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Item Quantity Part Number Description

1 1 102-003-02 User Manual, IR3080AR5503 Iron Roughneck
2 1 103-003-02 Technical Drawing Package, IR3080AR5503
3 1 105-003-01 Spare Parts List, IR3080AR5503
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IR3080AR5503 IR3080
This document contains proprietary and confidential information which is the property of National Oilwell
Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is loaned for
limited purposes only and remains the property of NOV. Reproduction, in whole or in part, or use of this
design or distribution of this information to others is not permitted without the express written consent of
NOV. This document is to be returned to NOV upon request or upon completion of the use for which it was
loaned. This document and the information contained and represented herein is the copyrighted property of
NOV.
© National Oilwell Varco
TITLE Owner’s Manual
CURRENT INITIAL IR3080AR5503 Iron Roughneck Assembly, 55"
DRAWN Bob Dominguez Reach Arm
CHECKED
SIZE DWG NO REV
APPVD
A EPL-1617-02 02
DATE 01/15/2007 SCALE 1/1 WT LBS N/A SHEET 1 OF 1
DCF0045 (REV B)
Document number EPL-1617
Revision 02
SECTION 1:
TABLE OF CONTENTS
www.nov.com
IR3080 Iron Roughneck
IR3080AR5503 Assembly, 55" Reach
Arm
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

IR3080AR5503 IR3080 Iron Roughneck User Manual
ADDITIONAL CODE SDRL CODE TOTAL PGS This document contains proprietary and confidential information
which is the property of National Oilwell Varco, L.P., its affiliates or
REMARKS subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
Reproduction, in whole or in part, or use of this design or
MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the RIG SOLUTIONS
express written consent of NOV. This document is to be returned to 12950 West Little York
CLIENT PO NUMBER NOV upon request or upon completion of the use for which it was Houston, TX 77041
loaned. This document and the information contained and
represented herein is the copyrighted property of NOV.
CLIENT DOCUMENT NUMBER © National Oilwell Varco
Client Document Number DOCUMENT NUMBER REV
102-003-02 02
www.nov.com
Document number 102-003-02
Revision 01
Page 2
REVISION HISTORY
02 1-15-2007 Revised and Updated BMD

00 3-15-2004 First Issue BMD
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

00 First Issue
01 Revised and updated
02 Revised and updated TOC, TDP, and SPL
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Revision 01
Page 3
TABLE OF CONTENTS
Section Document Number
1 TABLE OF CONTENTS.................................................................................. 102-003-02
2 SPECIFICATIONS .......................................................................................... 152-000-01
3 GENERAL DESCRIPTION ............................................................................. 202-000-02
4 GENERAL OPERATING PROCEDURES ...................................................... 352-000-04
5 MAINTENANCE
5.1 General Safety Precautions .................................................................... 302-301-02
5.2 Maintenance ............................................................................................. 302-100-02
6 ASSEMBLIES
6.1 Wrench ..................................................................................................... 402-000-04
6.2 Spinner Assembly ................................................................................... 402-100-03
6.3 Column\Guide\Arm Assembly ................................................................ 402-200-02
6.4 Remote Control Console Assembly....................................................... 402-300-04
7 TROUBLESHOOTING.................................................................................... 602-000-03
8 INSTALLATION .............................................................................................. 702-000-03
9 PARTS LIST
9.1 Technical Drawing Package.................................................................... 103-003-02
9.1.1 Installation Spares ............................................................................. 104-000-00
9.1.2 Recommended Spare Parts List ....................................................... 105-003-01
10 PRODUCT INFORMATION
10.1 Hydraulic Power Unit Manual ................................................................. 902-200-02
10.2 Contacting National Oilwell Varco ...........................................................................
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Revision 01
Page 4
MANUAL SYMBOLS AND CONVENTIONS

Throughout this manual, the technician will find various types of annotations, which require the
special attention of the technician.
DANGER - WARNING -CAUTION

The safety alert symbol is used to draw attention to a personal safety issue. (See Figure 1)
Figure 1. Safety Alert Symbol

Denotes an extreme intrinsic hazard exists which would result
DANGER* in the Probability of death or irreparable injury if proper
precautions are not taken
Denotes a hazard exists which can result in injury or death if

WARNING* proper precautions are not taken
Denotes a reminder of safety practices or directs attentions to

CAUTION* unsafe practices, which could result in personal injury if proper
precautions are not taken.
*This is recommended by SAE J115.
Carefully observe the following terms used throughout this manual. These terms mark
special messages throughout this manual to alert the operator to specific information
relating to the equipment.
These terms are used to draw attention to items of interest

! NOTICE ! to the operator or maintainer of the equipment,
components or attachments.
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Revision 01
Page 5
ABBREVIATIONS AND DEFINITIONS
Amp Amperes
BOP Blowout Preventer
CW Clockwise
CCW Counter Clockwise
DW Drawworks
E-Stop Emergency Stop
ELS Equipment Limit Switch
Ft/lbs Foot/Pounds
Gpm Gallons per minute
HE Hydraulic Enclosure
Hz Hertz
HVAC Heat, Ventilation & Air Conditioning
IR Iron Roughneck
ERLS Extend / Retract Limit Switch J-Box
LED Light Emitting Diode
MP Mud Pump
M/U Make Up
OD Outside Diameter
P&ID Piping & Instrument Diagram
Psi Pounds per square inch
RCC Remote Control Console
Rpm Revolutions per minute
Sec Seconds
TSP Torque Setting Panel
TD Top Drive
V Volts
Operator The person assigned the responsibility of physically operating and maintaining
the equipment.
PATENTS
There are several patents associated with the Iron Roughneck. These include:
• Automated Arm Assembly – Patent Pending Number 12038.0009.PZUS00.
• Jaw Dies – Patent Pending Number 60/410,215.
www.nov.com
Revision 02
SECTION 2:
SPECIFICATIONS
www.nov.com
IRON ROUGHNECK
Technical Specifications
Document Number
152-000-01
IRON ROUGHNECK
THIS PAGE INTENTIONALLY LEFT BLANK
Document Number
2 152-000-01
IRON ROUGHNECK
TABLE OF CONTENTS
GENERAL SPECIFICATIONS ..................................................................................................... 5

UTILITY REQUIREMENTS .......................................................................................................... 5
SIZE SPECIFICATIONS............................................................................................................... 6
Maximum Extend, Side Dimensions....................................................................................... 6
Maximum Extend, Maximum Lift, Side Dimensions................................................................ 7
Maximum Extend, Top Dimensions........................................................................................ 8
Maximum Retract, Side Dimensions ...................................................................................... 9
Document Number
152-000-01 3
IRON ROUGHNECK
Document Number
4 152-000-01
IRON ROUGHNECK
GENERAL SPECIFICATIONS
Components
Measurement Description
Weight (lbs.) 7,600 (3,447 kg)
Spinner Drill Pipe/Collar Capacity 3.5” – 8.5”
Spin Speed (5” pipe dia.) 80 rpm
Spin Torque 2,250 ft / lbs (3,050 N-m)
Wrench Drill Pipe/Collar Capacity 3.5” – 8.5”
Makeup Torque (maximum) 60,000 ft /lbs (81,349 N-m)
Breakout Torque (maximum) 80,000 ft / lbs (108,465 N-m)
Connection Height (Maximum) 68” (172.72 cm) Maximum
Connection Height (Minimum) 30" (76.2 cm) Minimum
Horizontal Travel 55.5" (141 cm)
Vertical Travel 38” (96.5 cm)
UTILITY REQUIREMENTS
Utility Requirements
Utility Measurement
Hydraulic System Pressure 3000 psi (206.8 bar)
Hydraulic System Flow rate 40 gpm (151 Ipm)
Electrical Control Requirements 24VDC (w/customer supplied HPU)
Document Number
152-000-01 5
IRON ROUGHNECK
SIZE SPECIFICATIONS
Maximum Extend, Side Dimensions
ALL DIMENSIONS ARE IN INCHES.
ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS,
UNLESS OTHERWISE SPECIFIED.
Figure 1.
Document Number
6 152-000-01
IRON ROUGHNECK
SIZE SPECIFICATIONS
Maximum Extend, Maximum Lift, Side Dimensions
Figure 2.
Document Number
152-000-01 7
IRON ROUGHNECK
SIZE SPECIFICATIONS
Maximum Extend, Top Dimensions
Figure 3.
Document Number
8 152-000-01
IRON ROUGHNECK
SIZE SPECIFICATIONS
Maximum Retract, Side Dimensions
Figure 4.
Document Number
152-000-01 9
Revision 02
SECTION 3:
GENERAL DESCRIPTION
www.nov.com
IRON ROUGHNECK
Introduction
and
General Description
Document Number
202-000-02
INTRODUCTION
AND GENERAL DESCRIPTION
IRON ROUGHNECK
Document Number
202-000-02 2
IRON ROUGHNECK
Figure 1. Typical Iron Roughneck, General View
Document Number
3 202-000-02
INTRODUCTION
AND GENERAL DESCRIPTION
IRON ROUGHNECK
GENERAL DESCRIPTION
This Operation and Maintenance Manual describes the day-to-day care and operation of
the Iron Roughneck. It is essential that the equipment operators have the required
knowledge, education and training before using the system.
The Iron Roughneck is a lightweight, compact, modular roughneck, which is mounted on

the rig floor and uses a hydraulic powered Automated Arm Assembly (patent pending) to
extend the roughneck, toward the mouse hole or well center, or retract the roughneck back
to the standby / park position. A column assembly allows the roughneck to move in a
vertical direction, as well as allowing it to rotate to align with either the mouse hole or well
center. A Extend/Retract Limit Switch J-box mounted on the column is used to select either
the mouse hole or the well center as the destination for the Iron Roughneck. This switch
determines the reach distance by the Automated Arm assembly. A locking pin in the
column allows the operator to manually rotate the Iron roughneck to face either the mouse
hole or well center.
The Iron Roughneck is capable of performing makeup and breakout operations using any
of a number of different size drill pipe/drill collars ranging from 3.5" to 8.5" (3.5” to 9.75” if
equipped with IR30120 wrenches) nominal drill pipe/drill collars size with one set of V-dies.
The Iron Roughneck system’s makeup and breakout tools are hydraulic pressure operated.
The spinner assembly, which utilizes a floating suspension system, allows the spinner
assembly to follow drill pipe/drill collars movement as threaded connections are spun in or
out. The torque wrench assembly, which utilizes a combination top wench and bottom
wrench assemblies, apply the clamp force and rotational force to hold and rotate the drill
pipe/drill collars to allow makeup or breakout the connections.
The Iron Roughneck uses an operator-controlled, electrically powered Remote Control

Console (RCC) located several feet away from the roughneck. A Hydraulic Enclosure
(HE), mounted on the frame of the Iron Roughneck, is available for use during setting of
torque and clamp pressure or during maintenance periods when the RCC is not available.
The HE is located on the Iron Roughneck. A Torque Setting Panel is mounted on top of the
HE. The Torque Setting Panel is used to adjust the torque setting for the Torque Wrench
assembly.
Document Number
4 202-000-02
IRON ROUGHNECK
Spinner Torque Setting

Assembly Panel
Arm
Torque Wrench Assembly
Assembly Hydraulic Enclosure
ERLS J-Box
Remote Control
Console
RN 300018
Figure 2. Typical Iron Roughneck Major Assemblies
Iron Roughneck Major Assemblies
Component Description
The Torque Wrench is a combination assembly of a
top wrench and bottom wrench. The top wrench
rotates relative to the bottom wrench by a single
hydraulic cylinder. Each wrench has two hydraulic
Torque Wrench Assembly cylinders directly connected to jaw clamping dies.
When two sections of pipe are being made-up or
broken out, this applies torque to the upper section of
pipe.
Document Number
5 202-000-02
IRON ROUGHNECK
Component Description
The Spinner Assembly is an integrated hydraulic
powered roller assembly for rotating pipe connections.
The Spinner assembly utilizes upper and lower rollers
that are hydraulic motor driven. The spinner assembly
Spinner Assembly
is spring suspended for self-adjustment on the pipe,
which allows the spinner assembly to follow drill
pipe/drill collars movement as threaded connections
are spun in or out.
The Automated Arm assembly is a folding arm that is
used for horizontal movement to extend and retract the
roughneck’s Spinner/Wrench assemblies. The
Automated arm allows horizontal movement to the two
Automated Arm Assembly
adjustable locations (mousehole and well center) from
the standby park position. A hydraulic lift cylinder on
the Automated Arm column allows vertical movement
of the Automated Arm Assembly.
• REMOTE CONTROL CONSOLE is used to
remotely control the Iron Roughneck.
• HYDRAULIC ENCLOSURE contains the electro-
hydraulic control valves. The electrohydraulic
control system can be remotely controlled from the
remote console, or locally controlled at the electro-
Controls hydraulic control manifold
• TORQUE SETTING PANEL is used to adjust make-
up torque limits. A local emergency shutdown is
also located on the Torque Setting Panel.
• ERLS J-Box is used to select mousehole or well
center as the destination of the roughneck.
The Hydraulic Power Unit supplies hydraulic power at
3000 psi to the Roughneck.
Hydraulic Power Unit *
*If equipped.
Document Number
6 202-000-02
Revision 02
SECTION 4:
GENERAL OPERATING
PROCEDURES
www.nov.com
IRON ROUGHNECK
General Operating
Procedures
Document Number
352-000-04
IRON ROUGHNECK
Document Number
2 352-000-04
IRON ROUGHNECK
TABLE of CONTENTS
IRON ROUGHNECK CONTROLS AND SETTINGS ................................................................... 5
Control System Description .................................................................................................... 5
Remote Control Console................................................................................................ 6
Extend / Retract Limit Switch J-Box ............................................................................... 8
Setting Extend / Retract Limit Switch J-Box................................................................... 9
Torque Setting Panel ................................................................................................... 12
Hydraulic Enclosure ..................................................................................................... 16
MAKEUP AND BREAKOUT OPERATIONS ............................................................................. 18
Start-Up Procedures............................................................................................................. 18
Positioning the Iron Roughneck for Operation...................................................................... 19
Making Connections............................................................................................................. 21
Makeup Initial Position ................................................................................................. 21
Normal Makeup Procedure .......................................................................................... 23
Breaking Connections .......................................................................................................... 25
Breakout Initial Position ............................................................................................... 25
Normal Breakout Procedure ........................................................................................ 27
Emergency Stop Procedures ............................................................................................... 29
Start after Emergency Stop .................................................................................................. 29
Document Number
352-000-04 3
IRON ROUGHNECK
Document Number
4 352-000-04
IRON ROUGHNECK
IRON ROUGHNECK CONTROLS AND SETTINGS

Control System Description
The Iron Roughneck control system provides the operator with onboard and remote
controls to operate all of the Iron Roughneck functions. The major components of the
control system include:
Remote Control Console (RCC)
Extend / Retract Limit Switch (ERLS)
Torque Setting Panel (TSP)
Hydraulic Enclosure (HE)
The following paragraphs and tables describe the Iron Roughneck control system’s
components.
Document Number
352-000-04 5
IRON ROUGHNECK
Remote Control Console
Figure 1. Typical Remote Control Console Panel
Document Number
6 352-000-04
IRON ROUGHNECK
Table 1. Remote Console Panel Controls

CONTROL RESPONSE
Pushing in shuts down hydraulic system. Pulling it out allows
E-STOP
hydraulic system to restart.
MAKEUP/BREAKOUT Rotary
Allows operator to control the operation of the Torque Wrenches.
Selector Control
WRENCH – UP / DOWN Rotary
Sends Torque Wrench up or down to level desired.
Selector Switch
OFF position causes spinner to open up and disengage from
SPINNER OFF / GRIP / SPIN Rotary tubular. GRIP causes spinner to close onto tubular. SPIN
Selector Switch causes spinner to spin tubular in direction desired, according to
chosen selection of SPINNER ROTATION switch (IN/OUT).
BOTTOM JAW OPEN/CLOSE
Controls opening and closing of Bottom Jaw of Torque Wrench.
Rotary Selector Switch
Three-position, return-to-center switch. Causes Iron Roughneck
IR MOVE – OUT / IN Rotary
to move in a horizontal direction either toward or away from
Selector Switch
tubular, as desired.
SPINNER ROTATION OUT/IN Selects direction of rotation of spinner. Spinner will spin in or out
Rotary Selector Switch when SPINNER switch is placed in SPIN position.
Lights green if makeup operation is complete (according to
MAKEUP COMPLETE Lamp
torque required Make-Up drill pipe/collar).
Lights red if the pr-set torque has not been reached for
MAKEUP REPEAT Lamp completion of the make-up operation. When this happens, the
torque process must be repeated.
Allows operator to monitor hydraulic system pressure coming
SYSTEM PRES Digital Gauge from the Hydraulic Pump Unit (HPU). Gauge reading is in psi.
Multiply reading by 10X to get actual pressure.
Allows operator to monitor the amount of torque being applied by
MAKEUP TORQUE Digital Gauge the Torque Wrench. Gauge reading is in Ft - Lbs. Multiply
reading by x100 to get actual torque being applied.
Document Number
352-000-04 7
IRON ROUGHNECK
Extend / Retract Limit Switch J-Box

An ERLS (Extend / Retract Limit Switch) J-box (see Figure 2) mounted on the structural
section of the Iron Roughneck controls extend and retract travel limits. Selecting either
MOUSEHOLE or WELL CENTER position affects the horizontal distance traveled by
the Automated Arm.
Figure 2. Extend /Retract Limit Switch J-Box
Shutdown power before working inside of extend / retract

limit switch (ERLS) J-Box. Failure to observe this precaution
can cause serious injury and / or damage to the equipment.
Document Number
8 352-000-04
IRON ROUGHNECK
Setting Extend / Retract Limit Switch J-Box

Unless stated otherwise, all adjustments mentioned below are found on the Extend /
Retract Limit Switch (ERLS) J-Box (see Figure 2).
1. Position Roughneck precisely over Well Center; shutdown power.
2. Open ERLS J-Box; four thumbscrews on cover.
3. Loosen screws on limit switch and fine adjustment brackets.
4. Slide switch until plunger contacts trip blade and retracts approximately 1/8",
tighten screws on brackets, and replace cover.
5. Rotate selector switch on Remote Control Console (RCC) to “WELL CENTER”.
6. Power up Roughneck, extend and retract Roughneck with Remote Control

Console.
7. If Roughneck is traveling short of Well Center, Move the switch farther from the
trip blade (towards back of machine) using the fine adjustment screws.
8. If Roughneck is traveling beyond Well Center, move the switch closer to the trip
blade (towards front of machine) using the fine adjustment screws.
9. Repeat process for Mouse Hole after selector switch is rotated to

“MOUSEHOLE”.
10. Tighten screws on ERLS J-Box.
Once the position (MOUSEHOLE or WELL CENTER) is

selected on the Remote Control Console (RCC), the
operator must remove a locking pin at the base of the Iron
Roughneck (see Figure 7), and manually rotate the Iron
! ! Roughneck Automated Arm to the left or right, as
appropriate, to align with either the Mousehole or the Well
Center. The Operator can then extend the Arm to the
chosen position.
Document Number
352-000-04 9
IRON ROUGHNECK
Drill Floor
RN300005
Figure 3. Typical view of an Iron Roughneck in the Retracted/Park Position
Drill Floor
RN300006
Figure 4. Typical view of an Iron Roughneck in the Extended Position
Document Number
10 352-000-04
IRON ROUGHNECK
Document Number
352-000-04 11
IRON ROUGHNECK
Torque Setting Panel
Figure 5. Torque Setting Panel Controls
Table 2. Torque Setting Panel Controls

CONTROL RESPONSE
TORQUE SETTING Control Used to set maximum makeup torque.
Indicates the amount of torque the system is providing during
TORQUE SETTING Gauge
makeup operation.
Causes hydraulic system to shut down immediately after this
EMERGENCY STOP pushbutton
control is pressed.
Indicates hydraulic pressure in the Upper and Lower Torque
JAW Pressure Gauge
Wrench jaw.
SYSTEM Pressure Gauge Indicates hydraulic pressure available within the Iron Roughneck.
Document Number
12 352-000-04
IRON ROUGHNECK
Adjusting the Makeup Torque

The makeup torque must be set before performing makeup or breakout of drill pipe/drill
collars.
1. Ensure the Hydraulic Power Unit is running correctly and the full pressure of
3000 psi is available according to the System Gauge on the Torque Setting
Panel.
2. Adjust Torque Setting Control Valve (see Figure 5) for Makeup Torque (Counter
Clockwise for decrease torque setting and Clockwise for increase torque setting).
3. To Set Makeup torque, actuate the Torque Control Valve (as if performing a
makeup sequence) and hold, while turning the Torque Setting Control knob. Turn
the Torque Setting Control knob while watching the Torque Gauge until the
desired torque is achieved.
4. Release the Torque Control Valve and lock the Torque Setting Control knob
using the locking nut found just behind the knob.
5. Check the torque setting by shifting the Torque Control Valve (pull the Torque
Control Valve out and hold). The Torque Setting Gauge will indicate current
torque setting.
Make-Up Torque is now set for the Top Wrench.
Document Number
352-000-04 13
IRON ROUGHNECK
Adjusting the Jaw Pressure

The pressure for the Top Jaw and the Lower Jaw must be set before adjusting torque or
performing makeup or breakout functions. The Jaw pressure desired will vary
according to the size of the tubular being handled.
Ensure the correct jaw pressure is chosen for the size of

tubular being handled. Excessive jaw pressure can damage
a tubular.
Exercise extreme caution when performing adjustments on

the hydraulic system. Fluid escaping under pressure can
easily cause serious injury or death to personnel and / or
damage to the equipment
1. Ensure the Hydraulic Power Unit is running correctly and the full pressure of
3000 psi is available according to the System Gauge on the Torque Setting
Panel.
2. In the Hydraulic Enclosure, choose either the TOP JAW Valve or the BOTTOM
JAW Valve, as desired and actuate, as in closing the jaw.
3. If maximum jaw pressure is desired, close the Ball Valve mounted in the
Hydraulic Enclosure. This bypasses the Downstream Relief Valve and allows the
full 3000 psi pressure to flow to the jaws.
4. If regulated jaw pressure is desired, open the Ball Valve. This allows the
Downstream Relief Valve to function.
5. While observing the Jaw Pressure Gauge on the Torque Setting Panel, turn the
adjustment stem on the Downstream Relief Valve until the Jaw Pressure Gauge
reads the desired pressure.
Jaw pressure for the Top and Bottom Jaws is now set.
Document Number
14 352-000-04
IRON ROUGHNECK
Document Number
352-000-04 15
IRON ROUGHNECK
Hydraulic Enclosure
Ball Valve Relief Valve

Torque
Control
Valve
Bottom Jaw Top Jaw

Valve RN300008 Valve
Figure 6. Hydraulic Enclosure Assembly
Document Number
16 352-000-04
IRON ROUGHNECK
Table 3. Hydraulic Enclosure Controls

CONTROL RESPONSE
VALVE Optional hydraulic manual valve for optional hydraulic Iron
(Valve No. 1) Roughneck circuit device.
TORQUE VALVE
Hydraulic manual valve to make or break a connection.
(Valve No. 2)
WRENCH LIFT VALVE Hydraulic manual valve to adjust the wrench assembly vertical
(Valve No. 3) height.
TOP JAW VALVE Hydraulic manual valve to clamp and unclamp the top jaws on a
(Valve No. 4) drill pipe connection.
BOTTOM JAW VALVE Hydraulic manual valve to clamp and unclamp the bottom jaws on
(Valve No. 5) a drill pipe connection.
SPINNER GRIP VALVE Hydraulic manual valve to engages and disengages the spinner
(Valve No. 6) grips onto tubular.
SPINNER ROTATION VALVE
Hydraulic manual valve to select spin rotation in or out.
(Valve No.7)
MOVE IN-OUT VALVE Hydraulic manual valve to extend and retract to and from well
(Valve No. 8) center or mousehole.
Manually adjusted pressure control relief valve to set top and
RELIEF VALVE
bottom jaw hydraulic clamp pressure.
Manual ball valve to control system pressure set. Keep close for
BALL VALVE
full system pressure. Open to relieve at set pressure.
Document Number
352-000-04 17
IRON ROUGHNECK
MAKEUP AND BREAKOUT OPERATIONS

This section explains basic Iron roughneck operating procedures. The primary function of
the Iron Roughneck is to makeup and breakout drill string connections.
The IR3080 is not to be used as a backup or substitute for the

top drive. The IR3080 is designed for a specific purpose.
Using it for other than its intended purpose may cause
personnel injury or damage to equipment.
Start-Up Procedures
Prior to field start-up operation, check over the Iron Roughneck assemblies,
Hydraulic power unit and controls, to assure all components are included and in
a serviceable condition. Refer to the “Set-up and Installation” section for
Installation and check out procedures.
Provide all electrical connections from SCR to HPU to Remote Control Console
and from Remote Control Console to Roughneck.
Provide hydraulic pressure in accordance with the instructions provided for your
unit.
Check the "SYSTEM" pressure gauge on the Torque Setting Panel should
indicate 3000 psi.
Check the pressure set for the Top Jaw and the Lower Jaw. The top jaw and
lower jaw pressures must be set before adjusting torque or performing makeup
or breakout functions. Refer to “Adjusting the Jaw Pressure” section for jaw
pressure setting instructions.
Check the Make up and breakout torque set. The makeup and breakout torque
must be set using the Torque Setting Panel. Refer to “Adjusting the Makeup
Torque” section for makeup torque setting instructions.
Document Number
18 352-000-04
IRON ROUGHNECK
Positioning the Iron Roughneck for Operation

1. Choose either well center or mousehole as the destination for the Iron Roughneck,
as appropriate, using the Well Center/Mouse Hole selector switch located on the
Iron Roughneck Remote Control Console (RCC).
2. Loosen nut on the rotation ring at the base of Iron Roughneck and insert locking
pin through stop ring and base. Push Iron Roughneck into alignment with either
the mousehole or well center, as required.
Extend and position Iron Roughneck over Well Center or Mouse Hole; once the
roughneck is in proper position, tighten rotation ring lock nut (see Figure 3).
If Iron roughneck travels long or short see “Setting the Extend/Retract Limit Switch
(ERLS) J-Box”.
Figure 7 Rotation Stop Ring
Document Number
352-000-04 19
IRON ROUGHNECK
Document Number
20 352-000-04
IRON ROUGHNECK
Making Connections
Makeup Initial Position
Ensure the following parts of the Iron Roughneck are in the indicated positions prior to
normal makeup operation (Making Connections):
Drill pipe pin should be in box end of drill pipe.
The SYSTEM PRESSURE gauge should indicate 3000 PSI.
Iron Roughneck in Park/Standby position (Automated Arm assembly is retracted).
Either Well Center or Mousehole, as required, is chosen on the Well Center /

Mouse Hole selector switch, and extend / retract limit switches adjusted and the
Iron Roughneck lined up with the chosen destination.
Rotational Locking Pin inserted and Rotation Ring and Locking Nut set.
The SPINNER selector switch is in the “OFF” position.
The SPINNER ROTATION selector switch is set to the “IN” position.
Makeup torque is pre-set on Torque Setting Panel.
The Makeup/Breakout selector switch is in the “START” position or position “0”.
The BOTTOM JAW selector switch is in the “OPEN” position.
Document Number
352-000-04 21
IRON ROUGHNECK
Figure 8. Remote Control Console, Making Connections
Document Number
22 352-000-04
IRON ROUGHNECK
Making Connections
Normal Makeup Procedure
Unless stated otherwise, all controls mentioned below are those found on the Remote
Control Console (RCC) see Figure 8.
2. Starting with the IRON ROUGHNECK in the Makeup Initial Position (see Figure 3),
with the Torque Wrench jaws open, several feet from the drill pipe/drill collar, select
the IR MOVE IN / OUT switch and choose position OUT. Completely extend the Iron
Roughneck to the chosen out position (extend position), see Figure 4.
Hold the IR MOVE IN /OUT (extend/retract) switch until the

Iron Roughneck comes to the preset stop as set by the ERLS
box. Do not prematurely release the switch. Allow the Iron
! ! Roughneck to travel to its designated stopping position.
The IR MOVE IN/OUT function (extend/retract) will not work if

Bottom wrench, Top wrench or Spinner is closed.
3. If necessary, adjust the vertical height of the Iron Roughneck by operating the
WRENCH UP or DOWN control. Place the center of the top and bottom jaws at the
correct pipe joint connection position.
4. Rotate the "BOTTOM JAW" rotary selector switch to CLOSE position. The bottom
jaws will close around the drill pipe tool joint.
Ensure that the BOTTOM JAW of the torque wrench is

engaged to the drill pipe/drill collars before rotating the
spinner or the Top Jaw of the torque wrench. Failure to
observe this precaution can cause serious injury and / or
damage to the equipment.
5. Rotate the SPINNER ROTATION rotary selector switch to position “IN”.
6. Turn the SPINNER rotary selector switch to position “SPIN”. The spinner rollers will
grip, and after a brief delay, the spinner will begin to spin in the drill pipe.
Document Number
352-000-04 23
IRON ROUGHNECK
Making Connections
Normal Makeup Procedure (continued)
7. When the drill pipe is spun in, rotate SPINNER switch to the “OFF” position. The
spinner rollers will stop rotating and the spinner will release.
Makeup sequences will be controlled by rotation of Makeup /

! ! Breakout Selector switch in a CLOCKWISE direction.
8. Once the drill pipe has been spun in, rotate the Makeup/Breakout selector switch
clockwise from position “0” to position “1”. The top wrench will rotate to a starting
position for makeup. (Green Indicator should be on)
9. Rotate the Makeup/Breakout selector switch clockwise to position “2”. The top jaw
will close.
10. Rotate the Makeup/Breakout selector switch clockwise to position “3”. The top
wrench will rotate right ("make up"). Rotation will stop when the set torque is
reached or when the wrench reaches end of stroke. The red MAKEUP REPEAT
light will come on if torque is not reached by the end of the Top Wrench stroke. If
the wrench reaches its end of stroke before the set torque is reached, repeat steps
8-11. If the set torque is reached, the green MAKEUP COMPLETE light remains
green.
11. Rotate the Makeup / Breakout selector switch to position “0”. The top wrench will
open and return to the start position.
If MAKEUP COMPLETE light (green light) remains illuminated,

! ! no further makeup is required. If MAKEUP REPEAT light (red
light) illuminates, repeat steps 8-11.
12. Rotate the BOTTOM JAW switch to the “OPEN” position. The bottom jaw will open.
13. Rotate the IR MOVE selector switch to the “IN” position. The Iron Roughneck will
move away from the drill pipe/drill collar to the parking position. Place the Iron
Roughneck in position for next use, or turn off system, as required.
The IR MOVE OUT function (extend) will not work if Bottom

! ! wrench, Top wrench or Spinner is closed.
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IRON ROUGHNECK
Breaking Connections
Breakout Initial Position
Ensure the following parts of the IRON ROUGHNECK are in the indicated positions
prior to normal breakout operation (Breaking Connections):
The top drill pipe and bottom drill pipe are connected.
The SYSTEM PRESSURE gauge should indicate 3000 PSI.
Iron Roughneck in Park/Standby position (Automated Arm assembly is

retracted).
Either Well Center or Mousehole, as required, is chosen on the Well Center /

Mouse Hole selector switch, and extend / retract limit switches adjusted and the
IRON ROUGHNECK lined up with the chosen destination.
Rotational Locking Pin inserted and Rotation Ring and Locking Nut set.
The spinner selector switch is set to the “OFF” position.
The SPINNER ROTATION selector switch is set in the “OUT” position.
The Makeup/Breakout selector switch is in the “START” position or position “0”.
The BOTTOM JAW selector switch is in the “OPEN” position.
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IRON ROUGHNECK
Figure 9. Remote Control Console, Breaking Connections
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26 352-000-04
IRON ROUGHNECK
Normal Breakout Procedure
Unless stated otherwise, all controls mentioned below are those found on the Remote
Control Console (RCC) see Figure 9.
2. Starting with the Iron Roughneck in the Makeup Initial Position (see Figure 3), with
the Torque Wrench jaws open, several feet from the drill pipe/drill collars, select the
IR MOVE IN / OUT switch and choose position OUT. Completely extend IR to the
chosen out position (extend position) see Figure 4.
Hold the IR MOVE IN /OUT (extend/retract) switch until the

Iron Roughneck makes comes to the preset stop as set by the
ERLS box. Do not prematurely release the switch. Allow the
! ! Iron Roughneck to travel to its designated stopping position.
The IR MOVE IN/OUT function (extend/retract) will not work if

Bottom wrench, Top wrench or Spinner is closed.
3. If necessary, adjust the vertical height of the Iron Roughneck by operating the
WRENCH UP or DOWN control. Place the center of the top and bottom jaws at the
correct pipe joint connection position.
4. Rotate the BOTTOM JAW switch to the “CLOSE” position. The bottom jaw of the
Torque Wrench will close.
Ensure that the BOTTOM JAW of the torque wrench is

engaged to the drill pipe/drill collars before rotating the
spinner or the Top Jaw of the torque wrench. Failure to
observe this precaution can cause serious injury and / or
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IRON ROUGHNECK
Normal Breakout Procedure (continued)
Breakout sequences will be controlled by rotation of Makeup /

! ! Breakout Selector switch in a COUNTER CLOCKWISE
direction
5. Rotate the Makeup/Breakout selector switch counter-clockwise from position “0” to

position “3”. The top jaw will close.
6. Rotate the Makeup/Breakout Selector switch to position “2”. The top wrench will
rotate left – breakout. Rotation will stop when wrench reaches end of stroke.
7. Rotate the Makeup/Breakout Selector switch button to position “1”. The top jaw will
open.
8. Rotate the Makeup/Breakout Selector switch to position “0”. The top wrench will turn
right to the start position.
9. Rotate the SPINNER ROTATION rotary selector switch to position “OUT”.
10. Turn the SPINNER Rotary Selector Switch to position SPIN. Spinner rollers will grip,
and the rollers will start spinning the pipe. If spinner cannot spin pipe, open spinner
grip and repeat steps 5-8.
11. When pipe is spun out, rotate SPINNER Rotary Selector switch to OFF position.
Spinner will stop rotation and spinner rollers will release.
12. Rotate BOTTOM JAW switch to OPEN position. Bottom jaw will open.
13. Rotate the IR MOVE Selector switch to “IN”. The Iron Roughneck will move to the
parking position. Place the Iron Roughneck in position for next use, or turn off
system, as required.
The IR MOVE IN function (retract) will not work if Bottom

! ! wrench, Top wrench or Spinner is closed.
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IRON ROUGHNECK
Emergency Stop Procedures

If problems occur during operation, the operator can press the E-STOP button on the
RCC. This will shut off electrical power to the remote control console and/or the
hydraulic system (if the hydraulic power unit is wired in series with the Iron Roughneck
controls).
Start after Emergency Stop

After emergency shutoff, the operator should reset all controls to the normal Start
position an check for any hydraulic or electrical problems before pulling out the E-Stop
button a restarting the operation.
Document Number
352-000-04 29
Revision 02
SECTION 5:
MAINTENANCE
www.nov.com
IRON ROUGHNECK
General Safety
Precautions
Document Number
302-301-02
IRON ROUGHNECK
Document Number
2 302-301-02
IRON ROUGHNECK
TABLE of CONTENTS
GENERAL PRECAUTIONS AND SAFETY PRACTICES............................................................ 5
General Description................................................................................................................ 5
Basic Safety Precautions ....................................................................................................... 5
Safety Practices ..................................................................................................................... 8
SAFETY WARNINGS AND PRECAUTIONS............................................................................... 9
Hazard Descriptions and Safeguards................................................................................... 13
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IRON ROUGHNECK
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IRON ROUGHNECK
GENERAL PRECAUTIONS AND SAFETY PRACTICES

General Description
The Iron Roughneck is a lightweight, compact, modular roughneck, which is mounted on the
rig floor to perform makeup and breakout operations of drill pipe/drill collars. The Iron
Roughneck uses an operator-controlled, electrically powered Remote Control Console
generally located several feet away from the Iron Roughneck.
The Iron Roughneck is equipped with either a hydraulic powered Automated Arm Assembly
or a track mounted carriage to move the roughneck's makeup and breakout tools, toward the
well center or mouse hole, or retract the roughneck back to a standby / park position. A
column/guide assembly allows the roughneck to move in a vertical direction. If equipped with
an Automated Arm Assembly, the Iron Roughneck can also rotate to align with the mouse
hole.
The system’s makeup and breakout tools are hydraulic operated. The spinner assembly (if
equipped), which utilizes a floating suspension system, allows the spinner assembly to follow
drill pipe movement as threaded connections are spun in or out. The torque wrench
assembly, which utilizes a combination top wench and bottom wrench assemblies, apply the
clamp force to hold and torque the drill pipe to allow makeup or breakout the connections.
The upper centralizer (if equipped) grabs the drill pipe pin end and aligns it axially with the
drill pipe box end. The lower centralizer (if equipped) aligns the Iron Roughneck axially with
the drill pipe. Please note that centralizers are used when the ERLS junction box is not
available.
For your particular Iron Roughneck model specification, please refer to the "Technical
Specifications" section located in the Operation and Maintenance Manual.
Basic Safety Precautions
CAUTION
Be sure to read and follow these General Safety Precautions before proceeding with
operation or maintenance of the Iron Roughneck:
To minimize chances of personnel injury and equipment damage when working on

equipment, provide a safe working area and ensure all items being worked on are adequately
and correctly supported and / or blocked. All systems need to be isolated, shutdown and
tagged as "OUT OF SERVICE" before any procedures are done. When other than routine
servicing is necessary, it is suggested that, if possible, the unit or sub-assembly be relocated
to an area where ample workspace, tools and handling accessories are available.
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IRON ROUGHNECK

Basic Safety Precautions (continued)
All personnel repairing or servicing the Iron Roughneck should be trained in safety,
operation, and maintenance as applicable. Those operating the Iron Roughneck may carry
out preventive maintenance. Specialists should perform other more complex types of
maintenance. A qualified and experienced mechanic who is familiar with the equipment and
the proper use of appropriate tools to complete each task should perform the mechanical
inspection, service, and repair of the Iron Roughneck.
As mentioned earlier, all personnel performing operations or maintenance tasks of any kind
should be trained in both general safety and hazard recognition around a drilling rig, as well
as specific instructions pertaining to the particular rig they are working. All operators and
maintenance personnel should be versed in the specifics regarding performance
characteristics and limitations of all rig equipment.
Promote good safety measures at all times around the equipment and throughout all phases
of operations. It is the equipment owners’ / operators’ responsibility to establish good safety
measures including personnel training and enforcement of safety practices.
Never experiment. Before working with or on any equipment, study the circuit drawings,
manuals, and instructions to familiarize yourself with the equipment.
All personnel should be protected from exposed mechanical dangers such as guards
fabricated from expanded metal and other similar hazards. Safeguards such as keeping
hands, hair, clothing, jewelry, rags, tools, etc. away from all moving parts should be familiar
and a part of all activities.
Always use appropriate Personal Protective Equipment (PPE) during inspection, service, or
repair of the Iron Roughneck
Equipment used in heavy lifting and moving of the unit and accessories during maintenance
must be sufficiently rated to handle the weights involved.
Protect against accidental start-up during maintenance by taking such precautions as

padlocking the electrical gear.
Do not attempt equipment operation with inadequate visibility. Poor lighting, bad weather
conditions, or other reasons can aggravate this. If you cannot see what you are doing, then
do not do it!
Operating and maintenance personnel should wear suitable protective clothing in addition to
any other personal safety devices that conditions may dictate.
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IRON ROUGHNECK

Basic Safety Precautions (continued)
Never rush. Consider the effect beforehand of what will happen before opening or closing
valves or prior to working with a machine.
Make sure that all parts of the system are in a parked or otherwise safe position. Always
block up cylinders holding crossheads, slides, and so forth that cannot otherwise be made
safe.
Be aware of what fellow workers are doing. Make sure that the equipment operator checks
with you before starting the machine.
Any personnel who intend to operate the unit need to be trained on the Iron Roughneck’s
operating controls and have a thorough understanding of the limitations and functions of the
tool.
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IRON ROUGHNECK

Safety Practices
Always wear a suitable hard hat for prevention of head injuries.
Always wear suitable protective footwear.
Always wear safety glasses for eye protection.
Always stand clear of moving components.
Always exercise appropriate CAUTION with pressure-containing equipment such as piping,

hoses, pumps, accumulators, tanks, valves, fittings, etc., both fluid (oil, water, drilling fluid)
or pneumatic.
Before doing any maintenance or repair, be sure the unit is separated from all electrical
power, hydraulic power, and pneumatic pressure. Where appropriate, be sure that
pneumatic and/or hydraulic pressure is properly bled-off. Energy related accidents
could result in bodily injury or death.
Make sure all components of the service loop have proper clearance to prevent them
from hanging-up or becoming "snagged".
Make sure components of the service loop do not rub or wear on any other component,
whether on the Iron Roughneck, or the rig floor.
Maintain the proper torque on all threaded connections (Piping, hoses, bolts, nuts, and
fasteners). When replacing threaded fasteners, always replace with new ones of the
same designation
Replace worn or defective parts with National-Oilwell specified parts. This is to protect
personnel working in proximity with the Iron Roughneck as well as maintaining the life of
the equipment.
To avoid injury, ALWAYS remove rings, watches, loose hanging jewelry, and loose clothing
prior to beginning work on Iron Roughneck.
When working above floor level, always wear a suitable safety belt/harness properly
connected to an anchor or support that is capable of holding the individual's weight safely.
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IRON ROUGHNECK
SAFETY WARNINGS AND PRECAUTIONS

The safety warnings and cautions contained herein are typical, but are not the only types of
general precautions that should be observed during all phases of operation and
maintenance. Primary safety responsibility must always rest with the individual and / or
group of individuals that are on location performing the many tasks at hand and dealing with
all of the contributing factors that create a safe or an unsafe situation. Any unusual
circumstances or sequence of events should always dictate a common sense response that
will overcome hazardous situations.
If an item is designated a WARNING, failure to comply could cause serious injury or death.
This is always the case whether it is implicitly stated in the text or not. In the case of a
CAUTION, personal injury and / or equipment damage is always at stake.
The Iron Roughneck is not to be used as a backup for a

top drive, rotary table, tong, or any other equipment that
may induce an opposing torque on the wrench
DANGER assembly, unless otherwise approved by NOV
Engineering. Using the Iron Roughneck for anything
other than its intended purpose may cause personnel
injury or damage to equipment.
The Iron Roughneck is not to be used for anything other

than its intended purpose as described within this
WARNING manual. Failure to heed this warning could result in
injury to personnel and damage to equipment.
Exercise extreme caution when performing maintenance

on the hydraulic system. Fluid escaping under pressure
WARNING can easily cause serious injury or death to personnel
and / or damage to the equipment.
Leaking joints, fittings, and connections should only be

WARNING tightened when the pressure source is isolated and cut
off and the system is depressurized.
Always use caution when inspecting equipment. Begin

only when equipment is shut down and isolated, and
CAUTION tagged “OUT OF SERVICE.” Any accidental or poorly
timed operation can cause serious injury and / or death
to personnel and / or damage to the equipment.
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IRON ROUGHNECK
STAND CLEAR of the Iron Roughneck during operation.

In the place of physical protection, such as a guard, a
sign will be mounted on or around the area of the Iron
Roughneck. During situations where maintenance must
CAUTION be performed on the Iron Roughneck, refer a
maintenance procedures listed in the Operation and
Maintenance manual for scheduled maintenance and
repairs. Failure to heed this warning could result in
serious injury to personnel and damage to equipment.
All equipment should be shut down, isolated and tagged

“OUT OF SERVICE” before any maintenance procedure
CAUTION is performed. Any unexpected start-up of equipment
during procedure can cause serious injury or death to
personnel and / or damage to the equipment.
Do not wear loose clothing, unbuttoned shirts,

shirtsleeves, or neckties while working on moving
CAUTION assemblies. Moving parts can cause serious injury or
death to personnel and / or damage to the equipment.
Always use lifting equipment, supports, and chains with

a minimum capacity of one and a half times that of the
CAUTION object being lifted or supported. Serious injury or death
can result from falling or swinging equipment
Prior to equipment operation, ensure that no loose bars,

tools and parts are lying in or on parts of the unit, as
CAUTION they could cause serious injury or death to personnel
and / or damage to the equipment
For your own protection, DO NOT USE SUBSTITUTE

PARTS without the approval of National Oilwell Varco.
CAUTION Failure to use proper parts could result in serious injury
or death or damage to equipment
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IRON ROUGHNECK
The hydraulic tank RETURN connector MUST be

connected before any system is operated; failure to do
CAUTION so could cause reservoir drain, fluid starvation and
equipment damage
DO NOT grip polished area with tongs or any other

CAUTION gripping device. This could cause equipment failure
Use only specified fluid types. Use only fresh fluids that
CAUTION are free of contamination. DO NOT MIX FLUIDS. Failure
to follow this caution could result in equipment failure.
Exercise extreme caution when performing welding

maintenance on or near the Iron Roughneck System.
Connect the welder's ground cable such that the welding
current does not flow through the Iron Roughneck's
cables or structural assembly. This ground cable should
be made directly to or close as possible to the part being
Caution welded to prevent electrical current from passing
through bearings in the Iron Roughneck System as this
will result in bearing damage and premature bearing
failure. All power and control cabling should be
disconnected prior to performing welding. Failure to
observe this precaution will result in damage to
equipment.
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IRON ROUGHNECK
! NOTICE !
When cleaning, use only an approved solvent to prevent damage and / or
deterioration of the equipment.
! NOTICE !
When using Teflon tape, always start the wrap about two (2) threads away
from the opening. This will prevent Teflon contamination of the hydraulic
system
Document Number
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IRON ROUGHNECK

Hazard Descriptions and Safeguards
List of Common Hazards

AREA HAZARD SAFEGUARDS
All truck, trailer or skid-mounted
Equipment chassis assemblies and pieces of equipment should be
subassemblies should always be inspected prior secured with blocks and / or
Securing
to each operation. Undesirable movement and / moorings prior to operation. All
Equipment
or malfunctioning equipment can cause serious equipment should receive a
injury or death thorough inspection before any
operation.
Equipment that falls or swings while being hoisted Keep all people from under and
Equipment or lifted can crush body parts or bodies between around the machine or item
Handling itself and immovable objects, causing serious during hoisting or lifting
injury or death. operations.
Keep guards in place and in
Drive systems can cut off fingers and hands. If
good condition. Keep hands and
Drive clothing is caught in a moving part, it can drag the
clothing clear of the drive system
Systems entire arm or body into the main drive system,
cavity at all times when the drive
causing serious injury or death.
is in motion.
Avoid striking or puncturing any
of the component parts or
Hydraulic system parts and connection lines can
Hydraulic connections. When working in
contain high pressure that can cause serious
Systems the area, slowly bleed pressure,
injury or death in certain circumstances.
disconnect and tag, prior to any
work on the system.
Some electrical system parts and connection Ensure all electrical power is
lines can contain high voltage that may cause turned off prior to any electrical
Electrical
serious injury or death when grounded by you, work. Avoid striking or
Systems
most metal objects, water, or any other electrical puncturing any component parts
conductor. or electrical connections.
Failure to adequately maintain lubrication and / or Institute a complete lubrication
Lubrication
filtration systems can result in various types of program at regular intervals and
/ Filtration
catastrophic equipment failure that can cause thoroughly inspect all systems
Systems
serious injury or death. prior to operation.
Document Number
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IRON ROUGHNECK
Maintenance
Document Number
302-100-02
IRON ROUGHNECK
Document Number
2 302-100-02
IRON ROUGHNECK
TABLE OF CONTENTS
PREVENTIVE MAINTENANCE.................................................................................................... 5
General Preventive Maintenance ........................................................................................... 5
Iron Roughneck Preventive Maintenance............................................................................... 7
Hydraulic System Preventive Maintenance ............................................................................ 8
Electrical System Preventive Maintenance ............................................................................ 9
GENERAL ASSEMBLY MAINTENANCE ................................................................................... 10
Iron Roughneck General Maintenance................................................................................. 10
General Electrical Maintenance ........................................................................................... 11
Major Repairs and Modifications .......................................................................................... 12
FUNCTIONAL TESTING MAINTENANCE ................................................................................. 13
LUBRICATION AND MAINTENANCE ........................................................................................ 16
Lubrication and Maintenance Schedule ............................................................................... 16
Recommended Lubricants And Fluids.................................................................................. 17
Hydraulic Fluids ........................................................................................................... 17
General Lubricants ...................................................................................................... 18
GENERAL STORAGE GUIDELINES ......................................................................................... 19
Storing And Preservation Of Equipment............................................................................... 19
Long Term Storage of Iron Roughneck Equipment .............................................................. 19
Initial Storage Procedures: ................................................................................................... 21
Storage Removal Procedures: ............................................................................................. 22
Preparing Equipment For Operation After Storage .............................................................. 23
Document Number
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IRON ROUGHNECK
Document Number
4 302-100-02
IRON ROUGHNECK
PREVENTIVE MAINTENANCE
General Preventive Maintenance
Appropriate and correct service methods and repair procedures are essential for the
reliable operation oft the Iron Roughneck and related equipment, and especially for the
safety of the crew. This manual provides general directions for the Iron Roughneck
operations and for service and repair work.
All maintenance should be performed from a routine maintenance schedule that provides a
checklist of items and / or procedures to be followed and a time frame or frequency interval
that these tasks are to be performed. Simple checklists or series of checklists can be
prepared for maintenance personnel. The Preventive / Periodic Maintenance Table on the
following page presents such a routine schedule.
This manual cannot anticipate all possible variations in techniques, tool, parts, and in the
skill level of individuals operation or maintaining the Iron Roughneck. This manual cannot
provide advice, cautions, or warnings for every potential situation. Accordingly, you must
first establish that you will not comprise crew safety or the integrity of the equipment by
your choice of methods, tools, or parts.
Individual circumstances may dictate changes to the suggested maintenance intervals.

Maintenance time frames may be different for a rig operating in blowing sand, offshore, or
in an arctic setting. Other factors to consider include actual run time, how hard the machine
is being worked, and any other factors that would require more frequent maintenance.
Careful consideration and a tendency to do a little more than the minimum maintenance are
keys to reaping the benefits of a regular maintenance program.
Reference all applicable OEM literature sections for additional detailed maintenance
information on individual components and assemblies.
Before performing maintenance on, or disconnecting any high-pressure flanges, piping,

hoses or vessels, ensure the unit has been bled to “zero” pressure. Shut down, isolate, and
tag the system controls as “Out of Service” so that others cannot pressurize the system
during maintenance or repairs. Always consider possible sources of trapped pressure.
Observe similar procedures for electrical connections, ensuring the system is locked out
before attempting any maintenance.
Open all hydraulic lines carefully. Make sure that the drainage oil is caught in a bucket so it
does not spill on the floor or over the machine. Cover fittings and plugs with a rag and then
unscrew slowly.
Document Number
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IRON ROUGHNECK
General Preventive Maintenance
Sometimes the tubing will stick in the fitting even after the retainer nut is completely
unscrewed. Slightly tap the tubing or plug to ensure it is loose. Oil should then slowly begin
to run out of the break.
Following these rules will prevent an accident even if the mistake of opening a line under
pressure has been made, since there is a chance to re-tighten the fittings. Furthermore, the
oil will be caught on the rag and not leak onto the machine or floor.
Replace all tubing, hoses, fittings, and other parts with pieces of identical size and material,
since the hoses and seals for some types of fire-resistant fluids are not interchangeable
with those for petroleum fluids, and vice-versa.
In restarting the system, turn the pump over slowly by starting and stopping the electric
motor a number of times. If all piping connections are not secure, leaks will show up.
Furthermore, if a mistake in piping or valving has been made, the action of the machine
may be slow enough not to cause any damage. Always check out the function of the
machine before putting the machine to work.
Always keep oil leaks cleaned up. Tighten or replace all leaky fittings and gaskets.
Keep body away from direct contact with hoses, fittings, and hydraulic devices when a
piece of equipment is running. Bursting pipes can be dangerous. Oil escaping through a
very small hole can penetrate the skin if close contact is made.
Some individuals are allergic to hydraulic fluids, so reasonable care should be taken to
avoid or limit contact with bare skin and, especially, the eyes.
Never attempt to increase the output of a piece of equipment by adjusting the valving
beyond its rated capacity, pressure rating, or strength.
Document Number
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IRON ROUGHNECK
Iron Roughneck Preventive Maintenance
Preventive / Periodic Maintenance Table 1

EQUIPMENT MAINTENANCE PROCEDURES DAILY WKLY MONTHLY 6-MONTH YEARLY
• Inspect equipment during

operation, noting any
abnormal sounds or
vibrations. • • • • •
• Investigate any fluid leaks
and take action as
IRON necessary.
ROUGHNECK • Apply grease to all Zerk
fittings per grease • • • •
schedule chart, Figure 1.
• Visually inspect pipe
spinner rollers. Verify that
• • • • •
they are still within their
wear limit.
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IRON ROUGHNECK
Hydraulic System Preventive Maintenance

• Monitor gauges for

correct pressure.
• Check all filters and / or
screens.
• Remove all water and / or
foreign material, and • • • • •
replace fluid as
necessary.
• Check all lines and
connections for any leaks,
and repair as necessary.
• Observe equipment
during operation, noting
any abnormal sounds or
vibrations. Adjust if
necessary.
HYDRAULIC • Inspect main hydraulic
SYSTEMS reservoir for any
indication of • • • •
contamination. Clean and
renew as needed.
• Clean and flush all
system filters, screens
and traps.
• Inspect and clean all
connections and lines.
• Replace system hydraulic
fluid.
• Check, recalibrate and
pressure test all system
•
lines and instrumentation.
• Clean, adjust, and / or
replace any components
necessary.
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IRON ROUGHNECK
Electrical System Preventive Maintenance
• If calibration is needed for

any aspect of the Iron
Roughneck, Contact
ELECTRICAL National Oilwell. • •
SYSTEM
• Clean, adjust and / or
replace any components
necessary.
Document Number
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IRON ROUGHNECK
GENERAL ASSEMBLY MAINTENANCE

Iron Roughneck General Maintenance
Cleaning
Clean the assembly with water once per day. This removes accumulated mud. No other
normal cleaning is required except as detailed elsewhere in this section.
Lubrication Schedule
Zerk fittings on the Iron Roughneck shall be lubricated with appropriate grease. All moving
parts shall be lubricated. Threaded fasteners should be lubricated with anti-seize
compound.
Replacement of Wear Parts

The only user-replaceable parts on the Iron Roughneck are the Pipe Spinner Rollers, the
Torque Wrench jaw dies, and the Valve Manifolds in the Hydraulic Enclosure. These items
shall be replaced as required by the condition of the parts.
Main Overhaul
If the Iron Roughneck needs to be overhauled, contact National Oilwell.
Hydraulic Hose and Fittings

All hydraulic hoses (particularly those which flex during normal operation of the equipment)
should be visually inspected once every working day. A thorough inspection of all hoses,
fittings, and rigid tube lines should be made at least once a month.
! NOTICE !
Daily hydraulic line inspection should be a routine part of all active, in-service hydraulic
systems.
Any hose, fitting and / or rigid tube line deterioration should be carefully examined as to
whether further use of the component would constitute a safety hazard. Conditions such as
the following should be sufficient reason for consideration of replacement:
Any evidence of hydraulic oil leakage at the surface of a flexible hose at its junction
with the metal end couplings.
Any blistering or abnormal deformation of the outer covering of a hydraulic hose
Hydraulic oil leakage at any threaded or clamped joint that cannot be eliminated by
normal tightening or recommended procedures
If any evidence of excessive abrasion, or scrubbing is found on the outer surface of a hose,
rigid tube, or hydraulic fitting. Means shall be taken immediately to eliminate the
interference of the elements in contact or otherwise protect the components.
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IRON ROUGHNECK

General Electrical Maintenance
General Switch Maintenance
All the switches used in this system are standard equipment.
Inspection / maintenance on monthly basis:

Check / tighten all switches and switch mountings.
Check all switches for signs of moisture, dirt, and damage.
Electrical Checks / Maintenance

Inspection / maintenance on a monthly basis:
Check the equipment temperature by touching the equipment.
Check that all wiring and earth grounds are in perfect condition.
Check to ensure all switches are firmly in their mounting holes at their various
locations.
Inspection / maintenance on a yearly basis:

Check / tighten all terminals, plugs, and socket screws at least once a year to avoid
loose connections.
Electrical Faults
In case of operation failure, check that all associated signals are present. For lights, LED's
and indication of electrical faults refer to visual inspection / maintenance procedures listed
earlier in this chapter "GENERAL ASSEMBLY MAINTENANCE"
Document Number
302-100-02 11
IRON ROUGHNECK

Major Repairs and Modifications
Major repairs and modifications should only be performed by National Oilwell technicians.
Contact National Oilwell for additional information.
Document Number
12 302-100-02
IRON ROUGHNECK
FUNCTIONAL TESTING MAINTENANCE

The need for functional testing as a part of the periodic maintenance is dependent on the
frequency of use of each system or function (rarely used systems or functions should be
tested to ensure proper operation when needed). The user should evaluate the need of
such testing.
Functions that may need testing:
• All valves and motors rarely in use should be function tested as a part of the
periodic maintenance schedule.
• All repeated analog signals from other systems should be tested / simulated on a
periodic basis.
• All trip / not available and status signals from the distribution boards should be
tested as a part of the periodic maintenance.
• Sensors and field equipment should be calibrated once a year to maintain
accuracy of the measured and logged data. Assure that all sensor readout
instruments are checked / calibrated as part of the sensor calibration.
Document Number
302-100-02 13
IRON ROUGHNECK
Document Number
14 302-100-02
IRON ROUGHNECK
WEEKLY
between rollers
4 places
each side
WEEKLY
MONTHLY
each side
WEEKLY
each side
WEEKLY 3 MONTHS
WEEKLY
each side brush surface under
1 MONTH each side
cylinders with grease
remove 2 each side
top and bottom clamp rings
to access grease pionts
4 places
WEEKLY RN 300013
each side
Figure 1. Typical Arm Mounted Iron Roughneck Lubrication Grease Points

Document Number
15 302-000-02
IRON ROUGHNECK
LUBRICATION AND MAINTENANCE

Lubrication and Maintenance Schedule
DAILY
These procedures in many ways are the easiest of all maintenance procedures. It includes
all of the routine checks that allow for a full 24 hours of operation under optimum operating
conditions. Typical checks to include are (but are not limited to):
Inspect all areas with moving parts. Ensure they are free and clear of debris.
Check all fluid levels.
Ensure all instrumentation and controls are in good working order.
Check and grease all fittings and bearings.
Ensure all safety equipment is present and functional.
This list can, and in some cases, should contain more items and more detailed instruction,
but the list includes all normal day-to-day checks to ensure safe and reliable operation.
WEEKLY
Check and grease all fittings, bearings, and wear plates (see Figure 1).
MONTHLY
Check panel interiors for moisture, cleanliness, and damages.
Check all equipment for abnormal conditions, such as discoloration due to high
temperature, corrosion damage, etc.
Document Number
302-000-02 16
IRON ROUGHNECK

Recommended Lubricants and Fluids
Hydraulic Fluids
Use an anti-wear (AW) hydraulic fluid. Anti-Wear (AW) hydraulic oil is generally a mineral
oil product that contains anti-wear additives along with rust and oxidation inhibitors. The
following tables give the recommended grades for various operating temperatures for the
Iron Roughneck hydraulic systems.
Hydraulic Fluids must pour freely at minimum operating temperature. The Hydraulic Fluid
Pour Point should be at least 30°F (17°C) lower than the expected minimum ambient
temperature. If the ambient starting temperature approaches the Hydraulic Fluid Pour
Point, heaters may be required to facilitate starting and insure proper lubrication of
components.
Oil with a low pour point should be used when operation is to be in a low temperature
environment.
Oil operating temperature should not exceed 180° Fahrenheit.
Do not mix different brands or types of oils.
The oil level should be visible in the sight gauge.
The hydraulic reservoir should be maintained full at all times.
Document Number
302-100-02 17
IRON ROUGHNECK

Recommended Lubricants and Fluids
Hydraulic Fluids
Recommended Hydraulic Fluids, for minimum start-up and operating temperatures are as
follows:
Operating Temperature Range

10°F to 125°F (-12°C to 52°C)
First Choice: Hydraulic Oil – Premium grade with anti-wear and anti-rust additives.
Viscosity 49 SUS @ 210°°F (6.9 cSt @ 100°°C)
Viscosity Index 105
Pour Point -22°°F (-30°°C)
ISO/ASTM Viscosity
46
Grade
Operating Temperature Range

-22°F to 63°F (-30°C to 17°C)
First Choice: Hydraulic Oil – Premium grade with anti-wear and anti-rust additives.
Viscosity 49 SUS @ 210°°F (6.1 cSt @ 100°°C)
Viscosity Index 153
Pour Point -58°°F (-50°°C)
ISO/ASTM Viscosity
32
Grade
General Lubricants
Recommended General Lubricants, for general preventive maintenance are as follows:
Ambient Temperature Range

Above -4°F (Above -20°C)
NLGI Grade Number 2 Lithium base, general-purpose, extreme pressure grease.
Ambient Temperature Range

Below -4°F (Below -20°C)
NLGI Grade Number 1 Lithium base, general-purpose, extreme pressure grease.
Document Number
18 302-100-02
IRON ROUGHNECK
GENERAL STORAGE GUIDELINES

Storing and Preservation of Equipment
From time to time it may be necessary to remove equipment from service for extended
periods of time. It is highly desirable to perform some basic preservation procedures to
maximize the storage life of the equipment and minimize the expense of activating the
equipment after storage.
Long Term Storage of Iron Roughneck Equipment

Before leaving the factory, Iron Roughnecks are protected only for shipment to destination.
The following guidelines and procedures should be followed for storage after arrival or
extended storage (six months or longer) on the rig.
Safety:
Safety must be a prime consideration during application of any rust inhibitors, since they are
combustible and generate explosive vapors. Follow the manufacturers recommended safety
precautions. All personnel must understand these precautions and be properly protected.
TO AVOID PERSONAL INJURY DUE TO COMBUSTIBLE LIQUIDS AND

CAUTION VAPORS, FOLLOW MANUFACTURER'S RECOMMENDED SAFETY
PRECAUTIONS.
Storage Location:
Store the Iron Roughneck and accessories under cover, or indoors, if possible. Iron
Roughneck should be stored away from blowing dust, salt spray, sources of vibration, etc.
Also, avoid storage areas where rapid temperature changes occur - this causes
condensation.
Storage Position:
Store the Iron Roughneck its shipping skid. Racks or pallets should be used for all other
parts of the Iron Roughneck, to insure that they are off of the ground, concrete, etc.
Note: Care must be given to positioning of stored components to allow periodic

reapplication of rust inhibitors, rotating of machinery, etc.
Replace any locking pins prior to storage and/or

CAUTION transporting the Iron Roughneck. Failure to observe this
precaution can cause serious injury and / or damage to
the equipment.
Document Number
302-100-02 19
IRON ROUGHNECK

Long Term Storage of Iron Roughneck Equipment (continued)
Cleaning:
Steam cleaning is acceptable, but should be limited to painted surfaces. Unpainted
surfaces must be thoroughly dried and protected with rust inhibitors. Care must be used to
avoid getting steam or water into electric J-Boxes, hydraulic system, bearing housings,
bushings, etc. No diesel-based cleaners should be used in cleaning junction boxes or other
electrical items.
Table 1 - Long Term Storage Procedure Schedule

INITIAL 1.5
PROCEDURE 3 MONTHS 6 MONTHS
STORAGE MONTHS
1. Coat all exposed bare metal and moving parts with
rust preventative (dry-film type rust inhibitors can also
be used). Remove all covers/guards to gain access
to all moving parts when necessary. Rotate parts X X
involved while applying rust preventative to ensure
parts are fully coated. Make sure that covers/guards
are replaced after coating.
2. Grease all pins and grease points. Rotate parts
while applying grease to ensure parts are fully X X
coated.
3. Add/replace desiccant packs inside each electrical
X X
box.
4. Rotate all rolling elements, and raceways. To
prevent etching or staining.
All bearings must be fully packed with Lithium-based
number 2 EP grease before prolonged storage. In
addition, bearings must be rotated. This prevents X X
moisture migration, which causes corrosion and rust
of the rollers and races, and which leads to premature
(if not immediate) failure, depending on the amount of
corrosion and rust.
5. Perform recommended Lubrication and Maintenance
procedures as indicated the National Oilwell X X
Operation and Maintenance Manual.
6. Ensure that all connections and covers are tightly
X X
sealed.
7. Clean exterior of Iron Roughneck to remove all mud,
dirt or other foreign material. Remove any rust and X X
then coat area with red oxide or zinc rich primer.
Document Number
20 302-100-02
IRON ROUGHNECK

Initial Storage Procedures:
In addition to the items indicated in Table 1, perform the following procedures at initial long-
term storage of the Iron Roughneck:
Relieve all hydraulic pressure, and disconnect hydraulic supply lines.

Seal or plug exposed ends, hydraulic, and electrical connection ends.
Cover all electrical control boxes [remote control console, junction box(es), ect.] with
paper impregnated with a volatile-type inhibitor followed by thick black plastic
sheeting (at least .006" thick). All sharp corners should be protected with wood
blocking. Add desiccant packs to keep dry.
The Extend/Retract limit Switch (ERLS – if equipped) J-box and Solenoid Junction
Box will stay on the Iron Roughneck. Seal all openings with plastic NPT caps, and
add desiccant packs inside each box.
Document Number
302-100-02 21
IRON ROUGHNECK

Storage Removal Procedures:
Remove all protective covers, wrappings, and desiccant packs. Inspect for corrosion or
damage. Repair as required.
Remove all storage plugs.
Drain and flush all oil, preservatives, and inhibitors.
Change all filters and clean all strainers.
Check and replace as necessary all rubber/elastomer parts: hydraulic hoses, seals, etc.
Replace all parts removed for separate storage.
Fill all Hydraulic systems to correct levels with specified hydraulic fluids. For Hydraulic Fluid
Specifications, refer to the “Recommended Lubricants” located in this section of the Operation
and Maintenance manual.
Perform recommended Lubrication and Maintenance Procedures as indicated. Refer to

“Maintenance Schedule and Maintenance Inspection Procedures” located in this section of
the Operation and Maintenance manual.
Test HPU motor windings and service loop cables. Test is to be performed by a qualified
electrician prior to start-up.
Prior to starting and operating the Iron Roughneck, perform a thorough inspection and
checkout to verify that all of the Iron Roughneck's systems are fully functional and
operational before returning the Iron Roughneck to service. Refer to the “Maintenance
Inspection Procedures” located in this section of the Operation and Maintenance manual.
Allow adequate "RUN-IN" time, starting slowly with no load, to check the Iron Roughneck for
hidden damage or faulty operations.
Document Number
22 302-100-02
IRON ROUGHNECK

Preparing Equipment for Operation After Storage
Remove all protective coatings and materials. Replace all oil and grease. Inspect for and
remove all rust and corroded wiring. Perform all electrical and mechanical safety checks
prior to energizing the system. Ensure all controls are in a safe position.
Document Number
302-100-02 23
Revision 02
SECTION 6:
ASSEMBLIES
www.nov.com
IRON ROUGHNECK
Wrench Assembly
Document Number
402-000-04
IRON ROUGHNECK
Document Number
2 402-000-04
IRON ROUGHNECK
TABLE of CONTENTS
WRENCH ASSEMBLY DESCRIPTION ....................................................................................... 5
WRENCH ASSEMBLY MAINTENANCE ..................................................................................... 8
Replacing Dies in Top and Bottom Wrench Assemblies ........................................................ 8
Lubrication and Inspection ................................................................................................... 10
Lubrication Schedule ................................................................................................... 10
Inspection Schedule..................................................................................................... 11
Document Number
402-000-04 3
IRON ROUGHNECK
TOP
WRENCH
TORQUE
CYLINDER
BOTTOM
WRENCH
RN300015
Figure 1. Wrench Assembly
Document Number
4 402-000-04
IRON ROUGHNECK
WRENCH ASSEMBLY DESCRIPTION

The Wrench Assembly is the component used to apply makeup or breakout torque to the
pipe (drill pipe/drill collars) being handled. The wrench assembly is controlled at the Remote
Control Console by using the four-position Makeup/Breakout selector switch.
The Wrench Assembly consists of top and bottom wrench assemblies. The bottom wrench
assembly, which supports the top wrench assembly, is mounted to the automated arm
assembly. The top wrench and the bottom wrench use two opposing hydraulic cylinders to
force die heads against the tool joint of the pipe (drill pipe/drill collars), holding the pipe in
place.
The bottom and top jaw cylinders use two separate pressurized fluid supply lines to control
clamping.
Wrench Assembly Specifications and Parameters

Wrench Assembly Specifications
Length 36”
Width 56-7/8”
Height 27-1/8”
Weight 3300 lbs
Wrench Operational Parameters
Size Range of drill pip/drill collars handled 3-1/2” to 8-1/2”
Maximum torque (makeup) 60,000 ft - lbs
Maximum torque (breakout) 80,000 ft - lbs
Document Number
402-000-04 5
IRON ROUGHNECK
Bearing
Top Jaw
Manifold TW Body
Weldment
Stop Pin Cylinder
Rod Pin Stop
Jaw Dies
Cylinder Cylinder
(WD4)
Lock Plates Die Holder TOP WRENCH
ASSEMBLY
View without Torque Cylinder

TW top plate Assembly
Bottom Wrench
Assembly
RN300020
Figure 2. Top Wrench Assembly
Document Number
6 402-000-04
IRON ROUGHNECK
Rear
Wear Block
Front Front Top Wrench

Wear Block Wear Block Assembly
Torque Cylinder
View with Assembly
BW top plate
BOTTOM WRENCH
ASSEMBLY
Bottom Jaw
Manifold
BW
Stop Pin
Body
Rod Pin Weldment
Cylinder
Stop
Jaw Dies
Cylinder Cylinder
(WD4)
Lock Plates Die Holder
View without
BW top plate
RN300022
Figure 3. Bottom Wrench Assembly
Document Number
402-000-04 7
IRON ROUGHNECK
WRENCH ASSEMBLY MAINTENANCE

Replacing Dies in Top and Bottom Wrench Assemblies
Changing Top Jaw Dies:
1. Set the Top Wrench jaws to close by rotating makeup/breakout knob CCW to
position “3”.
2. Shutdown power with E-Stop switch. Turn off and lockout power to the Iron
Roughneck before proceeding with replacement of dies in the Top Wrench
assembly.
3. Remove retaining pins and upper lock plates and keep lower lock plate in place (see
note); slide jaw dies out. Remove one jaw die on each side, allowing other jaw die
on same side to also be removed (see figure 2).
Note: During disassembly and reassembly of jaw dies removal of lower lock plate is
not necessary.
4. Install new dies and re-pin lock plates.
5. Remove lockouts and turn on power to the Iron Roughneck.
6. Rotate Makeup/Breakout selector knob CC back to position “0”.
Lock Plate Pin

Retaining Pin
Lock Plate
Jaw Die
WD4
Wide Die Holder
RN300021
Figure 4. Changing Jaw Dies
Document Number
8 402-000-04
IRON ROUGHNECK
Replacing Dies in Top and Bottom Wrench Assemblies (continued)

Changing Bottom Jaw Dies:
1. Set the Bottom Wrench jaws to close by rotating Bottom Jaw rotary selector switch
to “CLOSE” position
2. Shutdown power with E-Stop switch. Turn off and lockout power to the Iron
Roughneck before proceeding with replacement of dies in the Bottom Wrench
assembly.
3. Remove retaining pins and upper lock plates and keep lower lock plate in place (see
note); slide jaw dies out. Remove one jaw die on each side, allowing other jaw die
on same side to also be removed (see figure 2).
Note: During disassembly and reassembly of jaw dies removal of lower lock plate is
not necessary.
4. Install new dies and re-pin lock plates.
5. Remove lockouts and turn on power to the Iron Roughneck.
6. Rotate bottom jaw switch back to “OPEN” position

“OUT OF SERVICE” before any maintenance procedure is
CAUTION performed. Any unexpected start-up of equipment during
procedure can cause serious injury or death to personnel
Document Number
402-000-04 9
IRON ROUGHNECK
Lubrication and Inspection

For Lubrication and Hydraulic Fluid Specifications, refer to the “Recommended Lubricants
and Fluids” section located in Maintenance section in this manual. Always clean grease
fittings before pumping grease to help prevent contaminants from entering the system and
to increase the life of the components.
CHECK
FREQUENCY PROCEDURES TYPE
POINT
Grease cylinder pin fittings with 1 - 3
DAILY 1 NLGI Multipurpose Grease
strokes of a hand-operated grease gun.
Brush all moving surfaces parts with
WEEKLY 2 NLGI Multipurpose Grease
grease.

Document Number
10 402-000-04
IRON ROUGHNECK
Inspection Schedule
Perform Inspection at scheduled intervals as noted in inspection table.
CHECK
FREQUENCY PROCEDURES
POINT
3 Visually inspect Jaw Dies.
Flush out any drill mud, which may accumulate around the jaw dies or under the
DAILY 4 jaw cylinders, and in between the top jaw and bottom jaw assemblies. Use wire
brush as needed to keep jaw dies clean of metal shavings.
5 Check all hose and fitting for hydraulic oil leakage.
Visually inspect for loose or missing retention hardware. Make sure that all bolts,
6 washers, and hex nuts are secured and secondary locking device intact.
WEEKLY
7 Visually inspect that all pins and cotter pins are secured, and intact.
Inspect all hoses, fittings thoroughly for any evidence of chaffing or hydraulic oil
MONTHLY 8 leakage. Replace if necessary.
SEMI- Inspect hydraulic cylinder thoroughly for hydraulic oil leakage or damage, Repair
9 or replace if necessary.
ANNUAL
! NOTICE ! Inspect jaw dies frequently and replace if worn or damaged.
CAUTION Keep hands clear of Jaw Dies while dies are extending.
Maintain the original security devises, such as; safety wire,

CAUTION cotter pins lock nuts, retaining rings, loctite, ect. To prevent
parts from vibrating loose and falling.
All equipment should be shut down, isolated and tagged “OUT

OF SERVICE” before any maintenance procedure is
procedure can cause serious injury or death to personnel and
/ or damage to the equipment.
Document Number
402-000-04 11
IRON ROUGHNECK
Spinner Assembly
Document Number
402-100-03
IRON ROUGHNECK
Hydraulic Hydraulic
Motor Cylinder
Drive Roller
RN300016
Figure 1. Spinner assembly
Document Number
2 402-100-03
IRON ROUGHNECK
SPINNER ASSEMBLY DESCRIPTION

Spinner Assembly
The Spinner is mounted above the Wrench Assembly (see figure 1) and is used to spin
a drill pipe/drill collar connection IN prior to makeup torquing, and spin a drill pipe/drill
collar connection OUT after breakout torquing.
The pipe spinner has four sets of two drive rollers each. Two hydraulic motors drive
each set. This system can reach and centralize any diameter drill pipe/drill collar
between 3-1/2" to 8-1/2" size. The clamping is done with one hydraulic cylinder.
Spinner Support Assembly

The Spinner Support Assembly (see Figure 2), which supports the Spinner Assembly is
socket mounted to the Wrench Frame Assembly. The Spinner Support assembly, which
utilizes a floating suspension system, allows the spinner assembly to follow drill pipe/drill
collars movement as threaded connections are spun in or out.
Pipe Spinner Specifications and Parameters

Pipe Spinner Assembly Specifications
Length 36-5/8"
Width 35"
Height 26-1/2"
Weight 1250 lbs
Hydraulic Pressure Line 3/4" ID
Hydraulic Return Line 3/4" ID
Pipe Spinner Operational Parameters
Size Range of drill pipe/drill collars handled 3-1/2" to 8-1/2"
Maximum Spinner rpm 80 rpm (On 5-1/2" Drill Pipe)
Maximum Spinner Torque 2250 ft - lbs
Document Number
402-100-03 3
IRON ROUGHNECK
Spring Suspesion
Spring Assembly Assembly
Head Support Upper Pin
Spinner Assembly
Balance Spring
Wrench Frame
Interlock Spring Assembly
Pin Hole Lower Pin
RN300023
Figure 2. Spinner and Support Assembly
Document Number
4 402-100-03
IRON ROUGHNECK
SPINNER ASSEMBLY MAINTENANCE

Lubrication and Maintenance
For Lubricant and Fluid specifications, refer to the “Recommended Lubricants and
Fluids” section in this manual.
Daily:
1. Visually inspect Drive Rollers.
! NOTICE !
Inspect Drive Rollers frequently and replace if worn or damaged.
2. Flush out any drill mud, which may accumulate around the drive rollers or between
the inside of the spinner weldment and under the spinner hydraulic cylinder.
3. Use wire brush as needed to keep drive rollers clean of metal shavings.
4. Check all hose and fitting for hydraulic oil leakage.
Keep hands clear of Drive Rollers while Drive Rollers are

CAUTION rotating.
Weekly:
1. Inspect hydraulic motors for hydraulic oil leakage.
2. Apply grease to each grease fittings between the drive rollers (4 places) with 1-3
pumps of a hand-operated grease gun.
Monthly:
1. Inspect for loose, missing, or unsecured fasteners and take correction action to
tighten and secure parts.
2. Inspect all hoses, fittings thoroughly for any evidence of chaffing or hydraulic oil
leakage. Replace if necessary.
3. Inspect drive rollers for wear or damage. Replace if necessary.
Document Number
402-100-03 5
IRON ROUGHNECK
Semi-Annual (Every 6 Months)

1. Inspect hydraulic motors thoroughly for hydraulic oil leakage or damage. Repair or
replace if necessary.
2. Inspect hydraulic cylinders thoroughly for hydraulic oil leakage or damage. Repair or
replace if necessary.
Maintain the original security devises, such as; safety

CAUTION wire, cotter pins lock nuts, retaining rings, loctite, ect. To
prevent parts from vibrating loose and falling.

“OUT OF SERVICE” before any maintenance procedure
CAUTION is performed. Any unexpected start-up of equipment
during procedure can cause serious injury or death to
personnel and / or damage to the equipment.
Document Number
6 402-100-03
IRON ROUGHNECK
Column/Guide/Arm
Assembly
55" Reach
Document Number
402-200-02
IRON ROUGHNECK
Document Number
2 402-200-02
IRON ROUGHNECK
DESCRIPTION ....................................................................................................................... 5
General Arrangement ....................................................................................................... 5
Major Component Description .......................................................................................... 7
Column Assembly..................................................................................................... 7
Rotate Column Assembly ......................................................................................... 7
Guide Assembly........................................................................................................ 8
Arm Assembly........................................................................................................... 9
Hydraulic circuit Components ................................................................................. 11
Inline Hydraulic High-Pressure Filter ............................................................ 11
Wrench Lift Cylinder ..................................................................................... 11
Wrench Lift Manifold Assembly .................................................................... 11
Move In-Out Cylinders.................................................................................. 11
Move In-Out Manifold Assembly................................................................... 11
Rotation Manifold Assembly ......................................................................... 11
OPERATION......................................................................................................................... 12
Rotate Column Assembly ....................................................................................... 12
Setting the Rotation Target Switches ........................................................... 12
Positioning Hydraulic Rotation Column Assembly........................................ 13
Rotation Manual Override............................................................................. 14
Conventional Column Assembly............................................................................. 16
Positioning Conventional Column Assembly ................................................ 16
Lubrication and Inspection ................................................................................................ 17
Lubrication Schedule ...................................................................................................... 17
Inspection Schedule........................................................................................................ 18
Document Number
402-200-02 3
IRON ROUGHNECK
Figure 1. Column/Guide/Arm Assembly General Arrangement (typical)
Document Number
4 402-200-02
IRON ROUGHNECK
DESCRIPTION
The column-guide-arm assembly is a mechanical positioning unit of the Iron Roughneck system. At
various times during drilling operations, the Iron Roughneck System needs to be moved between several
locations on the rig, including the well centerline, one or more mouse holes, and a parking or storage
position. The Iron Roughneck's positioning movements are achieved by the column-guide-arm assembly.
The column-guide-arm assembly provides the vertical and horizontal movement of the Iron Roughneck.
All extend, retract, or lift operational movements for positioning the Iron Roughneck systems to the rig
positions, are controlled through a remote electro-hydraulic control system, or by the onboard manual
override hydraulic control system. Additionally, the automated arm section of the column-guide-arm
assembly holds the wrench assembly in the vertical position at all extension points.
General Arrangement
The Iron Roughneck's Column-Guide-Arm Assembly consists of the following assemblies and
components: Column Assembly; Guide Weldment; Arm Assembly; and hydraulic components.
The column assembly consists of a column base, column weldment and column turntable bearing. The
column bearing is mounted directly between the column base and column weldment surfaces. Equipped
on some models is a turntable bearing with an external gear for Column Rotation Systems. The column
assembly is attached into the drill floor by means of the column base that is stabbed into a socket mount
in the rig floor.
The guide assembly is mounted over the column structure and a self-balanced, automated arm assembly
is attached to the column guide assembly at a first connection point with a wrench assembly attached at
a second connection point. A pair of hydraulic cylinders is used for extension and retraction of the arm
assembly and a single trunnion mounted cylinder is used for the guide assembly lift.
Hydraulic circuit components properties vary on some models refer to the hydraulic schematic diagram in
the parts list section of the manual for rig specific column-guide-arm hydraulic circuit components.
Document Number
402-200-02 5
IRON ROUGHNECK
Figure 2. Column Assemblies (typical)
Document Number
6 402-200-02
IRON ROUGHNECK
Major Component Description

Column Assembly
The column assembly provides four key functions to the operations of the Iron Roughneck.
First, the Iron Roughneck's column base assembly is mounted into the drill floor socket, which
provides structural support for the Iron Roughneck.
Secondly, the column structure lower end provides an attachment point for the guide assembly lift
cylinder.
Third, the column weldment is fitted with two track rails to support the guide frame weldment and to
provide a guiding surface on which the guide assembly cam follower bearings ride against for vertical
and linear travel.
Fourth, when in a connection operations the column’s turntable bearing allows the Iron Roughneck
system to be positioned easily between orientation points of well center, mousehole, and park
position.
Rotate Column Assembly
Some IR models are equipped with a remote hydraulic rotation column system (see Figure 2). This
feature allows the Iron Roughneck to be hydraulic rotated around the turntable until it stops
automatically at one of the rotation index position points (well center or mousehole).
To rotate the column assembly, hydraulic power is applied to the drive motor, which in turn drives the
pinion gear. Since the ring gear bearing assembly is bolted directly between the column base and
column weldment seating surfaces the pinion gear and drive motor rotate around the ring gear, which
allows for precise positioning and stopping around the column assembly.
The column rotation system consists of a column structure weldment with a drive motor mounting, a
hydraulic drive motor with brake, a pinion gear and ring gear. The ring gear is part of the turntable
bearing assembly. The column rotation system brake is used to hold the Iron Roughneck's column
assembly in a park position during connection operations are being preformed.
Document Number
402-200-02 7
IRON ROUGHNECK
Guide Assembly
The Guide Assembly provides two key functions to the operation of the Iron Roughneck system. First,
the Guide Assembly lifts the Iron Roughneck tools vertically, and in addition also transfers the Iron
Roughneck load to the column structure. The hydraulic cylinder provided with the column-guide-arm
assembly is used to perform the guide assembly lifting operations. Secondly the Guide Assembly
provides the pivotal connection points for the Arm Assembly Links and extend-retract hydraulic
cylinders.
The guide assembly which is directly mounted to the column structure consists of a guide weldment
frame with four cam follower bearings and wear pads. The Guide frame guide pads are dimensionally
space against the column guide track for cam follower bearing alignment and loading. The trunnion
mounted lift cylinder that lifts the guide assembly vertically along the column's guide tracks is
attached to guide frame at one connection point with lift cylinder's second connection point attached
at the column weldment base.
Figure 3.. Guide Frame Assembly (typical)
Document Number
8 402-200-02
IRON ROUGHNECK
Arm Assembly
Figure 4. Arm Assembly
Document Number
402-200-02 9
IRON ROUGHNECK
Arm Assembly
The Iron Roughneck's Automated Arm assembly utilizes a hydraulic self-balanced, dual synchronized
four-sided arm assembly that is equipped with two hydraulic cylinders, to extend or retract the arm
links, and one hydraulic cylinder to lift the guide assembly. The Iron Roughneck Automated Arm
Assembly allows Iron Roughneck's wrench and spinner assemblies to be positioned horizontal and
vertical during drilling operations.
The Iron roughneck's Arm Assembly Links are a group of linking arms that are connected in a parallel
linking arrangement consisting of six link arms that are joined to a center connecting weldment that
hold the link arms parallel with a common axis. The Arm Assembly Links allow the Iron Roughneck's
wrench and spinner assemblies to reach maximum extension distance and rotation points between
well center, mousehole, and parking positions.
The Arm Assembly Links allow the Iron Roughneck's Automated Arm Assembly to travel in a linear
direction parallel to the drill floor, and allows the Automated Arm Assembly to retract into a compact
envelope to park the Iron Roughneck wrench and spinner assemblies during drilling operations.
Figure 5. Automated Arm Retract and Extend Positions
Document Number
10 402-200-02
IRON ROUGHNECK
Hydraulic circuit Components
! NOTICE !
Iron Roughneck equipment features may vary on some models. Refer to the hydraulic schematic
diagram in the parts list section of this manual for IR hydraulic components requirements.
Inline Hydraulic High-Pressure Filter

Mounted on the guide frame assembly directly below the lower left link assembly is an inline hydraulic
high pressure filter assembly with a visual indicator. The Iron Roughneck’s onboard hydraulic high
pressure filter assembly is immediately down stream from the Iron Roughneck’s hydraulic inlet
connection. The inline hydraulic high pressure filter is used to filter the hydraulic supply fluid prior to
circulating through the Iron Roughneck’s hydraulic components.
Wrench Lift Cylinder
Mounted on the guide frame assembly is a Lift Cylinder, which is used to lift the guide assembly
vertically to position the Iron Roughneck wrench and spinner assemblies.
Wrench Lift Manifold Assembly
Mounted down stream from the lift cylinder is a wrench lift manifold assembly with cartridge type relief
valve, counterbalance valve and flow valve. The relief valve is used to set the “up load” hydraulic
pressure setting to the lift cylinder. The counterbalance valve, is used to prevent an “over running”
load from moving the lift cylinder. The flow valve, is used regulate the hydraulic flow to the lift
cylinder.
Move In-Out Cylinders
Mounted on the guide frame assembly are two hydraulic cylinders, which are used to extend or
retract the automated arm assembly.
Move In-Out Manifold Assembly
Mounted down stream from the move in-out cylinders is a move in-out manifold assembly with
cartridge type cross over relief valves and pilot operated check valve. The cross-over relief valves are
used to set extend and retract hydraulic pressure setting to the move in-out cylinders. The pilot
operated check valve in the move in-out manifold assembly is used to hold the load. Mounted down
stream from the move in-out manifold assembly on each side of the move in-out hydraulic circuit are
two needle valves. The primary functions of the needle valves are to regulate the hydraulic flow to the
move in-out cylinders. The needle valves are factory set and normally no further adjustment is
required unless the move in-out cylinders and/or the valves has been serviced or repaired.
Rotation Manifold Assembly
Mounted on the guide frame assembly on some models is a rotation manifold assembly, which is
used to control the column assembly hydraulic rotation circuit. The rotation manifold assembly is an
integrated hydraulic manifold with directional valves, counterbalance valves, shuttle valves .pressure
reducing relief valve and a hand pump for manual override to allow rotation operations to be
controlled locally at the rotation manifold assembly.
Document Number
402-200-02 11
IRON ROUGHNECK
OPERATION
Setting the Rotation Target Switches
The rotation target sensors are used for rotation index positioning to position the Iron Roughneck to
the well center or to the mousehole locations. The rotation sensor components consist of a rotation
target switch and a magnetic rotation target.
The following procedure shows how to adjust the rotation sensor components. The rotation sensors
components are shown on Figure 2.
To adjust the rotation target switch and target:
1. Remove the screws and lock washers from the rotation target and remove the rotation targets
from their mounting surface on the column base upper plate.
2. Rotate the column to the direction of the first index point position (well center). Since the
proximity position points of rotation need to be first set up estimate the stop location and
extended the tools to reach and center up to the location position by toggling the Iron
Roughen to the correct orientation. Once the reach and rotation of the tools are center
proceed to set rotation target switches.
3. Select the nearest mounting target location on the column base upper plate, and install the
first rotation target. Install the target so that the target is mounted within proximity range below
fist target switch.
4. Make sure the rotation target is lined up with the target switch sensor.
5. Loosen the clamp holding the target switch sensor.
6. Adjust the first target switch sensor by sliding it up or down to achieve a gap of 1/4" between
the target switch sensor and the rotation target.
7. Tighten the clamp holding the target switch sensor.
8. To adjust the column's second index point position (mousehole) repeat steps 2 – 7.
9. Repeat the adjustments as necessary.
10. Verify the rotation operation. Ensure that the column rotates and stops at target position
settings (well center and mousehole positions).
Do not rotate the column more than what the Iron Roughneck will
allow with service loops connected. Otherwise, kinking of the
CAUTION service loops can cause premature failure and/or damage to the
equipment.
Document Number
12 402-200-02
IRON ROUGHNECK
OPERATION
Positioning Hydraulic Rotation Column Assembly
The following procedure shows how to position the hydraulic rotation column assembly to the well
center or to the mousehole position.
1. Ensure that the 2-way, manually-operated directional valve (DAAM-1) on the rotation manifold
is in the UNLOCK position for normal connection operation. To shift the valve twist the knob
to the detented position as labelled on the knob. Twist Counter-clockwise to lock and
clockwise to unlock.
2. Ensure that the 2-way 2-position DAMM-2 valve on the rotation manifold is in the LOCK
position for normal connection operation. To shift the valve twist the knob to the detented
position as labelled on the knob. Twist Counter-clockwise to lock and clockwise to unlock.
3. Choose either well center or mousehole as the destination for the Iron Roughneck, as
appropriate, using the Well Center/Mouse Hole selector switch located on the Iron Roughneck
Remote Control Console (RCC).
4. Shift the IR rotate selector switch on remote control console to rotate Iron Roughneck into
alignment with either the mousehole or well center, as required.
If Iron roughneck rotates past or rotates short of the rotation targets see "Setting the Rotation
Target Switches" in this section.
5. Extend and position Iron Roughneck tools over Well Center or Mouse Hole; once the
roughneck is in proper target position,
If Iron roughneck tools travels long or short see “Setting the Extend/Retract Limit Switch (ERLS)
J-Box” in the "General Operating Procedures" section of this manual.
Document Number
402-200-02 13
IRON ROUGHNECK
OPERATION
Rotation Manual Override
The Iron Roughneck rotation column assembly is equipped with a manual override to allow rotation
operations to be controlled locally at rotation manifold (see Figure 5). In the event of a power down of
the Iron Roughneck, or if a failure has occurred preventing the remote controlled hydraulic rotation
system from being operated from the remote control console location, follow the manual rotation
override instructions to manually rotate the Iron Roughneck to or away from the index rotation set
position.
Figure 6. Rotation Manifold Valve Assembly
Document Number
14 402-200-02
IRON ROUGHNECK
OPERATION
Rotation Manual Override (continued)
To Operate the Rotation Manifold Over Ride System:
The following procedure shows how to position the hydraulic rotation column assembly to the well
center or to the mousehole alignment positions manually.
1. Ensure that the 2-way, manually-operated directional valve (DAAM-1) on the rotation manifold
is in the LOCK position for manual override operations. To shift the valve twist the knob to the
detented position as labelled on the knob. Twist Counter-clockwise to lock and clockwise to
unlock.
2. Ensure that the 2-way manually-operated directional valve (DAMM-2) on the rotation manifold
is in the UNLOCK position for manual override operation. To shift the valve twist the knob to
the detented position as labelled on the knob. Twist Counter-clockwise to lock and clockwise
to unlock.
3. To manually pressurize the rotation circuit slowly push the hand pump handle downwards.
This will release and hold the brake off only.
4. Then manually push the Iron Roughneck into alignment to either the mousehole or well
center, as required.
When override operations have been completed. Return the 2-way manually operated
directional valves to the normal operation position. Twist Counter-clockwise to lock and
clockwise to unlock.
Document Number
402-200-02 15
IRON ROUGHNECK
OPERATION
Conventional Column Assembly
Positioning Conventional Column Assembly
1. Choose either well center or mousehole as the destination for the Iron Roughneck, as
appropriate, using the Well Center/Mouse Hole selector switch located on the Iron Roughneck
Remote Control Console (RCC).
2. Loosen nut on the rotation ring at the base of Iron Roughneck and insert locking pin through
stop ring and base. Push Iron Roughneck into alignment with either the mousehole or well
center, as required.
3. Extend and position Iron Roughneck tools over Well Center or Mouse Hole; once the
roughneck is in proper target position, tighten rotation ring lock nut (see Figure 3).
If Iron roughneck travels long or short see “Setting the Extend/Retract Limit Switch (ERLS) J-
Box”.
Figure 7. Positioning Conventional Column Assembly
Document Number
16 402-200-02
IRON ROUGHNECK
LUBRICATION AND INSPECTION

For Lubrication and Hydraulic Fluid Specifications, refer to the “Recommended Lubricants and Fluids”
section located in Maintenance section in this manual. Always clean grease nipples before pumping
grease to help prevent contaminants from entering the system and to increase the life of the
components.
CHECK
FREQUENCY PROCEDURES TYPE
POINT
Grease all linkage pin fittings.
1 (1 fitting/linkage pin each side) with 1 - 3 NLGI Multipurpose Grease
strikes of a hand-operated grease gun.
DAILY
Grease all cylinder pin fittings.
2 (1 fitting/cylinder pin each side) with 1 - 3 NLGI Multipurpose Grease
strokes of a hand-operated grease gun.
Grease all vertical track cam followers.
3 (1-fitting/ cam follower 2 each side) with 1 - NLGI Multipurpose Grease
3 strokes of a hand-operated grease gun.
Grease the Rotating Bearing on the
Vertical Track Assembly. Apply several
strokes of grease to the fittings, rotate the
MONTHLY Vertical Track Assembly, and apply several
more strokes. Repeat pumping grease and
4 rotating the Vertical Track Vertical Track NLGI Multipurpose Grease
Assembly to distribute the grease until
grease is visible around the top of the
rotating bearing seal.
Note: Remove top and bottom clamp rings
to access grease points.
All equipment should be shut down, isolated and tagged “OUT OF

SERVICE” before any maintenance procedure is performed. Any
CAUTION unexpected start-up of equipment during procedure can cause
serious injury or death to personnel and / or damage to the
equipment.
Document Number
402-200-02 17
IRON ROUGHNECK
COLUMN/GUIDE/ARM LUBRICATION AND INSPECTION

Inspection Schedule
CHECK
FREQUENCY PROCEDURES
POINT
5 Check all hose and fitting for hydraulic oil leakage.
DAILY Check the inline hydraulic filter. Replace as necessary if the indicator
6
indicates is red.
Visually inspect for loose or missing retention hardware. Make sure that
7 all bolts, washers, and hex nuts are secured and secondary locking
WEEKLY device intact.
8 Visually inspect that all pins and cotter pins are secured, and intact.
Inspect all hoses, fittings thoroughly for any evidence of chaffing or
MONTHLY 9
hydraulic oil leakage. Replace if necessary.
Change the Inline Hydraulic high-pressure filter element. Check the seal
on the filter and replace as necessary.
Note: Typically, filter elements are changed when necessary, or when

QUARTERLY 10 speed is noticeably reduced for normal operation.
• First, filter element change after the first 40 hours of operation.
• Then, every 500 operating hours or quarterly.
SEMI-
ANNUAL Inspect all hydraulic cylinders thoroughly for hydraulic oil leakage or
11
Every 6 damage, Repair or replace if necessary.
Months
12 Inspect for worn linkage bushings.
YEARLY
13 Inspect for worn side guide pads.
Maintain the original security devises, such as; safety wire, cotter
CAUTION pins lock nuts, retaining rings, loctite, ect. To prevent parts from
vibrating loose and falling.
Exercise extreme caution when performing maintenance on the

hydraulic system. Fluid escaping under pressure can easily cause
WARNING serious injury or death to personnel and / or damage to the
equipment.
Document Number
18 402-200-02
IRON ROUGHNECK

Assembly
Document Number
402-300-04
IRON ROUGHNECK
Document Number
2 402-300-04
IRON ROUGHNECK
TABLE of CONTENTS
REMOTE CONTROL CONSOLE................................................................................................. 5
Remote Control Console Controls.......................................................................................... 7
Remote Control Console Start-up Procedure ......................................................................... 8
MAINTENANCE ......................................................................................................................... 10
Specified Cleaning Methods................................................................................................. 10
Inspection Schedules ........................................................................................................... 10
Document Number
402-300-04 3
IRON ROUGHNECK

(RCC)
RN300024
Figure 1. Remote Control Assembly
Document Number
4 402-300-04
IRON ROUGHNECK
REMOTE CONTROL CONSOLE

The remote control console (RCC) shown in Figure 1 is typical of those provide by National
Oilwell Varco. The operator can perform makeup and breakout of drill pipe/drill collar
connections using the RCC. The RCC is either freestanding on the drill floor or located in
or close to the Driller's Cabin, and positioned to where the jaws of the IR can be observed
while operating the Iron Roughneck. The remote control console panel contains the IR
selector switches, Emergency stop pushbutton switch, status lamps, and readouts to
operate the Iron Roughneck.
The remote control console (RCC) contains the control circuitry that controls the
movements of various mechanical components of the Iron Roughneck. All operational
movements of the IR are controlled by one operator. These movements are controlled by
appropriate inputs from the operator’s remote control console (RCC) and positioning limit
sensors.
The IR operator can perform following actions from the remote control console (RCC):
Extend or retract the IR automated arm assembly.
Raise or lower the wrench assembly.
Clamp or unclamp the bottom or top jaws.
Actuate the make and break torque cylinder.
Actuate the grip rollers and rotation of the spinner assembly.
Stop the IR and shutdown the hydraulic and electrical systems.
! ! Jaw pressure setting is controlled from the torque setting panel.
All signal, control and power wiring connect to the RCC enters and leaves through the
cable entry ports of the cabinet. A 24 VDC, 10 AMP, power supply source is connected to
the RCC, and the plug and cable assembly connects the RCC to the Iron Roughneck
solenoid J-Box. Refer to the electrical control system documentation and electrical
diagrams for detail electrical information.
Document Number
402-300-04 5
IRON ROUGHNECK
RN300003
Figure 2. Typical Remote Control Console Panel
Document Number
6 402-300-04
IRON ROUGHNECK
Remote Control Console Controls

Controls and indictors are located on the panel board of the remote control console
assembly (see Figure 2).
Table 1 describes the RCC panel controls and their functions.

Table 1.
CONTROL RESPONSE
Pushing in shuts down hydraulic system. Pulling it out allows
E-STOP
hydraulic system to restart.
MAKEUP/BREAKOUT Rotary
Allows operator to control the operation of the Torque Wrenches.
Selector Control
WRENCH – UP / DOWN Rotary
Sends Torque Wrench up or down to level desired.
Selector Switch
OFF position causes spinner to open up and disengage from
SPINNER OFF / GRIP / SPIN Rotary tubular. GRIP causes spinner to close onto tubular. SPIN
Selector Switch causes spinner to spin tubular in direction desired, according to
chosen selection of SPINNER ROTATION switch (IN/OUT).
BOTTOM JAW OPEN/CLOSE
Controls opening and closing of Bottom Jaw of Torque Wrench.
Rotary Selector Switch
Three-position, return-to-center switch. Causes Iron Roughneck
IR MOVE – OUT / IN Rotary
to move in a horizontal direction either toward or away from
Selector Switch
tubular, as desired.
SPINNER ROTATION OUT/IN Selects direction of rotation of spinner. Spinner will spin in or out
Rotary Selector Switch when SPINNER switch is placed in SPIN position.
Lights green if makeup operation is complete (according to
MAKEUP COMPLETE Lamp
torque required Make-Up drill pipe/collar).
Lights red if the pr-set torque has not been reached for
MAKEUP REPEAT Lamp completion of the make-up operation. When this happens, the
torque process must be repeated.
Allows operator to monitor hydraulic system pressure coming
SYSTEM PRES Digital Gauge from the Hydraulic Pump Unit (HPU). Gauge reading is in psi.
Multiply reading by 10X to get actual pressure.
Allows operator to monitor the amount of torque being applied by
MAKEUP TORQUE Digital Gauge the Torque Wrench. Gauge reading is in Ft - Lbs. Multiply
reading by x100 to get actual torque being applied.
Document Number
402-300-04 7
IRON ROUGHNECK
Remote Control Console Start-up Procedure

Before applying power to the Iron Roughneck remote control console (RCC), perform a
through inspection of the equipment. There is no need to set or adjust any control inside
RCC cabinet.
To avoid possible personnel injury of equipment damage,

WARNING make sure the IR operational area is clear of personnel and
equipment during startup.
1. If the IR Remote Control Console (RCC) has been taken out of active service (i.e.
shut down and de-energized) the following start-up procedure shall be used and
performed by a qualified electrician.
2. Megger test the power cable if the console has been disconnected, or upon first
installation.
3. Ensure that the correct voltage and frequency is supplied from the distribution board
before the main switch is turned on in the console. This should be 24 VDC.
4. Make sure that no emergency stops (red mushroom buttons) are activated. If the
emergency stops have been activated, deactivate the emergency stops by turning
one-quarter turn counter clockwise and pulling out. There is one located on the
RCC. Others may be located elsewhere in the system depending on the exact setup
for a particular rig.
5. Test the function of the emergency stop circuits for the IR. If the emergency stops
work correctly, deactivate, as described in step 5a below, and go to step 6.
5a. After emergency shutoff, the operator should reset all controls to the normal Start
position an check for any hydraulic or electrical problems before pulling out the
E-Stop button a restarting the operation.
6. Ensure that all circuits are operational before starting any other testing. If not all
circuits are operational, only qualified control system personnel should operate the
IR.
Refer to "Long Term Storage of Iron Roughneck Equipment" in the Maintenance section of
this manual for information regarding storage and storage removal procedures of Iron
Roughneck electrical equipment.
Document Number
8 402-300-04
IRON ROUGHNECK
Document Number
402-300-04 9
IRON ROUGHNECK
MAINTENANCE
This section describes general maintenance and inspection procedures for the IR3080
Remote Control Console.

Specified Cleaning Methods
The interior and exterior of the Remote Control Console should be free of oil, water dust
and dirt. The exterior of the RCC should be wiped off clean with a non-abrasive cloth and
the interior blown out with compressed air at reduced pressure. Pressure washing or steam
cleaning is not an acceptable method to clean the RCC. Care must be used to avoid getting
steam or water into or around the RCC
Do not clean Remote Control Console (RCC) with

flammable solvent or pressure washing. Failure to heed
WARNING this warning could result in injury to personnel and
damage to equipment.
Inspection Schedules
Perform the following maintenance procedures.
Daily:
1. Inspect the control panel for damaged knobs and lens caps. Replace as required.
2. Make sure all indicators and lamps illuminate. Troubleshoot the electrical circuit;
replace electrical circuit components as required. There is no need to set or adjust
any controls inside the RCC cabinet. Refer to the electrical control system
documentation and electrical diagrams for detail electrical information.
3. With the IR shutdown, check the operation of the selector switches for smooth and
positive movement.
Document Number
10 402-300-04
IRON ROUGHNECK
MAINTENANCE
Inspection Schedules (continued)
Weekly:
Inspect the service loop power and control cables for any signs of wear or damage.
Monthly:
1. Check panel interiors for moisture, cleanliness, and damages.
2. Check all equipment for abnormal conditions, such as discoloration due to high
temperature, corrosion damage, etc.
3. Check / tighten all switches and switch mountings.
4. Check all switches for signs of moisture, dirt, and damage.
Semi-Annually:
Check/tighten all terminals, and plugs to avoid loose connections
Document Number
402-300-04 11
Revision 02
SECTION 7:
TROUBLESHOOTING
www.nov.com
IRON ROUGHNECK
Troubleshooting
Document Number
602-000-03
IRON ROUGHNECK
Document Number
2 602-000-03
IRON ROUGHNECK
TABLE of CONTENTS
TROUBLESHOOTING ................................................................................................................. 4
Identifying Troubleshooting Categories .................................................................................. 5
Mechanical Components ............................................................................................... 5
Hydraulic Circuits and Valves ........................................................................................ 5
Electrical and Control System Components................................................................... 5
Troubleshooting Operation Problems..................................................................................... 6
Operating Mode Problems ............................................................................................. 6
Move In-Out Positioning Problems ................................................................................ 8
Vertical Positioning Problems ........................................................................................ 9
Troubleshooting Mechanical Components ........................................................................... 10
Wrench Assembly ........................................................................................................ 10
Spinner Assembly ........................................................................................................ 12
Troubleshooting Hydraulic Components .............................................................................. 15
Hydraulic Enclosure ..................................................................................................... 15
Torque Setting Panel ................................................................................................... 16
Troubleshooting Electrical and Control System Components .............................................. 17
Document Number
602-000-03 3
IRON ROUGHNECK
TROUBLESHOOTING
The following sections describe general troubleshooting methods, guidelines, and tables for
troubleshooting of Iron Roughneck problems or components.
Be sure to read and follow the General Safety Precautions

before proceeding with troubleshooting or maintenance of
the Iron Roughneck:
When troubleshooting the Iron Roughneck, make sure hydraulic system pressure is at 3000
psi at the inlet supply side of the Iron Roughneck.
1. Ensure that all hoses and quick-disconnects are properly connected.
2. Check all hydraulic components, fittings, quick disconnects and hoses for leaks or
damage.
3. Ensure the Iron Roughneck is lubricated per the Maintenance section located in this
manual.
After each rig move and before operating the Iron Roughneck:
1. Ensure that the Iron Roughneck is properly installed in the socket.
2. Ensure all quick-disconnects are fully engaged.
3. Ensure the operating pressures are correct.
4. Verify the condition of filters.
5. Check for leaks
6. Lubricate entire Iron Roughneck and check fluid levels. Refer to the maintenance
section in this manual.
Personnel conducting the Trouble-Shooting Procedures should be experienced and thoroughly

familiar with the Iron Roughneck. The Personnel conducting the Trouble-Shooting Procedures
must read and understand the Operation and Maintenance Manual as well as understand the
functions of the Iron Roughneck.
There is no possible way to anticipate every problem or predicament that will be encountered.
Contact National Oilwell Varco for problems not covered in this document.
Document Number
4 602-000-03
IRON ROUGHNECK
Identifying Troubleshooting Categories

Potential Iron Roughneck failure falls into following categories:
Mechanical Components
If the arm assembly fails to move, check to ensure that the arm locking pin has been
removed.
If the guide assembly fails to move, check to ensure that the column locking pin has
been removed.
Hydraulic Circuits and Valves

If all hydraulic power on the Iron Roughneck is lost, check the HPU.
If hydraulic power to one section of the Iron Roughneck is lost, check hydraulic pressure
coming into HE using Torque Setting Panel.
If pressure check shows sufficient pressure is flowing into solenoid Directional Control
Valve(s) (DCV) at the HE. Operate the solenoid DCV manually to check if problem is
mechanical or electrical.
If pressure check shows sufficient pressure coming into HE, check hydraulic line
between HE and affected section of the Iron Roughneck.
If pressure check shows insufficient pressure coming into HE, check HPU.
Electrical and Control System Components

If Remote Console Panel loses electrical power, check for 24VDC in wiring coming into
RCC from the power supply.
The most common causes of control system malfunction are electrical supply voltage
and or improper interconnection wiring.
The following table contains troubleshooting tips for several common problems, including
problems with mechanical components, hydraulic system, and electrical and control
systems to the Iron Roughneck.
Document Number
602-000-03 5
IRON ROUGHNECK
Troubleshooting Operation Problems

This section describes troubleshooting potential operating malfunctions for the IR3080 Iron
Roughneck.
Operating Mode Problems
Table 1.
SYMPTOM PROBABLE CAUSE CORRECTION
No DC control power or E-Stop pushbutton tripped and Re-set E-Stop pushbutton

hydraulics to Iron Roughneck interrupting DC power to IR switch to restore IR controls and
controls and HPU. IR HPU.
No DC remote control power. HE limit switch is not activated and Check HE door is closed
interrupting DC remote power to IR completely to ensure limit switch
controls. activation.
Iron Roughneck runs slowly. Power unit return filter Replace filter element of HPU.
clogged/dirty.
Iron Roughneck pressure filter Replace filter element of Iron
clogged/dirty. Roughneck.
Hydraulic quick-disconnect not fully Check the quick-disconnect
shouldered. couplings between the HPU and
the Iron Roughneck. Tighten
until fully shoulder to ensure
that the two units are properly
connected.
Power Unit not delivery full flow. Check power supply flow. Refer
to utility requirements for GPM
minimum flow.
High oil viscosity and /or cold Check oil and replace with
ambient conditions. correct viscosity. Refer to the
“Recommend Lubricants and
Fluids” section located in this
manual.
No hydraulic pressure. Drive shaft or coupling failure. Inspect and insure rotation.
Rotation incorrect. Replace parts as necessary
Remove the pump pressure line to See if the suction strainer is
determine if the pump is delivering plugged or restricted in any
any fluid. way.
Determine whether the suction
line might be leaking.
See if the reservoir breather or
air vents are restricted.
Document Number
6 602-000-03
IRON ROUGHNECK
Operating Mode Problems (continued)

Table 1.
Hydraulic system runs hot Ambient air temp is too high Add cooling system or reduce
duty cycle.
Low fluid level Check the fluid level in the
hydraulic reservoir.
Hydraulic pressure is too low. Relief Valve failure or Inspect, isolate and replace.
maladjustment and/or system
leakage.
Hydraulic pressure is too Relief Valve failure or Inspect, isolate and replace.
high. maladjustment.
Clogged / dirty filter Replace filter element.
High oil viscosity and /or cold Check oil and replace with
ambient conditions. correct viscosity. Refer to the
“Recommend Lubricants and
Fluids” document located in this
manual.
Excessive internal circuit leakage. Check cylinder for internal
bypass, by blocking lines to the
cylinder, if full operating
pressure is re-established at
DCV. This positively indicates a
bypass through the cylinder.
Inspect, isolate and replace.
When operating the Iron The Iron Roughneck has a loose Place the IR to perform a
Roughneck, one solenoid connection, contaminated fluid or a makeup/breakout sequence and
does not function when defective solenoid. check the control operation.
sequenced. Inspect, isolate and replace.
Torque cylinder remains Torque cylinder limit switch failure Using a voltmeter, check to see
engaged in the retract or not adjusted properly. if signal changes during
position causing fluid to heat makeup/breakout. Replace or
up. adjust depth of limit switch as
necessary.
Document Number
602-000-03 7
IRON ROUGHNECK
Move In-Out Positioning Problems

Table 2.
Move In-Out positioning Low or no System hydraulic Check hydraulic system output
assembly moves in one pressure. and settings. Test pressures
direction or does not move at and adjust as required.
all.
Relief Valve on the manifold is Clean, repair, or adjust the
defective, contaminated or is not valve.
adjusted properly.
Counterbalance valve on the Move Clean, repair, or adjust the
In-Out cylinder is defective, valve.
contaminated, or is not adjusted
properly.
Defective solenoid DCV Operate the solenoid DCV
manually; repair of replace if
defective.
Linkage cylinders damaged or leak. Check cylinders repair or
replace.
Binding of linkage arms. Lubricate all grease points and
moving parts on the automated
arm assembly.
Move In-Out positioning WC limit switch is not adjusted Locate the ERLS J-box and
assembly extends but fails to correctly or limit switch defective. check WC limit switch trip plate
stop at the well center adjustment. Replace limit switch
position if defective.
Move In-Out positioning MH limit switch is not adjusted Locate the ERLS J-box and
assembly extends but fails to correctly or limit switch defective. check MH limit switch trip plate
stop at the mousehole adjustment. Replace limit switch
position if defective.
Move In-Out positioning Retract limit switch is not adjusted Locate the ERLS J-box and
assembly retracts but fails to correctly or limit switch defective. check retract limit switch trip
stop at the full retract position plate adjustment. Replace limit
or runs into the stops. switch if defective.
IR assembly does not rotate Locking pin not removed or rotation Remove locking pin and/or
to the left or right. stop rings not loosen. loosen rotation stop rings.
Mechanical interference. Make sure automated arm
assembly is not interfering with
the rig structure or other pieces
of equipment.
Rotation bearing binding or Check bearing. Lubricate or
damaged. replace.
Document Number
8 602-000-03
IRON ROUGHNECK
Vertical Positioning Problems

Table 3.
Vertical positioning assembly Power Supply not operating. Check Power supply pressure
moves in one direction or gauge for indication. Make sure
does not move at all. supply pressure remains at
system pressure set with the
operating valve energized.
Low or no System hydraulic Check hydraulic system output
pressure. and settings. Test pressures
and adjust as required.
Relief Valve on the manifold is Clean, repair, or adjust the
defective, contaminated or is not valve.
adjusted properly.
Counterbalance valve on the Move Clean, repair, or adjust the
In-Out cylinder is defective, valve.
contaminated, or is not adjusted
properly.
manually; repair of replace if
defective.
Linkage cylinders damaged or leak. Check cylinders repair or
replace.
Binding of linkage arms. Lubricate all grease points and
moving parts on the Guide
Assembly and Vertical Track.
Vertical positioning assembly Counterbalance valve on the Move Clean, repair, or adjust the
does not maintain vertical In-Out cylinder is defective, valve.
position. contaminated, or is not adjusted
properly.
Lift Cylinder leaks Check cylinder repair or
replace.
manually; replace if defective.
Document Number
602-000-03 9
IRON ROUGHNECK
Troubleshooting Mechanical Components

This section describes troubleshooting procedures for the Iron Roughneck mechanical
components.
Wrench Assembly
Troubleshooting the Wrench Assembly
Table 4.
Torque Cylinder does not Low or no System hydraulic Check hydraulic system output
makeup pressure. and settings. Test pressures
Cylinder damaged. Seals leaking. Check cylinders repair or
replace.
Torque setting valve is not Inspect, isolate and replace.
operating
Torque setting valve set too low Increase torque setting pressure
as required.
Torque setting valve stuck close, Check torque setting valve,
dirty, or defective. clean or replace.
Torque cylinder reaches its end of Recycle the torque wrench
stroke before the torque set point is sequence for an additional
reached. makeup stroke to fully make up
the tool joint.
Torque cylinder does not Low or no System hydraulic Check hydraulic system output
breakout. pressure. and settings. Test pressures
Torque cylinder drifts in Sticking or worn solenoid DCV. Inspect solenoid DVC for
makeup direction. contamination or wear, and
repair or replace.
Torque cylinder drifts in Sticking or worn solenoid DCV. Inspect solenoid DVC for
breakout direction. contamination or wear, and
repair or replace. This also may
occur over long periods of time
with IR at idle, but hydraulic
pressure is available. To avoid
this turn off HPU when IR is not
in use.
Torque cylinder does not Dirty return filter in HPU Replace filter element.
move or moves slowly Cylinder damaged. Seals leaking. Check cylinders repair or
replace.
Relief valve is not operating Inspect, isolate and replace.
Document Number
10 602-000-03
IRON ROUGHNECK
Wrench Assembly
Troubleshooting the Wrench Assembly (continued)
Table 4.
Top Jaw Wrench does not Low or no System hydraulic Check hydraulic system output
close pressure. and settings. Test pressures
Cylinder damaged. Seals leaking. Check cylinders and repair or
replace.
Jaw pressure relief valve is not Check Jaw pressure relief valve,
operating. Stuck close, dirty, or clean, or replace.
defective.
Jaw pressure relief valve set too Increase jaw pressure setting as
low. required.
Top Jaw Wrench does not Low or no System hydraulic Check hydraulic system output
open. pressure. and settings. Test pressures
replace.
Top Jaw Wrench cylinder Sticking or worn solenoid DCV. Inspect solenoid DVC for
drifts in close direction. contamination or wear, and
repair or replace.
Cylinder damaged. Seals leaking. Check cylinders repair or replace.
Top Jaw Wrench cylinder Sticking or worn solenoid DCV. Inspect solenoid DVC for
drifts in open direction. contamination or wear, and
repair or replace.
Cylinder damaged. Seals leaking. Check cylinders repair or replace.
Top Jaw Wrench cylinder Cylinder damaged. Seals leaking. Inspect cylinders repair or
does not move or moves replace.
slowly. Dirty return filter in HPU Replace filter element.
Top Jaw Wrench slips on tool Worn or broken dies Replace dies.
joint.
Hydraulic pressure too low Check pressure setting, and
increase as required.
Note: Set jaw pressure to
correct clamping point set .Use
caution not set jaw pressure
setting too high, could cause
damage or distort tool joint.
Document Number
602-000-03 11
IRON ROUGHNECK
Spinner Assembly
Troubleshooting the Spinner Assembly
Table 5.
Loss of power or torque. Power supply is not operating. Check hydraulic system output
and settings. Test pressures
Restricted hydraulic lines. Isolate cause of restriction and
correct. Check for pinched,
clogged, or otherwise
obstructed hydraulic lines.
Worn or defective hydraulic motors. Replace the hydraulic motors.
Worn or defective relief valves. Inspect, isolate, and replace
relief valve cartridges.
Spinner Motors run Low or no System hydraulic Check hydraulic system output
irregularly. pressure. and settings. Test pressures
Contaminated motors. Inspect, and clean motors or
replace.
Defective hydraulic motors. Repair hydraulic motors or
replace.
Defective motor, solenoid DCV or Inspect, isolate, and repair or
relief valves. replace motors or valves.
Spinner motors stop rotating Flow to the motors is restricted. Isolate cause of restriction and
while spinning in or spinning correct.
out. Defective hydraulic motors. Repair hydraulic motors or
replace.
Hydraulic motor drive shaft is Repair hydraulic motor or
broken. replace.
Spinner Grip wheels do not Low or no System hydraulic Check hydraulic system output
rotate. pressure. and settings. Test pressures
Flow restricted. Isolate cause of restriction and
correct.
Spinner Rotation Solenoid DCV is Inspect, isolate and replace.
not operating. DCV is stuck close, Check Spinner Rotation
dirty, or defective. Solenoid DCV, clean or replace.
Sheared drive roller keys. Replace keys.
Defective hydraulic motors or Repair hydraulic motors or
broken motor drive shaft replace.
Document Number
12 602-000-03
IRON ROUGHNECK
Spinner Assembly
Troubleshooting the Spinner Assemblies (continued)
Table 5.

Spinner Grip Wheels slip Insufficient clamping force Check hydraulic system output
and settings. Test pressures
Coating on new drill pipe is making Remove coating.
the surface too slippery.
Contamination on spinner grip Remove contamination.
wheels.
Spinner grip wheels are worn Replace spinner grip wheels.
Spinner Grip cylinder drifts in Sticking or worn solenoid DCV. Inspect solenoid DVC for
clamp or unclamp position. contamination or wear, and
repair or replace.
Defective counterbalance valve or Replace or adjust CB valve to
counterbalance valve is out of maintain clamp positioning with
adjustment. the operating valve in neutral.
Spinner Grip assembly does Low or no System hydraulic Check hydraulic system output
not clamp or unclamp. pressure. and settings. Test pressures
Flow restricted. Isolate cause of restriction and
correct.
replace.
Spinner Grip Solenoid DCV is not Inspect, isolate and replace.
operating. DCV is stuck close, dirty, Check Spinner Grip Solenoid
or defective. DCV, clean or replace.
Spinner Grip assembly does Lack of lubrication. Lubricate all grease points and
not move in unison. moving parts.
Defective bearings in the cylinder Repair or replace.
end connection or spinner arm.
Defective linkage. Check the arm pins and bores
and repair or replace.
Spinner Grip cylinder does Cylinder damaged. Seals leaking. Inspect cylinders and repair or
not move or moves slowly. replace.
Dirty return filter in HPU Replace filter element.
Power Supply is defective. Low or Check system output and
no System hydraulic pressure. settings. Test pressures and
adjust as required.
Document Number
602-000-03 13
IRON ROUGHNECK
Spinner Assembly
Troubleshooting the Spinner Assemblies (continued)
Table 5.

Spinner does not shoulder Hydraulic pressure low. Check hydraulic system output
pipe or cannot spin pipe after and settings. Test pressures
breakout sequence. and adjust as required.
Bottom jaw is clamped too high on Unclamp the lower jaws, lower
the box end of drill pipe the Iron Roughneck to the lowest
point on the box, re-clamp and
spin in/out.
Document Number
14 602-000-03
IRON ROUGHNECK
Troubleshooting Hydraulic Components

This section describes troubleshooting procedures for the IR3080 Iron Roughneck
hydraulic components.
Hydraulic Enclosure
Troubleshooting the Hydraulic Enclosure
Table 6.
Solenoid Directional Control Valve inoperative. Ensure Hydraulic Enclosure

Valve(s) Fail to Operate. Valve door is closed completely;
does not appear to shift. otherwise limit switch will not
set.
No electrical signal Check all wiring and insure
signal form control is reaching
the valve. Check to see if the
voltage is too low or the line
loss is excessive.
Bad Solenoid Check coil resistance. Compare
to good coil. Replace if more
than 5% different.
Valve stuck Try to use manual operation to
see if valve will shift or feels
stuck.
Component misadjusted Investigate other circuit controls
such as relief valves or flow
controls
Excessive hydraulic internal circuit Check pilot pressure. See if the
leakage pilot pressure is adequate and
the supply is stable.
Cylinder failed Try to determine if the cylinder
is damaged. Check cylinder for
internal bypass, by blocking
lines to the cylinder, if full
operating pressure is re-
established at DCV. This
positively indicates a bypass
through the cylinder.
Inspect, isolate and replace
Document Number
602-000-03 15
IRON ROUGHNECK
Torque Setting Panel

Troubleshooting the Torque Setting Panel
Table 7.
Relief Valve fail to function No hydraulic pressure Check hydraulic system output
properly and settings. Test pressures
Hydraulic lines incorrectly Check hydraulic lines are
connected. connected properly.
Relief valve defective and/or Inspect, isolate and replace.
damaged.
Torque Gauge does not return Gauge not adjusted to zero Reset gauge and recheck
to zero. torque setting.
Defective gauge Replace.
Document Number
16 602-000-03
IRON ROUGHNECK
Troubleshooting Electrical and Control System Components

The electrical and control system configuration described in this section are typical, but not
universal. Refer to the Iron Roughneck Control Console operation manual for description of
operation and see your technical drawings parts list manual for electrical and control
system diagrams and information.
The Iron Roughneck control system consists of a remote control console and service loops
connected to and from a combination of a few basic types of components.
Inputs from the operator and feedback on machine movement are directed into the remote
control console. The control console also initiates the system’s outputs.
If a particular function on the Iron Roughneck is not working, determine if the control
system received the input and if the corresponding output was energized.
If an input is valid but the related output does not perform correctly, either the control
system and/or its related hardware have failed, or an interlock condition exits.
Troubleshooting a problem with the control system involves determining which of the
control systems components has failed.
Follow appropriate electrical diagnostic procedures to check the Iron Roughneck

electrical components and consult the corresponding troubleshooting tables.
To determine the state of a component testing should be preformed by a qualified

electrician.
Replace any faulty electrical components upon detection.

If you cannot bring the control system into the operating mode. Contact National Oilwell
Varco for additional information.
Document Number
602-000-03 17
Revision 02
SECTION 8:
INSTALLATION
www.nov.com
IRON ROUGHNECK
Installation
Document Number
702-000-03
IRON ROUGHNECK
Document Number
2 702-000-03
IRON ROUGHNECK
TABLE of CONTENTS
PRE-INSTALLATION REQUIREMENTS AND PROCEDURES .................................................. 5
General Requirements ........................................................................................................... 5
Initial Inspection...................................................................................................................... 5
Customer verification of hydraulic fluid cleanliness ................................................................ 5
Equipment Differences ........................................................................................................... 5
Electrical System and Components........................................................................................ 6
Hydraulic System and Components ....................................................................................... 6
Special Tools.......................................................................................................................... 7
Equipment Motion Hazards .................................................................................................... 7
INSTALLATION ........................................................................................................................... 9
Installing the Iron Roughneck ................................................................................................. 9
Lifting the Iron Roughneck ................................................................................................... 10
Mounting the Iron Roughneck .............................................................................................. 11
Installing the Remote Control Console ................................................................................. 12
Installing the Service Loops ................................................................................................. 14
Installing the Hydraulic Power Unit....................................................................................... 15
Customer System Configuration........................................................................................... 16
Customer Hydraulic/Electrical Connection Schedule ................................................... 16
NOV System Configuration .................................................................................................. 17
NOV Hydraulic/Electrical Connection Schedule........................................................... 17
CHECKOUT PROCEDURE ....................................................................................................... 18
Iron Roughneck Installation Checkout Procedure ................................................................ 18
HPU Installation Checkout procedure .................................................................................. 18
Controls Installation Checkout Procedure ............................................................................ 18
Startup Checkout Procedure ................................................................................................ 19
System Setting Checkout Procedure.................................................................................... 19
Limit Switches Settings Checkout Procedure....................................................................... 20
Document Number
702-000-03 3
IRON ROUGHNECK
Document Number
4 702-000-03
IRON ROUGHNECK
PRE-INSTALLATION REQUIREMENTS AND PROCEDURES

The following assumes that all pre-installation planning and rig-up has been accomplished
prior to installation of the IR3080 Iron Roughneck.
General Requirements
Although many installation layouts arrangements are possible critical preparation and
installation consideration must be preformed before attempting to install the IR3080 Iron
roughneck.
Before installing the IR3080 Iron Roughneck system, consider the ideal location of the Iron
Roughneck, HPU, Service Loop, and Remote Control Console to ensure location
accessibility and safety. Installation considerations help to prevent clearance possible
restrictions.
Prior to field installation operation, check over that the Iron Roughneck assembly and
controls, to assure all components are included and in serviceable condition. Fill all
lubricants systems to correct levels with specified lubricants
Initial Inspection
After unpacking all IR3080 components and parts, Inspect as follows:
1. Inventory all components and parts. In case of missing or incorrect parts, notify
National Oilwell Varco.
2. Inspect all components and parts for shipment damage and corrosion. If damage to
a component or part occurred during shipment, notify the carrier. If corrosion beyond
reasonable limits is present, notify National Oilwell Varco.
Customer verification of hydraulic fluid cleanliness

Prior to attaching any National Oilwell Varco equipment the customer’s hydraulic plumbing,
the customer must ensure that the hydraulic fluid/system cleanliness is at a level of ISO
440615/12 or better.
Equipment Differences
The Nov IR3080 Iron Roughneck is manufactured in different arm reach range versions.
Each IR3080 models are hydraulically and electrically similar. The illustrations and text in
this section do not cover on any one version but rather covers the common systems and
components.
Document Number
702-000-03 5
IRON ROUGHNECK

Electrical System and Components
The IR3080 control system requires 24VDC with customer supplied HPU. For detailed
information, refer to the electrical documentation book. Refer to the Iron Roughneck
electrical documentation book for grounding the Iron Roughneck’s electrical components
and associated accessories.
Electrical systems are designed d for the intended purpose I the drilling industry. All
electrical wiring, junction boxes, sensors, glands, and related equipment are designed for
the specific application, environment and particular operating zone.
Before beginning work on this equipment, familiarize yourself wit the electrical
schematics, as well as the equipment power and voltage requirements
When performing g installation, maintenance, or repairs on the equipment, isolate all

power. Lock out switches and tag them to prevent injury.
Prior to connecting or disconnection wires, cables, verify all wires, cables are properly
labeled to ensure proper reconnection.
Hydraulic System and Components

Hydraulic systems and components are designed for the intended use in the drilling industry.
The hydraulic pressure for this equipment can be as high as 3,000 psi.
Before beginning work on any portion of the hydraulic system, familiarize yourself with
the hydraulic and electrical schematics.
Isolate, lock out, and tag the hydraulic an electrical power controls.
Take precautions when bleeding down residual system pressure, using bleed valves or
equivalent techniques.
Properly discharge all system stored fluid pressure.
Collect all residual hydraulic fluid in a container to prevent rig or environmental

contamination.
Take precautions to prevent hydraulic oil from leaking into other open electrical or
mechanical components such as junction boxes.
Document Number
6 702-000-03
IRON ROUGHNECK

Special Tools
The following table lists special tools and support equipment required to install and
commission an IR3080 Iron Roughneck.
Description Supplier & Model No. Accuracy Range

Fluke Various <1% FS N/A
Hydraulic Pressure Test Gauge Various 3-5%-FS 0-3000 psi (0-206 Bar)
Equipment Motion Hazards

The IR3080 equipment travels either horizontally or vertically.
Avoid placing objects in or near the path of motion for this

WARNING equipment. Such interference could cause serious injury
and/or death to personal and/or damage to the equipment.
Keep the working envelope/zone of the equipment free from

WARNING personnel.
Document Number
702-000-03 7
IRON ROUGHNECK
Document Number
8 702-000-03
IRON ROUGHNECK
INSTALLATION
Installing the Iron Roughneck
Figure 1. Typical IR3080 Iron Roughnecks
Document Number
702-000-03 9
IRON ROUGHNECK
INSTALLATION
Lifting the Iron Roughneck
1. Locate the Iron Roughneck and lift the assembly to the drill floor as follows.
Figure 2 Typical Iron Roughneck stored in Lifting Skid
Release and remove the ratchet strap from the lifting skid.
Attach equipment used to lift the Iron Roughneck from lifting skid to drill floor using the
lifting assembly.
Lift Iron Roughneck into position perpendicular wit drill floor, then out of column socket
Attach lifting devices to the lifting lugs and hoist the Iron Roughneck to hang over the
drill floor mount socket.
Document Number
10 702-000-03
IRON ROUGHNECK
INSTALLATION
Mounting the Iron Roughneck
Refer to the following drawings:
IR3080 General Assembly
IR3080 Assembly
The IR3080 General Assembly and IR3080 Assembly drawings provide mounting
specifications.
2. Mount the Iron Roughneck at the drill floor as follows:
Insert base into drill floor mount socket.
Check Column for vertical alignment, shim as necessary.
Disengage lifting device and remove lifting link and turnbuckle from lugs.
Remove the shipping/parking lock pins.
Figure 3. Leveling IR column base
Document Number
702-000-03 11
IRON ROUGHNECK
INSTALLATION
Installing the Remote Control Console
Figure 4. Remote Control Console
The remote Control Console (RCC) contains the control circuitry that controls the movements
of the various mechanical components of the Iron Roughneck.
The Remote Control Console (RCC) is either freestanding on the drill floor or located in or
close to the Driller'
s Cabin, and positioned to where the jaws of the IR can be observed while
operating the Iron Roughneck. Mount the Remote Control Console (RCC) in an accessible
non-hazardous safe area.
Document Number
12 702-000-03
IRON ROUGHNECK
INSTALLATION
Installing the Remote Control Console
Make sure the operator can see the roughneck area of the rig
CAUTION floor, as well as the Iron Roughneck assembly from where the
Remote Control Console is positioned.
In order to comply with the hazardous area rating of the IR

WARNING remote control console, it must be placed in a non-hazardous
or Division-2 / Zone-2 hazardous area on the drill floor.
Refer to the following drawings:
IR3080 General Assembly
IR3080 Assembly
IR3080 Control Panel Internal Wiring Diagram
Connect the RCC as follows:
1. Locate and install the IR Remote Control Console. The RCC can be installed at the drill
floor or at the driller’s cabin.
Check the E-STOP buttons are pressed down on the RCC and the Torque setting
Panel.
Make electrical connections from HPU to RCC and from the RCC to the Iron
Roughneck.
Document Number
702-000-03 13
IRON ROUGHNECK
INSTALLATION
Installing the Service Loops
Refer to following Hydraulic/Electrical System configurations:
1. Customer System Configuration.
2. NOV System Configuration.
Check that all circuit breakers at the HPU are OFF.

Locate the hydraulic service loops. Connect the hydraulic supply and return hose from
the HPU to the Iron Roughneck.
Exercise extreme caution when performing maintenance on

the hydraulic system. Fluid escaping under pressure can
WARNING easily cause serious injury or death to personnel and / or
Locate the electrical power and controls cables.
Make electrical connections from SCR to HPU.
Make electrical connections from HPU to Remote Control Console and from Remote
Control Console to Roughneck.
Document Number
14 702-000-03
IRON ROUGHNECK
INSTALLATION
Installing the Hydraulic Power Unit
1. Locate HPU and isolate in coming power OFF.
All equipment should be shut down, isolated and tagged “OUT OF

SERVICE” before any maintenance procedure is performed. Any
CAUTION unexpected start-up of equipment during procedure can cause
serious injury or death to personnel and / or damage to the
equipment.
Before connecting and/or disconnecting hydraulic connection

fittings, the installation in the vicinity is to be cleaned, and all
! ! openings closed by caps to ensure that dirt cannot enter the
system.
Exercise extreme caution when performing maintenance on the

hydraulic system. Fluid escaping under pressure can easily cause
WARNING serious injury or death to personnel and / or damage to the
equipment.
Fill all hydraulic systems to the correct levels with specified hydraulic fluids. For
hydraulic fluid specifications, refer to “Recommended Lubricants and Fluids” section
located in the maintenance section of the Operation and Maintenance manual.
Locate the HPU service loops. Connect the hydraulic supply and return from the HPU to
the IR.
Document Number
702-000-03 15
IRON ROUGHNECK
INSTALLATION
Customer System Configuration
Customer Hydraulic/Electrical Connection Schedule

Description Specification
Hydraulic Supply Pressure Connection 3,000 PSI, 40 GPM, 1-1/4” FJIC
Hydraulic Return Connection 1-1/2” FJIC
Electrical Supply Connection 24VDC
Electrical Control Connection 37 Conductor Cable
Document Number
16 702-000-03
IRON ROUGHNECK
INSTALLATION
NOV System Configuration
NOV Hydraulic/Electrical Connection Schedule

Description Specification
Hydraulic Supply Pressure Connection 3,000 PSI, 40 GPM, 1-1/4” FJIC
Hydraulic Return Connection 1-1/2” FJIC
Electrical Power Supply Connection 460VAC, 60Hz, 3 PH, 100A
Electrical Supply Connection 24VDC
Electrical Control Connection 37 Conductor Cable
Document Number
702-000-03 17
IRON ROUGHNECK
CHECKOUT PROCEDURE
Iron Roughneck Installation Checkout Procedure
Make sure that the IR is fully inserted in the socket and column is vertically aligned.
Grease all Roughneck grease points.
Check that all service loop hydraulic lines and electrical power add control cables are
connected.
Make sure all QD’s are properly engaged.
HPU Installation Checkout procedure

Check the HPU hydraulic service loop. Check that the hydraulic hoses are free from
snag hazards, leak free, free of crimped hoses, properly secured.
Check the quick-disconnect coupling connection between the HPU and the Iron
Roughneck to ensure that coupling connections are tightened.
Check fluid level in HPU.
Verify the condition of the filter.
Controls Installation Checkout Procedure

Check that the electrical cables are free from snag hazards free of crimped or kinked
cables, and properly secured.
Check the location and installation the IR Remote Control Console (RCC). The console
can be installed at drill floor or at the driller’s cabin.
Check the location and installation the IR Remote Control Console (RCC). The console
can be installed at drill floor or at the driller’s cabin.
Check the HPU hydraulic service loop. Connect the hydraulic supply (1 hose) and return
(1 hose) from the HPU to Roughneck.
Check the electrical connections from SCR to HPU.
Check the electrical connections from HPU to Remote Control Console and from
Remote Control Console to Roughneck.
Document Number
18 702-000-03
IRON ROUGHNECK
CHECKOUT PROCEDURE
Startup Checkout Procedure
Before applying power to the Iron Roughneck remote control console (RCC), perform a
through inspection of the equipment. There is no need to set or adjust any control inside
RCC cabinet.
To avoid possible personnel injury of equipment damage, make

WARNING sure the IR operational area is clear of personnel and equipment
during startup.
Check the E – STOP buttons is pressed on the Remote Control Console (see Figure 2)
and the E-STOP button is also pressed on the Torque Setting Panel.
Check that the hydraulic enclosure door is fully closed, in order to activate the door limit
switch.
Power up HPU and Remote Control Console (RCC).
Check for Hydraulic Leaks; Check both filter replacement indicators on HPU and
Roughneck.
Check power supply flow.
Check system pressure.
System Setting Checkout Procedure

Check system pressure gauge at the torque setting panel indicates 3000 PSI.
Make sure the operating pressures are correct.
Check pressure set for the top jaw and bottom jaw. The top jaw and bottom jaw
pressures must be set before adjusting torque set of performing makeup breakout
functions.
Check makeup torque set.
Document Number
702-000-03 19
IRON ROUGHNECK
CHECKOUT PROCEDURE
Limit Switches Settings Checkout Procedure
Check Rotational Alignment over well center and mouse hole.
Check Extend Limit Switch Set.
Power up Iron Roughneck. Operate the Move in/out controls for a short distance to
verify that the Iron Roughneck extends and retracts in the directions as indicated by the
controls.
Check Iron Roughneck Well Center destination distance travel. If extend travel is short
of target, adjust and reset limit switch.
Check Iron Roughneck Well Center stopping position. If Iron Roughneck travels beyond
the stop position, adjust and reset limit switch.
Repeat process for mouse hole after selector switch on Remote Control Console is
rotated to “Mouse Hole”
Figure 5. ERLS J-Box Limit Switches
Document Number
20 702-000-03
Revision 02
SECTION 9:
PARTS LIST
www.nov.com
Arm
REFERENCE REFERENCE DESCRIPTION

RIG/PLANT
IR3080AR5503 Technical Drawing Package
subsidiaries (all collectively referred to hereinafter as "NOV"). It is
REMARKS loaned for limited purposes only and remains the property of NOV. National Oilwell Varco
Reproduction, in whole or in part, or use of this design or
MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the RIG SOLUTIONS
express written consent of NOV. This document is to be returned to 12950 West Little York
NOV upon request or upon completion of the use for which it was Houston, TX 77041
CLIENT PO NUMBER loaned. This document and the information contained and
DOCUMENT NUMBER REV

Client Document Number
103-003-02 02
www.nov.com
Revision 01
Page 2
REVISION HISTORY

CHANGE DESCRIPTION

00 First Issue
01 Revised and Updated
02 Revised and updated to include electrical diagrams
www.nov.com
Revision 01
Page 3
TECHNICAL DRAWING PACKAGE

This document provides a list of drawings for the model IR3080AR5503 iron roughneck
assembly, engineering reference number: IR3080AR5503.
Drawings by Assembly
Description Drawing No Rev
Section A: General
IR3080 Iron Roughneck Assembly ...............................................................IR3080AR5503 A
IR3080 Iron Roughneck General Assembly .................................................IR3080GA01 -
Lifting Skid Assembly ....................................................................................LS01 B
Schematic, Hydraulic Control .......................................................................HC02 -
Section B: Column/Guide/Arm Assembly

Arm Assembly ...............................................................................................AR01 B
Arm, Right Top Assembly.......................................................................AR01-01 4
Arm, Lower Left Assembly......................................................................AR01-02 7
Arm Assembly ........................................................................................AR01-03A -
Arm Assembly ........................................................................................AR01-03B -
Arm Assembly ........................................................................................AR01-03C -
Guide Assembly .....................................................................................AR01-10 9
Base Assembly.......................................................................................AR01-11 3
Section C: Spinner Assembly

Spinner and Support Assembly ....................................................................SA01 A
Spinner Assembly...................................................................................SP01 C
Roller Assembly ...............................................................................SP01-03 B
Spring Bracket Assembly.................................................................SP01-09 A
Section D: Wrench Assembly

Wrench Assembly .........................................................................................WA02 -
Top Wrench Assembly ...........................................................................TW02 C
Bottom Wrench Assembly ......................................................................BW02 E
Torque Wrench Assembly ......................................................................BW02-13 B
www.nov.com
Revision 01
Page 4
Drawings by Assembly
Description Drawing No Rev
Section E: Electrical Controls

Electrical Controls Kit ....................................................................................0001-0579-70 A
Control Console (GAD) .................................................................................0001-0365-68 B
Hydraulic Enclosure (GAD)...........................................................................0001-0591-40 A
Torque Set Panel (GAD)...............................................................................0001-0531-51 B
Make-Break Switch (GAD)............................................................................0001-0496-24 B
ERLS-J-Box (GAD) .......................................................................................0001-0365-61 A
Solenoid J-Box (GAD)...................................................................................0001-0579-72 A
Console Internal Wiring Diagram (INW)........................................................1433-803-03 A
Termination Diagram (TER)..........................................................................1433-010-00 A
Section F: Installation Spares

IR3080 Installation Spares Kit.......................................................................104-000-00 -
Section G: Recommended Spares

Recommended Spare Parts List ...................................................................105-003-01 01
www.nov.com
Revision 02
SECTION A:
GENERAL
www.nov.com
Revision 02
SECTION B:
COLUMN/GUIDE ARM
ASSEMBLY
www.nov.com
Revision 02
SECTION C:
SPINNER ASSEMBLY
www.nov.com
8 7 6 5 4 3 1
LTR DESCRIPTION OF CHANGE MADE CHKD DATE APPD
D REDRAWN IN SOLIDWORKS, UPDATED BOM NT. KA 4/27/04 BW

21
1 11 E ADDED DETAIL VIEW C, MODIFIED ITEM 10 &11 NT. KA 6/01/04 BW
2 ADDED ITEM #22 &23
F UPDATED PINS & BUSHINGS NT. KA 7/25/04 BW

4
1 7 8 UPDATED ITEM #10 NT. KA 01-Apr-05 BW
D B 17
B 15/16" 5 D
6
9
36 5/8" 21
1/16"
10
22 6
7/8"
3 8 2
2 7
DETAIL C 12
SCALE 2X 8
3 10
C 11 C
SECTION B-B 7
4
6
10
9 22 8 1/2"
8
C 3
4
9 7/8"
26"
1
12
8 1/2"
13 16 15 14 3
22 1 SP01-06 CYLINDER CLEVIS .00

21 1 SP01-04 CYLINDER
31"
B 36 5/8" 20 1 7804875 ELBOW, AEROQUIP 2062-6-8S B
19 1 g7800108 ADAPTER, AEROQUIP 202702-6-8S .12
18 1 7804123 ELBOW, AEROQUIP 2062-6-6S
17 1 7800776 ADAPTER, AEROQUIP 202702-6-6S
16 2 700021617 SCREW, HEX HD CAP 3/8-16 X 3 GR5 ZINC PL .00
15 2 6300062 NUT, HEX 3/8-16UNC CAD PLTD
14 2 7619041 WASHER, REG SPG LOCK 3/8" CD PL
13 2 7621024 WASHER, FLAT 3/8" N TYPE A 0.812 OD CD PL .01
12 4 218319/005 RETAINING SAFETY SNAP PIN .00
11 1 SP01-10-01 PIN ARM/ ARM
10 2 7815566 RETAINING SAFETY SNAP PIN
9 2 SP01-52 BUSHING FLANGE, ORKOT .00
19 8 2 SP01-51 BUSHING ORKOT
7 2 SP01-50 BUSHING FLANGE ORKOT
6 2 SP01-08 PIN CYLINDER/ARM .00
5 2 SP01-07 PIN ROLLER/ARM .00
4 1 hc01-05aas MANIFOLD 5 ASSEMBLY, SPINNER
3 2 SP01-03 SPINNER ROLLER ASSEMBLY .00
12 2 1 SP01-02 RIGHT ARM SPINNER .00
1 1 SP01-01 LEFT ARM SPINNER .00
ITEM NO. QTY. PART NO. DESCRIPTION / MATERIAL / SPECIFICATION WT. EA.
UNLESS OTHERWISE SPECIFIED
A 18 PROPRIETARY INFORMATION DIMENSIONS ARE IN INCHES DIMENSIONAL TOL. MATERIAL SPEC A
BREAK SHARP CORNERS 1/32 FRACTIONS ± 1/16
THIS DOCUMENT CONTAINS NATIONAL-OILWELL TITLE
FILLET RADII X.XXX ± .015
PROPRIETARY AND CONFIDENTIAL INFORMATION.
IT IS LOANED FOR LIMITED PURPOSES ONLY AND CONCENTRICITY X.XX ± .03
DESIGNED BY DATE
SPINNER ASSEMBLY
REMAINS THE PROPERTY OF NATIONAL-OILWELL. SQUARENESS X.X ± .1
IT MAY NOT BE REPRODUCED IN WHOLE OR PART
PARALLELISM ANGLE ± .50 DEGREE DRAWN BY DATE
OR DISCLOSED TO THIRD PARTIES WITHOUT THE
PRIOR WRITTEN CONSENT OF NATIONAL-OILWELL. RFS EXCEPT WHEN M MODIFIED SURFACE RMS 125 KA 7/7/03 SIZE DRAWING No. REV
20 THE DOCUMENT IS TO BE RETURNED TO NATIONAL-
OILWELL UPON REQUEST AND IN ALL EVENTS
UPON COMPLETION OF THE USE FOR WHICH IT
SIMILAR TO SUPERSEDES CHECKED BY
BW
DATE
7/10/03 D SP01 08
WAS LOANED. NEXT ASS'Y SUPERSEDED BY P.E. APPROVAL DATE SCALE EST WT SHEET
JB 7/10/03 N/A 900LBS 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 1
D ADDED ITEM #12 &13 NT. KA 6/01/04 BW

10 5 E CHANGED TO NORDLOCK WASHERS NT. KA 7/25/04 BW
D 5 3 5
D
4
12
8 7 DETAIL B 7 8
5
11 15 1/2"
SCALE 3X
9
4 10
A
2
12
C C
B
6 13 13 14
3 11 6 13 14
1
23 3/16" .28
9 1
11
B 2 B
A
SECTION A-A
14 12 6300081 NUT, HEX 1/2"-13UNC CD PL .04
13 24 7634040 WASHER, NORDLOCK NL1/2 1/2" ZINC PL .38
12 1 SP01-03-11 FORGED EYE BOLT 1/2 X 3 1/4 .44
11 8 7800202 ELBOW, AEROQUIP 2062-10-8S .05
10 4 568224/020 0-RING 2.012 OD. X 1.734 ID .00
8 1/2" 9 2 SP01-03-06 GREASE FITTING 1/4-28 UNF STRAIGHT .00
8 16 700631208 SCREW, SOC HD CAP 1/2-13UNC X 3 CD PL .20
7 16 7612018S WASHER, HI-COLAR SPG LOCK 1/2 SST .00
6 12 700032611 SCREW, HEX HD CAP 1/2"-13 X 6-1/2" LG CD PL .41
5 4 HM001 HYDRO MOTOR .00
4 4 SP01-03-05 SEAL SPACER FOR ROLLER .00
3 2 SP01-03-03 ROLLER BODY 0
2 4 SP01-03-02 ROLLER
1 1 sp01-03-01 ROLLER BRACKET, SPINNER
UNLESS OTHERWISE SPECIFIED
A PROPRIETARY INFORMATION DIMENSIONS ARE IN INCHES DIMENSIONAL TOL. A
DESIGNED BY DATE
SPINNER ROLLER ASSEMBLY
OR DISCLOSED TO THIRD PARTIES WITHOUT THE
PRIOR WRITTEN CONSENT OF NATIONAL-OILWELL. RFS EXCEPT WHEN M MODIFIED SURFACE RMS 125 KA. 6/11/03 SIZE DRAWING No. REV
THE DOCUMENT IS TO BE RETURNED TO NATIONAL-
BW
DATE
7/3/03 D SP01-03 E
JB 7/3/03 N/A 243.3 LBS 1 OF 1
8 7 6 5 4 3 2 1
Revision 02
SECTION D:
WRENCH ASSEMBLY
www.nov.com
8 7 6 5 4 3 1
A UPDATED VIEWS NT. KA 5/12/04 BW
B UPDATED VIEWS, ADDED ITEM #4 THRU 11 NT. KA 8/15/04 BW
5 4 8 7 6 2
D 5 6 7 8 9
D
C C
10 1/8"
21 11/16"
1 1/2"
27 1/8"
B 10 1/8" B
10
11
10
11 1 7800071 ELBOW, AEROQUIP 2023-8-8S
21 1/2" 10 2 7804213 ELBOW, AEROQUIP 2062-12-8S .64
9 1 BW02-13-01-07 PIN, 1.75 DIA .00
8 4 7619033 WASHER, REG SPG LOCK 1/4" CD PL 0
7 4 2405190 SCREW, DR HD HEX HD CAP 1/4"-20 X 3/4" LG GR5 CD PL
12 1/2" 6 2 BW02-13-03 LOCKING PLATE
5 2 sp01-03-06 GREASE FITTING 1/4-28 UNF STRAIGHT
4 1 BW02-13-01-06 PIN, 2.00 DIA.
3 1 BW02-13 TORQUE CYLINDER ASSEMBLY
56 7/8" 2 1 TW02 TOP WRENCH ASSEMBLY (IR3080)
1 1 BW02 BOTTOM WRENCH ASSY (IR3080)
UNLESS OTHERWISE SPECIFIED MATERIAL SPEC
A PROPRIETARY INFORMATION DIMENSIONS ARE IN INCHES DIMENSIONAL TOL.

A
BREAK SHARP CORNERS 1/32 FRACTIONS ±
1/16
DESIGNED BY DATE
WRENCH ASSEMBLY IR3080
PARALLELISM ANGLE ± .50 DEGREE
NT. 11/15/03
OR DISCLOSED TO THIRD PARTIES WITHOUT THE DRAWN BY DATE
PRIOR WRITTEN CONSENT OF NATIONAL-OILWELL. RFS EXCEPT WHEN M MODIFIED SURFACE RMS 125 NT. 11/15/03 SIZE DRAWING No. REV
THE DOCUMENT IS TO BE RETURNED TO NATIONAL-
KA.
DATE
11/15/03 D WA02 B
BW. 11/15/03 N/A 2900LBS 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 DWG No.
BW02
SHT
1 1
A ADDED ITYEMS 28, 29, 30, & 31 REVISED ITEM 19 KRA BDW 05-Sep-03 JB
B REVISED ITEMS 6 & 7 KRA BDW 18-Sep-03 JB
C REMOVED DIMENSIONS BDW KRA 07-Oct-03 BDW
D REMOVED ITEMS 16, 17, 18, 21, & 26 NT KRA 14-Jan-04 BDW
E ADDED ITEMS 32 THRU 37, REVISED ITEM 30 KRA NT 13-Feb-04 BDW
D 19 21 30
F ADDED ITEMS 38, 39, 40, REVISED ITEM 20, 31 KRA BDW 06-Apr-04 BDW D
G REV'D ITEMS 16-19, 21, 26, ADD QTY ITEM 30 KRA BDW 02-Jun-04 BDW
H ADDED ITEM 33 KRA NT 29-Nov-04 BDW
I ITEM 3 WAS QTY, ADDED SHT 2 CEL BDW 02-Jun-05 BDW
12 26
11
29 32
23
12
5
C C
9
8
2
33 8 BW02-31 SHIMS, STEEL WEAR BLOCK .36

SECTION A-A 13 14 20 32 1 HC01-04 AS MANIFOLD ASSY, BOTTOM JAW 30
1 31 4 7815526 PIN, HAIRPIN COTTER 18-8 SST MCMASTER-CARR 92391A778 .00
30 7 7000306-11 SCREW, HEX HD CAP 1/2"-13 X 1-3/4" LG GR5 CD PL .14
29 1 BW02-29 BRACKET, MANIFOLD MOUNTING .00
28 4 7622084 WASHER, FLAT 1/2 N TYPE B 1.00 OD. .00
27 1 BW02-28 BEARING, ORKOT 1 3/4 ID x 2 OD x 2 3/8 LG .14
26 4 7802956 ADAPTER, AEROQUIP 202713-8-8S .32
25 1 BW02-14 FRONT WEAR BLOCK WRENCH 2
24 1 BW02-27 FRONT WEAR BLOCK WRENCH 2
23 2 TW02-05 CYLINDER STOP PLATE 46
22 4 tw02-03 SLIDE PLATE 6
21 2 6300081 NUT, HEX 1/2"-13UNC CD PL .04
B 20 8 TW01-22 SPRING PIN 1/4 X 1 1/2 LG SS .00 B
19 2 7619050 WASHER, REG SPG LOCK 1/2" CD PL .01
18 2 6300062 NUT, HEX 3/8-16UNC CAD PLTD .02
17 2 7619041 WASHER, REG SPG LOCK 3/8" CD PL .01
16 2 700022211 SCREW, HEX HD CAP 3/8-16 X 4-1/2 GR5 CD PL .00
15 1 BW01-15 WRENCH REAR WEAR BLOCK .00
14 7 WL.75UNC-SS LOCKWASHER 3/4 UNC STAINLESS .04
A A
13 8 BH.75UNC1.75SS HEX BOLT, 3/4"-10 UNC X 1-3/4" SS .36
12 2 TW02-12 JAW CYLINDER .00
11 4 TW01-08 STOP PIN 2
10 2 TW01-07 ROD PIN .19
9 2 TW01-06 ROD WASHER .00
8 2 TW01-04 BALL BUSHING 2
7 4 7815527 PIN, HAIRPIN COTTER 18-8 SST MCMASTER-CARR 92391A120 .00
6 4 BW02-30 PIN, LOCK PLATE 17-4PHH1150 .00
5 4 AC01-01-03 WIDE DIE 4 (WD4) 2
4 2 AC01-02-01-02 LOCK PLATE 2 .84
3 4 AC01-02-01-01 LOCK PLATE 1 .43
2 2 AC01-02-01 WIDE DIE HOLDER .00
1 1 BW02-01 BOTTOM WRENCH WELDMENT (IR3080) .00
MATERIAL SPEC
PROPRIETARY INFORMATION APPLICABLE SPECS UNLESS OTHERWISE SPECIFIED
A DIMENSIONS ARE IN INCHES DIMENSIONAL TOL. A
THIS DOCUMENT CONTAINS PROPRIETARY AND BREAK SHARP CORNERS 1/32 FRACTIONS ± 1/64 SEE L/M
CONFIDENTIAL INFORMATION WHICH BELONGS TITLE
TO NATIONAL OILWELL. IT IS LOANED FOR LIMITED FILLET RADII X.XXX ± .015
PURPOSES ONLY AND REMAINS THE PROPERTY
OF NATIONAL OILWELL. REPRODUCTION, IN WHOLE OR
CONCENTRICITY X.XX ± .03
DESIGNED BY DATE
BOTTOM WRENCH
IN PART, OR USE OF THIS DESIGN OR DISTRIBUTION
OF THIS INFORMATION TO OTHERS IS NOT PERMITTED
SQUARENESS
PARALLELISM
X.X ± .1
ANGLE ± .50 DEGREE DRAWN BY DATE
ASSEMBLY
WITHOUT THE EXPRESS WRITTEN CONSENT OF
NATIONAL OILWELL. THIS DOCUMENT IS TO BE
RFS EXCEPT WHEN M MODIFIED SURFACE RMS 250 M E ANDERSON 7/15/03 SIZE DRAWING No. REV
RETURNED TO NATIONAL OILWELL UPON REQUEST
AND IN ANY EVENT UPON COMPLETION OF THE USE
BDW
DATE
7/25/03 D BW02 I
FOR WHICH IT WAS LOANED. LAYOUT No. NEXT ASS'Y SUPERSEDED BY P.E. APPROVAL DATE SCALE EST WT SHEET
JB 7/25/03 1:4 LBS 1 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 DWG No.
BW02
SHT
2 1
I SEE SHT 1 FOR REVISIONS CEL BDW 02-Jun-05 BDW
D 30
16 32 D
15
22
18
28 17
6 27
C C
1
5
33 2
14 13 12
33
8
23
B 31 B
11
4
9
20
10
7
20
PROPRIETARY INFORMATION
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION
A WHICH BELONGS TO NATIONAL OILWELL. IT IS LOANED FOR LIMITED PURPOSES

ONLY AND REMAINS THE PROPERTY OF NATIONAL OILWELL. REPRODUCTION,
IN WHOLE OR IN PART, OR USE OF THIS DESIGN OR DISTRIBUTION OF THIS
A
INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT THE EXPRESS WRITTEN
CONSENT OF NATIONAL OILWELL. THIS DOCUMENT IS TO BE RETURNED TO
NATIONAL OILWELL UPON REQUEST AND IN ANY EVENT UPON COMPLETION
TITLE
OF THE USE FOR WHICH IT WAS LOANED.
DESIGNED BY DATE
BOTTOM WRENCH
DRAWN BY DATE
ASSEMBLY
M E ANDERSON 7/15/03 SIZE DRAWING No. REV
CHECKED BY
BDW
DATE
7/25/03 D BW02 I
P.E. APPROVAL DATE SCALE EST WT SHEET
JB 7/25/03 1:4 0 LBS 2 OF 2
8 7 6 5 4 3 2 1
8 7 6 5 4 3 DWG No.
BW02-13
SHT
1 1
-MODEL#: C REDRAWN IN SOLIDWORKS, MODIFIED PINS NT KA 2/16/04 BW
-BORE DIA: 5"
D REORGANIZED MODEL, MODIFIED PIN NT KA 4/25/04 BW
-ROD DIA: 2-1/2" 27 5/16"
E ADDED G-SWITCH NT KA 8/10/04 BW
-PORT SIZE: SAE-12, POSITION #2 FULLY RETRACT
2"
-ROD MATERIAL: 17-4 SS 1 3/4" MOVED HARDWARE TO UPPER LEVEL
-MOUNTING STYLE: FIXED CLEVIS

-STROKE: 11"
D -DISTANCE CEN TER TO CENTER D
WHEN FULLY RETRACT: 27-1/4"
-MAX WORKING PRESSURE: 3000PSI
-FORCE AT MAX WORKING PRESSURE
+EXTEND: 58900 LBS
+RETRACT: 44200 LBS
-VOLUME OF OIL CONSUMED, EXTENSION STROKE: .94 GALLON
-VOLUME OF OIL CONSUMED, RETRACTION STROKE: .7 GALLON
-APROXIMATE WEIGHT: 150LBS
3
*G-SWITCH P/N:
7844092 - SWITCH, LIMIT TOPWORX-SUNSOURCE 77-14539-B20
3 15/16"
18 1/8"
4 7/16"
C 2X 1/4-20 UNC - 2B 1/2"
2 1/4" 2 C
15/16"
1/2" 3"
1.750
G-SWITCH
SEE NOTE*
2.250 2 3/8"
3"
1.125
1
1 7/8"-12 UNF
1.000
+.004
B 2.000
+.002 B
2X 1/4-20 UNC - 2B 1/2"
1.125
2 15/16" 2.250
1.125
1 7/8-12 UNF
R2"
5 1/2"
3/4"
1 1/4" 3 1 7025102 SCREW, HEX SOC FLAT PT SET 1/4-20 X3/8 .01
2 1 BW02-13-01-02 TORQUE CYLINDER CLEVIS .00
2 1/2" 5" 1 1 BW02-13-01 TORQUE CYLINDER BODY .00
MATERIAL SPEC
A 1/4-20 UNC - 2B 1/2" THIS DOCUMENT CONTAINS PROPRIETARY AND
DIMENSIONS ARE IN INCHES DIMENSIONAL TOL. A
(FOR SET SCREW) CONFIDENTIAL INFORMATION WHICH BELONGS
FILLET RADII TITLE
TO NATIONAL OILWELL. IT IS LOANED FOR LIMITED X.XXX ± .015
DESIGNED BY DATE TORQUE CYLINDER ASSEMBLY
SQUARENESS X.X ± .1
PARALLELISM ANGLE ± .50 DEGREE DRAWN BY DATE IR3080
RFS EXCEPT WHEN M MODIFIED SURFACE RMS 250 KA 9/3/03 SIZE DRAWING No. REV
BW
DATE
9/3/03 D BW02-13 E
JB 9/3/03 1:3 155 LBS 1 OF 1
8 7 6 5 4 3 2 1
Revision 02
SECTION E:
ELECTRICAL CONTROLS
www.nov.com
DRILLING SYSTEMS AND ENGINEERING
BILL OF MATERIAL
Description ELECTRICAL CONTROL KIT
Part Number 0001-0579-70 Page 1 of 1
Revision A
ITEM QTY
PART NO. DESCRIPTION
NO. REQ’D
0001 0001-0579-71 ASSEMBLY – ELECTRO-HYDRAULIC 1.0000
0002 0001-0365-61 ERLS J-BOX ASSY, IR3080ARM55 1.0000
0003 0001-0365-68 CONTROL CONSOLE ASSY, IR-3080 1.0000
Drawing Number
PL 0001-0579-70
BILL OF MATERIAL
Description CONSOLE
Revision A
ITEM QTY
NO. REQ’D
0001 0000-9643-60 RLY-TIMER,24VDC,2NO INST CONTA 2.0000
0002 0000-9608-70 RLY- 24VDC,4 FORM C(4PDT),3AMP 6.0000
0003 0000-6889-07 RLY-SKT,FUW/KH TYPE P&B RELAY, 6.0000
0004 0000-6889-08 RLY-HOLD DOWN SPRING FUW/P&B 6.0000
0005 0000-9639-60 CONN-PLUG, 7 ,#12 SOCKETS,30A, 1.0000
0006 0000-9640-79 CONN-RECP, 7M,#12AWG,PANEL MOU 1.0000
0008 31T00503 CONN-RECEP,37M,12AWG,EX PANEL 1.0000
0009 0000-6863-37 RAIL-DIN,35X7.5MM,EN 50022,2M 3.0000
0010 0000-9606-91 TB- 32A,800V,GRAY 5.2MM UK 3 N 60.0000
0011 0000-6934-67 TB-END CVR,U/W UK5,D-UK4/10 1.0000
0012 0000-7000-27 TB-END CLAMP,FUW E/UK SERIES 6.0000
0013 0000-6962-37 TB-MARKER STRIP SET,TYPE KLM-A 1.0000
0014 0001-0591-73 PLATE-MTG,TOP,IR CONSOLE 1.0000
0015 0000-9644-32 HEATSHRINK TUBING-1000V,1/C, 1.0000
0017 0001-0591-68 WELDMENT, IR CONSOLE 1.0000
0018 0000-9643-62 SW-SEL,2POS,MAINTAINED CONTACT 2.0000
0019 0000-9643-63 SW-SEL,3POS,MAINTAINED CONTACT 1.0000
0020 0000-9643-66 CONT-BLK,STACKABLE,SEALED,1NO- 7.0000
0021 0000-6953-82 SW-SEL,2POS,MNTN SW,EEX'D', 1.0000
0022 0000-9643-64 SW-SEL,3POS,SPRING RETURN CENT 2.0000
0023 0000-9643-61 PB-EMERGENCY STOP,MAINTAINED 1.0000
0025 0000-9643-65 CONT-BLK,STACKABLE,SEALED,2NC 1.0000
0026 0000-9644-35 PB-PADLOCK ATTACHMENT 1.0000
0027 0000-9603-04 KEEPER-PLATE,LINK-LOCK,MEDIUM 2.0000
0027 0000-9603-05 LATCH- LINK-LOCK,MEDIUM DUTY 2.0000
0032 0000-9643-67 PL- 24VAC/DC,GREEN,LED,PRESS 1.0000
0033 0000-9643-68 PL- 24VAC/DC,RED,LED,PRESS TO 1.0000
0035 0000-9641-68 INDICATOR-DIGITAL,PNL MTG,IS, 1.0000
0036 0000-9641-69 INDICATOR-DIGITAL,PNL MTG,IS, 1.0000
0037 0001-0496-24 SW MAKE UP/BREAK OUT 1.0000
0040 0000-9638-12 CABLE- 7COND,18AWG,600VAC,ICEA 5.0000
0041 0000-9638-16 BOX-SINGLE GANG 1.0000
0042 0000-9638-17 COVER-SINGLE GANG BLANK COVER 1.0000
0043 0000-9638-18 CARD-ELECTRIC AMPLIFIER 1.0000
0044 0000-9638-19 HOLDER-AMPLIFIER CARD 1.0000
0046 7821604 DRAIN-UNIVERSAL,1/2"NPT,ECD 1.0000
0047 0000-9622-10 GLAND-CABLE,1/2",NON-ARMORED, 2.0000
0048 0000-9638-11 CONN-1/2"NPT,SIZE 20,EXPL PROO 1.0000
0052 0000-9640-97 ISOLATOR-CYLINDRICAL VIBRATION 4.0000
0053 0000-9642-63 PIN-QUICK RELEASE,PUSH BUTTON, 2.0000
0054 0001-0580-36 BASE, MOUNTING IRON ROUGHNECK 1.0000
0055 0001-0589-33 N/P-SW,WELL CNT/MOUSE HOLE 1.0000
0056 14T00341 PL-TIE DOWN,30.5MM,METAL 12.0000
0057 0000-6942-83 WIRE DUCT-1.50WX2.25H,GRY,6 FT 2.0000
0058 0000-6942-26 WIRE DUCT-1.00WX2.25H,GRY,6 FT 4.0000
0059 0001-0390-19 CABLE- 1COND,16AWG,600VAC,DARK 300.0000
0060 0000-6802-23 CABLE- 1COND,20AWG,600VAC,DARK 300.0000
Drawing Number
PL 0001-0365-68
BILL OF MATERIAL
Description HYDRAULIC ENCLOSURE
Revision A
ITEM QTY
NO. REQ’D
0001 0001-0591-41 ENCLOSURE-HYDRAULIC WELDMENT 1.000
0002 HC01-13-02 BAR-SPRT,SOLENOID VLV,HYD ENCL 2.000
0003 HC01-13-03 CHANNEL-SOLENOID ID TAG,1.5X 1.000
0004 0001-0591-77 DOOR-HYDRAULIC ENCL 1.000
0005 0000-6911-61 SCREW-THUMB,1-11/16"LONG,1/4"- 2.000
0007 4532-0066-00 TUBING-SEAMLESS, .75 X .065 W 1.000
0008 HC01-06 VALVE-MANIFOLD,8 SOLENOID VALV 1.000
0009 0000-9646-99 SW-LIMIT,ROLLER PLUNGER,1PDT 1.000
0013 HC01-07 SHUTTLE VALVE 1.000
0014 HC01-08 BALL VALVE 1.000
0015 HC01-09 VALVE-RELIEF,INTERNAL SOCKET 1.000
0060 0001-0591-76 N/P-ID,HYDRAULIC ENCLOSURE, 1.000
0061 0001-0566-58 N/P-ID,CHANNEL TAG 1.000
0070 2302035042 TEE-FEMALE RUN,3/4"FEMALE JIC 1.000
0072 4512-0200-07 CONN-STRAIGHT,5/8"MALE ORB X 16.000
0075 4512-0100-10 HOSE END-SWIVEL 90 DEG ELBOW, 3.000
0076 4512-0200-01 HOSE END-SWIVEL STRAIGHT,1/2" 4.000
0077 4512-0200-08 BULKHEAD-90 DEG,1/2"MALE JIC X 3.000
0078 7800127 BULKHEAD-STRAIGHT,1/4"MALE JIC 3.000
0079 7802391 CONN-STRAIGHT,3/4"MALE ORB X 1.000
0081 4512-0033-01 CONN-STRAIGHT,1/4"FEMALE NPT X 4.000
0082 7817188 REDUCER-1/2"JICF X 3/8"JICM 2.000
0084 7804123 ELBOW-90 DEG,#6SAE X #6JIC 2.000
0085 7817450 REDUCER-SWIVEL STRAIGHT,1/2" 1.000
0090 4512-0026-14 ELBOW-90 DEG,1/4"MALE JIC X 1.000
0091 7805817 HOSE END-SWIVEL STRAIGHT,1/4" 8.000
0092 610008304 HOSE-PTFE WITH EXTERNAL STAINL 10.00
0093 4598-0002-64 HOSE-HYDRAULIC,3/8"I.D.,3000 5.000
0095 4514-0400-20 TEE-MALE BRANCH,3/8"MALE ORB X 1.000
0096 7800261 CONN-SWIVEL STRAIGHT,3/8"MALE 2.000
0097 7800080 CONN-STRAIGHT,3/8"MALE NPT X 2.000
0098 4512-0200-09 REDUCER-1/2"MALE ORB X 3/8"FEM 1.000
0100 4512-0200-10 ELBOW-90 DEG,3/4"MALE ORB X 1.000
0103 7804121 ELBOW-90 DEG,3/8"MALE ORB X 1.000
0104 7802788 CAP-1/4"JIC,STEEL 1.000
0120 4514-0400-02 ELBOW-90 DEG,3/4"MALE ORB X 1.000
0121 7817401A REDUCER-TUBE END,3/4"FEMALE 1.000
Drawing Number
PL 0001-0591-40
BILL OF MATERIAL
Description HYDRAULIC ENCLOSURE
Revision A
ITEM QTY
NO. REQ’D

0125 0000-9657-02 BULKHEAD-90 DEG,3/4"MALE JIC X 2.000
0127 4512-0026-01 CONN-STRAIGHT,3/4"MALE NPT X 1.000
0128 7804829 ELBOW-90 DEG,1/4"MALE ORB X 1.000
0130 7800718 CROSS-3/4"FEMALE NPT,STEEL 1.000
0132 0000-9657-01 ELBOW-45 DEG,3/4"FEMALE NPT X 1.000
0134 780278824 CAP-1-1/2"JIC,STEEL 1.000
0135 7804820 ELBOW-90 DEG,3/4"MALE NPT X 1.000
0137 7802955 CAP-1/2"JIC,STEEL 2.000
Drawing Number
PL 0001-0591-40
BILL OF MATERIAL
Description TORQUE SET PANEL
Revision B
ITEM QTY
NO. REQ’D
0001 0001-0591-48 ENCLOSURE-TORQUE SETTING PNL, 1.0000
0002 0000-9607-86 PB-IS,RED,STAY-PUT,38MM HEAD, 1.0000
0003 4510-0050-00 GAUGE,5KPSI DUAL SCALE PANEL 2.0000
0004 HC01-12-04 GAUGE 0-3000 PSI SS U CLAMP 1.0000
0005 0000-9645-40 VALVE-RELIEF,KNOB ADJUSTMENT, 1.0000
0006 0001-0591-61 N/P-ID,FRONT,TORQUE SETTING 1.0000
0006 0001-0591-62 PLATE-FNT,TORQUE SETTING PNL 1.0000
0007 HC01-12-03 PANEL GUARD 2.0000
0008 0000-9644-34 PB-PADLOCK ATTACHMENT 1.0000
Drawing Number
PL 0001-0591-51
BILL OF MATERIAL
Description MAKE-BREAK ROTARY SWITCH
Revision B
ITEM QTY
NO. REQ’D
0001 0001-0591-66 SHAFT-.375RB X 3.56LG,ROTARY 1.0000
0002 0001-0591-29 PLATE-ROTARY SWITCH,1/4"PL X 1.0000
0003 0001-0591-30 PLATE-ROTARY SWITCH,1/4"PL X 1.0000
0004 0001-0591-31 LEVER-ROTARY SWITCH,3/8"PL X 1.0000
0006 0001-0591-33 SHAFT-CAM,2.125"SS RB X 1.243" 1.0000
0007 0001-0591-34 HANDLE-ROTARY SWITCH,2.17" 1.0000
0008 0000-9645-92 SPRING-EXTENSION,2.5"LG,2.00 1.0000
0009 0000-9641-38 S/S PLT-0.375 X SZ X SZ,#304 1.0000
0010 0001-0591-32 SHAFT-ROTARY SWITCH,.563"SS 3.0000
0011 0000-9644-05 BEARING-FLANGED,1/2 OD X 3/8ID 2.0000
0012 0000-9644-04 BEARING-SLEEVE,3/8 OD X 1/4 ID 1.0000
0013 0001-0591-35 SHAFT-ROTARY SWITCH,3/8" RB 1.0000
0014 0001-0591-28 SHAFT-ROTARY SWITCH,1/2" 1.0000
0015 0000-9644-07 BOLT- 1/4-20 X 2.125,HEX HEAD, .0000
0016 0000-9646-99 SW-LIMIT,ROLLER PLUNGER,1PDT 2.0000
0017 3111-1903-01 NUT-1/4-20 ,HEX HD ,S/S .0000
Drawing Number
PL 0001-0496-24
BILL OF MATERIAL
Description ERLS JBOX
Revision -
ITEM QTY
NO. REQ’D
0001 0001-0581-61 BOX, S/S ASSEMBLY 1.0000
0002 MK6431D194A BRACKET, FINE ADJUSTMENT 2.0000
0003 MK6431D194B BRACKET, SWITCH MOUNT 2.0000
0004 MK6431D194H CLAMP PLATE, 2-HOLE 3.0000
0005 MK6431D194D LEVER ARM 1.0000
0006 MK6431D194E FLANGE BEARING 2.0000
0007 MK6431D194C TRIP PLATE 1.0000
0008 MK6431D194F CONNECTING ROD 1.0000
0009 MK6431D194G COLLAR 2.0000
0010 MK6431D194K CLAMP PLATE, 1-HOLE 2.0000
0011 0000-9647-00 SW-LIMIT,SPERICAL PLUNGER,1PDT 3.0000
0012 0000-9643-90 GLAND-CABLE,1/2"NPT,ARMORED & 1.0000
0013 0000-9642-55 BALL JOINT-ROD END 2.0000
0014 0000-9642-56 SEAL-0.991 OD X 0.500 ID X 2.0000
0015 0000-6922-49 TB-MTG RAIL NS15 .5000
0016 0000-9645-32 TB-END BRKT,E/MK 1,GRAY 2.0000
0017 0000-9642-53 TB-END COVER,GRAY,D-MBK 2.5/E 1.0000
0018 0000-9645-31 TB-MINIATURE,250V,MBK 2.5/E-EX 7.0000
0019 0000-9618-58 CABLE- 7COND,18AWG,600VAC,ICEA 6.0000
0020 0000-9643-95 BUSHING-RED,3/4"MNPT X 1/2"FNP 1.0000
0022 0001-0365-82 N/P-ID, ERLS J-BOX 1.0000
0023 7821604 DRAIN-UNIVERSAL,1/2"NPT,ECD 1.0000
0024 0000-9645-30 TB-MARKER STRIP,BNB-ZB 5.2,#1- 2.0000
0025 0000-9653-71 BOLT-KIT,I.R. ERLS BOX,SEND 1.0000
Drawing Number
PL 0001-0365-61
BILL OF MATERIAL
Description SOLENOID J-BOX
Revision A
ITEM QTY
NO. REQ’D
0001 0000-9609-71 CABLE-37COND, 14AWG,600V,ICEA 56.0000
0002 0000-9623-49 GLAND-CABLE,1-1/4",ARMORED,EXP 1.0000
0003 7815688 PLUG-HEX HD,1/2"NPT,316SS 5.0000
0004 0000-9627-36 TB-UK5N,24-10AWG,IEC 41AMPS, 56.0000
0005 0000-9605-88 TB-GROUND,GRN & YEL,USLKG5 10.0000
0006 0001-0591-39 ENCLOSURE-JUNCTION BOX 1.0000
0007 0000-9628-64 GLAND-CABLE,1/2"NPT,NON-ARMORE 10.0000
0008 0000-7000-27 TB-END CLAMP,FUW E/UK SERIES 4.0000
0009 0000-6934-67 TB-END CVR,U/W UK5,D-UK4/10 3.0000
0010 0000-6863-37 RAIL-DIN,35X7.5MM,EN 50022,2M 2.0000
0011 0000-9643-95 BUSHING-RED,3/4"MNPT X 1/2"FNP 1.0000
0012 0000-9643-90 GLAND-CABLE,1/2"NPT,ARMORED & 1.0000
0013 0000-9622-11 GLAND-CABLE,1/2",NON-ARMORED, 1.0000
0018 0000-9639-62 CONN-PLUG,37 ,#12 SOCKETS,30A, 1.0000
0019 0000-9644-31 HEATSHRINK TUBING-1000V,1/C, 1.0000
0020 0000-9641-98 TRANSMITTER-PRESSURE,0-3K PSI, 1.0000
0021 0000-9641-99 TRANSMITTER-PRESSURE,0-5K PSI, 1.0000
0023 7801660 TB-FIXED BRIDGE,34A,10 POS, 2.0000
0060 0001-0609-63 N/P-ID,SOLENDOID J-BOX, 1.0000
Drawing Number
PL 0001-0579-72
Revision 02
SECTION F:
INSTALLATION SPARES
www.nov.com
IRON ROUGHNECK
INSTALLATION
and
COMMISSIONING
SPARES
Document Number
104-100-00
DOCUMENT OR DRAWING NO. PAGE
104-100-00 1 of 1
SUBJECT
INSTALLATION and COMMISSIONING SPARES KIT REVISED DATE REV.
MODEL IR-3080 IRON ROUGHNECK

PREPARED BY DATE CHECKED BY DATE
B.M.D. 8-9-05
ITEM NO. PART NO. QTY DESCRIPTION
1 AR01-11-03 8 SHIM 1/2”
2 AR01-11-04 8 SHIM 3/8”
3 AR01-11-05 8 SHIM 1/4”
4 ARO1-11-06 8 SHIM 1/8”
5 AR01-11-07 8 SHIM 1/16”
6 HC01-11 1 FILTER CARTRIDGE
Document Number
104-100-00
Revision 02
SECTION G:
RECOMMENDED SPARES
www.nov.com
Arm
REFERENCE REFERENCE DESCRIPTION

RIG/PLANT
IR3080AR5503 Recommended Spare Parts List
subsidiaries (all collectively referred to hereinafter as "NOV"). It is National Oilwell Varco
REMARKS loaned for limited purposes only and remains the property of NOV. 1530 W. Sam Houston Parkway N
Reproduction, in whole or in part, or use of this design or Houston, Texas 77043
MAIN TAG NUMBER DISCIPLINE distribution of this information to others is not permitted without the
express written consent of NOV. This document is to be returned to
NOV upon request or upon completion of the use for which it was Phone: (713) 935-8000
CLIENT PO NUMBER loaned. This document and the information contained and Fax: (713) 935-8269
DOCUMENT NUMBER REV

Client Document Number
105-003-01 01
www.nov.com
Revision 01
Page 2
REVISION HISTORY

CHANGE DESCRIPTION

01 First issue
01 Revised and updated to include spares for electrical controls
www.nov.com
Revision 01
Page 3
1 DEFINITIONS
This section provides definitions for part classifications, accessibility of spare parts, and
recommendations.
1.1 Part Classification

Part Class Part Type Part Description
Class A Maintenance Expendable items requiring periodic service or replacement.
Items
Class B Repair Items Wearing parts, which normally have an extended, but not
indefinite life.
Class C Major Repair Parts ordinarily replaced only during major overhaul.
Items
1.2 Spare Parts Accessibility

Spares Definition
Category
Area 1 Equipment operating within easy access to a National Oilwell Varco store or
customer’s own regional warehouse and expendable parts anticipated for
operation of one year.
Area 2 Equipment operating in remote areas.
Group I Spares for one unit per year.
Group II Spares to support up to two units operating in the area per year.
1.3 Recommendations
Operations Recommendations
Equipment in 1 Lot of Spares for each unit.
accessible
Area 1
Equipment in 1 Lot of Group I Spares for each unit per year,
accessible OR
Area 2 1 Lot of Group II Spares for approximately each 2 units
2-3 years Multiply Class A spares by 2.
operations
www.nov.com
Revision 01
Page 4
Document or Drawing Page
105-003-01
Subject
Recommended Spare Parts List Revised Date Rev.
IR3080AR5503 Iron Roughneck 1-15-07 01

Prepared By Date Checked By Date
BMD 3-11-04
ASSEMBLIES
PART NO. DESCRIPTION PER
IRON ROUGHNECK
AR01-RSP ARM ASSEMBLY 1
AR01-01-RSP ARM, RIGHT TOP ASSEMBLY 1
AR01-02-RSP ARM, LOWER LEFT ASSEMBLY 1
AR01-03A-RSP ARM, ASSEMBLY 1
AR01-03B-RSP ARM, ASSEMBLY 1
AR01-03C-RSP ARM, ASSEMBLY 1
AR01-10-RSP GUIDE ASSEMBLY 1
AR01-11-RSP BASE ASSEMBLY 1
BW02-RSP BOTTOM WRENCH ASSEMBLY 1
BW02-13-RSP TORQUE CYLINDER ASSEMBLY 1
LS01-RSP LIFTING SKID ASSEMBLY 1
SA01-RSP SPINNER & SUPPORT ASSEMBLY 1
SP01-RSP SPINNER ASSEMBLY 1
SP01-03-RSP ROLLER ASSEMBLY 1
SP01-09-RSP SPRING BRACKET ASSEMBLY 2
SPAR-0001-0579-70 ELECTRICAL CONTROLS KIT 1
TW02-RSP TOP WRENCH ASSEMBLY 1
www.nov.com
1 OF 1
AR01-RSP
SUBJECT REVISED DATE REV.
ARM ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
PART NO. DESCRIPTION CLASS WEIGHT AREA AREA 2
* IN LBS 1 GROUP
I II
AR01-03-04 PIN, ARM C 0 2 4

AR01-03-05 PIN, ARM C 0 2 4
AR01-09-03 PIN, ARM C 0 2 4
AR01-17 PIN C 0 1 2
AR01-18 PIN C 0 1 2
AR01-19 PIN C 0 1 2
AR01-20 PIN C 0 1 2
AR01-06 BEARING, SLEWING C 0 1 2
AR01-08 CYLINDER, LIFT C 0 0 2
AR01-08-01 ROD GLAND w/SEALS, CYLINDER B 1 1 2
AR01-08-02 PISTON SEAL/TUBE KIT, CYLINDER B 1 1 2
AR01-14 CYLINDER, EXTEND/RETRACT B 1 1 2
AR01-14-01 ROD GLAND w/SEALS B 1 1 2
AR01-14-02 PISTON SEAL/TUBE KIT, CYLINDER B 1 1 2
7805052 ZERK, GREASE 1/8” UNF SST B 4 8 16
1 OF 1
AR01-01-RSP
ARM, RIGHT TOP ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
PART NO. DESCRIPTION CLASS* WEIGHT AREA AREA 2
IN LBS 1 GROUP
I II
AR01-01-01A BUSHING, FLANGED C 8 8 8

AR01-01-01A-01 BUSHING, FLANGED C 4 4 4
1 OF 1
AR01-02-RSP
ARM, LOWER LEFT ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
IN LBS 1 GROUP
I II

AR01-01-01A-01 BUSHING, FLANGED C 4 4 4
1 OF 1
AR01-03A-RSP
ARM ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
IN LBS 1 GROUP
I II

1 OF 1
AR01-03B-RSP
ARM ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
IN LBS 1 GROUP
I II

1 OF 1
AR01-03C-RSP
ARM ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
IN LBS 1 GROUP
I II

1 OF 1
AR01-10-RSP
GUIDE ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
AR01-07 BEARING, CAM FOLLOWER C 1 2 2

AR01-07-01 NUT, CAM FOLLOWER C 1 2 2
AR01-07-02 WASHER, CAM FOLLOWER C 1 2 2
HC01-01 MANIFOLD 1, EXTEND/RETRACT C 0 0 1
HC01-02 MANIFOLD 2, WRENCH LIFT C 0 0 1
HC01-10 FILTER C 0 0 1
HC01-11 FILTER CARTRIDGE A 1 3 6
7500743 NEEDLE VALVE C 0 1 1
1 OF 1
AR01-11-RSP
BASE ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
PART NO. DESCRIPTION CLASS WEIGHT ARE AREA 2
* IN LBS A1 GROUP
I II
AR01-11-03 SHIM, 1/2” C 0 2 4

AR01-11-04 SHIM, 3/8” C 0 2 4
AR01-11-05 SHIM, 1/4” C 0 2 4
AR01-11-06 SHIM, 1/8” C 0 2 4
AR01-11-07 SHIM, 1/16" C 0 2 4
1 OF 1
BW02-RSP
SUBJECT
BOTTOM WRENCH ASSEMBLY, REV. H REVISED DATE REV.
6-29-05 C
BMD 6-29-05
ACCESSIBILITY
AREA
* IN LBS A1 GROUP
I II
AC01-01-03 WIDE DIE 4 ((WD4) A 12 40 80

AC01-02-01 WIDE DIE HOLDER C 0 0 2
AC01-02-01-01 LOCK PLATE 1 C 0 4 8
AC01-02-01-02 LOCK PLATE 2 C 0 2 4
TW01-04 BALL BUSHING C 0 1 2
TW01-06 ROD WASHER C 0 2 4
TW01-07 ROD PIN C 0 2 4
TW01-08 STOP PIN C 0 2 4
TW01-22 SPRING PIN C 0 2 4
TW02-12 CYLINDER, JAW C 0 1 2
TW02-12-01 SEAL KIT, CYLINDER B 1 2 4
1100204 MANIFOLD C 0 0 1
7828645 CARTRIDGE, CHECK VALVE C 0 0 1
7828647 CARTRIDGE, SYNCHRONIZING FLOW DIV/COMB C 0 0 1
1 OF 1
BW02-13-RSP
TORQUE CYLINDER ASSEMBLY, REV. E
5-4-05 B
BMD 5-4-05
ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
7844092 LIMIT SWITCH C 0 1 1

BW02-13-01 CYLINDER C 0 0 1
BW02-13-01-03 ROD GLAND W/SEAL KIT B 1 1 2
BW02-13-01-04 PISTON SEAL/TUBE KIT B 1 1 2
1 OF 1
LS01-RSP
LIFTING SKID ASSEMBLY
BMD 2/2/04
ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
LS01-08 RATCHET STRAP C 0 1 2

LS01-04 TURNBUCKLE C 0 1 2
LS01-07 PIN, LIFTING LINK C 0 1 2
6500812S PIN, COTTER B 0 2 4
1 OF 1
SA01-RSP
SPINNER & SUPPORT ASSEMBLY, REV. B
3-12-05 A
BMD 3-12-05
ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
6500816S PIN, COTTER B 0 2 4

AR01-18 PIN C 0 1 2
IR3080AR55-
SPRING C 0 1 2
09
7817499 ROD END C 2 2 4
6320121 NUT, HEX JAM C 2 2 4
SP01-11 EYEBOLT C 0 1 2
1 OF 1
SP01-RSP
SPINNER ASSEMBLY, REV. F
6-29-05 C
BMD 6-29-05
ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
SP01-04 CYLINDER C 0 0 1
SP01-04-01 ROD GLAND W/SEAL KIT, CYLINDER B 1 1 2
SP01-04-02 SEAL/TUBE KIT, CYLINDER B 1 1 2
SP01-50 BUSHING, FLANGED C 2 2 4
SP01-51 BUSHING C 2 2 4
SP01-52 BUSHING, FLANGED C 2 2 4
1100205 MANIFOLD C 0 0 1
218319/005 PIN, RETAINING SAFETY B 2 2 4
7815566 PIN, SAFETY B 2 2 4
7828642 RELIEF VALVE CARTRIDGE C 0 0 1
7828619 COUNTERBALANCE CARTRIDGE C 0 0 1
1 OF 1
SP01-03-RSP
ROLLER ASSEMBLY, REV. E
7-1-05 B
BMD 7-1-05
ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
568224/020 O-RING B 4 4 8
HM001 HYDRAULIC MOTOR C 1 4 8
SP01-03-02 WHEEL B 8 8 16
SP01-03-05 SEAL SPACER B 2 8 16
7634040 WASHER B 24 24 48
700032611 SCREW, HEX HEAD CAP, 1/2-13 X 6-1/2 B 12 12 24
6300081 NUT, HEX 1/2-13UNC B 12 12 24
1 OF 1
SP01-09-RSP
SPRING BRACKET ASSEMBLY
BMD 2/2/04 2/2/04

ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
7817499 ROD END BALL JOINT C 2 2 4

6320121 NUT, HEX JAM C 2 2 4
SPAR-0579-70 1 OF 1
IR CONTROLS KIT 0001-0579-70 A
MJF 1-19-06
ACCESSIBILITY
AREA
* IN LBS A1 GROUP
I II
0000-9643-60 RELAY TIMER B 1 1 2

0000-9608-70 RELAY B 1 1 2
0000-6889-07 RELAY SOCKET B 1 1 2
0000-6889-08 RELAY HOLD DOWN SPRING B 1 1 2
0000-9639-60 PLUG 7-CONTACT B 0 1 2
0000-9640-79 RECEPTICLE 7-CONTACT B 0 1 2
31T00503 RECEPTICLE 37-CONTACT B 0 1 2
0000-9643-62 2-POS SELECT SW MAINTAINED B 1 1 2
0000-9643-63 3-POS SELECT SW MAINTAINED B 1 1 2
0000-9643-64 3-POS SELECT SW SPRING RETURN CENTER B 1 1 2
0000-9643-66 SELECT SW CONTACT BLOCK 1NO-1NC B 2 2 4
0000-9657-73 SEL SW REPLACEMENT KNOB – HYPALON B 1 1 2
0000-9659-20 OPTIONAL–METAL WING LEVER SEL SW KNOB B 0 0 0
0000-9643-61 RED PUSH-PULL BUTTON B 1 1 2
0000-9643-65 PUSH-PULL BUTTON CONTACT BLOCK 2NC B 1 1 2
0000-6953-82 2-POS SELECT SW MAINTAINED EEXD B 1 1 2
0000-9643-67 GREEN PILOT LIGHT B 1 1 2
0000-9643-68 RED PILOT LIGHT B 1 1 2
0000-9641-68 SYSTEM PRESSURE METER B 1 1 2
0000-9641-69 TORQUE METER B 1 1 2
0000-9638-18 AMPLIFIER CARD B 1 1 2
0000-9638-19 AMPLIFIER CARD HOLDER B 1 1 2
0000-9646-99 MKE-BRK SW & HYD ENC DOOR- LIMIT SW B 1 1 2
0000-9647-00 ERLS LIMIT SWITCH B 1 1 2
0000-6911-61 HYD ENC THUMB SCREW B 2 2 4
0000-9659-00 SOLENOID B 1 1 2
HC01-07 SHUTTLE VALVE B 1 1 2
HC01-09 RELIEF VALVE B 1 1 2
0000-9607-86 RED PUSH-PULL BUTTON EEXD B 1 1 2
4510-0050-00 0-5000 PSI DUAL SCALE PRESSURE GAUGE B 1 1 2
HC01-12-04 0-3000 PSI PRESSURE GAUGE B 1 1 2
0000-9645-40 RELIEF VALVE B 1 1 2
0000-9641-98 0-3000 PSI PRESSURE TRANSMITTER B 1 1 2
0000-9641-99 0-5000 PSI PRESSURE TRANSMITTER B 1 1 2
0001-0377-96 37 CONTACT PLUG AND CABLE ASSEMBLY B 1 1 2
1 OF 1
TW02-RSP
SUBJECT
TOP WRENCH ASSEMBLY, REV. G REVISED DATE REV.
6-29-05 D
BMD 6-29-05
ACCESSIBILITY
AREA
* IN LBS A1 GROUP
I II
AC01-01-03 WIDE DIE 4 ((WD4) A 24 80 160

AC01-02-01 WIDE DIE HOLDER C 0 0 2
AC01-02-01-01 LOCK PLATE 1 C 0 4 8
AC01-02-01-02 LOCK PLATE 2 C 0 2 4
TW01-04 BALL BUSHING C 0 1 2
TW01-06 ROD WASHER C 0 2 4
TW01-07 ROD PIN C 0 2 4
TW01-08 STOP PIN C 0 2 4
TW01-22 SPRING PIN C 0 2 4
TW02-12 CYLINDER, JAW C 0 1 2
TW02-12-01 SEAL KIT, CYLINDER B 2 2 4
1100203 MANIFOLD C 0 0 1
7828645 CARTRIDGE, CHECK VALVE C 0 1 2
Revision 02
SECTION 10:
PRODUCT INFORMATION
www.nov.com
MAINTENANCE MANUAL
HYDRAULIC POWER UNIT
HYDRAULIC POWER UNIT

FOR
THE IR 3080 IRON ROUGHNECK
MAINTENANCE MANUAL
TABLE of CONTENTS
Ø INSTRUCTION SHEET
Ø DRAWING LIST DRAWING NO.
1. START-UP KIT 2302061-016
2. RECOMMENDED SPARES LIST 2302061-019
3. BILL of MATERIAL 2302061-000
4. GENERAL ASSEMBLY 2302061003
5. RESERVOIR ASSEMBLY 2302061005
6. PUMP and MOTOR ASSEMBLY 2302061007
7. HIGH PRESS. FILTER ASSEMBLY 2302061012
8. HEADER ASSEMBLY 2302061011
9. HEAT EXCHANGER ASSEMBLY 2302061017
10. ELECTRICAL SCHEMATIC 1431-806-31
11. HYDRAULIC SCHEMATIC 2302061-001
Ø GENERAL INFORMATION LIST
1. FLUID RECOMMENDATIONS
2. CONTAMINATION EVALUATION GUIDE
3. STORAGE RECOMMENDATIONS
4. FILTRATION RECOMMENDATION
5. FLUID SUPPLIER RECOMMENDATION
6. PIPING INFORMATION FOR HYD. SYSTEMS
7. HYDRAULIC SYSTEM SERVICE SUGGESTIONS
Ø HPU COMPONENT INFORMATION
DESCRIPTION DRAWING NO
KIT, START-UP IR 3080 HPU 2302061-016
LIST of RECOMMENDED SPARES 2302061-019
BILL of MATERIAL IR 3080 HPU 2302061-000
ASSEMBLY, DRAWING HPU 2302061003
ASSEMBLY, DRAWING RESERVOIR 2302061005
ASSEMBLY, PUMP/MOTOR I/R 3080 2302061007
ASSEMBLY, HIGH PRESS FILTER 2302061012
ASSEMBLY, HEADER-SUPPLY & RETURN 2302061011
ASSEMBLY, HEAT EXCHANGER 2302061017
SCHEMATIC, ELECTRICAL 1431-806-31
SCHEMATIC, HYDRAULIC HPU 2302061-001
1 OF 1
2302061-016
KIT, START-UP
IR 3080 HYDRAULIC POWER UNIT
Larry DeSmit 1/27/04 Ron McKinney 1/27/04

1 7804882 2 ELEMENT, BREATHER FILTER
2 2302070-019 2 ELEMENT, SUCTION FILTER ATZ-300
3 2302070-018 2 ELEMENT, HIGH PRESSURE FILTER
4 2302070-017 4 ELEMENT, RETURN TANK TOP FILTER
5
6
7
8
9
10
1 OF 2
2302061-019
LIST, RECOMMENDED SPARES
LARRY De SMIT 1/27/04 RON McKINNEY 1/27/04
DEFINITIONS
I. CLASS OF PART
CLASS A: MAINTENANCE ITEMS - EXPENDABLE ITEMS REQUIRING PERIODIC

SERVICE OR REPLACEMENT.
CLASS B: REPAIR ITEMS - WEARING PARTS WHICH NORMALLY HAVE AN
EXTENDED, BUT NOT INDEFINITE LIFE.
CLASS C: MAJOR REPAIR ITEMS - PARTS ORDINARILY REPLACED ONLY DURING
MAJOR OVERHAUL.
II. ACCESSIBILITY TO SPARE PARTS
AREA 1: EQUIPMENT OPERATING WITHIN EASY ACCESS TO A NATIONAL-

OILWELL STORE OR CUSTOMER’S OWN REGIONAL WAREHOUSE AND
EXPENDABLE PARTS ANTICIPATED FOR OPERATION OF ONE YEAR.
AREA 2: EQUIPMENT OPERATING IN REMOTE AREAS.
GROUP I: SPARES FOR ONE UNIT PER YEAR.
GROUP II: SPARES TO SUPPORT UP TO TWO UNITS OPERATING IN THE AREA

PER YEAR.
RECOMMENDATIONS
I. AS A GENERAL RULE FOR EQUIPMENT OPERATING IN AN ACCESSIBILITY AREA 1,

WE RECOMMEND:
1 LOT OF SPARES FOR EACH UNIT.
II. AS A GENERAL RULE FOR EQUIPMENT OPERATING IN AN ACCESSIBILITY AREA 2,

WE RECOMMEND:
1 LOT OF GROUP I SPARES FOR EACH UNIT PER YEAR,

OR
1 LOT OF GROUP II SPARES FOR APPROXIMATELY EACH 2 UNITS
OPERATING IN THE AREA.
III. FOR ONLY TWO TO THREE YEARS OPERATION, MULTIPLYCLASS A SPARES ONLY BY
2
2 OF 2
2302061-019
LIST, RECOMMENDED SPARES
LARRY De SMIT 1/27/04 RON McKINNEY 1/27/04
ACCESSIBILITY
AREA
* IN LBS 1 GROUP
I II
7804882 ELEMENT, BREATHER FILTER A 2 2 4

2302070-019 ELEMENT, SUCTION FILTER ATZ-300 A 2 2 4
2302070-018 ELEMENT, HIGH PRESSURE FILTER A 2 2 6
2302070-017 ELEMENT, RETURN TANK TOP FILTER A 4 6 12
L724113135 PUMP, PISTON TYPE AXIAL C 1
2302070-001 VALVE, RELIEF 1.5" CD 62 FLANGE MOUNT C 1
4510-0051-00 SWITCH, FLOAT BARKSDALE C 1
7811704 LEVEL, SIGHT LUBE DEVICE G640-12-A1 C 1
2302070-005 VALVE, THERMOSTATIC FPE -12 SAE ELEMENT C 1
2302070-012 COUPLING, MAGNALOY 500 U C 1
4510-0050-00 GUAGE, PRESSURE 63 MM 5000 PSI B 1 2
4512-0100-03 FITTING, STAUFF -4 SAE TEST C 1
7805665 FITTING, STAUFF DGA-20-1/4 , TEST C 1
4514-0400-24 FITTING, STAUFF TEST PORT SAE-6 C 1
0000-9642-64 CONN-PLUG, 7M, #12 AWG, EX TYPE B 1
0000-9642-65 CONN-RECP, 7F, #12AWG, EX TYPE B 1
1 OF 2
2302061-000
BILL of MATERIAL IR 3080 HPU
ASSEMBLY
Larry DeSmit 04 FEB 04 Ron McKinney 04 FEB 04

1 L724113135 1 PUMP, PISTON VARIABLE VOLUME
2 4503-0220-51 1 MOTOR, 75 HP @ 1800 RPM EXP. WITH C-FACE
3 2302070-003 2 FILTER, RETURN HYDAC
4 2302004-012 1 ATZ SUCTION FILTER
5 2302070-008 1 HEAT EXCHANGER OIL AIR
6 2302070-009 1 ADAPTER, PUMP TO MOTOR VESCOR
7 2302070-001 1 VALVE, RELIEF VICKERS FLANGE MOUNT
8 2302070-002 1 VALVE, CHECK VICKERS FLANGE MOUNT
9 4510-0051-00 1 SWITCH, FLOAT BARKSDALE
10 4509-0098-02 1 VALVE, BALL 3/4" STOCKHAM
11 7811704 1 LEVEL, SIGHT LUBE DEVICE
12 2302070-005 1 VALVE, THERMOSTATIC FPE
13 7805834 1 FILTER, BREATHER PARKER
14 2111934 1 MODIFICATION, ADAPTER FILTER BREATHER
15 2302070-014 1 FITTING, BULKHEAD WEATHERHEAD
16 2302070-010 1 STARTER PACKAGE
17 2302070-012 1 COUPLING, MAGNALOY
18 2302070-004 1 FILTER, HI-PRESS. HYDAC
19 2302061-004 1 SKID
20 2302061-006 1 RESERVOIR, 60 GALLON STAINLESS STEEL
21 2302070-006 1 FITTING, SUCTION FORMRITE
22 2302070-007 1 FITTING, SUCTION FORMRITE
23 4512-0200-11 2 HOSE, SUCTION 2.0"
24 4514-0400-22 1 REDUCER
25 7804231 2 ELBOW, AEROQUIP
26 7802365 1 ADAPTER, AEROQUIP
30 4504-0200-00 2 GLAND, CABLE
31 4504-0200-01 1 REDUCER, CONDUIT 3" x 1.25"
32 4504-0200-02 1 REDUCER, CONDUIT 2.5 x 1.25"
33 0000-9642-64 1 CONN-PLUG,
34 0000-9642-65 1 CONN-RECP,
35 4504-0170-04 1 CONDUIT, BODY OUTLET 3/4 HUBS
36 7815510 2 PLUG, PARKER
38 780590718 2 FITTING, AEROQUIP HOSE
40 2302035-051 2 FITTING, AEROQUIP
42 4598-0002-15 1 ELBOW, MALE 3/4 NPT
43 4512-0028-03 1 ELBOW, 90 DEG. 3/4 NPT
44 7828433 3 CAP, AEROQUIP
45 4514-0221-00 1 COUPLING, 1/4" NPT
46 4514-0400-21 2 FLANGE, 24 SAE CD 62 x -20 SAE
47 4513-0404-00 3 PIPE, 1/4" SCH 40 304 SS
48 7805708 1 FERRULE, AEROQUIP
2 OF 2
2302061-000
BILL of MATERIAL IR 3080 HPU
ASSEMBLY
Larry DeSmit 04 FEB 04 Ron McKinney 04 FEB 04

49 7813085 1 NUT, AEROQUIP
50 7806848 4 GLAND, CABLE HAWKE
51 4504-0136-00 1 PLUG, CONDUIT RECESSED 3/4NPT
53 4514-0005-07 1 FLANGE, SPLIT 2.0" CODE 61
54 2302035-065 1 TEE, PARKER
55 4514-0400-03 1 CONNECTOR, MALE -12 JIC x -12 SAE
62 4510-0050-00 1 GUAGE, PRESSURE 63 MM 5000 PSI
63 2302035-037 1 REDUCER, SAE 24 x -20 JIC
64 4514-0400-23 3 ELBOW, -12 SAE x -8 JIC 90 DEG
66 7819707 1 TEE, STOCKHAM 832 ST RUN RDCR OUT 3/4 X 1/2
67 7815689 3 PLUG, HEX HD 3/4 NPT 3000# 316SS
70 7819669 1 TEE, AEROQUIP
71 4512-0100-03 1 FITTING, STAUFF -4 SAE TEST
72 5504107 4 BOLT, EYE 1"-8 x 2.5: LONG
73 1104-0064-01 6 CABLE, 4 COND 2 AWG V,125D
74 0000-9636-40 25 CABLE, 4 COND. 14 AWG, EXANE, ARMO
75 7828288 4 CABLE, 7 COND/14 AWG ARMORED & SHEATHED
76 4504-001-04 2 BREATHER, DRAIN
77 2302035-061 20 HOSE, AEROQUIP
78 2302035-062 20 HOSE, AEROQUIP
79 610009416 20 HOSE, AEROQUIP
80 610009420 15 HOSE, AEROQUIP
82 4504-0038-00 1 ELBOW, -90 1/2" CONDUIT
83 4504-0151-03 4 BUSHING, REDUCER CONDUIT 3/4 x 1/2
84 4504-0151-04 1 BUSHING, REDUCER CONDUIT 1:x1/2"
85 2111762 1 NAMEPLATE, NATIONAL OILWELL LOGO
87 7815690 1 PLUG, HEX HD 1" NPT 3000# 316SS
88 7828411 1 CAP, PARKER
89 780278824 1 CAP, AEROQUIP
90 7805665 1 FITTING, STAUFF TEST
91 4514-0400-24 1 FITTING, STAUFF TEST PORT
92
8 7 6 5 4 3 DWG No.
2302061003
SHT
1 1
10 5/8" LTR DESCRIPTION OF CHANGE MADE CHKD DATE APPD
62 1/2" REF
REF
4 5
D D
38 1/2" REF
15 14
12 13 15 10 11 12 14 14 12
SECTION A-A 16
38 1/2"
12" REF
CL COOLER
14 15
C C
2
8
3
7
9
1
A A 20' 2302035061 HOSE, AEROQUIP -8 26

84 7/32" REF
20' 2302035062 HOSE, AEROQUIP -12 25

20' 610009416 HOSE, AEROQUIP -16 24
15' 610009420 HOSE, AEROQUIP -20 23
2' 4512-0200-11 HOSE, SUCTION 22
2' 7828288 CABLE, 7 COND/ 14AWG, ARMORED & SHEATHED 21
10' 1104-0064-01 CABLE, 4 COND/ 2AWG, V, 125D EG C, ARMORED & SHEATHED, ECANE 04C2BN 20
B 10' 0000-9636-40 CABLE, 4 COND/ 14AWG, ARMORED & SHEATHED, LSI OPERATING CO. , LLC 4C14BN 19 B
57 1/4" REF
6 1 0000-9642-64 CONN-PLUG, 7M, #12AWG, EX TYPE 18

1 0000-9642-65 CONN-RECP, 7F, #12AWG, EX TYPE 17
1 4504-0136-00 PLUG, CROUSE HINDS 16
46 1/2" REF
2 4504-0001-04 BREATHER DRAIN, CROUSE HINDS 15

3 4504-0151-03 REDUCER, CROUSE-HINDS 14
33 1/8" REF
3 7806848 GLAND, CABLE HAWKE 12
1 4504-0200-00 GLAND, CABLE 11
1 2302061014 TAG, PORT IDENTIFICATION SUPPLY & RETURN COMPACT HPU ROUGH NECK 9
1 2302061017 ASSEMBLY, HEAT EXCHANGER HPU 75HP 8
1 2302061011 ASSEMBLY, HEADER SUPPLY & RETURN 7
12 3/8"
REF
1 2302061012 ASSEMBLY,FILTER HIGH PRESSURE 75HP COMPACT UNIT 6
1 2302070011 POWER SUPPLY & FILTER 5
1 2302070010 STARTER PACKAGE 4
1 2302061007 ASSEMBLY, ELECTRIC MOTOR 75 HP (LEFT HAND) 3
1 2302061005 ASSEMBLY, RESERVOIR HPU 75HP 2
60" REF 1 2302061004 FRAME, COMPACT HPU IRON ROUGHNECK 1
36" REF QTY. PART NO. DESCRIPTION / MATERIAL / SPECIFICATION ITEM NO.
MATERIAL SPEC
A THIS DOCUMENT CONTAINS PROPRIETARY AND
BREAK SHARP CORNERS FRACTIONS ±
TO NATIONAL OILWELL. IT IS LOANED FOR LIMITED FILLET RADII X.XXX ±
CONCENTRICITY X.XX ±
DESIGNED BY DATE
ASSEMBLY, COMPACT HPU 75HP
SQUARENESS
PARALLELISM
X.X ±
ANGLE ± .50 DEGREE
L M DeSMIT
DRAWN BY
05 JAN 04
DATE
IRON ROUGHNECK
RFS EXCEPT WHEN M MODIFIED SURFACE RMS M TYRA 05 JAN 04 SIZE DRAWING No. REV
L M DeSMIT
DATE
14 JAN 04 D 2302061003
L M DeSMIT 14 JAN 04 1:8 4,820 LBS 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 DWG No.
2302061005
SHT
1 1
D 1 21 4 22 D
36
7
14
37
6
29 32
28 23
29
3
14
27
30 9 11 8 15 16
C C
18 1/8" REF
2 6826012G ELBOW, STD M.I. 90 DEG 1 1/2 THD 38
20 1 4504-0151-03 REDUCER, CROUSE-HINDS 37
21 1 7806848 GLAND, CABLE HAWKE 36
31
1 4510-0051-00 TEMP / LEVEL SWITCH 165F 35
1 6700460304 PIPE, 1/2" x 33", SCH 80 ,SS 34
1 6812002-SS COUPLING, PIPE 1/4" SST 33
1 25021081 CROUSE HINDS 32
2 1 2302070014 FITTING, BULKHEAD WEATHERHEAD 31
17 19 1 7805687 ELBOW, PARKER 30
18 2 2302035057 FITTING, AEROQUIP HOSE 29
1 7819669 TEE, AEROQUIP 28
1 7805321 FITTING, PARKER 27
26 2 6701229 PIPE, 1-1/2 SCH 40 304 S/S CD SMLS X 9 1/2" LG. 26
1 7815354 PLUG, PARKER 25
26 1 7828566 CONNECTOR, PARKER 24
50" REF
38 1 7815458 PLUG, PARKER 23

1 7815449 PLUG, PARKER 22
38 1 7804425 ELBOW, AEROQUIP 21
5 1 7802396 ADAPTER, AEROQUIP 20
B 34 1 7813085 NUT, AEROQUIP 19 B
1 7805708 FERRULE, AEROQUIP 18
1 7805691 ELBOW, PARKER 17
33 1 7800717 ELBOW, AEROQUIP 16
1 6817066S NIPPLE, STD PIPE 3/4" X CLOSE GALV 15
2 2302070003 FILTER, RETURN HYDAC 14
35
1 2302070007 FITTING, SUCTION FORMRITE 13
1 780584540 FLANGE, AEROQUIP 12
1 7828433 CAP, AEROQUIP 11
1 2302004012 FILTER, SUCTION STRAINER/SO FAIREY 10
1 7804095 ELBOW, AEROQUIP 9
1 83900606 VALVE, BALL 3/4" STOCKHAM 8
8 700015730 SCREW, HEX HD CAP 5/16-18 X 1 SST 7
13 24
8 7616037 WASHER, REG SPG LOCK 5/16 304 SST 6
10 25
12 1 7400843 TUBING, HYD. 3/4" X .06 WALL X 24" LG. 304 SST ANNEALED 5
1 7811704 LEVEL, SIGHT LUBE DEVICE 4
1 7805834 FILTER, BREATHER FAIREY ARLON 3
INSIDE RESERVOIR 1 2111934 ADAPTER, AEROQUIP 2041-20-20S MODIFIED 1 1/2" - 16 UN-2B 2
VIEW 1 2302061006 RESERVOIR, COMPACT HPU IRON ROUGHNECK 1
QTY. PART NO. DESCRIPTION / MATERIAL / SPECIFICATION ITEM NO.
MATERIAL SPEC
CONFIDENTIAL INFORMATION WHICH BELONGS
FILLET RADII X.XXX ± .015 TITLE
TO NATIONAL OILWELL. IT IS LOANED FOR LIMITED
DESIGNED BY DATE
ASSEMBLY, RESERVOIR
SQUARENESS
PARALLELISM
X.X ± .1
ANGLE ± .50 DEGREE
L M DESMIT
DRAWN BY
19 JAN 04
DATE
COMPACT HPU 75HP
RFS EXCEPT WHEN M MODIFIED SURFACE RMS 250 ADA 19 JAN 04 SIZE DRAWING No. REV

M TYRA
DATE
20 JAN 04 D 2302061005
2302061003 LDS 20 JAN 04 1:8 435 LBS 1 OF 1

8 7 6 5 4 3 2 1
8 7 6 5 4 3 DWG No.
2302061007
SHT
1 1
D 1 D
23 22
C C
3 2
12 10
1 7805830-19 FITTING, AEROQUIP 27
7 1 4514-0400-03 ADAPTER, AEROQUIP 26
13 15
1 4514-0400-29 ADAPTER, PARKER 25
9 1 2302035042 TEE, PARKER 24
16 1 4504-0200-00 GLAND, CABLE 23
6 14 1 7805907-15 FITTING, AEROQUIP 21
B 1 780590718 FITTING, AEROQUIP HOSE 19 B
17 11 1 4512-0100-03 TEST PORT #4 SAE 17
1 7800189 ADAPTER, AEROQUIP 15
1 4510-0050-00 GAUGE, 63MM DIA ASHCROFT 13
1 4514-0400-24 TEST PORT #6 SAE 12
25 26 27 24 16 8 9 14 1 7804309 ELBOW, AEROQUIP 11
20 18 19 1 7805665 FITTING, STAUFF 10
2 4514-0400-21 FLANGE FITTING, CODE62 SAE 9
1 2302070001 VALVE, RELIEF VICKERS 8
1 2302070002 VALVE, CHECK VICKERS 7
1 780584532 FLANGE, AEROQUIP 449-74446-32 6
1 2302070006 FITTING, SUCTION FORMRITE 5
1 L724113135 PUMP, OILGEAR 4
1 2302070009 ADAPTER, PUMP TO MOTOR VESCOR 3
1 2302070012 COUPLING, MAGNALOY 2
1 2302070015 MOTOR, 75 HP @ 1800 RPM EXP. 1
MATERIAL SPEC
BREAK SHARP CORNERS FRACTIONS ±
TO NATIONAL OILWELL. IT IS LOANED FOR LIMITED FILLET RADII X.XXX ±
CONCENTRICITY X.XX ±
DESIGNED BY DATE
ASSEMBLY, PUMP/MOTOR
SQUARENESS
PARALLELISM
X.X ±
ANGLE ± .50 DEGREE
L M DESMIT
DRAWN BY
14 JAN 04
DATE
IRON ROUGHNECK
RFS EXCEPT WHEN M MODIFIED SURFACE RMS M TYRA 14 JAN 04 SIZE DRAWING No. REV
L M DESMIT
DATE
14 JAN 04 D 2302061007
2302061003 L M DESMIT 14 JAN 04 1:4 1 OF 1
8 7 6 5 4 3 2 1
4 3 2 1
LTR D E S C R IP T I O N O F C H A N G E MAD E C H K D D ATE APPD
4.53 REF
D D
(4) 3/8" TAPS
REF
2.36
C C
2 2
DWG No.
2302061012
3 3
11.84 REF
SHT
1
9.67 REF 2 7804502 ELBOW, PARKER 2
1 2302070004 FILTER, HI-PRESS. HYDAC 1
MATERIAL SPEC

DIMENSIONS ARE IN INCHES
BREAK SHARP CORNERS
FILLET RADII
DIMENSIONAL TOL.
FRACTIONS ±
X.XXX ± TITLE
A
OF NATIONAL OILWELL. REPRODUCTION, IN WHOLE OR CONCENTRICITY X.XX ±
DESIGNED BY DATE ASSEMBLY,FILTER HIGH PRESSURE
SQUARENESS X.X ± L M DeSMIT 14 JAN 04 75HP COMPACT UNIT
NATIONAL OILWELL. THIS DOCUMENT IS TO BE RFS EXCEPT WHEN M MODIFIED SURFACE RMS M TYRA 14 JAN 04 SIZE DRAWING No. REV
L M DeSMIT
DATE
14 JAN 04 C 2302061012
FOR WHICH IT WAS LOANED.
LAYOUT No. NEXT ASS'Y SUPERSEDED BY P.E. APPROVAL DATE SCALE EST WT SHEET
2302061003 L M DeSMIT 14 JAN 04 1:2 1 OF 1
4 3 2 1
4 3 2 1
D D
13
EXISTING HEADER PLATE
REF 2302061004
C C
12
4 1
7 2
9 8
DWG No.
3
2302061011
10
B
11
1 7805308-11 FITTING, AEROQUIP HOSE 13
SHT
1
1 780590718 FITTING, AEROQUIP HOSE 10
MATERIAL SPEC
BREAK SHARP CORNERS
FILLET RADII
1/32
DIMENSIONAL TOL.
FRACTIONS ±
X.XXX ± TITLE
A
DESIGNED BY DATE ASSEMBLY, HEADER
SQUARENESS X.X ± L M DeSMIT 14 JAN 04 SUPPLY & RETURN HPU 75HP
L M DeSMIT
DATE
14 JAN 04 C 2302061011
2302061003 L M DeSMIT 14 JAN 04 1:2 1 OF 1
4 3 2 1
4 3 2 1
D D
11
19
22
7 6
20
27
22 7
2
22
10
8
21 3
C 5
C
23 12
24
22
13
7
4 25
15
16 14
26 22
8.00 REF
1 7815430 PLUG, 1/4" BSPP 27
1 7817401 REDUCER, PARKER 26
DWG No.
1 2302035042 TEE, PARKER 12 R6X-S 25
1 2302004026 VALVE, CHECK #12 SAE 5 PSI CRACKING PARKER 24
2302061017
B 1 7805830-11 FITTING, AEROQUIP 18
14.25 REF

1 4512-0100-03 TEST PORT #4 SAE 16
1 7815410 PLUG, BRENNAN 15
1 2302042017 VALVE, RELIEF SUN 14
1 7800261 ADAPTER, PARKER 13
SHT
1 7817188 REDUCER, AEROQUIP 12
1
9
1 2302070023 UNION, PARKER 10
.44 REF 1 2302061018 SUPPORT, HEAT EXCHANGER HPU 75HP 9
TYP 1 7805687 ELBOW, PARKER 8
3 4514-0400-03 ADAPTER, AEROQUIP 7
1 2302070005 VALVE, THERMOSTATIC FPE 6
8.00 REF 9.63 REF 1 7804437 ELBOW, PARKER 3
1 7802394 CONNECTOR, WEATHERHEAD 2
17 1 2302070029 COOLER, HYDRAULIC FAN DRIVEN OILAIR 1
16 PROPRIETARY INFORMATION APPLICABLE SPECS UNLESS OTHERWISE SPECIFIED
MATERIAL SPEC
18
BREAK SHARP CORNERS
FILLET RADII
DIMENSIONAL TOL.
FRACTIONS ±
X.XXX ± TITLE
A
30.75 REF PURPOSES ONLY AND REMAINS THE PROPERTY
DESIGNED BY DATE ASSEMBLY, HEAT EXCHANGER
SQUARENESS X.X ± L M DeSMIT 15 JAN 04 COMPACT HPU 75HP
L M DeSMIT
DATE
15 JAN 04 C 2302061017
2302061003 L M DeSMIT 15 JAN 04 1:4 1 OF 1
4 3 2 1
SECTION “GENERAL”
DESCRIPTION LITERATURE DESCRIPTION LIT. NO
GENERAL INFO FLIUD RECOMMENDATIONS BULLETIN 90000
CONTAMINATION EVALUATION GUIDE BULLETIN 90004
STORAGE RECOMMENDATIONS BULLETIN 90006
FILTRATION RECOMMENDATION BULLETIN 90007
FLUID SUPPLIER RECOMMENDATION BULLETIN 90008
PIPING INFORMATION FOR HYD. SYSTEMS BULLETIN 90011
HYDRAULIC SYSTEM SERVICE SUGGESTIONS BULLETIN 910000
BASIC INFORMATION IR 3080 HPU
BASIC INFORMATION
THE ABOVE PICTURE SHOWS THE IR 3080 HYDRAULIC POWER UNIT WITH THE FRAME AND
MOTOR STATER REMOVED.
PRESSURE SETTINGS AS FOLLOWS:

PUMP COMPENSATOR: 3050 TO 3200 PSI
MAIN RELIEF VALVE: 3500 PSI
FAN MOTOR RELIEF VALVE: 400 PSI
SYSTEM SHUTDOWN SETTINGS:

HIGH OIL TEMPERATURE: 145 TO 160 F
LOW OIL LEVEL: WHEN LEVEL DROPS MORE THAN 36”
RESERVOIR CAPACITY 80 US GALLONS

FLUID TYPE AW 46 (WHEN OPERATING IN EXTREME TEMPERATURES USE AW 68)
UNIT WEIGHT: 4600# “WET”
HPU COMPONENT INFORMATION
NOI PART # DESCRIPTION

L724113135 PUMP, PISTON VARIABLE VOLUME
2302070-001 VALVE, RELIEF VICKERS FLANGE MOUNT
2302070-002 VALVE, CHECK VICKERS FLANGE MOUNT
2302004-012 ATZ SUCTION FILTER
2302070-003 FILTER, RETURN HYDAC
2302070-004 FILTER, HIGH PRESS. HYDAC
7805834 FILTER, BREATHER PARKER
2302070-022 HEAT EXCHANGER
4503-0220-51 MOTOR, 75 HP @ 1800 RPM EXP. WITH C-FACE
2302042-017 VALVE, RELIEF SUN
2302070-009 ADAPTER, PUMP TO MOTOR VESCOR
2302070-012 COUPLING, MAGNALOY
7811704 LEVEL, SIGHT LUBE DEVICE
2302070-005 VALVE, THERMOSTATIC FPE
PUMP, VARIABLE DELIVERY 3
ENGINEERING
PVM 064, 076, 098 &130
"C" FRAME
Installation Drawing Side Ported w/Thru-Shaft
NOI # L724113135
519343-301 sh. 3
NOTE: DIMENSIONS SHOWN IN ( ) ARE IN MILLIMETERS
Telephone: (414) 327-1700 OILGEAR Reissued: March, 2002

2300 So. 51st. Street
Fax: (414) 327-0532
Milwaukee, WI USA 53219
DS-47972-A
PUMP, VARIABLE DELIVERY ENGINEERING 4
PVM 064, 076, 098 & 130
"C" FRAME
Installation Drawing Shaft & Control Options
519343-301 sh. 4
OILGEAR Telephone: (414) 327-1700

Reissued: March, 2002
2300 So. 51st. Street Fax: (414) 327-0532
DS-47972-A Milwaukee, WI USA 53219
PUMP, VARIABLE DELIVERY ENGINEERING 5
PVM 064, 076, 098 &130
"C" FRAME
Installation Drawing Assembly Data
519343-301 sh. 5
Telephone: (414) 327-1700 OILGEAR Reissued: March, 2002

Fax: (414) 327-0532
Milwaukee, WI USA 53219
DS-47972-A
BULLETIN 947070
SERVICE INSTRUCTIONS
OILGEAR TYPE “PVM” OPEN LOOP PUMPS
PURPOSE OF INSTRUCTIONS
These instructions are written to simplify your work when installing, operating and maintaining these Oilgear Type "PVM" Pumps.
Your acquaintance with the constructions, principle of operation and characteristics of these units will help you attain satisfactory
performance, reduce down-time and increase the units’ life. Some units have been modified from those described in this bulletin and
other changes may be made without notice.
Figure 1. Typical Oilgear PVM Open Loop Pumps (00020 and 00018).
REFERENCE MATERIAL
Fluid Recommendations .........................................................................................Bulletin 90000
Contamination Evaluation Guide ............................................................................Bulletin 90004
Filtration Recommendations ...................................................................................Bulletin 90007
Piping Information ..................................................................................................Bulletin 90011
I. PREPARATION AND INSTALLATION

A. MOUNTING charge circuit when used. Mount reservoir on a level foundation
with reservoir bottom at least six (6) inches above the floor level
PUMP WITHOUT RESERVOIR. The pump may be mounted in to facilitate fluid changes.
any position. For convenience, the recommended mounting po-
sition is with the driveshaft on a horizontal plane. Secure the unit B. PIPING AND FITTINGS
to a rigid mounting surface. See section B on Piping Infor-
mation. See referenced Piping Information bulletin and individual cir-
cuit diagram before connecting pump to system. Inlet velocity
PUMP WITH RESERVOIR. These units are usually fully piped must not exceed 5 fps (1,5 mps). Inlet should be unrestricted and
and equipped although it may be necessary to connect super- have a minimum of fittings. An inlet strainer is not recommended.
THE OILGEAR COMPANY

Issued June, 2001 Milwaukee, WI 53219 BULLETIN 947070
B. PIPING AND FITTINGS F. FLUID COOLING
HORIZONTAL MOUNTING. Arrange line from the highest When pump is operated continuously at rated pressure or fre-
case drain or alternate case drain so the case remains full of quently at peak load, auxiliary cooling of fluid may be neces-
fluid (non-siphoning). Case pressure should be less than 25 psi sary. Fluid temperature should not exceed limits specified in ref-
(1,7 bar). For higher case pressures and special shaft seals re- erenced Oilgear bulletin on Fluid Recommendations.
quired, contact our factory. Each drain line must be a separate
line, unrestricted, full sized and connected directly to the reser-
voir below the lowest fluid level. Provisions for opening this G. AIR BREATHER
line without draining (siphoning) reservoir should be made.
On most installations, an air breather is mounted on top of the
VERTICAL MOUNTING. See referenced Installation of Verti- fluid reservoir. It is important for the breather to be of adequate
cally Mounted Axial Piston Pumps, Bulletin 90014. size to allow airflow in and out of the reservoir as fluid level
changes. Keep breather case filled to the fluid level mark. About
WARNING once every six months remove the cover, wash screen in solvent,
clean and refill case to level mark on the screen. See manufactures
Running the pump in Neutral position (zero delivery) for recommendations.
long periods of time without supercharge can damage the
pump. H. FLUID, FILLING AND STARTING RECOM-
Systems and pump must be protected against overloads by sepa-
MENDATIONS
rate high-pressure relief valves. Install bleed valve(s) at highest
point(s) in system. Refer to instruction plate on the unit, reservoir, machine and/or
referenced Fluid Recommendations bulletin. Fire resistant flu-
C. POWER ids and phosphate ester fluids can be used in accordance with
fluid manufactures recommendations.
Power is required in proportion to volume and pressure used.
Motor size recommendations for specific applications can be Pump all fluid into reservoir through a clean (beta 10 ratio 4 or
obtained from The Oilgear Company. Standard low starting torque more) filter. Fill reservoir to, but not above, high level mark
motors are suitable for most applications. on sight gage. Remove case drain line and fill pump case with
hydraulic fluid.
CAUTION
Turn driveshaft a few times by hand with a spanner wrench to be
Never start or stop unit under load unless system is approved sure parts are free.
by Oilgear. It may be necessary to provide delivery bypass in
some circuits.
D. DRIVE
See rotation direction plate on units housing. Clockwise units
Table 1. Torque To Turn Shaft
should not be driven counter-clockwise. See Section X, Con-
versions for changing clockwise units to counterclockwise or
vice versa. Use direct drive coupling. Size and install coupling
per manufactures instructions. Size Unit 011, 014 & 022
CAUTION Approx. Torque to turn 1.7 - 2.1
driveshaft - ft. lbs.
Do not drive coupling onto pump driveshaft. If it is too tight, Nm. 2,3 - 2,8
it may be necessary to heat coupling (see manufactures in-
structions).
Misalignment of pump shaft to drivers shaft should not exceed
0.005 inches (0,13 mm) Total Indicator Readout (TIR) in any
plane.
With pump under no load, or with pump control at neutral,
E. FILTRATION turn drive unit on and off several times before allowing pump to
attain full speed. Running the pump and operating the control
To assure long life from your hydraulic system, keep fluid clean can usually fill the system. Watch the fluid level in the reservoir
at all times. See reference bulletin on Filtration Recommenda- and stop pump if the level reaches low level mark. Add fluid
tions and on Contamination Evaluation. Oilgear recommends and start again. With differential (cylinder) systems, fluid must
use of a filter in the pressure return line. Replace filter element(s) not be above high level when the ram is retracted or below the
when filter condition indicator reaches change area at normal low Level when extended. Bleed air from the system by loos-
temperature. Drain and thoroughly clean filter case. Use replace- ening connections or opening petcocks at the highest point in the
ment element(s) of same beta 10 ratio (normally a ratio of 4 with system. Close connections or petcocks tightly when solid stream
hydraulic oils). of fluid appears.
Bulletin 947070 Page 2 © 2001THE OILGEAR COMPANY - ALL RIGHTS RESERVED

Figure 2. Cut-a-way (cross-section) of typical PVM Pump (01010).
II. CONSTRUCTION
Refer to Figures 2, 7 and 8. A driveshaft (21) runs through the

centerline of pump housing (1) and valve plate (45) with pump
cylinder barrel (38) splined to it. A bearing (26) supports the
front of the driveshaft and a (bushing type) bearing (67) sup-
ports the rear of the driveshaft. The pump cylinder barrel is car-
ried in a hydrodynamic (journal type) cylinder bearing (35). A
port plate (43), containing crescent shaped ports, is located on a
valve plate (45) that has matching crescent shaped ports. Pump-
ing piston/shoe assemblies (39) in the cylinder barrel are held
against a swashblock (29) by a shoe retainer plate (40). The shoe
retainer is held in position by the fulcrum ball (41). The fulcrum
ball is forced outward by a shoe retainer plate spring (42). The
spring acts against the pump cylinder barrel forcing it against the
port plate while also forcing the piston shoes against the
swashblock. The semi-cylindrical shaped swashblock limits the
piston stroke and can be swiveled in an arc shaped saddle-bear-
ing (30). The swashblock is swiveled by a control piston (19).
Page 3 Bulletin 947070

III. PRINCIPLE OF OPERATION
same and the pressure acting on either end

of the control piston are the same. The
resultant hydraulic forces on the ends of
the control piston cancel each other out
(the control piston is balanced). Therefore,
the force of the control piston spring (20)
controls the control piston position.
Rotating the driveshaft (21) clockwise
turns the splined cylinder barrel (38) that
contains the pumping piston assemblies
(39). When the cylinder is rotated, the pis-
tons move in and out of their bores as their
shoes ride against the angled pump
swashblock (29).
As the cylinder rotates, the individual pis-

ton bores are connected, alternately, to
upper (Port A) and lower (Port B) cres-
cent shaped ports in the valve plate (45).
While connected to the lower side (suc-
tion) Port B, each piston moves outward,
drawing fluid from Port B into the piston
bore until its outermost stroke is reached.
At that point, the piston bore passes from
the lower crescent port to the upper cres-
cent port.
While rotating across the upper crescent

port, each piston moves across the angled
swashblock face and is forced inward.
Each piston displaces (delivers) fluid
through the upper crescent to Port A until
its innermost stroke is reached. At that
point, the piston bore passes from the up-
per to the lower crescent again and the op-
erating cycle is repeated.
A study of the diagram will show that the
degree of swashblock angle determines the
length of piston stroke (difference between
outermost and innermost position) thereby
determining the amount of delivery from
the pump. Reducing the swashblock angle
Figure 3. Pump Starting & Raising Pressure (5V-12134-L, Sheet 2). will reduce the pump delivery.
A PUMP DRIVEN CLOCKWISE (RIGHT HAND) IS DESCRIBED. DIA-

GRAMS ARE SHOWN FROM TOP (PLAN) VIEW.
A. STARTING (See Figure 3)

The control piston spring (20) positions the control pin (31) and pump
swashblock (29) so the pump will deliver maximum volume to raise pres-
sure in the system.
B. RAISING PRESSURE
Pump delivery (and resultant pressure) is fed to both sides of the control
piston (19). Flow to the unloading side of the control piston is direct. Flow
to the loading (bias) side of the control piston is through the control se-
quence valve (54). [Note: - flow through the pilot operated control relief
valve (55) is blocked]. The areas on either end of the control piston are the
Bulletin 947070 Page 4

III. PRINCIPLE OF OPERATION (cont'd)
from the relief valve is now allowed past

the sequence valve, into the pump case and
drain. At the same time, the control se-
quence valve blocks flow from the pump
high-pressure line to the pilot operated
control relief valve (high-pressure flow
must now go through the stability orifice
OP2). Flow from the bias side of the
control piston is allowed to bleed through
the control relief valve and control se-
quence valve into the case and drain. Note
that pressure is still ported to the unload-
ing side of the control piston (19). The
control piston is no longer balanced and
the pressure on the unloading side of the
control piston forces the control piston to
compress the control piston spring.
The control piston now moves the con-
trol pin (31) and shifts the swashblock
(29) to a position towards neutral (no de-
livery) where the pump (is unloaded) de-
livers just enough volume to maintain
(make-up for component slip losses or
leakage) system pressure as regulated by
the adjustable pilot operated control re-
lief valve (55).
D. HOLDING PRESSURE (See

Figure 3).
If the system pressure drops below preset
compensating pressure (in the event of
increased leakage of system components
and/or opening of system valves etc.), the
control relief valve conical plunger seats
(stopping flow to drain). Pressure on both
ends of the main relief plunger is now bal-
anced, the main relief plunger closes, the
spring shifts the position of the control se-
quence valve to allow additional flow to
the bias side of the control piston. The
control piston spring positions the control
piston (and control pin/swashblock) for in-
Figure 4. Pump Compensating (Unloading) (5V-12134- Sh.3). creased delivery until the control relief
valve preset pressure is reached again.
C. PRESSURE COMPENSATING (Pump Unloading)

As previously noted, pump delivery flow ( and resultant pressure) passes
through the control sequence valve (54). Flow (and pressure) is also ported
through orifices in the center of the pilot operated control relief valve (55)
to the adjustable pilot relief valve (in upper portion of the body).
See Figure 4. When system pressure exceeds the pilot valve setting the
pilot cone plunger opens. Pressure on the topside of the main relief plunger
is relieved. A pressure imbalance now exists (across the main spool); the
pressure on the lower side of the main relief plunger raises the main spool
and allows flow (and pressure) through the relief valve. Exhaust flow from
the main relief plunger is ported to the stem end of the control sequence
valve. The orifice in the end of the control sequence valve spool results in
a pressure drop and the spool is forced against the opposing spring. Flow
Page 5
IV. SPECIFICATIONS
See Referenced material and individual application circuit for exceptions.
Table 2. Nominal Performance Data with 150-300 SSU viscosity fluids
UNIT THEORETICAL RATED MAXIMUM FLOW RATE MINIMUM INLET MAXI- POWER
MAXIMUM CONTINUOUS PRESSURE at 1800 rpm, rated PRESSURE MUM INPUT
DISPLACEMENT PRESSURE continuous pressure psia (bar abs) SPEED at rated
& 14,7 psia (bar abs) continuous
inlet condition pressure &
1800 rpm
in 3/rev ml/rev psi bar psi bar gpm l/min 1800 rpm 2400 rpm 3600 rpm rpm hp kw
011 0.66 10,8 3750 258,6 4250 293,1 4.2 15,9 5.5 (0,38) 8.2 (0,57) 17.2 (1,19) 3600 12.8 9,5
014 0.86 14,1 3750 258,6 4250 293,1 5.9 22,4 4.6 (0,32) 7.8 (0,54) 17.4 (1,20) 3600 16.4 12,1
022 1.35 22,1 3750 258,6 4250 293,1 9.5 36,0 9.5 (0,66) 11.1 (0,77) 22.5 (1,55) 3600 26.1 19,5
Table 3 Nominal Dimensions and Weights
UNIT WIDTH LENGTH HEIGHT WEIGHT FACE

in. mm. in. mm. in. mm. lb. kg. MOUNT
011 SAE "A"
014 7.03 178,5 7.95 201,9 6.48 164,6 36 16,3 2 Bolt
022
See Installation drawings for more detailed dimensions and port configurations

V. MALFUNCTIONS AND CAUSES E. EXCESSIVE or HIGH PEAK PRESSURE
A. UNRESPONSIVE OR SLUGGISH CONTROL 1. Faulty control piston (19), sequence valve (54) or control
valve (55) operation.
1. Swashblock saddle bearing (30) worn or damaged. 2 Faulty output circuit components (pay particular attention to
2. Control piston (19) or sequence spool (54) binding in bore. system relief valves).
3. Control piston spring (20) broken, sequence valve spool 3. Worn or broken saddle bearing (30).
spring (53) binding or otherwise damaged.
F. EXCESSIVE NOISE
B. INSUFFICIENT PUMP VOLUME
1. Pump incorrectly being stopped or started under load.
1. Delivery limited by stroke limiter screw (70), 2. Low fluid level in reservoir or insufficient supercharge re-
2. Delivery limited by faulty control piston (19), or control sulting in cavitation.
relief valve (55) operation. 3. Air entering hydraulic system.
3. Obstructed suction circuit or insufficient supercharge vol- 4. Fluid too cold or viscosity too low.
ume. 5. Suction line problem i.e.; obstructions in line, line too long,
4. Insufficient drive motor speed. line diameter too small or too many bends and/or loops in
5. Worn or grooved cylinder barrels (38), port plate (43) and/ line.
or valve plate (45) matching surfaces. 6. Broken or worn piston and shoe assemblies (39).
6. Worn or broken saddle bearing (30). 7. Pump rotating in wrong direction.
7. Worn or damaged piston and shoe assemblies (39) or pis-
ton bores in cylinder (38). G. EXCESSIVE HEATING
8. Worn or damaged piston shoe or swashblock (29).
1. Operating pump above rated or peak pressure.
C. IRREGULAR OR UNSTEADY OPERATION 2. Low fluid level in reservoir or insufficient supercharges.
3. Air entering hydraulic system.
1. Faulty control piston (19), sequence valve (54) or control 4. Worn piston pump.
valve (55) operation. 5. Worn or grooved cylinder barrel (38), port plate (43) and/or
2. Fluid level in reservoir is low or supercharge is insuffi- valve plate (45).
cient. 6. Faulty output circuit components (continuous blowing relief
3. Air entering hydraulic system. valves or slip through valves, cylinder, etc.).
4. Worn axial piston pump. 7. Insufficient cooling provision or clogged coolers.
5. Faulty output circuit components (cylinders, motors, valves
etc.). VI. TESTING AND ADJUSTING
D. LOSS OF PRESSURE WARNING Shut pump off and release pressure from sys-
tem before disassembling components. Failure to comply with
1. Worn piston pump. these instructions could result in personal injury or death. Block-
2. Worn or grooved cylinder barrel (38), port plate (43) and/ ing pressure line between pump and system (or pump) high-
or valve plate (45) matching surfaces. pressure relief valve will result in damage and could result in
3. Worn piston and shoe assemblies (39) or piston bores in personal injury.
cylinder (38).
4. Faulty output circuit components.
5. Worn or broken saddle bearing (30).
Table 4. Nominal Case Slip vs. High Pressure at 1800 rpm (viscosity of 160 SSU).
Pump Size Case Slip at Full Stroke and Indicated Pressure at 1800 rpm
500 psi 1000 psi 2000 psi 3000 psi 3750 psi
cipm 25 45 85 135 180
011 lpm 0,41 0,74 1,39 2,21 2,95
cipm 35 50 105 160 220
014
lpm 0,54 0,82 1,72 2,62 3,61
cipm 40 60 110 170 240
022
lpm 0,66 0,98 1,80 2,79 3,94

A. PISTON PUMP B. VALVE PLATE GROUP
To check for worn piston pump, measurement of the leakage can If pump is a THRU-SHAFT unit with another pump or other
be made from the case drain while pump is under pressure. After device coupled to the rear of the pump, it will be necessary to
the unit is warm, either install a flow meter in the drain line or remove that unit and oring (59). If thru-shaft convertible cover
have the flow from the drain line directed into a large container (63) is used, remove socket head cap screws (64) and oring
or reservoir. The pump case must remain full of fluid during this (62).
test.
Block unit on bench with of driveshaft horizontal. Remove valve
CAUTION: plate assembly (45) by removing four socket head cap screws
(50 & 56) and valve plate assembly. When used, shaft coupling
Do not run a pump on stroke against a blocked output un- (57) with retaining rings (58) will come with valve plate assem-
less it is protected by a high pressure relief valve and then bly. The port plate (43) is located on the valve plate assembly by
run no longer than necessary to check slip. Limit discharge dowel pin (44). Remove the port plate from the valve plate as-
to prevent dropping reservoir fluid below low level. sembly. Extreme care must be taken not to damage the faces
of the port plate and the matching faces of both the valve
With an accurate high-pressure gage in the pressure line, start plate and cylinder barrel.
the pump and stall (or block) output device to raise system pres-
sure to maximum (as set by system relief valve). Read the flow The control sequence valve can be removed if necessary by re-
meter or time the case drain flow used to fill a known size con- moving sequence valve spool plug (51) with oring (52), with-
tainer and calculate the flow rate in terms of cubic inches per drawing sequence valve spool spring (53) and sequence valve
minute (cipm). The leakage should conform to Table 4 (page 7). spool (54). The relief valve control cartridge assembly (55) can
Additional leakage indicates wear, but does not become critical also be unscrewed from the valve plate if necessary.
until it impairs performance.
Rear shaft bearing (67 or 77) is pressed into valve plate. The
rear shaft bearing can be removed if necessary.
VII. DISASSEMBLY C. ROTATING GROUP
A. PREPARATION Extreme care must be taken not to damage cylinder wear surface
(that matches against the port plate), the bearing diameters or
When disassembling or assembling unit, we recommend choos- the piston shoes. Remove orings (13 & 14) from the pump hous-
ing an area where no traces of dust, sand or other abrasive par- ing (1). Do not remove roll pins (12) unless damaged.
ticles, which could damage the unit, are in the air. We also rec-
ommend not working near welding, sandblasting, grinding Remove the rotating group by slowly turning the driveshaft (21)
benches and the like. Place all parts on a CLEAN surface. To while pulling the cylinder barrel (38) from the housing. Mark
clean parts, which have been disassembled, it is important to use (number) each pump piston shoe assembly (39) and its respec-
CLEAN solvents. All tools and gages should be clean prior to tive bore in cylinder barrel and shoe retainer plate (40). See
working with these units and new CLEAN threadless rags used Figure 5. Lift out shoe retainer plate (40) with pistons and re-
to handle and dry parts. move fulcrum ball (41) and shoe retainer plate spring (42).
WARNING: NEVER attempt to remove or install any com-
ponent or assembly while unit or system is running. Always
stop the pump, shut-off power and release pressure from the
system before servicing or testing. Be sure provisions have
been made so case drain line can be disconnected from the
unit without causing the line to drain (siphon) the reservoir.
Disconnect case drain from upper most case drain port and drain SHOE RETAINER (40)
pump case through the other (lower) drain port. If plugs are in-
accessible, it may be necessary to remove pump from mounting PISTON/SHOE ASSEMBLY (39)
(and drive motor) before draining it.
Refer to figures 7 and 8. Depending upon what part or parts are FULCRUM BALL (41)
to be inspected, it may not be necessary to completely take apart SHOE RETAINER SPRING (42)
all assemblies.
CYLINDER BARREL (38)
WARNING- Assistance from others and use of a hoist and/
or proper lifting techniques are strongly recommended to
prevent personal injury.
It will be advantageous to tag similar parts (particularly screws Figure 5 Rotating Group Disassembly (5V-12134-L, sheet 4).
plugs and orings) during disassembly to be certain they dont
become confused with similar parts and to assure they will be Remove cylinder bearing retainer ring (37) and pull the hydro-
returned to original location. Do not remove (locator) roll pins dynamic cylinder bearing (35) and roll pin (36), if necessary,
unless they are deformed or other wise in need of replacement. from the housing. Note the position of the roll pin inside the
case.

D. DRIVESHAFT GROUP C. ROTATING GROUP
Remove driveshaft key (22 or 23) if used and driveshaft bearing Inspect cylinder barrel (38), piston bores and the face that mates
retainer ring (28). Grasp outboard end of driveshaft (21) and with port plate (43) for wear. Remove minor defects on the face
pull out from pump housing. Remove shaft retaining ring (27) by lightly stoning or lapping the surface. If defects can not be
and front driveshaft bearing (26). Remove shaft seal retainer removed by this method, replace the cylinder barrel.
(25) and driveshaft seal (24) from housing only if necessary (if
seal is removed it can not be reused it must be replaced). If Inspect hydrodynamic cylinder bearing (35) for damage and re-
used, do not remove screw (61) and thru-shaft coupling spacer place if necessary. Check all piston and shoe assemblies (38) to
(60) unless necessary. be sure they ride properly on the swashblock (29).
E. SWASHBLOCK GROUP See Figure 6. Check each shoe face for nicks and/or scratches.
Check the shoe for smooth pivot action on the piston. If one or
Remove socket head cap screws (34), housing cover (33) and more piston/shoe assembly needs to be replaced, replacement of
oring (32). Reach into the housing through the opening and pull all piston/shoe assemblies is necessary. When installing new pis-
out the swashblock (29) along with control pin (31). The saddle ton/shoe assemblies or rotating group, make sure pistons are free
bearing (30) is seated in the housing by an integral pintle that in their respective bores.
engages a hole in the housing. Pull saddle bearing (30) back
(parallel to driveshaft axis) until pintle disengages from the hous-
ing and then pull the saddle bearing out in the same manner that
the swashblock was removed.
F. CONTROL GROUP
Do not remove flow reversing plugs (8). For flow reversal
procedure, see X. CONVERSIONS. If used, note which side
of the control cylinder the stroke limiter screw (70) is on.
Control piston spring (20) may be under compression. There-
fore, slowly turn control end plugs (17) with orings (18) slowly
out of the control piston cylinder in the unit housing. If used,
remove maximum volume stop assembly (70 thru 76 &18). Be-
fore removing the control piston (19) and the control piston spring
(20) note which side of the control cylinder they were in.
Remove the control piston spring (20) and the control piston
(19) from the control cylinder bore. Figure 6. Piston and Shoe Inspection (5V-12134-L, sheet 4).
VII. INSPECTION D. DRIVESHAFT GROUP

A. GENERAL Check driveshaft seal (24) for deterioration or cracks. Seal can
not be reused if removed from housing. Replace (press out) only
Clean all parts thoroughly. Inspect all seals and orings for hard- if necessary. Check front driveshaft bearing (26) for binding or
ening, cracking or deterioration and replace if necessary. Check roughness. See section B and check rear shaft bearing (67 or
all locating pins for damage and springs for cracking or signs of 77). Check driveshaft and its splines for wear. Replace any part
fatigue. necessary.
WARNING- always wear safety goggles when using solvents E. SWASHBLOCK GROUP
or compressed air. Failure to wear safety goggles could re-
sult in serious personal injury.
Inspect the swashblock (29) face for wear and/or scoring. If de-
fects are minor, stone the hardened swashblock lightly. Be sure
B. VALVE PLATE GROUP to stone lightly. If damage is extensive replace the swashblock.
Inspect the valve plate (45) and hardened port plate (43) sur- Compare saddle bearing (30) thickness in worn area to thick-
faces, that mate with each other, and the rear of the cylinder ness in an unworn area. Replace saddle bearing if difference is
barrel (38) for excessive wear. Remove minor defects by lightly more than 0.010 inches (0,254 mm). Check mating surface of
stoning the surface with a hard stone that is flat to within 0.001 swashblock for cracks or excessive wear. There is a small hole
(0,03 mm). Be sure to stone lightly. Any excessive stoning will in the pintle of the saddle bearing (where saddle bearing plugs
remove the hardened surfaces. If wear or damage of these com- into pump housing). This hole ports fluid through the swashblock
ponents is extensive, replace the component. to the face of the saddle bearing (providing lubrication). Check
this hole and orifice OP1 (5) to be sure they are open. Swashblock
Check the fit of the control sequence valve spool (51) in the port movement in saddle bearing must be smooth. Replace
plate. It should move smoothly in the bore. Check the sequence swashblock and/or saddle bearing if necessary.
valve spool spring (53) for cracks or signs of fatigue. It, too
should be able to move (compress and decompress) smoothly in F. CONTROL GROUP
the bore. Inspect and flush out the relief valve control cartridge
assembly (55). Be sure plunger operates smoothly and orifice in
bottom of plunger is clean and clear. Inspect seals and orings for hardening, cracking or deteriora-
tion and replace if necessary. Check control piston spring (20)
Check the rear shaft bearing (67 or 77) in the valve plate for for cracks or signs of wear, be sure it does not bind in the control
signs of excessive wear. This bearing (67 or 77) can be pressed piston (19). Be sure the control piston does not show signs of
out and replaced. excessive wear and that it slides smoothly in the control cylin-
der bore. Check OP2 (68) to be sure orifice is not blocked.
IX. ASSEMBLY WARNING-The assembled rotating groups for some sizes of
pumps may be heavy, assistance from others and proper lift-
ing techniques is strongly recommended to prevent personal
A. PREPARATION injury. The rotating group can now be carefully installed over
the tail of the driveshaft and into the pump housing (1). While
Refer to figures 7 and 8. The procedure for assembling the unit is installing the rotating group, support the weight of the cylinder
basically the reverse order of disassembly procedures. During barrel, as cylinder spline is passed over the tail shaft, to avoid
assembly, install new gaskets, seals and orings apply a thin film scratching or damage. Push cylinder barrel forward on the
of CLEAN grease or hydraulic fluids to sealing components to driveshaft, until the cylinder spline reaches the driveshaft spline;
ease assembly. If a new rotating group is used, lubricate thor- rotate the cylinder barrel slightly to engage the shaft splines.
oughly with CLEAN hydraulic fluid. Apply fluid generously to Continue to slide the cylinder barrel forward until it encounters
all wear surfaces. the hydrodynamic cylinder bearing (35). Lifting the tail end of
the driveshaft slightly helps cylinder barrel and hydrodynamic
B. CONTROL GROUP cylinder bearing engagement. Continue pushing cylinder barrel
forward until the piston and shoe assemblies (39) contact the
swashblock (29). On units with thru type driveshafts, place the
If used, install maximum volume stop assembly [stroke limiter rear shaft-coupling etc. on the rear of the driveshaft. If removed,
screw (70) with orings (72) and back-up ring (71) in place], install roll pins (12) in pump housing (1). Install orings (13 &
maximum volume stop body (73) with oring (18), stroke limiter 14) in pump housing.
bonnet (74) with oring (75) and jam nut (76)] from the side they
were removed from. From the other side of the control piston The pump housing assembly is now ready to receive the valve
cylinder bore, insert the control piston (19) with spring bore fac- plate group.
ing out. Slide the control piston spring (20) into the bore and
then insert and screw the control end plug (17) with oring (18)
in tightly. F. VALVE PLATE GROUP
C. SWASHBLOCK GROUP Extreme care must be taken not to damage the faces of the
valve plate and matching faces of both the valve plate and
cylinder barrel.
If removed, press new driveshaft seal (24) into pump housing.
Working through the bore for the housing cover (33), insert the If rear shaft bearing (66 or 77) was removed, press bearing into
saddle bearing (30) in the pump housing so the integral pintle the valve plate until it protrudes from the face of the valve plate
engages the hole in the housing. Place the control pin (31) in the the amount shown in Table 5.
swashblock (29) in a position to engage the slot in the control
piston. Again, reaching through the bore for the housing cover,
insert the pin into the control piston slot and push the swashblock
(29) against the saddle bearing being sure the raised surface of
the swashblock is received by the indented surface of the saddle Table 5. Rear Shaft Bearing Protrusion
bearing. Visually, be sure the holes (to receive the driveshaft)
align up with the center of the hole in the pump housing for the
driveshaft. Place housing cover (33) with oring (32) in place
and secure with socket head cap screws (34). PROTRU- PUMP SIZE
SION 011 014
D. DRIVESHAFT GROUP 022
Place seal retainer (25) in its bore. Press front driveshaft bearing For Thru
(26) onto driveshaft (21) and lock in place with shaft retainer Shaft Valve
ring (27). Insert the driveshaft assembly (21) through the shaft Plates
seal, into the case, through the hole in the saddle bearing and in. 0.075 +.01
swashblock until the front driveshaft bearing bottoms in its bore. mm. 1,905 +,25
Lock in place with bearing retainer ring (28).
For Non
E. ROTATING GROUP Thru Shaft
Valve Plates
With roll pin (36) in place, slide the hydrodynamic cylinder bear- in. 0.20 +.03
ing (35), returning the roll pin into the position noted upon disas- mm. 5,08 +,76
sembly, into the pump housing. Lock in place with cylinder bear-
ing retainer ring (37). Note: - ends of retaining ring must be in
groove machined in housing (1).
See Figure 5. Place the cylinder barrel (38), wear surface down,
on a clean cloth. Place the shoe retainer spring (42) in the center Screw the relief valve control cartridge (55) into the valve plate.
of the barrel with the fulcrum ball (41) on top of it. Insert the Slide (narrow end first) control sequence spool (54) into its bore
piston and shoe assemblies (numbered on disassembly) into their in the valve plate. Place sequence valve spool spring (53) into
corresponding (numbered) holes of the shoe retainer plate (40). the counter bore of the control sequence valve and secure by
As a unit, fit the pistons into their corresponding (numbered) screwing the sequence valve spool plug (51) with oring (52)
bores in the cylinder barrel. DO NOT FORCE. If aligned prop- into place.
erly, the pistons will fit smoothly.

When used, install rear shaft coupling (57) with retainer rings X. CONVERSIONS
(58) in place on driveshaft before installing valve plate group
assembly to pump housing (1). A. LEFT HAND TO RIGHT HAND DRIVE OR
Using dowel pin (44) to locate, place port plate (43) on the face VICE VERSA
of valve plate (45). On units with non-thru type driveshafts, the
rear shaft bearing fits through the port plate and will center the To convert a pump built for right hand (clockwise) driven rota-
port plate on the face of the valve plate. On units with thru type tion to a pump for left hand (counter clockwise) drive, or vice-
driveshafts, the rear shaft bearing (77 or 67) fits in a groove of versa, the following four steps will be necessary.
the port plate and will center it on the face of the valve plate.
1. The position of the two flow reversing plug assemblies (8,
Assistance from others and proper lifting techniques is 9, 10 & 11) and the two SAE plugs (6) with orings (7) will
strongly recommended for the following procedure to pre- have to be interchanged. See illustrations (parts of Figure 8)
vent personal injury. Be sure orings (13) and (14) are in place. for proper positions for either left hand or right hand rota-
The valve plate (45) group can now be carefully installed over tion.
the tail of driveshaft (21) and slide up to mate with the pump 2. Reverse the orientation of the control piston (19) and con-
housing (1). Roll pins (12) should engage matching bores in the trol piston spring. See illustrations (parts of Figure 8) for
valve plate assembly. Finger tighten socket head cap screws (50 proper positions for either left or right hand rotation. Also
and or 56) and then alternately tighten down. note that if an optional maximum volume stop assembly (70,
71, 72, 73, 74,75, 76 & 18) is used, it will have to be switched
For convertible thru-shaft units, place thru-shaft coupling spacer with control end plug assembly (17 & 18).
(60) on end of shaft and secure with screw (61). Install oring 3. The valve plate assembly (45) will have to be removed and
(62) in thru-shaft convertible cover (63) and tighten to backside the port plate (43) replaced with a port plate manufactured
of valve plate with screw (64). For thru-shaft coupled units, infor the new rotation direction.
stall oring (59) and secure rear unit to valve plate group with 4. The type designation on the units nameplate (65) will have
screws (78) and lock washers (79). to be changed accordingly.
SEE SECTION I. PREPARATION and INSTALLATION

XI. PARTS LIST
Parts used in this assembly are per Oilgear Specifications. Use Oilgear parts to ensure compatibility with assembly requirements. When
ordering replacement parts, be sure to include pump type designation and serial number stamped on nameplate, bulletin and item
number. To assure seal and packing compatibility, specify type of hydraulic fluid used.
ITEM ITEM
NO. DESCRIPTION NO. DESCRIPTION
1. Housing, Pump 41. Ball, Fulcrum
2. Plug, SK 42. Spring, Shoe Retainer Plate
3. Plug, SAE 43. Plate, Port
4. Seal, Oring 44. Pin, Dowel
5. Plug, Orifice 45. Plate, Valve
6. Plug, SAE 46. Plug, SAE
7. Seal, Oring 47. Seal, Oring
8. Plug, Flow Reversing 48. Plug, SAE
9. Seal , Oring 49. Seal, ORing
10. Seal, Oring 50. Screw, SHC
11. Ring, Back-up 51. Plug, Control Sequence Valve Spool
12. Pin, Roll 52. Seal, Oring
13. Seal, Oring 53. Spring, Control Sequence Valve
14. Seal, Oring 54. Spool, Control Sequence Valve
15. Plug, SAE 55. Assembly, Relief Valve Control Cartridge
16. Seal, Oring 56. Screw, SHC
17. Plug, Control End 57. Coupling, Thru-shaft
18. Seal, Oring 58. Ring, Retainer
19. Piston, Control 59. Seal, Oring
20. Spring, Control Piston 60. Spacer, Thru-shaft Coupling
21. Driveshaft 61. Screw, SHC
22 or 23. Key, Driveshaft 62. Seal, Oring
24. Seal, Driveshaft 63. Cover, Thru-shaft Convertible
25. Retainer, Seal 64. Screw, SHC
26. Bearing, Front Driveshaft 65. Plate, Name
27. Ring, Shaft Retainer 66. Screw, Drive
28. Ring, Bearing Retainer 67. Bearing, Rear Shaft
29. Swashblock 68. Plug, Orifice
30. Bearing, Saddle 69. Plug, NPTF
31. Pin, Control 70. Screw, Stroke Limiter
32. Seal, Oring 71. Ring, Backup
33. Cover, Housing 72. Seal, Oring
34. Screw, SHC 73. Body, Max. Volume Stop
35. Bearing, Hydrodynamic Cylinder 74. Bonnet, Stoke Limiter
36. Pin, Roll 75. Seal, Oring
37. Ring , Cylinder Bearing Retainer 76. Nut, Jam
38. Barrel, Cylinder 77. Bearing, Rear Shaft
39. Assembly, Piston & Shoe 78. Screw, SHC
40. Plate, Shoe Retainer 79. Washer, Lock
ORING & BACK-UP RING SIZES

ARP 568 Uniform Size Number with Durometer
ITEM PUMP SIZE ITEM PUMP SIZE

NO. 011, 014 & 022 NO. 011, 014 & 022
4 902-90 47 902-90
7 904-90 48 904-90
9 904-90 49 904-90
10 008-90 52 904-90
11 008 59 042-70
13 242-70 62 028-70
14 010-90 71 014
15 908-90 72 014-90
18 920-90 75 912-90
32 151-70

Figure 7. Exploded Parts Drawing (519272-101 sht. 1 of 6). Parts list on page 12
Figure 8. Cross Section and Plan View Parts Drawing (519272-101 sh. 2 of 6). Parts list on page 12
NOTES
Page 15
XII. AFTER SALES SERVICES SPARE PARTS AVAILABILITY:
Oilgear builds products that last. However, it is the nature of this Prepare for future needs by stocking Oilgear original factory
parts. Having the correct parts and necessary skills “in-plant”
type of machinery to require proper maintenance regardless of enables you to minimize down-time. Oilgear has developed parts
the care that goes into its manufacture. Oilgear has several ser- kits to cover likely future needs. Oilgear field service techni-
vice programs to help you. cians also stand ready to assist your maintenance people in
trouble-shooting and repairing equipment.
“STAY-ON-STREAM” SERVICE: OILGEAR EXCHANGE SERVICE

By signing up for Oilgear’s “Stay-On-Stream” program you can Standard replacement pumps and motors are available to users
prepare for problems before they happen. Certain field tests of Oilgear equipment where comparable units will be returned
such as fluid testing, slip testing and electronic profile record- in exchange. When standard replacements must be modified to
ing comparisons can be performed by our field service people replace units which are special, shipment will depend on avail-
or your own trained personnel. These tests can indicate probability of parts, assembly and test time necessary.
lems before they become “down-time” difficulties.
To obtain this service, place an order for an exchange unit and
SERVICE SCHOOLS: provide the serial number and type designation. The replace-
ment unit will be shipped F.O.B. our factory. Milwaukee, Wis-
Oilgear holds schools to train your maintenance personal. A consin. User retains the replacement and returns the worn unit
“general” hydraulic or electronic school is conducted in our Mil- prepaid to The Oilgear Company for reconditioning and test.
waukee plant on a regular basis. “Custom” schools, specifically When the unit is reconditioned and stocked, the user is billed
addressing your particular hydraulic and electrohydraulic equip- the cost of reconditioning or a flat rate exchange price if one has
ment can be conducted in your plant. been applied to that particular type of unit.
THE OILGEAR COMPANY

BULLETIN 947070 Milwaukee, WI 53219 Litho in USA
Bulletin_47070-A_7 10/14/03 10:43 AM Page 2
PVM Open Loop Pumps
Bulletin 47070-A
Table of Contents
Performance Assurance page 3
Features and Benefits page 4-5
Specifications page 6
Dimensions and Weights page 7
Controls
Pressure Compensator page 8

Standard Load Sense w/Pressure
Compensator Override page 8
Table of Contents
Adjustable Load Sense w/Pressure

Compensator Override page 9
Remote Pressure Compensator page 9
Performance Curves
Efficiency, Delivery, Horsepower, Etc. page 10-11
Sound page 12-13

Inlet Suction/Supercharge page 14-17
Multiple Pumps
Pump Combinations page 18

Ordering Information page 19
2 Copyright 2003 ■ The Oilgear Company ■ All Rights Reserved

PERFORMANCE ASSURANCE –
STANDARD WITH EVERY OILGEAR PUMP
Every Oilgear product is shipped to you

with our Performance Assurance — a corporate
As a customer, you also benefit from access to
Oilgear’s impressive technical support network.
Performance Assurance
commitment to stay with your installation until You’ll find factory trained and field-experienced
our equipment performs as specified. application engineers on staff at every Oilgear
facility. They are backed by headquarters staff
Hydraulic equipment and systems have been who can access the records and knowledge learned
Oilgear’s primary business since 1921. For from decades of solving the most difficult
decades, we have developed hydraulic techniques hydraulic challenges.
to meet the unique needs and unusual fluid power
problems of machinery builders and users When your design or purchase is complete, our
worldwide, matching fluid power systems to a service is just beginning. If you ever need us, our
tremendous range of applications and industries. Oilgear engineers will be there, ready to help you
Our exclusive Performance Assurance program is with the education, field service, parts and repairs
built upon that strong foundation. to assure that your installation runs smoothly —
and keeps right on running.
3
PVM Open Loop Pumps

Rugged cylinder design Hardened cylinder surfaces
■ Hardened nodular iron ■ Greater resistance to
construction for improved contamination
Multiple controls available. performance and ■ Provides longer life
■ A fast shift valve assists ■ Allows operation with
contamination resistance
pump in coming back Cylinder mounted in low viscosity or other
9
on stroke polymerous hydrodynamic 5 special fluids
■ All units are shipped with journal bearings
“meter-out” pressure ■ Allows operation with
Rotation Convertibility
compensated, load low viscosity or other ■ Right hand driven pumps
sensing control special fluids are easily converted to
■ Delivers high ■ Provides infinite
left hand driven pumps
performance bearing life or vice versa
in a compact package ■ Enables compact design 2 ■ Constant port locations
3 (suction, pressure)
4
regardless of pump
rotation
Features and Benefits
Valve plate selection

SAE Splined or Keyed shaft ■ Rear or top and bottom
■ For convenient coupling 6 port connections
to your specific rotary available
power source, heavy-duty
shafts allow high through
torque capability
8
Quiet port plate design
1 ■ Minimizes noise
at typical electric
and drive motor
speeds
■ Low sound levels
(see Sound Curves)
■ Allows easy
inspection
and maintenance
12 7
One piece polymerous bearing Through-shaft availability

■ Allows running on 10
(after removal of rear cover)
low viscosity or other ■ Full through-shaft torque
special fluids Hardened steel shoes with capability for most units
■ Permits constant control specially designed face for (see Multiple Pump
11
reaction with low increased fluid retention, Combinations, Page 18)
hysteresis Patented pressure lubricated running on hardened allows multiple pump
■ Allows high performance swashblock swashblock surface installation from single
in high cyclic ■ Delivers high ■ Running surfaces driveshaft
applications performance for high hardened ■ Close-coupled dual
■ Eliminates troublesome pressure high cycle ■ Provides a higher design further provides
yoke bearings operation degree of contamination a compact package
■ Provides long life ■ Provides long life resistance ■ Has provisions for
■ Allows higher pressure mounting other SAE
operation size pumps, equipment etc.
■ Enables operation with ■ Can be used to drive
low viscosity or other auxiliary devices (see
special fluids Multiple Pump Combina-
■ Provides long life tions, Page 18)
4
Plus the following not shown in the cross section photo
(13) Isolated front shaft bearing (16)Can be easily mounted in any position
■ Enables operation with low viscosity or ■ Easy to install
other special fluids ■ Dual case drain available for mounting
■ Allows side loading flexibility
(14) Multiple capacities in each compact (17)Built in purge port

frame size ■ Aids in purging trapped air from pump
■ Permits selection of volume capacity that during start-up
most closely match your needs while
providing maximum control range (18)Designed without gaskets
■ Unitized one-piece nodular iron housing ■ All mating surfaces and passages designed
reduces number of potential leak paths with o’ring seals to prevent leakage
Features and Benefits (cont’d)

(15) Totally enclosed
■ Impervious to high pressure washdown
■ Can be operated in hazardous environments
with totally enclosed drive motors
5
SPECIFICATIONS
Nominal Performance Data with 150-300SSU viscosity fluids

FLOW RATE
at 1800 rpm, POWER
rated continuous INPUT
THEORETICAL RATED pres. & 14,7 at rated
FRAME UNIT MAXIMUM CONTINUOUS MAXIMUM psia (bar abs) MINIMUM INLET PRESSURE MAXIMUM cont. pres.
SIZE SIZE DISPLACEMENT PRESSURE PRESSURE inlet condition psia (bar abs) SPEED & 1800 rpm
in3/rev. ml/rev. psi bar psi bar gpm l/min 1200rpm 1500rpm 1800rpm rpm. hp kw
011 0.66 10,8 3750 258,6 4250 293,1 4.3 16,3 5.0 (,34) 5.3 (,37) 5.6 (,39) 3600 12.8 9,5
A 014 0.86 14,1 3750 258,6 4250 293,1 5.8 22,0 5.0 (,34) 5.0 (,34) 5.0 (,34) 3600 16.4 12,1
022 1.35 22,1 3750 258,6 4250 293,1 9.5 36,0 6.6 (,46) 7.6 (,52) 8.6 (,60) 3600 26.1 19,5
076 4.67 76,5 3750 258,6 4250 293,1 32.4 122,6 6.1 (,42) 6.3 (,43) 8.2 (,57) 2450 85.7 63,9
C 098 6.00 98,3 3750 258,6 4250 293,1 41.2 156,0 6.8 (,47) 7.2 (,50) 8.3 (,57) 2450 109.2 81,4
130 7.94 130,2 3750 258,6 4250 293,1 57.8 218,8 6.7 (,46) 7.1 (,49) 8.7 (,60) 2450 150.8 112,5
Specifications
6
SINGLE PUMP
Nominal Dimensions
FRAME LENGTH WIDTH HEIGHT WEIGHT
SIZE UNIT SIZE in. mm. in. mm. in. mm. lbs. kg FACE MOUNT
Dimensions and Weights

A 011, 014 & 022 7.95 201,9 7.3 185,4 6.48 164,6 37.5 17,0 SAE "A" 2 Bolt
C 076, 098 & 130 11.9 302,3 10.5 266,7 10.2 259,6 136 61,7 SAE "C" 2/4 Bolt
DUAL PUMP
Nominal Dimensions
FRAME LENGTH WIDTH HEIGHT WEIGHT

SIZE in. mm. in. mm. in. mm. lbs. kg
A/A 16.2 410,5 7.3 185,4 6.48 164,6 77 35,0
C/A 20.3 516,4 10.5 266,7 10.2 259,6 185 84,1
C/C 24.3 617,0 10.5 266,7 10.2 259,6 282 128,2
7
Pump Controls* PUMP CONTROLS* Any, single or multiple, combination of

remote or load sense controls can be combined with the
built-in pressure compensator control if desired.
PRESSURE*
Pressure Compensator “P-1NN” Standard Load Sense “P-1NN/F”
Ensures maximum pump flow until unit reaches preset control W/ Pressure Compensator
pressure setting and then regulates output flow to match the A constant output flow is maintained for a given (customer
requirements of the system while maintaining preset output supplied) flow control valve setting regardless of changes in
pressure. Pressure can be adjusted from 350 psi (24,1 bar) drive speed and/or working pressure. The load sense
working pressure up to the rated pressure rating of the pump. differential is 180 psi and is not adjustable.
Pump Controls*
* Be sure system and pumps are protected, with a high-pressure relief valve, against overloads.
For detailed circuits of a particular size pump and control combination, contact your Oilgear Representative.
8
Adjustable Load Sense w/Pressure “P-1NN/J” Remote Controls for Pressure

Compensator Override Compensator Functions
Adjustable load sense w/pressure compensator “P-1NN/J”. A customer supplied remote control valve can be easily
A constant output flow is maintained for a given added to any of the “PVM” Pumps allowing pressure
(customer supplied) flow control valve setting regardless adjustment control to be convenient to the operator while
of changes in drive speed and/or working pressure. The the pump may be located convenient to the operated
load sense differential is adjustable from 180 to 700 psi. device.
Pump Controls*
* Be sure system and pumps are protected, with a high-pressure relief valve, against overloads.
For detailed circuits of a particular size pump and control combination, contact your Oilgear Representative.
9
Performance curves are based on a viscosity of 160 SSU.

PVM-011 PVM-014
Performance Curves
PVM-022
10
Performance curves are based on a viscosity of 160 SSU.

PVM-076 PVM-098
PVM-130 Performance Curves
11
Sound curves are based on a viscosity of 500 SSU.
PVM-011 PVM-014
Sound Curves
PVM-022
12 * Be sure system and pumps are protected against over loads with a high pressure relief valve.
Sound curves are based on a viscosity of 500 SSU.
PVM-076 PVM-098
Sound Curves
PVM-130
13
INLET SUCTION/SUPERCHARGE
Inlet/supercharge curves are based on a viscosity of 500 SSU.
PVM-011
Inlet/Suction Curves
PVM-011
14
PVM-014
PVM-014
15
PVM-022
PVM-022
16
PVM-076 PVM-098
PVM-130
17
MULTIPLE PUMP COMBINATIONS

Two or more Oilgear “PVM” axial piston variable delivery pumps can be integrally coupled
together and driven from a single shaft. In most cases (see Specifications) both pumps can be
used at full rated output. Pump deliveries can be combined for large volume circuits or
deliveries can be used individually. See the following table and calculations for Allowable
Thru-shaft Torque.
How to calculate torque for each pump
T (in. lbs.) = Pressure (psi) x Displacement (cu. in./rev.) *

5.625
Multiple Pump Combinations
Add the respective torques for each unit:

T1 = front pump torque required
T2 = second pump torque required
Tn = Additional pump or torque for any other driven device
T1 + T2 + Tn Sum must be less than T max. shown in table
Tmax (in. lbs.)

Pump Frame Size Thru-shaft Capability
A 1100
C 5252
* Assumes 90% mechanical efficiency.
18
HOW TO ORDER
BLOCK NUMBER
EXPLANATION 1 2 3 - 4 - 5 6 7 - 8 9
VARIABLE PUMP P V M - 011 - A2 U B - L DA
EXAMPLE
Continued from above
BLOCK NUMBER
EXPLANATION 10 - 11 - 12 13 14 15 - 16 - 17 - 18
VARIABLE PUMP B - P - 1 NN /J SN - CN - 05 - XXX
EXAMPLE
1 = UNIT 10 = SHAFT END

P = Pump See Table 1
Table 1 Shaft End
How to Order
2 = TYPE
V = Variable A Frame C Frame
3 = DESIGN TYPE B .875 Dia Keyed 1.500 Dia Keyed
M = Pump Series C 13T, 16/32 Spline 17T, 12/24 Spline
S 9T, 16/132 Spline 14T, 12/24 Spline
4 = UNIT SIZE
011 = 0.66 cipr Y .750 Dia Keyed 1.250 Dia Keyed
014 = 0.86 cipr
022 = 1.35 cipr
076 = 4.67 cipr 11 = PRESSURE CONTROL
098 = 6.00 cipr P = Pressure Compensator
130 = 7.94 cipr 12 = CONTROL MODIFIER 1
5 = DESIGN SERIES 1 = Single PC Setting
B1 = A Frame 13 = CONTROL MODIFIER 2
A2 = C Frame NN = None
6 = SAE DESIGN SERIES 14 = CONTROL MODIFIER 3
U Blank = PC Only
7 = SEALS /F = Unadjustable LS
B = Nitrile (standard) /J = Adjustable LS
P = EPDM Seals w/PTFE shaft seal 15 = STROKE LIMITER OPTION
V = Viton NN = None
8 = ROTATION SN = Adjustable Maximum
L = Left-hand (CCW) 16 = AUXILIARY ADAPTERS (for thru-shaft)
R = Right-hand (CW) Blank = None (for all RP/SP units)
9 = VALVE PLATE TYPE CN = SAE C Adapter & Coupling
(C frame only)
DA = Thru-shaft, side ported w/SAE ports CP = Cover Plate
(A or C frame) AN = SAE A Adapter & Coupling
DF = Thru-shaft, side ported, w/flange AA = SAE A A -Adapter & Coupling
ports (C frame only) BN = SAE B Adapter & Coupling
GA = Side ported w/SAE ports (C frame only)
(A or C frame)
GF = Side ported, w/flange ports 17 = GEAR PUMPS
(C frame only) Blank = None
05 = 0.488 cipr
SA = Rear ported w/SAE ports 07 = 0.67 cipr
(A or C frame) 10 = 0.976 cipr
SF = Rear ported w/flange ports 14 = 1.403 cipr
(C frame only) 20 = 2.015 cipr
18 = SPECIAL PUMP MODIFIER
(Assigned by factory when necessary)
19
World Headquarters
The Oilgear Company
2300 South 51st Street Milwaukee, WI USA 53219
phone: 414/327-1700 fax: 414/327-0532
www.oilgear.com
For more information about your application or the products
in this brochure, please contact your nearest Oilgear facility.
AUSTRALIA
Oilgear Towler Australia Pty. Ltd.
BRAZIL
Oilgeardo Brazil Hydraulica Ltd.
CANADA
The Oilgear Company
FRANCE
Oilgear Towler S.A.
GERMANY
Oilgear Towler GmbH
INDIA
Oilgear Towler Polyhydron Pvt. Ltd.
Towler Automation Pvt. Ltd.
ITALY
Oilgear Towler S.r.l.
JAPAN
The Oilgear Japan Company
KOREA
Oilgear Towler Korea Co. Ltd.
MEXICO
Oilgear Mexicana S.A. de C.V.
SPAIN
Oilgear Towler S.A.
TAIWAN
Oilgear Towler Taiwan Co. Ltd.
UNITED KINGDOM
Oilgear Towler Ltd.
UNITED STATES OF AMERICA

The Oilgear Company
Bulletin 47070-A
Revised October, 2003
Printed in USA
NOI # 2302070-001 & 2302070-002
NOI #2302004-012
NOI # 2302070-003 RETURN FILTER
1. TECHNICAL 1.3. CLOGGING INDICATORS
SPECIFICATIONS
(Example)
1.1. FILTER HOUSING
Construction
VR 2 C.0 /-V
The return line filter consists of a
separate filter head with a
suspended filter bowl and bolt-on Type of indicator
cover plate. VR return line indicator
VMF return line indicator
Connections for clogging
indicators are standard.
(Exceptions: sizes 75 and 165 are Pressure setting
available with or without indicator 2 2 bar
connection.)
1.2. FILTER ELEMENTS Indicator type code
B. visual
Hydac filter elements fulfil the
C. electrical
following ISO test criteria.
D. visual/electrical
ISO 3724 Verification of flow
fatigue characteristics
Modification number
ISO 4572 Contamination retention 0 the latest version is always supplied
capacity
ISO 4572 Multi-pass method for
Supplementary details
evaluating filtration performance
V Viton
ISO 3968 Evaluation of pressure
drop versus flow characteristics
ISO 2942 Bubble point test
For further details on clogging indicators, please see:
ISO 2941 Verification of collapse / brochure no.: E 7.050../..
burst resistance
Reliable filter operation is only
guaranteed with original 1.4. SEALS
Hydraulic symbol
HYDAC filter elements. Choice of Perbunan (= NBR) or
The filter elements are also Viton (= FPM for HFD fluids, see
suitable for use in dynamic Point 3.1. "Supplementary
applications due to their high details").
pressure stability; max. 1.5. SPECIAL MODELS AND
permissible Dp across the ACCESSORIES
element:
Connections for filling the
Betamicron® (BN3HC): 25 bar hydraulic system via the return
Paper (P/HC): 10 bar line filter element (size 330 and
Wire mesh (W/HC): 30 bar over)
Betamicron®/Aquamicron® Threaded connection in the outlet
(BN/AM): 10 bar Tank breather filter in the head,
Aquamicron (AM):
®
10 bar built-in on size 75 and 165
Fluid compatibility 1.6. SPARE PARTS
Suitable for mineral oils, See Original Spare Parts List and
lubrication oils, non-flam fluids, Maintenance Instructions,
synthetic and rapidly no.: E 7.106.E../..
biodegradable oils. For use with
water, please contact our sales/
technical department. 2. GENERAL
For further details on filter Mounting
elements, please see: Tank-top filter
brochure no.: E 7.200../..
Temperature range
-30 °C ... +100 °C
(short-term -40 °C)
Pressure setting of the return
line clogging indicator
Dpa = 2 bar -0.2 bar
(compared with atmospheric
pressure)
Other pressure settings on
request.
Cracking pressure of bypass
valve
DpO = 3 bar +0.5 bar
Other pressure settings on
request.
2
3. MODEL CODE
(also order example)
3.1. COMPLETE FILTER
RFM BN/HC 165 G 10 D 1 . X /-L24
Filter type
RFM
Filter material of element

BN/HC Betamicron® (BN3HC)
P/HC paper
W/HC stainless steel wire mesh
BN/AM Betamicron®/Aquamicron® (size 330 and over)
AM Aquamicron® (size 330 and over)
Size
75, 165, 330, 500, 661, 851
Type of connection
G threaded connection (only on RFM 75, 165, 330, 500)
F flange connection (not possible on RFM 75 and 165)
KIT in-tank mounting kit (all sizes) ù see point
SET in-tank mounting set (only on RFM 330 and 500) ú 3.1.1
S in-tank welding set (only on RFM 75, 165, 330, 500) û
Filtration rating in µm
BN3HC : 3, 5, 10, 20
P/HC : 10, 20
W/HC : 25, 50, 100, 200
BN/AM : 3, 10
AM : 40
Type of clogging indicator

Y with plastic blanking plug ù
W1) no indicator connection ú
A with steel blanking plug ú
B with visual indicator ú
BM with visual indicator ú for other clogging
C with electrical indicator ú indicators, see brochure no. E 7.050../..
D with combined visual/electrical indicator ú
E/ES with pressure gauge ú
F with pressure switch (only up to 42 V) û
Type code
1 version with 1 inlet for RFM 330-851
1 version with threaded connection G1 for RFM 75/165
2 version with 2 inlets for RFM 330-851
2 version with threaded connection G3/4 for RM 75/165
Modification number
X the latest version is always supplied
V FPM seals, filter suitable for rapidly biodegradable oils and phosphate esters (HFD-R)
L... light with corresponding voltage (24V, 48V, 110V, 220V) ù only on clogging
LED 2 light-emitting diodes up to 24 volt û indicators type D
BA filling connection (not possible for size 75 and 165)
G threaded connection in the outlet (size 330 and over)
T with tank breather filter (only size 75 and 165)
Vxx with pipe extension (xx stands for the final dimension of the extension)
01206487 drawing no. for re-machining the cover plate (size 330/500 for vertical mounting of the clogging indicator)
1)
only for size 75 and 165
3
3.1.1 In-tank mounting 3.2. REPLACEMENT ELEMENT
RFM BN/HC 165 KIT 10 W 1.0 0330 R 010 BN3HC /-KB
Type of connection Size

In-tank mounting kit (all sizes) 0075, 0165, 0330, 0500, 0660, 0850
- bowl with element and O-ring
Type
R
Filtration rating in µm
BN3HC: 3, 5, 10, 20
P/HC: 10, 20
W/HC: 25, 50, 100, 200
BN/AM: 3, 10
AM: 40
Filter material
BN3HC, P/HC, W/HC, BN/AM, AM
V FPM seals, filter suitable for rapidly biodegradable oils and
phosphate ester (HFD-R)
W NBR seals, filter suitable for oil-water emulsions
(HFA, HFC) (only for W/HC elements)
RFM BN/HC 330 SET 10 W 1.0 KB without bypass valve
Type of connection 4. FILTER SPECIFICATIONS

In-tank mounting set (only on RFM 330 and 500)
bowl with element and O-ring, plus adaptor ring Filter type Connection Element size Weight [kg]
incl. element
75 G 3/4 0075 R... 0.9
G1
165 G 3/4 0165 R... 1.1
G1
330 G1 1/2 0330 R... 3.9
SAE DN 40 0330 R...
500 G1 1/2 0500 R... 4.5
SAE DN 40 0500 R...
661 SAE DN 65 0660 R... 9.0
851 SAE DN 65 0850 R... 10.5
RFM BN/HC 75 S 10 W 1.0
Type of connection
In-tank welding set (only on RFM 75, 165, 330, 500)
bowl with element and O-ring, plus steel housing
4
5. FILTER CALCULATION / 5.2. DP-Q GRAPHS - FILTER ELEMENTS
SIZING The element graphs apply to mineral oil with a
kinematic viscosity of 30 mm²/s. The pressure drop
The total pressure drop of a filter at a certain flow rate is changes proportionally to the change in viscosity
the sum of the housing Dp and the element Dp. (see Example 5.3.).
The pressure drop can either be determined with the aid
of our FSP Filter Sizing Program, which is available free
of charge, or by using the following graphs.
BN3HC
5.1. DP-Q HOUSING GRAPHS TO ISO 3968 3µm
1,4
1.4
The housing graphs apply to mineral oil with a density Size 75 5µm
of 0.86 kg/dm3 and a kinematic viscosity of 30 mm²/s for 1.2
1,2 Size 165
the largest nominal width per size in each case.
11
For turbulent flows the differential pressure changes
3µm
proportionally to the density. For laminar flows it 10µm
Dp in bar
0.8
0,8
changes proportionally to the density and the viscosity.
0.6 20µm
0,6
5µm
0.4
0,4 10µm
RFM 75/165 20µm
0.2
0,2
0
0 10 20 30 40 50 60 70 80 90 100
Dp in bar
flow rate in l/min
3µm
1.4
1,4
Size 330
Size 500
1.2
1,2
3µm
Q in l/min 1
RFM 330/500 5µm
Dp in bar
0.8
0,8
5µm
10µm
0.6
0,6
10µm
Dp in bar
20µm
0.4
0,4
20µm
0.2
0,2
0
0 50 100 150 200 250 300 350 400
Q in l/min flow rate in l/min

RFM 661/851
3µm
1
1
Size 661
0.9
0,9 3µm
Size 851
Dp in bar
0.8
0,8
0.7 5µm
0,7
5µm
0.6
Dp in bar
0,6
0.5
0,5 10µm
0.4 10µm
0,4
20µm
Q in l/min 0.3
0,3 20µm
0.2
0,2
0.1
0,1
0
0 100 200 300 400 500 600 700
flow rate in l/min
5
W/HC 5.3. EXAMPLE
0.4
0,4
BG 75
General
viscosity (mm²/s)
Dptotal = Dphousing + Dpelement x
0.35
0,35
30 mm²/s
0.3
0,3
Dphousing = to be determined from point 5.1.
Dpelement = element pressure drop at flow rate Q and
0.25
0,25 BG 165
Dp in bar
0.2
0,2
viscosity 30 mm²/s according to point 5.2.
Example
0.15
0,15
BG 330 System data: RFM 165 with BN3HC element (10 mm);
0.1
0,1 viscosity = 46 mm²/s (ISO VG 46 at 40 °C);
BG 500
BG 660 Q = 50 l/min;
0.05
0,05 BG 850
0 Þ Dphousing = 0.02 bar (at Q)

0 100 200 300 400 500 600 700
Dpelement = 0.19
flow rate in l/min 46 mm²/s
Dptotal = 0.02 bar + 0.19 x
30 mm²/s
P/HC - 10 µm = 0.31 bar
BG 75 BG 165
0.4
0,4
For ease of calculation, our FSP Filter Sizing
0.35
0,35
Program is available on request, free of charge.
0.3
0,3
0.25
0,25
Dp in bar
BG 330
0.2
0,2
0.15
0,15
BG 660
0.1
0,1 BG 500
BG 850
0.05
0,05
0
0 100 200 300 400 500 600 700
flow rate in l/min
P/HC - 20 µm
BG 75
0.4
0,4
0.35
0,35
0.3
0,3
0.25
0,25
Dp in bar
BG 165
0.2
0,2
0.15
0,15
0.1
0,1 BG 330
BG 500
0.05
0,05 BG 660
BG 850
0
0 100 200 300 400 500 600 700
flow rate in l/min
BG = Size
6
6.2. RFM 330 - 851
SIZE 330 / 500 SIZE 661 / 851
Inlet
clogging indicator filling

connection
filling connection
connection for clogging
indicator
Outlet Outlet
View from below View from below
Type d1 d3 d4 d5/b11 d7 d9 d10 b1 b2 b3 b4 b9 b10 h1 h2 h3 h4 h6 h7

330 122 G1½ 11 G2 170 185 210 155 98 87 159 106 51 265 3 18
330 122 SAE DN 40 M12 11 G2 170 185 69.9 35.7 210 155 98 87 159 106 51 265 3 18
500 122 G1½ 11 G2 170 185 210 155 98 87 240 106 51 285 3 18
500 122 SAE DN 40 M12 11 G2 170 185 69.9 35.7 210 155 98 87 240 106 51 285 3 18
661 165 SAE DN 65 13.5 G2½ 220 88.9 50.8 252 200 122 110 300 126 55 340 3 9
851 165 SAE DN 65 M12 13.5 G2½ 220 88.9 50.8 252 200 122 110 381 126 55 420 3 9
7. NOTE
All details in this brochure are subject to technical modifications.
8
NOI # 2302070-004
1. DESCRIPTION 1.1.2 Materials 2. TECHNICAL
DF SERIES: SPECIFICATIONS
1.1. FILTER HOUSING
Filter Head: GGG 40
1.1.1 Basic design Filter Bowl: Cold impact 2.1 GENERAL
Filters of the DF, MDF and LF formed steel 2.1.1 Designation and hydraulic
series consist of the filter head symbols
MDF SERIES:
and a screw-in filter bowl. High pressure filter DF
Filter Head: GGG 40
Size 660 of the DF filter is also Medium pressure filter MDF
Filter Bowl: Cold impact
available with a two-piece bowl Inline filter LF
formed steel
(tube and cover plate) as an
LF SERIES: Filter without clogging indicator,
additional version. When
Filter Head: Al without bypass valve (A)
changing the element, sizes 500
and 660 have the advantages of Filter Bowl: Size 30 - 330: Al
diamond knurling and a ring on Size 660:
the bowl. For size 990 and above Cold impact
the two-piece bowl version is formed steel
used. 1.1.3 Seals
The standard models of the DF, NBR (Perbunan)
MDF and LF are supplied without 1.1.4 Special models
a bypass valve. Moreover, sizes Filters with protective finish
30 to 280 are supplied without a Filters with bypass valve
pressure release plug. Size 330
and above are supplied with a Filters with pressure release plug Filter without clogging indicator,
pressure release plug as (size 280 and below) with bypass valve (A../-B6)
standard. The connection for a Viton seals
clogging indicator is available as 1.1.5 Accessories
standard. Visual and/or electrical clogging
indicator.
The clogging indicators must be
Model with one-piece bowl tightened to the recommended
torque ratings,
(see brochure no.: E 7.050../..)
Outlet Inlet Mating flanges for filters with
SAE flange connection.
1.2. NOTE Filter with visual clogging
For larger flow rates and lower indicator (B)
filter element pressure ranges, see brochure:
BN3HC Inline Filters (RFL)
BH3HC no.: E 7.104../..
V/HC
W/HC
For stainless steel filters,
see brochure:
Industrial Processing Filters
no.: E 7.700../..
Model with two-piece bowl Stainless steel filters also

available for offshore applications.
For information, contact our Filter with electrical clogging
sales/technical department. indicator (C)
Outlet Inlet 1.2.1 Filter elements
See Filter Element brochure
no.: E 7.200../..
1.2.2 Cleaning of elements
Please note:
Only wire mesh (W) and metal
filter element fibre (V) elements can be
BN3HC cleaned.
BH3HC Filter elements with
V/HC
Betamicron®-H or Betamicron®-N
W/HC
filter material cannot be cleaned. Filter with visual and electrical
1.2.3 Spare parts clogging indicator (D)
See brochure: Spare Parts and
Maintenance Instructions,
no. E 7.501.E./..
The lamp can either be fitted

to the normally open contact (3)
or the normally closed contact (2)
2
2.1.2 Model Code
(also order example)
DF BH/HC 60 G 10 C 1 . 1 / -V
Filter Type
DF high pressure filter
MDF medium pressure filter
LF inline filter
Filter element material

BH/HC Betamicron®-H3HC element ù absolute
BN/HC Betamicron®-N3HC element û filtration
V/HC metal fibre element ù nominal
W/HC wire mesh element û filtration
Size
DF 30/60/110/140/160/240/280/330/500/6601)/990/1320
MDF 30/60/110/160/240
LF 30/60/110/160/240/330/660
Type of connection
G threaded connection
F flange connection
Filtration rate in µm
3 ù
5 ú Betamicron®-H (BH3HC) ù absolute
10 ú Betamicron®-N (BN3HC) û filtration
20 û metal fibre (V) ù nominal
25 wire mesh (W/HC) û filtration
Type of clogging indicator

A = without clogging indicator ù see separate
B = with visual clogging indicator ú brochure on
C = with electrical clogging indicator ú clogging indicators
D = with combined visual and electrical indicator û brochure no.: E 7.050../..
Type code
1 = standard connection for inlet and outlet (one-piece filter bowl)
2 = standard connection for inlet and outlet (two-piece filter bowl) sizes 660 to 1320
Modification number
1
no details = standard
-V = FPM (Viton) seals, filter suitable for phosphate ester (HFD-R)
-W = NBR (Perbunan) seals, filter suitable for oil-water emulsion (HFA), water polymer solution (HFC)
-L24 = light with 24 V DC ù
-L48 = light with 48 V DC ú
-L110 = light with 110 V DC ú on type "D"
-L220 = light with 220 V DC ú indicators only
-LED = 2 light emitting diodes for up to 24 V DC û
-B6 = with bypass valve (cracking pressure 6 bar)
-SO 184= pressure release/oil drain plug (up to size 280)
1)
for DF series, this filter is available with type code 1 and 2
3
2.1.3 Type of construction 2.1.7 Pipe connection sizes Proof of fatigue strength for
Inline filter (threaded connection to ISO 228) complete filters to HYDAC test
2.1.4 Mounting method and the relevant type codes standard. Min. 1 mill. stress
4 mounting holes in filter head cycles, from 0 bar to permissible
DF 30 G G½ 1.1 operating pressure (= pmax).
2.1.5 Approx. weights
with without DF 60 G G¾ 1.1 For other temperature ranges,
element element DF 110 G G¾ 1.1 please contact our sales/technical
department.
DF 30 1.9 kg 1.8 kg DF 140 G G¾ 1.1
DF 60 4.1 kg 3.9 kg 2.2.2 Permissible Dp across element
DF 160 G G1¼ 1.1 Betamicron®-H (BH3HC): 210 bar
DF 110 6.0 kg 5.7 kg
DF 240 G G1¼ 1.1 Betamicron®-N (BN3HC): 25 bar
DF 140 6.6 kg 6.2 kg
DF 160 9.6 kg 9.1 kg DF 280 G G1¼ 1.1 Metal fibre (V): 210 bar
DF 240 11.3 kg 10.6 kg DF 330 G G1½ 1.1 Wire mesh (W): 30 bar
DF 280 15.9 kg 14.5 kg DF 330 F SAE flange 1.1 2.2.3 Compatibility with
DF 330 22.6 kg 21.4 kg DN 50 / 6000 psi hydraulic media
DF 500 26.9 kg 25.2 kg DF 500 G G1½ 1.1 Mineral oils:
DF 6602) 30.5 kg 28.3 kg test criteria to ISO 2943
DF 6603) 36.2 kg 34.0 kg DF 500 F SAE flange 1.1
DN 50 / 6000 psi Lubricating oils:
DF 990 43.4 kg 40.0 kg test criteria to ISO 2943
DF1320 52.4 kg 48.0 kg DF 660 G G1½ 1.1
2.1 Suitable for use with non-flam
MDF 30 1.9 kg 1.8 kg fluids, synthetic oils and rapidly
MDF 60 3.2 kg 3.0 kg DF 990 G G1½ 2.1
biodegradable oils. For use with
MDF110 3.7 kg 3.2 kg DF 990 F SAE flange 2.1 water please check with our
MDF160 7.2 kg 6.7 kg DN 50 / 6000 psi sales/technical department.
MDF240 8.1 kg 7.4 kg DF 1320 G G1½ 2.1 2.2.4 Flow fatigue resistance
LF 30 0.8 kg 0.7 kg DF 1320 F SAE flange 2.1 to ISO 3724
LF 60 1.5 kg 1.3 kg DN 50 / 6000 psi High fatigue resistance due to
LF 110 1.8 kg 1.5 kg MDF 30 G G½ 1.1 solid filter material supports on
LF 160 3.7 kg 3.2 kg MDF 60 G G¾ 1.1 both sides and high inherent
LF 240 4.3 kg 3.6 kg stability of filter materials.
LF 330 8.2 kg 7.0 kg MDF 110 G G¾ 1.1
MDF 160 G G1¼ 1.1 2.2.5 Pressure setting of
LF 660 17.8 kg 15.6 kg
clogging indicator
2.1.6 Housing volumes MDF 240 G G1¼ 1.1 Dpa = 5 bar - 10%
Filter type LF and DF LF 30 G G½ 1.1
2.2.6 Cracking pressure of
Size Volume LF 60 G G¾ 1.1 bypass valve
30 0.13 l LF 110 G G¾ 1.1 DpO = 6 bar + 10%
60 0.20 l
LF 160 G G1¼ 1.1 2.2.7 Bypass valve graphs
110 0.33 l
LF 240 G G1¼ 1.1 The bypass valve graphs apply
140 1) 0.40 l
LF 330 G G1½ 1.1 to mineral oil with a density of
160 0.60 l
0.86 kg/dm³.
240 0.80 l LF 660 G G1½ 1.1
280 1) 1.45 l The differential pressure of the
330 1.50 l 2.1.8 Mounting position valve changes proportionally to
500 1) 2.30 l Vertical the density.
660 3.00 l
2.1.9 Flow direction
990 1) 4.20 l
Inlet and outlet: side connection
1320 1) 5.60 l
At the same level, on
Filter type MDF opposite sides.
Size Volume
Dp in bar
2.2. HYDRAULIC DATA

30 0.10 l
2.2.1 Operating pressure/
60 0.18 l
temperature A: sizes: 0660 D E: sizes: 0110 D
110 0.32 l B: sizes: 0500 D / 0030 D
The operating pressure is C: sizes: 0280 D F: sizes: 0240 D
160 0.55 l D: sizes: 0330 D G:sizes: 0160 D
generally dependent on the / 0140 D / 0060 D
240 0.79 l
operating temperature.
The following apply: Q in l/min as a % value of the size
d mind max= -10 °C+100 °C
DF 30 - 6603): pmax= 420 bar
DF 6602) - 1320: pmax= 315 bar
(420 bar available on request)
MDF all sizes: pmax= 210 bar
LF all sizes: pmax= 100 bar
d mind max= -30 °C-10 °C
only possible with Perbunan
(NBR) seals.
DF 30 - 6603): pmax= 210 bar
DF 660 - 1320:
2)
pmax= 157.5 bar
1)
for DF series only LF sizes 30 - 330: pmax= 100 bar
2)
size 660, type code 2
LF size 660: pmax= 75 bar
3)
size 660, type code 1
4
2.3. HOUSING GRAPHS 3. FILTER CALCULATION 3.1.2 Calculation guidelines
The housing graphs apply to Due to the high contamination
3.1. TOTAL DIFFERENTIAL
mineral oil with a density of retention capacity of the
PRESSURE ACROSS THE
0.86 kg/dm³ and a kinematic Betamicron® elements, we
COMPLETE FILTER
viscosity of 30 mm²/s. recommend that the calculation of
The total differential pressure of the filters (with clean element and
For turbulent flows the differential
the clean filter is the sum of at operating viscosity) be based
pressure changes proportionally
housing and element differential on the following initial pressure
to the density.
pressure at operating viscosity. drop:
For laminar flows the pressure
changes proportionally to the Dptotal = Dptotal = 0.2 x pressure setting of
density and the viscosity. Dphousing at Q + f x Dp element at Q clogging indicator.
DF/MDF/LF 30 Dptotal = total differential For pressure setting of clogging
pressure across indicator see point 2.2.5.
complete filter Other calculations are possible,
Dphousing at Q = housing differential depending on the system.
Dp in bar
(obtainable from housing graphs An approximate calculation of the

see point 2.3.) filter size can be made by means
Dpelement at Q = element differential of the pre-selection chart - see
pressure at 30 mm²/s point 3.2.
at max. flow in l/min:
(obtainable from element graphs
Q in l/min see brochure no. E 7.200/..,
Filter Elements)
DF/MDF/LF 60/110/140*
f = viscosity conversion factor -
see point 3.1.1.
3.1.1 Viscosity conversion factor f
Dp in bar
Q in l/min
factor f
DF/MDF/LF 160/240/280*
Dp in bar
Q in l/min
DF/LF 330/500*/660/990*/1320*
operating viscosity (mm²/s)
Dp in bar
Q in l/min
* only for DF model

5
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
3.2. FILTER PRE-SELECTION
12345678901234567890123456789012123456789012345
Size 30 - 140
CHART 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
The pre-selection chart applies to
a viscosity of 30 mm²/s at the
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
usual hydraulic loads and 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
favourable application conditions 12345678901234567890123456789012123456789012345
and applies to the following filters: 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Filter type: DF, MDF, LF 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Element type: ...D...BN3HC and 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Q in l/min
...D...BH3HC
The following example explains 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
the procedure using the pre- 12345678901234567890123456789012123456789012345
selection chart: 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Example: 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Filters with Betamicron elements
®
l System related details: 12345678901234567890123456789012123456789012345
Dp = 1.5 bar
12345678901234567890123456789012123456789012345
Flow rate of variable 12345678901234567890123456789012123456789012345
Viscosity 30 mm²/s
displacement pump: 12345678901234567890123456789012123456789012345
Qp = 120 - 350 l/min 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Max. operating pressure: 12345678901234567890123456789012123456789012345
pB = 280 bar 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Required filtration rating: 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
5 µm absolute 12345678901234567890123456789012123456789012345
Filter material: 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
BH3HC 12345678901234567890123456789012123456789012345
Size 160 - 280
l Method: 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Determination of filter type 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Max. operating pressure: 12345678901234567890123456789012123456789012345
pB = 280 bar 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
thus pB £ pmax 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Þ filter type: DF (see point 2.2.1) 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
l Determination of calculation
12345678901234567890123456789012123456789012345
Q in l/min
flow rate QA 12345678901234567890123456789012123456789012345

12345678901234567890123456789012123456789012345
QA = max. flow rate through 12345678901234567890123456789012123456789012345
the filter 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
QA= Qp max. = 350 l/min 12345678901234567890123456789012123456789012345
l Determination of filter size 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
®
For a calculation flow rate of 12345678901234567890123456789012123456789012345

Dp = 1.5 bar
12345678901234567890123456789012123456789012345
QA = 200 l/min and a filtration 12345678901234567890123456789012123456789012345
Viscosity 30 mm²/s
rating of 5 µm absolute, the filter 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
size according to the 12345678901234567890123456789012123456789012345
pre-selection chart is 500 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Filter type: 12345678901234567890123456789012123456789012345
DF BH/HC 500 .. 5 .. 12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Size 330 - 1320
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Q in l/min
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
®
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
Dp = 1.5 bar
12345678901234567890123456789012123456789012345
Viscosity 30 mm²/s
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
12345678901234567890123456789012123456789012345
6
4. DIMENSIONS
DF/MDF/LF 30 G DF/LF 60 - 660 G DF/LF 660 - 1320 G DF/LF 330 - 1320 F
MDF 60 - 240 G
flange connection to ISO/DIS 6261

SAE J 518 C 6000 psi (420 bar)
DF 330 - 1320 G/F
Threaded connection to ISO 228
Dimensions in mm
Typ b 1 b 2 b3 b4 Ø d1 Ø d2 d 3 d4 Ø d5 h1 h2 h 3 h4 h5 SW t 1* t 2*
LF 30 G 69 33 45 30 67 52 G½ M 5 – 125.5 35 7 75 – 24 15 6
LF 60 G – 137.5 –
LF 110 G 92 50 56 32 84 68 G¾ M 6 – 205.0 40 6 75 – 27 17 9
LF 160 G – 190.5 –
LF 240 G 128 65 85 35 116 95 G 1¼ M 10 – 250.5 47 6 95 – 32 21 14
LF 330 G 130 – 252.5 –
LF 660 G 162 85 115 60 159 127 G 1½ M 12 – 417.5 50 6 105 – 36 23 17
DF/MDF 30 G 68/ 33/ 45/ 30/ 67/ 52/ G½ M 5 – 127.5/ 34/ 7 75 – 24 15 6

66 54 43 21 60 45 130 36
DF/MDF 60 G – 137.5/133 –
DF/MDF 110 G 93/ 50/ 84/ 68/ – 205 /201 85/ –
56 32 G¾ M 6 40 6 27 17 9
92 66 78 59 75
DF 140 G – 248.5 –
DF/MDF 160 G – 193.5/178 –
DF/MDF 240 G 128/ 65/ 117/ 95/ – 253.5/237 105/ –
85 35 G 1¼ M 10 47 6 32 21 14
124 80 112 84 85
DF 280 G – 435.5 –
DF 330 G 167 G 1½ – 255.5 –
DF 330 F 160 SAE DN 50 – 255.5 –
DF 500 G 167 G 1½ – 348.5 –
138 115 60 159 130 M 12 52 6 115 36 23 17
DF 500 F 160 SAE DN 50 – 348.5 –
DF 660 G 167 G 1½ – 426.0 –
DF 660 F 160 SAE DN 50 – –
1)
DF 660 G 167 G 1½ 420 350
1)
DF 660 F 160 SAE DN 50 420 350
DF 990 G 167 G 1½ 576 500
138 115 60 159 132 M 12 152 52 6 112 36 23 17
DF 990 F 160 SAE DN 50 576 500
DF 1320 G 167 G 1½ 742 670
DF 1320 F 160 SAE DN 50 742 670
* = thread depth
1)
= size 660 with type code 2
5. NOTE
The information in this brochure relates to the operating conditions and applications described.
For applications or operating conditions not described, please contact the relevant technical department.
Subject to technical modifications.
7
NOI # 2302070-022
NOI # 4503-0220-51
Sun Hydraulics : RPEC Page 1 of 4
NOI # 2302042-017
Capacity:
Pilot operated, balanced piston, Relief valve 25 gpm (95 L/min.)
Functional Group: Model:

Products : Cartridges : Relief : 2 Port : Pilot Operated, Balanced Piston RPEC
Product Description
Pilot-operated, balanced-piston relief cartridges are normally closed pressure
regulating valves. When the pressure at the inlet (port 1) reaches the valve
setting, the valve starts to open to tank (port 2), throttling flow to regulate the
pressure. These valves are accurate, have low pressure rise vs. flow, they are
smooth and quiet, and are moderately fast.
http://www.sunhydraulics.com/cmsnet/cppprint.aspx?Cat_Level_0=1&Cat_Level_1=2&Cat... 2/5/2004
Technical Features
l Will accept maximum pressure at port 2; suitable l Main stage orifice is protected by a 150 micron
for use in cross port relief circuits. If used in cross stainless steel screen.
port relief circuits, consider spool leakage.
l Not suitable for use in load holding applications l Back pressure on the tank port (port 2) is directly
due to spool leakage. additive at a 1:1 ratio to the valve setting.
l All 2-port relief cartridges (except pilot reliefs) are l Incorporates the Sun floating style construction to
physically and functionally interchangeable (same eliminate the effects of internal parts binding due to
flow path, same cavity for a given frame size). excessive installation torque and/or cavity/cartridge
machining variations.
Technical Data
US Units Metric Units
Cavity T-10A Series 1
Model Weight .30 lb 0,15 kg
Typical Response Time 10 ms 10 ms
Adjustment Nut Torque 108 lbf in. 12 Nm
Maximum Valve Leakage 2 in³/min.@1000 psi 32,8 cc/min.@70 bar
Capacity 25 gpm 95 L/min.
Valve Installation Torque 30 - 35 lbf ft 45 - 50 Nm
Factory Pressure Settings Established at 4 gpm 15 L/min.
Full Adjustment-Number of Clockwise Turns to
5 5
Increase Setting
Allen Wrench Hex Size 5/32 in. 4 mm
Maximum Operating Pressure 5000 psi 350 bar
Valve Hex Size 7/8 in. 22,2 mm
Adjustment Nut Hex Size 9/16 in. 15 mm
Seal Kits
Buna 990-010-007
Viton 990-010-006
Related Information
Materials of Construction
Option Selection
RPEC - L A N
Preferred Options
Control Adjustment Range Seal
L Standard Screw A 100 - 3000 psi (7 N Buna-N
Adjustment - 210 bar), 1000
psi (70 bar)
Standard Setting
W 150 - 4500 psi
(10,5 - 315 bar),
1000 psi (70 bar)
Standard Setting
Standard Options
C* Tamper Resistant - Factory B 50 - 1500 psi (3,5 V Viton
Set - 105 bar), 1000
F Hex Head Screw with psi (70 bar)
Locknut Standard Setting
K Handknob C 150 - 6000 psi
O Handknob with Panel (10,5 - 420 bar),
Mount 1000 psi (70 bar)
Standard Setting
N 60 - 800 psi (4 -
55 bar), 400 psi
(30 bar) Standard
Setting
Q 60 - 400 psi (4 -
25 bar), 200 psi
(14 bar) Standard
Setting
* Special setting required, specify at time of order. No charge.
Related Information
Explanation of Sun cartridge control options - US units.
Explanation of Sun cartridge control options - metric units.
Two-piece, floating cartridge construction.
Model Code : RPEC Print Date : 5 February 2004
Copyright © 2003 Sun Hydraulics Corporation.

All rights reserved.
Terms and Conditions - Statement of Privacy
NOI # 2302070-009
PUMP ADAPTERS
FLEXIBLE DRIVE COUPLINGS
DAMPENING ELEMENTS
VC
®
VESCOR Specialists in
Hydraulic Reservoirs
and Accessories
VC PUMP MOUNTS for NEMA FRAME ELECTRICAL MOTORS VC
MOTOR SIZE 324/326TSC 324/326TC 364/365TSC 364/365TC 404/405TSC 404/405TC

HP/1800 RPM 40/50 40/50 60/75 60/75 100/125 100/125
SHAFT DIAMETER 1.875 2.125 1.875 2.375 2.125 2.875
KEY SIZE 1/2 1/2 1/2 5/8 1/2 3/4
SHAFT LENGTH 3.500 5.000 3.500 5.625 4.000 7.000
MOTOR SIZE 324/326USC 324/326UC 364/365USC 364/365UC 404/405USC 404/405UC

HP/1800 RPM 25/30 25/30 40/50 40/50 60/75 60/75
SHAFT DIAMETER 1.625 1.875 1.875 2.125 2.125 2.375
KEY SIZE 3/8 1/2 1/2 1/2 1/2 5/8
SHAFT LENGTH 3.000 5.375 3.500 6.125 4.000 6.875
X=PERMISSIBLE INSIDE RADIAL CLEARANCE Y=PUMP END FLANGE THICKNESS X=PERMISSIBLE INSIDE RADIAL CLEARANCE Y=PUMP END FLANGE THICKNESS
HORIZONTAL MOUNTING ONLY
STYLE 13 ADAPTER HORIZONTAL MOUNTING ONLY
STYLE 14 ADAPTER
X=PERMISSIBLE INSIDE RADIAL CLEARANCE Y=PUMP END FLANGE THICKNESS

STYLE 16 ADAPTER HORIZONTAL MOUNTING ONLY
If your pump is not listed or is a non-standard pump, contact us for special machining and/or information.
Most models listed also available in dampened design. Consult factory for more information.
20 NOTE: WITH VESCORS' POLICY OF CONSTANTLY IMPROVING ITS PRODUCTS, SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1 NOV 97
VC For NEMA FRAMES 324TC/TSC/UC/USC thru 405TC/TSC/UC/USC VC
XAJ XAK XBF FACE VESCOR

PUMP FLANGE BOLT PUMP MOUNTING ADAPTER MOUNTING TO PART
TYPE CIRCLE PILOT HOLES STYLE HORIZ /VERT FACE NUMBER
STANDARD SAE PUMP FLANGES

SAE A 2 Bolt 4.19 3.251 3/8-16 14 yes no 7.68 1945+
13 yes no 6.30 260199

2 Bolt 5.75 14 yes no 7.68 1974
SAE B 4.001 1/2-13
4 Bolt 5.00
14 yes no 8.88 1969
13 yes no 9.88 260599
13 yes no 6.30 260399
2 Bolt 7.12 5/8-11 14 yes no 7.68 1984

SAE C 5.001
4 Bolt 6.38 1/2-13
16 yes no 8.38 168799
14 yes no 8.88 1983
13 yes no 9.88 260799
14 yes no 7.68 1986

SAE D 2 Bolt 9.00 6.001 3/4-10
14 yes no 8.88 1985
16 yes no 7.05 260999
16 yes no 7.68 3370
16 yes no 8.38 234299

2 Bolt
SAE D 9.00 6.001 3/4-10 16 yes no 8.75 1883
4 Bolt
16 yes no 8.88 3372
16 yes no 9.63 235099
16 yes no 10.63 261399
SAE 2 BOLT 45° OFFSET MOUNTING FLANGES

13 yes no 6.30 2147
SAE B (45°) 2 Bolt 5.75 4.001 1/2-13 14 yes no 7.68 2133
14 yes no 8.88 2191
14 yes no 7.68 2119
SAE C (45°) 2 Bolt 7.12 5.001 5/8-11 14 yes no 8.88 2120
13 yes yes 9.88 2121
4 BOLT SQUARE MOUNTING FLANGES

14 yes no 7.68 1999
4HC 4 Bolt 8.485 3.751 5/8-11
14 yes no 8.88 1949
+NON STOCK SPECIAL ORDER ITEM
NOTE: WITH VESCORS' POLICY OF CONSTANTLY IMPROVING ITS PRODUCTS, SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. 21
1 NOV 97
NOI # 2302070-012
Flexible Drive Couplings
INDEX:
Magnaloy Coupling
DesignFeatures..............2
Load Lock Design.................................2
Radial Lug Design.................................2
Lug Design Comparisons....................2
Premiium Flexible
Drive Couplings...........2
Performance Specifications................3
Dimension Specifications....................4
Standard Bore & Keyway
Combinations.........................................5
Bore Tolerances.....................................5
Additional Specifications.....................5
Splined Couplings.................................6
Clamp Type Couplings.........................6
Steel Bushed Couplings.......................6
Splined Coupling
Specifications.........................................7
Clamp Type Coupling
Specifications.........................................7
Insert Selection Guide..........................8
Service Factors & Load
Characteristics.......................................9
Selection Method..................................9
Installation...........................................10
Recommended Torques
for Fasteners........................................11
Mis-Alignment
Capabilities..........................................11
Technical Bulletin
& Notes.................................................12
PM 90
Coupling ........................13
Drive Lug Features.............................13
Performance Specifications.............14
Dimensional Specifications.............14
Bore Tolerances..................................14
Bore & Keyway Combinations........15
Insert Materials...................................15
Other Magnaloy
Products...........................16
magnaloy coupling company P.O. Box 455 Alpena, MI 49707 989-356-2186 1

A Division of Douville Johnston Corporation Fax: 989-354-4190 http://www.magnaloy.com
Magnaloy Coupling Design Features
“Load-Lock” Design is simple and effective. The drive-lug

configuration is tapered from top to base, as are the mating
lugs of the opposing coupling hub. Under load, the insert
conforms to the tapers, inter-locking the two hubs. This load-
lock design protects bearings and equipment by eliminating
end thrust in both directions... and it requires only one
set-screw in each hub.
Radial Lug Design is logical and efficient. The most common failure of an
elastomeric insert type drive coupling is hysteresis failure of the elastomeric
element - breakdown of the elastomer due to cyclical overworking
and associated heat generation. Magnaloy Coupling’s drive lugs
are in a true radial orientation. Applied forces are evenly distributed
in the compressive direction only, eliminating the heat generating
radial component. True compressive loading reduces internal heat
generation and improves elastomer life.
F
MAGNALOY COUPLING DESIGN
F Under loaded conditions, the resultant forces applied
on the element segments are evenly distributed in the
compressive direction only. This results in no radial
F forces to multiply the internal heat generation.
F
Fc Fr CONVENTIONAL DESIGN A
F Under loaded conditions this jaw design results in the
applied forces exerting components in the compressive
and radical directions. These forces change direction
and magnitude along the jaw arc which greatly increase
F the internal movement of the element which causes heat
Fc generation.
Fr
Fc
CONVENTIONAL DESIGN B
Fr
This more conventional straight sided jaw design also
F exerts component forces in the compressive and radial
directions when under load. The radial component is
outward (acting to extrude the element) and changes
Fc in magnitude only, as does the compressive component,
along the jaw surface. The component forces resulting
F
Fr from this design also causes increased internal
movement in the element.

Magnaloy ® is a registered trademark of the Douville Johnston Corp.
Premium Flexible Drive Couplings
Magnaloy is the original lightweight, heavy-duty

flexible drive coupling. Light weight magnesium
construction makes Magnaloy couplings 76% lighter
than cast iron and 36% lighter than aluminum units...
and they’re stronger than either!
The benefits are many... Reduced loads on
bearings, shafts and pumps, for longer component
life. Easier handling and installation. Rust proof and
corrosion resistant.
Magnaloy’s close machining tolerances
(TIR of .002”) assures vibration - free operation and
easy, accurate alignment without need for special
tools. Solid magnesium alloy permanent mold
castings are heat treated and offer the highest
strength-to-weight ratio available.
Coupling Performance Specifications

Rated Torsional Horse Power Rating@
Coupling Maximum Wr2 Insert Torque Rigidity 100 1200 1800
Model Bore lb.- ft2. Number lb.- in. lb-in/Deg rpm rpm rpm
170N 340.7 42 .55 6.5 9.8
100 1-1/8 .0046 170U 511.0 53 .82 9.8 14.7
170H 1,022.1 182 1.65 19.8 29.7
270N 398.3 55 .64 7.6 11.5
200 1-3/8 .0068 270U 597.4 68 .96 11.5 17.2
270H 1,194.9 234 1.92 23.0 34.5
370N 701.4 81 1.12 13.5 20.2
300 1-5/8 .022 370U 1,052.1 148 1.68 20.2 30.3
370H 2,104.2 336 3.36 40.4 60.6
470N 1,056.3 138 1.69 20.3 30.4
400 1-7/8 .031 470U 1,584.5 310 2.5 30.4 45.6
470H 3,168.9 488 5.1 60.8 91.3
570N 2,194.8 314 3.5 42.1 63.2
500 2-3/8 .071 570U 3,292.2 695 5.3 63.2 94.8
570H 6,584.4 1,571 10.5 126.4 189.6
670N 4,946.7 676 7.9 94.9 142.5
600 2-5/8 .16 670U 7,420.1 1,510 11.9 142.5 213.7
670H 14,840.1 2,960 23.7 284.9 427.4
770N 11,639.8 1,805 18.6 223.5 335.2
700 2-7/8 .34 770U 17,459.7 2,104 27.9 335.2 502.8
770H 29,099.5 - 46.5 558.75 838.0
870N 21,889.4 3,680 35.0 420.3 630.4
800 3-7/8 .95 870U 32,834.1 - 52.5 630.4 945.6
870H 47,062.2 - 75.2 903.0 1,354.5
970N 47,842.3 8,428 76.5 918.6 1,377.9
900 4-3/4 4.20
970U 71,763.5 - 114.8 1,377.9 2,066.8

Dimensional Specifications
Magnaloy Coupling Dimensional Specifications
X
Models 100, 200, 300, 400 T W
100 200 300 400
A 2.54 3.10 3.58 4.24
B 2.600 2.900 3.450 3.980
C 2.00 2.25 2.90 3.05
D 0.56 0.68 0.78 1.00
E 0.68 0.84 0.96 1.06 C B
F 0.42 0.42 0.44 0.54
G 0.31 0.43 0.56 0.73
W 1/16 1/16 1/16 1/16
X 0.90 0.90 0.98 1.20
T 1/4-20 5/16-18 5/16-18 3/8-16
D E F G
TOLERANCES: 2 Place Decimals + .01
3 Place Decimals + .001 A
X
Model 500 T W
500
A 4.67
B 4.800
C 4.00 X*: Maximum Space between
D 1.04 shaft ends to allow full
E 1.23
shaft engagement
in Hub Bore.
CB
F 0.64
G 0.70 Y*: Minimum spacing
between shaft ends.
W 1/16
X 1.41
T 3/8-16
* Given for reference only.
TOLERANCES: 2 Place Decimals + .01
D E F G
X
Models 600, 700, 800, 900 T W
600 700 800 900
A 5.98 6.99 7.99 10.15
B 5.975 6.900 8.600 11.400
C 4.50 5.19 7.00 8.30
D 1.60 2.08 2.25 2.75
E 1.33 1.32 1.62 2.20 C B
F 0.62 0.89 1.00 1.32
G 1.13 1.13 1.58 1.88
W 1/16 1/16 1/16 1/16
X 1.36 1.97 2.25 2.89
T 3/8-16 1/2-13 1/2-13 3/4-10
TOLERANCES: 2 Place Decimals + .01 D E F G


Bore & Keyway Combinations
Standard Bore and Keyway Combinations

Magnaloy “Standard” Bore & Key Combinations Magnaloy “Standard” Bore & Key Combinations
Model Bore/Key Model Model Bore/Key Model
100
200
300
400
500
600
700
800
100
200
300
400
500
600
700
800
900
900
Code Code Bore Key Code Code Bore Key
M __ __ __ 01203 3/8 x 3/32 • • M __ __ __ 12414 1 3/4 x 7/16 • • • • •
M __ __ __ 01403 7/16 x 3/32 • • M __ __ __ 12816 1 7/8 x 1/2 • • • • • •
M __ __ __ 01404 7/16 x 1/8 • • M __ __ __ 13016 1 15/16 x 1/2 • •
M __ __ __ 01604 1/2 x 1/8 • • • M __ __ __ 20016 2 x 1/2 • • • • •
M __ __ __ 01804 9/16 x 1/8 • • • M __ __ __ 20416 2 1/8 x 1/2 • • • • •
M __ __ __ 02005 5/8 x 5/32 • • • M __ __ __ 20816 2 1/4 x 1/2 • • • • •
M __ __ __ 02006 5/8 x 3/16 • • • • M __ __ __ 21220 2 3/8 x 5/8 • • • • •
M __ __ __ 02206 11/16 x 3/16 • • • • M __ __ __ 21620 2 1/2 x 5/8 • • • •
M __ __ __ 02404 3/4 x 1/8 • • • M __ __ __ 22020 2 5/8 x 5/8 • • • •
M __ __ __ 02406 3/4 x 3/16 • • • • • • M __ __ __ 22420 2 3/4 x 5/8 • • •
M __ __ __ 02806 7/8 x 3/16 • • • • • • M __ __ __ 22824 2 7/8 x 3/4 • • •
M __ __ __ 02808 7/8 x 1/4 • • • • • • M __ __ __ 30024 3 x 3/4 • •
M __ __ __ 03008 15/16 x 1/4 • • M __ __ __ 30824 3 1/4 x 3/4 • •
M __ __ __ 10006 1 x 3/16 • • • • • • M __ __ __ 31228 3 3/8 x 7/8 • •
M __ __ __ 10008 1 x 1/4 • • • • • • M __ __ __ 31628 3 1/2 x 7/8 • •
M __ __ __ 10408 1 1/8 x 1/4 • • • • • • M __ __ __ 32028 3 5/8 x 7/8 • •
M __ __ __ 10608 1 3/16 x 1/4 • • M __ __ __ 32428 3 3/4 x 7/8 • •
M __ __ __ 10808 1 1/4 x 1/4 • • • • • M __ __ __ 32832 3 7/8 x 1 • •
M __ __ __ 10810 1 1/4 x 5/16 • • • • • • • M __ __ __ 40032 4 x 1 •
M __ __ __ 11210 1 3/8 x 5/16 • • • • • • • M __ __ __ 40432 4 1/8 x 1 •
M __ __ __ 11212 1 3/8 x 3/8 • M __ __ __ 40832 4 1/4 x 1 •
M __ __ __ 11412 1 7/16 x 3/8 • • • M __ __ __ 41232 4 3/8 x 1 •
M __ __ __ 11610 1 1/2 x 5/16 • • • M __ __ __ 41632 4 1/2 x 1 •
M __ __ __ 11612 1 1/2 x 3/8 • • • • • • M __ __ __ 41640 4 1/2 x 1 1/4 •
M __ __ __ 12012 1 5/8 x 3/8 • • • • • • M __ __ __ 42040 4 5/8 x 1 1/4 •
M __ __ __ 12412 1 3/4 x 3/8 • • • • • M __ __ __ 42440 4 3/4 x 1 1/4 •
Shaded Area: AGMA semi-standard bore key combinations.
Bore Tolerances
Part Number Usage: Magnaloy Coupling Hub part numbers Over Include Tolerance
may be specified using the following format: Start with let- -- 1 +.0008/ +.0003
ter “M” designating Magnaloy, followed by 3 digit Model 1 2 +.0013/ +.0005
2 3 +.0018/ +.0008
Code (100, 200, etc.), then the specific 5 digit Bore Key 3 4 +.0020/ +.0010
Code. 4 5 +.0023/ +.0010
Example: Model 500 hub with a 1 3/8 bore and 5/16 key-
way would be specified as: M50011210 - No bore hubs are
designated as ‘R’ code, ie: M500R.
Additional Coupling Specifications

Model Number 100 200 300 400 500 600 700 800 900
Maximum Bore 1-1/8 1-3/8 1-5/8 1-7/8 2-3/8 2-5/8 2-7/8 3-7/8 4-3/4
Complete Coupling Approx. Wght. 3/4 1 2 3 4 7 12 18 38
(Solid Hub)
Number of Drive Lugs 3 3 3 3 4 6 6 6 6

Hub Movement for Insert Removal .74 .74 .75 .98 1.12 1.02 1.50 1.63 2.27
Basic Insert Number 170 270 370 470 570 670 770 870 970

Insert Selection Guide
Magnaloy Coupling’s full range of flexible inserts

permit custom design performance for a wide range
of applications. All insert materials offer complete
electrical insulation, as Magnaloy’s design elimi-
nates all metal-to-metal contact.
Neoprene (Code N) - Black material -

Standard material with Magnaloy Coupling.
Good general purpose material offering good
resiliency
o
and
o
load
o
capabilities.
o
Temp range -
30 F to +250 F (-34 C to =121 C) optional 80A
durometer (painted gold) and 90A durometer
(painted silver) are available for slight
increased load capability and less resiliency.
Nitrile (Buna N) (Code B) - Painted blue -
Excellent material with petroleum products.
Excellent compression set and abrasion o
resistance
o o
characteristics.
o
Temp range -60 F to
+250 F (-51 C to +121 C).
Urethane (Code U) - Yellow
Excellent mechanical and physical
properties. Offers good medium duty
durability and resiliency. Urethane tends to
soften in higher temperatureso
ando humid con-
ditions.
o
Temp o
Range -30 F to +150 F
(-34 C to +66 C).
Part Number Usage: Magnaloy Coupling Viton (Fluorocarbon) (Code V) - Red material -
Insert part numbers may be specified using Excellent fluid compatibility and high
the following format: Start with letter ‘M’ temperature characteristics. Good
designating Magnaloy followed by 3 digit compression
o o
set and
o
resiliency.
o
Temp range -
20 F to +350 F (-29 C to +177 C).
insert model size (170, 270, etc.) then the
specific material code letter. If an optional Hytrel (Code H) - Blue-green material - Superior
durometer is being specified, after the physical and mechanical properties and
material code letter supply the durometer excellent fluid compatibility and high temper-
number divided by 10. ature characteristics. Hardness (50D)
EXAMPLES: Urethane insert for Model 300, M370U; approaches that of plastic and offers little
80 Duro Neoprene for Model 200, M270N8. resiliency. Excellent performanceo under heavy
o
dutyo conditions.
o
Temp range -65 F to +300 F
(-54 C to +149 C).
Other materials are available for special applications.
Consult factory for recommendations and availability.

Insert Selection Guide
Service Factors - Load Characteristics
Type of Prime Mover
Load Standard Motor High Torque I.C. Engine I.C. Engine
Classification or Turbine Motor 6 or more cyl. less than 6 cyl.
Uniform (U) 1.0 1.5 1.5 2.0*
Moderate (M) 1.5 2.0 2.0* 2.5*
Heavy (H) 2.0* 2.5* 2.5* 3.0*
Uniform Load: Steady loading, non-reversing, torque does not exceed rating.
Moderate Load: Uneven loading with moderate shock, frequent starts,
infrequent reversals, peak torque may exceed average rate of prime
mover by 125%.
Heavy Load: Uneven loading with heavy shock, frequent reversals, peak
torque may exceed average rating of prime mover by 150%.
*Recommend use of Urethane or Hytrel Insert.
Drive Unit Load Sym. Selection Method

Agitators U 1. Several specifics must be considered to make the best
Blowers U choice of couplings:
Compressors • Centrifugal U
• Rotary M A. Type of prime mover and load characteristics
• Reciprocating H* (see table above).
Conveyors U B. Shaft diameter and key size or spline configuration
• Reciprocating M
• Screw M (No. of teeth, pitch ratio, pressure angle).
• Shaker H C. Horsepower rating of loads to be transmitted.
Cranes & Hoists M D. Maximum operating speed (rpm).
Crushers H* E. Maximum operating misalignment.
Elevators M
• Freight & Pass. H* F. Clearance limitations.
Fans • Centrifugal U 2. Calculate effective hp/100 rpm by use of table above
• Propeller M and select the minimum size couplings recommended.
• Cooling Tower H
3. VERIFY YOUR SELECTION:
Generators U
• Welding H A. Check for maximum bore size.
Mills H* B. Check dimensions for adequate clearance.
Machine Tools M C. Indicate any special insert specification and/or
Mixers M coupling coating for environmental protection, if
Paper Mill Machinery M
required.
Pumps • Centrifugal U
• Rotary M Equation: Effective HP per 100 RPM = rated HP x Service
• Reciprocating H* Factor x 100/RPM
• On Injection H*
Molding Equip. Example: 150 HP 4 cyl. Diesel Engine Driving
Screens • Air & Water U Reciprocating Irrigation Pump operating
Washing at 3250 RPM
• Freight & Pass. H
Service Factor = 3.0 (Hytrel Insert recommended)
Stokers U
Textile Machinery M Eff. HP per 100 RPM = 150 HP x 3.0 x 100/3250
Woodworking Machinery M RPM = 13.85 HP/100 RPM Model 600 rating with
Winches H* Hytrel Insert is 23.7 HP/100 RPM
NOTE: Above service factors are intended for use as a general guide only.
* Recommend use of Steel Bushing and Clamp with Splined Bores.

Installation Instructions
Shaft spacing should be within range given by

dimensions ‘W’ and ‘X’ as shown in charts on page 4.
Position each hub on proper size shaft - Magnaloy
couplings are bored to standard “push fit” tolerances,
if a tight fit exists check shaft for burrs.
Maximum benefits are obtained with hubs posi-
tioned to allow complete shaft engagement within
bore. However, some equipment designs do not
permit this condition - maximum shaft engagement
should be utilized in any case.
Alignment - Place a straight edge (scale) at top

and side of coupling. Use a .005 inch feeler gauge
under scale for final inspection. This will indicate
accurate parallel and angular alignment.
Magnaloy’s precision tooled outside surfaces
permit this simple, but accurate alignment method.
Secure equipment mounts and recheck alignment

for movement.
Install the insert in the coupling positioning hubs in
contact with lip around outside of insert.
Before tightening set screws, run the coupling and
check for separation of hubs or creep . Recheck
alignment and tighten set screws.
With the Steel Bushed/Clamp type couplings, to
facilitate installation on the shaft, it may be necessary
to slightly loosen the set-screw over the keystock.
When securing the coupling to the shaft, first tighten
the clamp bolt, then tighten the set--screw against
the keystock.

Mis-Alignment Capabilities
Magnaloy couplings offer four-way flexibility (parallel,

angular, axial and torsional) and require no lubrica-
tion. They are easily installed and properly aligned
without use of special tools or equipment - a straight
edge and hex wrench are the only tools required.
Magnaloy’s insert reduces noise and vibration and
permits needed flexibility for proper operation within
alignment capabilities.
Recommended Torques
for Fasteners
Model Set Screw Clamp Screw
100 60-70 in. lbs. 130-140 in. lbs.
200 130-140 in. lbs. 130-140 in. lbs.
300 130-140 in. lbs. 210-220 in. lbs.
400 190-200 in. lbs. 210-220 in. lbs.
500 190-200 in. lbs. 300-310 in. lbs.
600 190-200 in. lbs. 35-36 ft. lbs.
700 300-310 in. lbs. 35-36 ft. lbs.
800 300-310 in. lbs. 49-50 ft. lbs.
900 100-110 ft. lbs. 100-110 ft. lbs.
Intended as a general guide for fastener torques
with Magnaloy Couplings.
Perfect alignment of equipment shafts, in most cases, is impractical to obtain or maintain,

and misaligned equipment produces excess stress on bearings and coupling. Magnaloy’s
insert design will accept misalignment strain and, when excessive, will cause insert wear as
a visual and audible indication of misalignment problems. However, Magnaloy’s inserts are
inexpensive and easily replaced; under normal conditions the insert seldom requires
replacement.
Maximum
1o Angular
Mis-Alignment
Mis-Alignment
Capabilities
Maximum
.015 in. Parallel
Mis-Alignment

LIQUID LEVEL GAGE-FRONT MOUNT, DIAL PROBE THERMOMETER IN WELL
This gage can be installed from the front of the reservoir when wall is heavy enough to tap .500-20UNF thread or
from the inside to tighten nuts. Exclusive design with a well protecting the sensing probe - allows removal of
thermometer without loss of fluid. Easy reading dual scale dial thermometer has probe extending deep into
reservoir and is not affected by ambient temperatures. Furnished complete - ready for installation. All “O” rings
and hex nuts included. Available to 142.00 (3606.80mm) mounting centers per special order.
STANDARD MATERIALS: OPERATING CONDITIONS:
! Aluminum construction ! See ENG. STD. 109
! Buna N seals
! Borosilicate glass with redline on white background for
distinct level reading and maximum fluid compatibility NOI # 7811704
HOW TO ORDER:
WHEN ORDERING, SPECIFY THE FOLLOWING
AFTER THE SERIES NUMBER, SEPARATE EACH G645 PATENTED
WITH A DASH (-). SELECT MOUNTING CENTERS.
3.00 (76.20mm) TO 12.00 (304.80mm) AVAILABLE
FROM STOCK.
-A- Aluminum gage body (standard)

-B- Brass gage body (optional)
-S- Steel gage body (optional)
-Y- Stainless steel gage body (optional)
-1- Buna N seals (standard)
-2- Butyl seals (optional)
-3- Viton A® seals (optional)
-4- Ethylene propylene seals (optional)
-5- Silicone seals (optional)
EXAMPLE:
G645-10-A-1 Buna N seals
Aluminum gage body
10.00 (254.00mm) centers
Series G645
SERIES A - CENTERS B - SIGHT C - LENGTH

NUMBER INCHES (mm) INCHES (mm) INCHES (mm)
05 (127.00) 3.50 (88.90) 6.62 (168.15)
08 (203.20) 6.50 (165.10) 9.62 (244.35)
G640
10 (254.00) 8.50 (215.90) 11.62 (295.15)
12 (304.80) 10.50 (266.70) 13.62 (345.95)
MODIFICATIONS AVAILABLE MADE TO ORDER - CONSULT OUR FACTORY

(MINIMUM ORDER MAY BE REQUIRED)
LIQUID LEVEL GAGE-FRONT MOUNT LUBE DEVICES, INC.

DIAL PROBE THERMOMETER IN WELL 1864 NAGLE AVE., P.O. BOX 1810, MANITOWOC, WI 54221-1810
4/03 BULLETIN F327-45 PHONE: (920) 682-6877
E-MAIL: sales@lubedevices.com
FAX: (920) 684-7210
WEBSITE: www.lubedevices.com
NOI # 2302070-005
Model 0750
Three-Way or
Two-Way (Water Saver)
Thermostatic Valve
Three-Way
0750 3/4" NPT
0750D1 3/4" NPT Low Flow
0750J12 3/4" SAE O-Ring
0750J12D1 3/4" SAE O-Ring Low Flow
0752 1/2" NPT
0752D1 1/2” NPT Low Flow
Two-Way (Water Saver)

0750JW 3/4” NPT
0750JWJ12
0752JW
3/4" SAE O-Ring
1/2" NPT
Features
Fluid Power Energy (FPE) Thermostatic Valves utilize the principle of
expanding wax, which in the semi-liquid state undergoes large expansion Wide Range of
rates within a relatively narrow temperature range. The self-contained ele- Temperatures
ment activates a stainless steel sleeve, which directs flow. All FPE
Thermostatic Valves are factory set at predetermined temperatures: no fur-
Mountable Housing
ther adjustments are necessary. A wide range of temperatures are avail-
able for water and oil temperature control applications.
Heavy Duty
When used in a diverting application, on start-up the total fluid flow is rout-
ed back to the main system in the three-way valve or blocked by a sleeve Self-Contained
in the two-way version. As fluid temperature rises to the control range,
some fluid is diverted to the cooling system in the three-way valve or to
drain in the two-way version. As fluid temperature continues to increase, Replaceable Element Without
more flow is diverted. When the thermostat is in a fully stroked condition, Breaking Connections
all fluid flow is directed to the cooling system in the three-way valve or to
drain in the two-way version. FPE Thermostatic Valves may also be used Non-Adjustable
in a mixing application.
Rugged Construction
In a mixing application, hot fluid enters the “B” port and colder fluid enters
the “C” port. The flows mix and the thermostat adjusts to reach the desired
Tamper-Proof
temperature, exiting the “A” port.
FPE Thermostatic Valve Housings are made from cast aluminum or cast Operate In Any
bronze, with other materials available. Position
Optional 0750 features: Plated elements and Viton® or Neoprene seals. Compact
Other options available upon request.
FLUID POWER ENERGY, INC. MADE IN

W229 N591 Foster Court • Waukesha, WI 53186
262 • 548 • 6220 Fax 262 • 548 • 6239

ISO 9001-2000 U. S. A.
www.fpevalves.com
Model 0750
* (Replace * with body material type; AL=Aluminum, B=Bronze)
Note: Two-way water-saver valves must

PRESSURE RATINGS have weep hole
MATERIAL PSI
For port sizes not shown consult factory
AL, B 150
PART # DESCRIPTION
*0750-1 VALVE BODY (*See table for material)
Three-Way Valve Two-Way Valve 0750-3 CAP
Flow vs. Pressure Drop 0750-4 SPRING
0750**-6 O-RING (Standard material is Buna-N)
Low Flow 1/2 3/4
0750-7 SNAP RING
0750-9 SLEEVE (Specify weep hole or low flow)
0760-Temp THERMOSTAT (Temp to follow dash)
0750-10 PLUG (2-way valve only)
FPE Model 0700* Replacement Kit (Includes the following:)

0750-4 SPRING
0750**-6 O-RING (Standard material is Buna-N)
0760-Temp THERMOSTAT (Temp to follow dash)
(For Viton® (V) or Neoprene (E) O-Ring material, replace ** with V or E)
FLOW IN U.S. GPM Viton® is a registered trademark of Dupont Dow Elastomers
SAE 10 @ 100° F
Recommended Pressure Drop is 2 to 7 PSI
To Order
FLUID POWER ENERGY, INC. Specify Model Number, nominal
temperature desired, and housing
W229 N591 Foster Court • Waukesha, WI 53186 material. For Model coding information,
262 • 548 • 6220 Fax 262 • 548 • 6239 visit our website or consult your
factory representative.
www.fpevalves.com
FPE-0750-050803
MOTOR CONTROL COMPONENT INFORMATION
DESCRIPTION
SQ D CONTACTOR INFO
SQ D OVERLOAD INFO
SOLA POWER SUPPLY
SQ D CIRCUIT BREAKER INFO
JUNCTION BOX INFO
Document name NOV Service Centers
Revision
Americas Europe
NOV Service (Houston) NOV Service and Repair (Aberdeen/Montrose)
12950 W. Little York Forties Road
Houston, Texas 77429 Montrose
+1 713 856 4128 Scotland
DD10 9ET
NOV Repair (Houston) +44(0)1674 677 222
5900 Brittmoore Road
Houston, Texas 77041 NOV Service (Kristiansand)
+1 281 847 9990 Skibaasen 2
4636 Kristiansand – Norway
NOV Service and Repair (Houston) +47 38 19 20 00
Facility Under Construction
5100 North Sam Houston Parkway West NOV Service (Stavanger)
Houston, Texas Lagerveien 8
4069 Stavanger – Norway
NOV Service and Repair (New Iberia, Hwy 90) +47 51 81 81 81
8404 West Hwy. 90
New Iberia, Louisiana 70560 NOV Service (Molde)
+1 337 359 8000 Granfjaera 24
6415 Molde – Norway
NOV Service and Repair (Broussard) +47 71 20 20 20
1030 Cruise Avenue
Broussard, Louisiana 70518 NOV Service (Asker)
+1 337 837 3890 Blakstadmarka 26
1374 Asker – Norway
NOV Service and Repair (New Iberia, Sugar Mill) +47 64 00 50 24
150 Sugar Mill Road
New Iberia, Louisiana 70560 NOV Repair (Stavanger)
+1 337 365 3423 Dusavik Base
Midtre Basevei 4
NOV Service and Repair (Leduc/Edmonton) 4029 Stavanger – Norway
6621 – 45 Street +47 51 83 56 00
Leduc, Alberta, Canada
T9E 7E3
+1 780 986 1712 Asia
NOV Service and Repair (Singapore)
NOV Service and Repair (Macaé) No. 9 Tuas Avenue 5
Av. Prefeito Aristeu Ferreira da Silva, 70 Singapore 639335
Macaé – RJ – RJ +65 6861 1566
CEP 27930-070
+55 (22) 2773 5401 Middle East
NOV Service and Repair (Dubai)
P.O. Box 61490
R/A No.13, Plot MO 0682
Daimler Chrysler Street
Jebel Ali Free Zone
Dubai, UAE
+971 4 8838776
www.nov.com

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Bill of Material

Item Quantity Part Number Description

NEXT ASSY PRODUCT

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

Client Document Number DOCUMENT NUMBER REV

02 1-15-2007 Revised and Updated BMD

Revision Change Description

Section Document Number

1 TABLE OF CONTENTS.................................................................................. 102-003-02

2 SPECIFICATIONS .......................................................................................... 152-000-01

3 GENERAL DESCRIPTION ............................................................................. 202-000-02

4 GENERAL OPERATING PROCEDURES ...................................................... 352-000-04

8 INSTALLATION .............................................................................................. 702-000-03

MANUAL SYMBOLS AND CONVENTIONS

DANGER - WARNING -CAUTION

Figure 1. Safety Alert Symbol

Denotes a hazard exists which can result in injury or death if

Denotes a reminder of safety practices or directs attentions to

*This is recommended by SAE J115.

These terms are used to draw attention to items of interest

ABBREVIATIONS AND DEFINITIONS

• Automated Arm Assembly – Patent Pending Number 12038.0009.PZUS00.

• Jaw Dies – Patent Pending Number 60/410,215.

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GENERAL SPECIFICATIONS ..................................................................................................... 5

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Figure 1. Typical Iron Roughneck, General View

The Iron Roughneck is a lightweight, compact, modular roughneck, which is mounted on

The Iron Roughneck uses an operator-controlled, electrically powered Remote Control

Spinner Torque Setting

Figure 2. Typical Iron Roughneck Major Assemblies

Iron Roughneck Major Assemblies

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IRON ROUGHNECK CONTROLS AND SETTINGS

Remote Control Console (RCC)

Extend / Retract Limit Switch (ERLS)

Torque Setting Panel (TSP)

Hydraulic Enclosure (HE)

Remote Control Console

Figure 1. Typical Remote Control Console Panel

Remote Control Console

Table 1. Remote Console Panel Controls

Extend / Retract Limit Switch J-Box

Figure 2. Extend /Retract Limit Switch J-Box

Shutdown power before working inside of extend / retract

Setting Extend / Retract Limit Switch J-Box

2. Open ERLS J-Box; four thumbscrews on cover.

3. Loosen screws on limit switch and fine adjustment brackets.

5. Rotate selector switch on Remote Control Console (RCC) to “WELL CENTER”.

6. Power up Roughneck, extend and retract Roughneck with Remote Control

9. Repeat process for Mouse Hole after selector switch is rotated to

10. Tighten screws on ERLS J-Box.

Once the position (MOUSEHOLE or WELL CENTER) is

Figure 3. Typical view of an Iron Roughneck in the Retracted/Park Position

Figure 4. Typical view of an Iron Roughneck in the Extended Position

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Torque Setting Panel