Farr KT5500 - Monthly Maintenance Checklist

KT5500 5-
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” Tong & CLInCHER® BaCKup
SECTIon ConTEnTS
3.23
TECHnICaL ManuaL
MaInTEnanCE
J. MONTHLY MAINTENANCE CHECKLIST - POWER TONG
Thefollowingmaintenancechecklistisintendedasaguidelineratherthanadefinitivemaintenanceschedule.Yourequipmentmay
requiremore,orless,maintenancedependinguponthefrequencyofuse,thepercentageofmaximumtorquethatyourequipmentis
routinelysubjectedto,andthefieldconditionsunderwhichyourequipmentoperates.Farrrecommendsthatthefollowinginspection
andmaintenanceproceduresbeperformedmonthly,orinconjunctionwithyourmaintenanceforeman’sexperienceandbestestimate
ofwhenyourequipmentisdueforthismaintenance.
1.
Rotatecageplate/rotarygearuntiltheopeningintherotarygearfacestowardstherearofthetong.
3.
Cleantheexteriorofthetoolthoroughly,usingeitherwater(ifusingapressurewasherensurealow-pressurewashwand
isused),oranappropriatesolvent-basedgrease-cuttingcleanersuchasVarsol.Ensureadequatecontainmentisinplace
topreventenvironmentalcontaminationfromresidualhydraulicfluid,dirtygrease,andcleaningagents.
4.
Removetheaccesspanelonthesideofthetongdirectlyadjacenttotheshiftermechanism.
5.
Cleantheinteriorofthetongthoroughly,usingeitherwater(donotuseapressurewasher),oranappropriatesolvent-
basedgrease-cuttingcleanersuchasVarsol.Ensureadequatecontainmentisinplacetopreventenvironmentalcon-
taminationfromresidualhydraulicfluid,dirtygrease,andcleaningagents.Makeanoteifanymetalshavingsormetal
piecesareflushedoutofthegeartraincavity-ifshavingsormetalpiecesareseenthetongmustbeoverhauledbefore
itisreturnedtoservice.
6.
Inspectallfastenersandfastenersafetywires(ifequipped).Replaceanymissingfasteners-useGrade8boltsonlyun-
lessotherwisespecified.Re-torqueallexternalfastenerstoSAEspecifications.
7.
Repairorreplaceanydamagedormissingexternalbodyparts,suchastorquegaugemounts,hydraulicsupports,safety
doorprotectors,etc.
8.
Performavisualinspectionofallfastenersandprotrudingbodypieces(example:hydraulicvalvemounts,inlet&outlet
linesupports,tonglegs,shifterhandlepivotlugs).Tightenorreplacelooseormissingfasteners.Farrrecommendsthat
damagedormissingbodypartsberepairedorreplacedassoonaspossible.
9.
Inspecttongforsignsofprematurewear,ormovingpartsthatarerubbing(baremetalwherethereusedtobepaintisa
goodindicationofwear.
10.
Inspectallpaint-locationsinwhichthepainthasbeendamagedmustberepairedpriortothetongbeingreturnedto
service.Prepareareastobepaintedtoensuretheyarefreeofgrease,dirt,orsolvent.Touchupusingasolvent-based
acrylicpaint-“McCoyGrey”ispaintcolornumberRAL7015(contactFarrsalesforpaintnumberforcustompaintapplica-
tions).Allowsufficienttimeforpainttodrybeforeproceeding.
11.
Inspectallexternalwelds.Anyweldthatiscrackedorseparatingmustberepairedandrepaintedbeforereturningthe
tongtoservice.
DO NOT PERFORM ANY FURTHER ACTIONS OR MAINTENANCE WHILE THE TONG IS CON-
NECTED TO ANY HYDRAULIC POWER SUPPLY. FARR RECOMMENDS THAT ALL HYDRAULIC
LINES ARE FULLY DISCONNECTED, AND RESIDUAL HYDRAULIC PRESSURE IS BLED OFF.
ENSURE ADEQUATE CONTAINMENT IS IN PLACE TO PREVENT ENVIRONMENTAL CONTAMI-
NATION FROM RESIDUAL HYDRAULIC FLUID.
2.
Depressurize hyDrAulic system in prepArAtion for mAintenAnce:
1) Rotatethetongtothe“openthroat”position.Ensuretongandbackupdoors(ifequipped)areclosed.Fullyextend
theliftcylinder
2) De-energizethepowerunit.
3) RepeatedlyactuatethetongmotorcontrolvalveleverINBOTHDIRECTIONStodissipateanyresidualpressure
inthevalveandmotor.
4) RemovethehydraulicSUPPLYlinefromtheequipment.
5) RepeatedlyactuatetheremainingcontrolvalveleversINBOTHDIRECTIONStodissipateanyresidualpressure
intheremainderofthehydrauliccontrolsystem.
7) DisconnectthehydraulicRETURNlinefromtheequipment.
8) Disconnectremaininghosessuchascasedrains,orlinesconnectedtotheturnscounter.
HYDRAULIC PRESSURES AS HIGH AS OPERATING PRESSURE MAY REMAIN TRAPPED IN
SMALL AREAS OF THE EQUIPMENT. ENSURE ALL MAINTENANCE IS CARRIED OUT BY A
QUALIFIED SERVICE TECHNICIAN, AND THAT ADEQUATE PERSONAL PROTECTIVE EQUIP-
MENT IS USED TO GUARD AGAINST PRESSURE INJURIES