 129 fos 58-18 (625) 23,025 2407s. 780 os 94-16(750) 33,600 2208. bs. BSH Ds, Tie 14 (875) #525 668. bs 507 bs 7-72 (7.000), 59,700 2057. bs. 7A os 114 (7.000) 61,125 1019s, 764 fs. TAB 12 (1.125) 77,025, 1444 fs, 10853 bs. 14-12 (5.129) 96,600 2012 Ros 7509 F165, 198-12 (1.375) 778,350 2712 Ros 2084 15 112-121-500), 142,275 3557 fos 2668 F165, "SAE GRADE 8 - COARSE THREAD SE CLAMP LOAD. PLAIN, PLATED, 17a 20.250) 2,850) 72h bs fs. 16183125) 4725; 25 os 18 Ros 016575), 3975 A es. 39 bs. TA6- 14 (4379) 9,600 7O A bs. 2A es, 12 13,(500) 12,750, 106 fe B07 bs, 6-12 (5625) 76.350) 155 Ros. 15 Ros Be 11 625) 20,325 22 bs 759 fs, 410750), 30,075 TER. Ws, 282 fs, 718"- 9 (875) 41,550 605. bs. 454 os 78.000) 54,525 909°. bs. 682 fs, 18-7 (1-125) 68,700 1288 fs, 966. bs. TA? (1-125), 87,225 1817 bs, 7369 bs, 16.375) 703,950 2382 bs 1767 fs 112 -61.500), 126,450 3164 Rs, 2371 os. 36 ERNE tect ues LETIONS SOMPL Fare DRILLING & ACCOY | ERGY FORWARD Mowe GtopatMaintenance 4. Disconnect al hydraulic nes rom the hyéraulic valve assemble, including main motor lines, backup, safety door, and rains. 2. Remove the four /8° hex cap screws securing the vave assembly to the fop plate, and it valve assembly away. 3, not ready done, elsconnect and remove oad cell and load call spacer wekiinent REMOVAL OF BACKUP 4. Construct 2 support that wil suppor the entire weight ofthe backup assembly ‘5. tthe tong and backup and lower onto structure constructed in step 1 unt the weight ofthe backup is completely ‘removed trom the front leg and rear support springs. 6. Free the front leg springs by removing the V8" hex cap screw that supports the botiom spring spacers. Remove the cater pins securing the rear leg support rod, and remove the support rod 7. ft the tong, and front and rear legs, up and away from the backup. Use caution not fo lose the springs and tp spring washers, which wil come foase from the font legs when the fong is ited REMOVAL OF LEG ASSEMBLIES 8 Sot the tong and leg assembly onto a fat surface, Ensure thatthe majority ofthe weight remains supported by the "gid sing andthe crane. Remove the two 3/4” 5° hex bolls, lockwashers, and 3/4nuts securing the rear ofthe reer fog assembly, and the two 34° x 3-1/2" hex bots and lockwashers securing the front of he rear leg assembly. 2. Remove the festoners securing each front leg mount fo the bottom plate, 10. Ut the tong up and away from the legs - ensure that none ofthe log assombies or weldiments topple over when the tongis ited away. Place the long on a sutabe surface that wil suppor the entire weight of the tong and alow access fo the bottom of the tong 11. Remove the two eight 38" x 3-1/2" cap screws, lockwashers, and nuts securing the rigid sling assembly 10 the top plate (fur per side). The entre gid sing assembly may now belted away fro the tong, REMOVAL OF TOP PLATE 12. not already done, compete the elsconnection of al iydaulc lines om the motor. Remove the four 1/2 cap screws securing tha motor tothe top pate, and Ifthe motor and motor gear away, 18. not already done, remove the two jaw assemblies fom the fong. 14. Remove the two external snap rings from the door pivot shaft. Remove the door pot shaft- if necessary, use a harn- ‘mer and @ soft metal dive o ap the shat out. Remove the door assembly. 15, Remove the door latch shalt the same way the pivot shaft was removed. 16. Ensure the safety door push-pull cable has been freed atthe hydraulic valve end. Remove the fasteners securing the safely door actuator and push-pull assembly tothe top plate, and remove the entre actuator assembly, 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| FARR ORDER TO PREVENT DAMAGE TO THE BOTTOM CAGE PLATE OR| PERSONAL INJURY TO THE MECHANIC 17. Remove the four cageplate bolts, washers, and nuts, and the four cageplate spacers. The cageplates may now be removed. There is no need to remove the backing pin assembly om the top Cageplate unless maintenance on the backing pin is required the tap and bottom plato may be split apart - use caution fe pull the fop pla sraight up trom the bottom plate so that there sno binding on the dowel pins used fr positioning, 2. For addtional access fo the geer train the bottom gearbox cover may be removed by removing the remaining fasten- ‘ers Securing ito the bottom plate. Technical Manual EUR ua 37 3 12. Remove th to 98" 3:1/2Bos fom he contro the fog jus bend he capelace pening, Note at one of : 7 a al ses Socaes to Drakeband tae oh ote plat wos 12. Rome he te 30% 5 hx bts ookwasors. and "hex rust scare the bon gearbox covert the we toon « SS 5 20. Remove the remainder of the 3/8" nuts and bolts from around the perimeter of the tong. Once the bolts are removed 8Maintenance G, ASSEMBLY PROCEDURES “Assembly of Far Hydraulic Power Tongs is simple, and can be accomplished without the use of special to's. The instruc: tions on tis page are presented as @ guide only, and are similar fo the assembly sequence our technician would use while ‘assembling the fong in our plant. RereR To PAGES 3.10 - 3.11 FOR TORQUE SPECS WHEN TIGHTENING HEX BOLTS AND HEX HEAD CAP SCREWS. WHEN RE-ASSEMBLING LOAD-BEARING COMPONENTS (CHAIN SLINGS, RIGID SLINGS, BACKUP LEGS) NOTE THAT THE ASSOCIATED FASTENERS MUST BE TIGHTENED TO THE CORRECT TORQUE SPECIFIED FOR THAT SIZE| OF FASTENER. THREADED FASTENERS USED IN LOAD-BEARING DEVICES| ‘MUST BE SECURED WITH RED LOCTITE™. Fer recommends that each metal component, especialy those that wll be subjected fo metal-to-metal contace while the tong s operational, be coated witha ight coating of grease before assembly 1. Position the tong body gear case on a suitable stationary support such thatthe bottom body pate Is accessible. 2. Assemble seven inner ring / needle bearing assembles - press seven inner rings into seven needle bearings. 1. Pressne ofthe bearing assembles assembled in stop 2 into large reduction gear (PN 101-3292) folowed by a bear- jing spacer (PN 101-3872) and 9 second bearing assembly 4. Orient ihe gear assembly from step 3 50 that the smaller gear is facing up. Side gear shaft (PN 101-3296) into the fear assembly, making sure the fireaded hole nthe top ofthe shat i acing up, centering in the gear assembly as best as abe. 5 Place a thrust washer (PN 02-£0001) over each end ofthe gear shat, and then place the bottom (oon threaded) end ofthe gear shaft into the goar box cover (PN 101-2317). 6 Place three 218" x 3/4" dowel pins in (0 thelr respective locations in the side wal ofthe gearbox cover, an fasten the (gearbox cover tothe bottom ofthe bottom plat with four 98" NC x 2-1/2" hex cap screws and 38" lackwashers 2 3 2 se ZO & 5G 3 \CCOY | Nome cLowat 3.8 ESTEEM technica! Manvol 7Maintenance ASSEMBLY SEQUENCE (continued... 7. Press one ofthe bearing aesembiioe assombled in step 2 info the smaller reduction gear (PN 101-3291) folowed by a bearing spacer (PN 101-3812) and a second bearing assembly, 8. Orient he gear assembly kom step 7 50 thatthe smaller gears facing down. Slide gear shaft (PN 101-3296) ito the ‘gear ascombiy, making sure the threaded hal i the top of tho shat i facing up, centering in the gear assembly a5 best as able, 9. Place a thrust washer (PN 02:£0001) over each end ofthe gear shaft, and then place the bottom (non-threaded) end (ofthe gear shaft into the gear box cover (PN 101-3317) 10, ress one bearing assembly assembled in Step 2 into each ofthe three idler goars (PN 101-3299). Side an idler {gear shot (PN 101-3297) through each iar gear assembly and center inthe gear assembles as well as able. Slide 2 thrust washer (PN 02-E0001) over each en, and place the bottom (unteaded) ends of the shatts through the bottom plate ASSEMBLY SEQUENCE (continual: 2 1. Assemble rotary gear assembly geor a8 shown. Refer fo assembly drawing on p9ge 6.12 fr farther information. ° (SEE ILLUSTRATION NEXT PAGE) ING & RIL OM ARR 6 . |E ni Technical Monvol ES | 5.3Idler AssemblyIdler Assembly | : i : a 6 tom: Type Description ‘aty_| Part Number 2 [at rar 1 [worsens oh S| at Ran tr Berg ren op CE aR TBE | 1 [aon = i a reer Pg TUTE rim aeooer 28 ¢ | Coc tare sam aecoor &S 8) Getecte imal oraomr [tart eran Rg wa ned 7 [eesoer MOWING GLOBAL ENERGY FORWARD AAC Technical Manual 55CM Technical Manval Reduction Gear Assembly (Small) ACCOY | ENE Sionsob ‘OMPLI DRILLIN FARR COY | Reduction Gear Assembly (Small) EIA ae med tem | Type Description Gy |__ Part Number A Pat__| Reduction Goar 1_ | 107-3207 [8 Part | Needle Roller Bearing Drawn Cup 1-14" x 1-8/8"x1-555"| 1 | 02-9009 c Part | Inner Ring 1x 1-1/4"x 1-375 1_[o2-9027 D | Pat | Bearing Spacer 1 [107-3612 5 Patt | Geor Shaft “1 [rorsza6 FE Part | Thrust Washer 2 02.£0007 c Pat | Grease Fiting, 14" sraight thread 1 [020007 Fal MenaPera Reduction Gear Assembly (Large) : Sa EEE eter onaReduction MLL » . 3 i tom | Type Description ‘@y_|_Part Number A Part | hiner Ring Px rx TOS" 2 [o2.o027 2 | Pat | Beorng Spacer 1 [1018012 | Pat | Needle Rolor Soaring Drawn Cup 11x VS/6"s F355" 2 [02.0009 D_| Pan | Gear Shar + [107-3296 - E_ | Pet | Tonst washer 2 [o20001 iz | Part | Grease Fiting, 14" sath tread + [02-0097 %O 6 Pan | Reduction Gear 1 _ [101-3202 of ga z6 ZO OO & cl cCOy | MOVING GLOBAL ENERGY FORWARD rN Technical Manual eaeeran Rotary Assembly 5.10 Technical Manval AL ENERGY FORWARD Mowne ou FARR,Reimer a _ Rotary Assembly ‘tom [Type ‘Description ‘Gty_| Part Number A_| Pat | YONG K 2-17 Hex Gop Serew 1 [09-1056 B_ | Pat | 26° NC «4-1/2 Hex Gop Serow 4 [09-1068 c Part | 3/8" Flatwasher 1 | 09-5006 oD "Part Knob 7 ~ 1 02-0017 | Pan | Backing Pie Retnor [101-4040 [Te [Pan [a@"No Sua 1 [101-4058 [oe Part | Backing Pin re 101-4039 g || Par__| Top Cagopiate : 7_| 7013303 _ © | [Port [Cageplate Spacer [Tr 3399) — | Assembiy_[ lw De Ki (2-38" shown 500 PG 26) 2 L_| Assembly | Rotary Goar Assombiy (See Pp. 6 12-519) 7 > 2 | [aT Pant [Botom Capepiate - 1 [101-3304 z | Pat | 28° Lockwasher @_[ons105 & Po Pan | 7H Hx nr ; + [02-5506] U 8 o Part__| Backing Fin Bot Spacer 1 _ | 107-4038 ye |___Fan | Jaw Retoiner Bot 2 2 [roses (02 | [os [en [14 Sr Tread Grease Fig 2 [02-0097 Es [ot _ | Par__| "x 1° Socket Head Shoulder Screw 2 | 3 [| pen [37° 051" Socket Heed Shoulder Seow 2 ve Part 2-211 O-Ring Z [2 [oz-0340 Technical Manval 5.11oe ‘avitos sone Wwe) “Sonne | ACODS 3 5 3 2 3 $ 5 = & Technical Manual Pe 5.12i =e = RIL DCCOW | FARR Rotary Gear Assembly em |__ Type Description —_| ey [Part Number A Part | 7/16" Hex Jam Nut _ ~ 2e_| 02.£0005 3 Pat__|_ PTFE Thrust Washer a 36_| 02.0073 © Part | Gam Rotter ‘3 | 10r-4079 2 Part |_ PTFE Shoulder Bushing ~ ae | 02.0075 E Pat | Roller Shaft : 19 | 107-4655 F Pat | Pain Bushing 19 | o2-€0076 c Pat__ | Rotary Gear 1 _| 107-3301 Technical Manual 5.13Tong Body Assembly 5.14 Technical Manual AS ACEOY. | eSx8iSionseT ae aca Tong Body Assembly nem | Tyee —Deserintion @y_| Part Number A_| Assembly | Door Assembly (See Pp. 8.22 - 6.23) _ 1 | Pan _ | External Snap Ring [Ls _[o2.£o008 © | Pant | Shoulder Bushing 2 | 02-€0003, D_ | Part | Ooor Fost [2 [01-3308 | Pat _| 90° NGx3" Hex Gap Scrow = 15 [09-1058 | F Part | 378° NC x3-1/2" Hex Cap Screw 1109-1060 | [S| Assembly | Rigid Sing Assembly (Soe Pp. 524-626) 1 = & | [ca cassemiy [Motor Assombiy (S00 Fp. 510-610) [7 [assembly [Hyerauie Vale Assombly (See Pp. 516-517) [TT Pa [a0 «5° Hox Cap Serow | 09-1066 @ L Port _| Top Pate 1_| 10-3367 2 M Part__| Body Spacer 2 [tors 8 WL Pan | Botom Pte 7 [worse 3 P Par__| Gearbox Cover +_| 101-3397, a a |___Fan | 98 Lockwasher 44_| 09-5106 2 [Pat [0° NG Hoe Net 30-5006 g S| Port | Wear Button 16 _| 101-3380 2 T Part _| #4" NC x 12" Hex Socket FHCS — 71609-4003 3 u Part | Leg Plate (yp, wolded to ont log woliment- shown foritustaton) | _@ | 107-8094 a V_| Weldment | Lined Brakeband Weldment (See Pp. 5.20- 5.21) 2 _ | #01-3303, W_[_Pan | 26°NC x 2.12" Hox Bot _ <_ [09-7056 Technical Manval Section Contents 5.15Hydraulic Assembly ET ees ONS 3 g ORI FaRR. ccoy | 5.16 Technical ManvelFORWARD GLOBAL EMERG 8 FARR Hydraulic Assembly Type Description @y_[_ Part Number Part TA NO x 9/4" Hex Cap Screw 2 | 09-1005 Pat | _172°NC Thin Nylock Nut ~ 3_| 09-56108 Pat | 1/2" Narrow Washer ~ 3_ | essr10 : Part | Cable Guide Holder 1_| 101-4236 Part | Gable Guide Holder Retainer - 2_| 2.60025 E Part ‘Safety Door Valve ~ 1_| 08-0337 Part |_1/4°NPT 90 Degree Fiting 6 | 05.0264 F | Weldment | Valve Mount - 1__[ 101-4101 | _Weldment | Torque Gauge Mount =z 1 [101-4403 | Assombiy_|_DVA3S Valve Assembly | varies J Part |_12°NCx 4-172" Hox Cap Screw 3 | cote K Part HITOH PIN 148 2.938:1 Z 1 ame Pat |_1/4" Narrow Washer ~ ¢ | 09-1189 | ™ Pat | _14°NC Nylock Nut 4_| 09708 W Pat | vave : 7_| tose | Pr Part 1A" NG x 2° Hox Cap Scrow [oma ooro7s een @ Part | 88° NC x1 Hex Cop Screw = 4 _| 06-1086 R Part | 98" Lockwasher 6 | 09-5106 s Part | _9°NG x2" Hox Cap Screw 4 _|_os1054 7 Part Valve Body - ee acl | 081927) Part | GKEB Check Vaio a 1 _| 080461 5.17 Teil onalCer aa Motor Assembly 598 EEE etic nonootMotor Assembly jams — arama o A | Part | 20 (1-14) Sot Flange Kt =an 2 [ozeor7 z es Part O-Ring 2 Part 7/16" Lockwasher |e = c Part | RINEER GA 15-13/6.5 (2 SPEED) Hydraulic Motor 4 __| 87-0008 — [_o Part 1/2" Lockwasher ~ 4 09-5110. ¥ e F Part 90 Degree Flange Fitting 7 02-9216. GC Part 1/4" NC x 3/8" Hex Socket Set Screw _ ~ 2 09-0507 3 ee 1 | oe-e0009 pe HT Bat | Severe Noto Ray BAW BAH TAA ot Show) 7 7 "Technical Manual Peo 5.19CeBIT mc Brakebands ABCDE 5.20 Technical ManualBrakebands tem | Type Description @ty_| Part Numbor A_| Part | WNC Hox Not 1 | 09-5806 B_| Pon | 3° Lockvashor a 1 [e-5106 C_|_Watdment | Lined Brekeband Weldiment - 2_| 101-3303, D_ | Assembly | Bobi Washer Assembly @[rorsere & | [Cem Pan [0 0019-14" Hex Gan Saw Ce “ F Part__| Brakeband 1_ [101-3976 [co] ba [0° 5" Steer Ba 2 [oe ooss 8 Technical Mowe! 5.27Door Assembly eee ed ikem | Type Description ‘@y_| Part Number A Part__| Cable Guide Holder : | 071-4235 at _|__Part | Satety Door Plunger 7 [107-4360 | ‘A2_| Pat __| Pust-Pul Control Cable 1 e2.€0026 | ‘A2_| Part __| 716° UNF Hox Jam Nut + 00-5508 | ["s Part | Cable Guide Guarc 7 [rorasr | c_| Part | 3° Lockwasher las | oserosaeme| | Pent | Yo NCx 1.44" Hex Gap Screw 1 09-1657 E Part | aa" NOx 4-1/2" Hex Cap Screw 1 [09-1064 F_|__Por__| 140 Straight Thread Grease Fitng | 02-0097 6 Part__| Shoulder Bushing 2 _| 02-0003 H Part__| Detent aw button 7 | 02.0899 z Part | Top Plate (shown for tutration) 1 _|10raa67 | k_|__Pat | 98° NC Hex Nut 2 [09.5806 | Part | External Snap Ring «| o2e0004 M_| Pat | Dor Post 2 _| 107-3306 | Wetament_| Doar Weicient 1 [1074300 | Part | Compression Sorina 1 | 0460.0080-1725 a Part__ | Wave Spring 1 _[o2267 | __Part | Loren Wolamont 1 | 107-3690 S| Pan [70°14 Shoulder Bot 1 _[onozza edi Monel EEN 5.28Ree Rigid Sling Assembly item [Troe Description iy] Pat Number A__| Woldnert | Riis Sing Weidnont 1 [rorata7 B [Pant [0.140" 2636" ich Po 2 [2028 —e Part 3/4" Narrow Washer ~ 4 09-5013 D Part Rigid Sing Pin_ 2 | 02-£0008 E Part 3/8" NC x 3-1/2" Hex Cap Screw : é 09-1060 g F Part__| Rigid Sing Leveling Bolt Z + [oz-c0038 e 6 Pant__| 12" NC Hex Nut ¢_[os-9i24 | Cs [101-3997 J | Part Rigid Sling Adjustment Bolt Spacer 4 101-4138 K Part | 3/8 Lockwasher a 09-5106 _ L Part__| 876°C Hex Nut ~ @ looses | MOVING GLOBAL ENERGY FORWARD - Technical Manvel | 5.25I l = RAC DRILLING & IO Wad COMPLETIONS Moun GLosal ExeRG¥ FORWARD FaeBackup Assembly Pera ec (aera |ierseet Description Part Number [la ‘Assembly | Hydraulic Cylinder Assembly 101-4336 [Pen | cy 101-3076 | Pat | erat tang Rina - [ozo | Part [34 Narow Raster cosor3 | Wotrnent |Back Bod Hkient [rorassr F | Asseiy | dow Oi Kt (2-96" shown - see F213) é Part Cylinder Pin ~ | 101-4329 H Part Jaw Retainer Bolt = | 101-4264 Z| Pat | 90°11” Socket Head Shove Sw _K Part External Retaining Ring | 02-£0037 . Pant [ever in — [101-3990 2 ‘| Pan | 90°51 Socket Fad Shar Seow 8 o Pat__|2213 O-Ring 02.0347 5 [Part | 1 Pan Noon Washer coroo4s = P Pat | Cam arm - 101-3672 2 0 | Par | Gonprsston Load Ooi, 06-108 7 [reomec | § R__| Weldment [Load Gel Holder Weldment [or-4340 3) OST past Noro awashor coat | 5 TL Pat | 516°NC 4 Hox Con Soom e024 ac hence! EE 5.27Rear Leg Assembly 2 sO ob = _ a Og | [ew 7 Deseo [ay [Par number rail ati ee conee [a foesrre a 8 Pant__| 9/4°NC x 3-1/2" Hex Cap Screw 1 | 09-1300 [_¢ Part Rear Leg Spring 2 997-13 | g D | Wetament | Beckup Support Pato — 2] 107-3085 0: [Pat [Sano x 5 Hx Cop Sew 100.1308 2 F | tent | Reor Log Were 1 [ror 3888 WU GO| Pat [34° Hex ut : 2 [oosere y® HL Part [0 1.125 ch Fn - 2 [cazoows 3 Z| Par Super od = 7 [rors 8 3 hnical Manvel (Ee 9907m 5.30 Peon Technical Manvol Front Leg Assembly FareFront Leg Assembly NG & a ZO g | (rom | te Description y_| Pat Number nO = A Part 9/8" NC x 3-1/2" Hex Cap Screw a 09-1060 ae @ | Welemeni_[ Front Log Welament 101-3661 ¢ Part | 318° Lockwasher _ 09-5106 o Part 3/8" NC Hex Nut _ : 09-5806 | Pert | 1-9 Pan Narrow Fetwasher [tor-1048 |e Pat [Leg Spring : = 2 [020920 U [Part | Botom Spang Sonpor ae ee [Part | 88° NOx?" Hox Cop Scow 2 [oo.1054 MOVING GLOBAL ENERGY FORWARD Technical Manual 7Cera This page intentionally left blank Z\ ERM Section Contents | eo Technical Manual iS COY | coir iS FARRoroenoesemce | nome fessreeseatsanm| EIU TUS) lsoc ze Correa reese racer ea ‘Sana PROYECTO “cen DECOST ‘HAQUNA/EGUIPO/ARER Taforron | 30 aowsreacow > MANTENMENTO TARR MACHO SW 762 1 servcio recwco eseeciauzavo mseeccon tue Necnaacarnomacto — | uno] 1 reason] ro, a cy BESCUENTO. _ 7px arg i RC a ete TOTAL FAA Tao) fs ran RESTORES Ivers 409) NIMIENTO ACEPTACION POR EL PROVEEDOR ems secribo Poblo Carcedo Pablo Me Coicedo SATISFACCION: [NOMBRE DE QUIEN RECIBE EL SERVICIO [FIRMA DE QUIEN RECIBE EL SERVICIO