Troubleshooting; Tong Will Not Develop Sufficient Torque - Farr KT5500 Technical Manual

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Adequate maintenance and proper fluid selection is essential for minimizing hydraulic-related failures. All troubleshooting must be
performed by a technician trained in hydraulic systems, and familiar with the equipment design, assembly and operation.
The following troubleshooting instructions are intended to be guidelines only. Any faults not solved through the use of this guide should
be referred to our engineering department for their evaluation and recommendations.
A.

TONG WILL NOT DEVELOP SUFFICIENT TORQUE

1. Malfunctioning relief valve on tong hydraulic circuit.
a. POSSIBLE PROBLEM: Relief pressure set too low.
SOLUTION: Increase setting. To check, block the oil line beyond the relief valve and determine pressure with a gauge.
b. POSSIBLE PROBLEM: Relief valve is stuck.
SOLUTION: Check for contamination of oil that may inhibit the way the valve actuates. Remove valve and clean, ensur-
ing that the valve spring operates smoothly.
c. POSSIBLE PROBLEM: Relief valve is leaking.
SOLUTION: Check valve seat for scouring. Check oil seals. Check for particles stuck under the valve system.
2. POSSIBLE PROBLEM: Directional valve is leaking.
SOLUTION: Check directional valve. Neutral position should return fluid directly to the reservoir. Replace or repair valve to
ensure correct operation.
3. POSSIBLE PROBLEM: Power unit is not producing adequate pressure.
SOLUTION: Troubleshoot power unit (see user's manual for your particular unit).
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.
6. POSSIBLE PROBLEM: Worn or damaged tong motor causing slippage.
SOLUTION: Replace or repair worn or damaged motor.
7. POSSIBLE PROBLEM: Damaged bearings or gears causing excessive drag.
SOLUTION: Replace or repair worn or damaged gears or bearings.
8. POSSIBLE PROBLEM: Jaws slipping on pipe.
SOLUTION: Ensure jaw dies are not worn to the point that they cannot grip. Ensure the correct sized jaws are in use.
9. POSSIBLE PROBLEM: Torque gauge is indicating incorrectly
SOLUTION: Incorrect gauge is being used. Ensure gauge is the proper range, and has been properly calibrated for the arm
length of the equipment in use.
SOLUTION: Gauge has been damaged. Check gauge operation and calibration on independent system.
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