Iron Roughneck Ir30380

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com
Reference Reference Description
WITH 55 & 88 ARM ASSEMBLY
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
National Oilwell Varco
RIG SOLUTIONS
12950 West Little York
Houston, TX 77041
Document Number Rev.
D811000084-MAN-001 01
Owners Manual
IR3080 & IR30120
with 55 & 88 Arm Assembly
Customer - Rig Name Variable
Product Picture
(size graphic frame
vertically as needed)
D811000084-MAN-001
Revision 01
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Revision History
01 12.07.2007 Create 1 Manual for All IR3080 & IR30120 K Staten K Schmidt B Winter
Writer Checker
Name

Name
Release
Approval
Name
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
Change Description
Revision Change Description
Table of Contents
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Chapter 1: General Information
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Chapter 2: Description
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Wrench Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Spinner Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Spinner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Spinner Support Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Column-Guide-Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Major Component Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Rotate Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hydraulic Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Inline Hydraulic High-Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Wrench Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Wrench Lift Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Move In-Out Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Move In-Out Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Rotation Manifold Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
IR3080 with 88 Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Automated Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Automated Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Link Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Link Assembly with Tilting Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Guide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Vertical Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Automated Arm Hydraulic Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Automated Arm Hydraulic Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Inline Hydraulic High-Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Lift Cylinder Cross Port Relief Valve (if equipped) . . . . . . . . . . . . . . . . . . . . 2-25
Linkage Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Move In-Out Cylinders and Manifold Valve (if equipped) . . . . . . . . . . . . . . . 2-25
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Remote Control Console Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Iron Roughneck Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
IR3080 with 55 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Utility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
IR3080 / 55 Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
IR3080 with 88 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
IR30120 with 55 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
IR30120 / 55 Size Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
IR30120 with 88 Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Chapter 3: Installation
Pre-installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Requirements and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Customer Verification of Hydraulic Fluid Cleanliness . . . . . . . . . . . . . . . . . . 3-1
Equipment Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Hydraulic System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing The Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Lifting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Mounting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Installing the Remote Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Installing the Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
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Installing the Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Customer System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
NOV System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Checkout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
HPU Installation Checkout procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Controls Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Startup Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
System Setting Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Limit Switches Settings Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Chapter 4: Operation
Controls And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Remote Control Console Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Limit Switch J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Extend / Retract Limit Switch J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Setting Extend / Retract Limit Switch J-Box . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Positioning the Iron Roughneck for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Torque Setting Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Adjusting the Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Adjusting the Jaw Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Hydraulic Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Hydraulic Rotation Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Rotate Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Setting the Rotation Target Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Rotation Manual Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Rotation Manifold Override System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Makeup and Breakout Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Start-Up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Makeup Initial Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Normal Makeup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Breaking Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Breakout Initial Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Normal Breakout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Emergency Stop Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Start after Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Chapter 5: Maintenance
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Preventive / Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lubrication and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
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Wrench Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Column-Guide-Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Automated Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Inspection Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Wrench Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Column-Guide-Arm Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Automated Arm Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Spinner Assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Remote Control Console Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Day-to-Day Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Safety Warnings And Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Recommended Lubricants And Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Hazard Descriptions and Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
General Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
General Switch Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Electrical Checks / Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Electrical Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Major Repairs and Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Iron Roughneck General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Lubrication Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Replacement of Wear Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Main Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Hydraulic Hose and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Functional Testing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
General Storage Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
General Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Storing and Preservation of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Long Term Storage of Iron Roughneck Equipment . . . . . . . . . . . . . . . . . . 5-27
Initial Storage Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Storage Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Preparing Equipment for Operation After Storage . . . . . . . . . . . . . . . . . . . 5-30
Major Component Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Wrench Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Replacing Dies in Top and Bottom Wrench Assemblies . . . . . . . . . . . . . . . 5-31
Remote Control Console Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Specified Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Chapter 6: Troubleshooting
Troubleshooting Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Identifying Troubleshooting Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Hydraulic Circuits and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Electrical and Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Operation Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
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Operating Mode Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Move In-Out Positioning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Vertical Positioning Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Troubleshooting Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Troubleshooting Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Spinner Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Troubleshooting Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Hydraulic Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Torque Setting Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Troubleshooting System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Electrical and Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
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General Information
Conventions
This manual is intended for use by field engineering, installation, operation, and repair
personnel. Every effort has been made to ensure the accuracy of the information
contained herein. National Oilwell Varco (NOV), will not be held liable for errors in this
material, or for consequences arising from misuse of this material.
Notes, Cautions, and Warnings
Notes, cautions, and warnings provide readers with additional information, and to advise
the reader to take specific action to protect personnel from potential injury or lethal
conditions. They may also inform the reader of actions necessary to prevent equipment
damage. Please pay close attention to these advisories.
Note:
Caution:
Warning:
i i
The note symbol indicates that additional information is
provided about the current topic.
!
The caution symbol indicates that potential damage to
equipment, or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.
The warning symbol indicates a definite risk of
equipment damage or danger to personnel. Failure to
follow safe work procedures could result in serious or
fatal injury to personnel, significant equipment
damage, or extended rig down time.
General Information
1
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Illustrations
Illustrations (figures) provide a graphical representation of equipment components or
screen snapshots for use in identifying parts, or establishing nomenclature, and may or
may not be drawn to scale.
For component information specific to your rig configuration, see the technical drawings
included with your Varco documentation.
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General Information
1
Safety Requirements
The National Oilwell Varco equipment is installed and operated in a controlled drilling rig
environment involving hazardous situations. Proper maintenance is important for safe and
reliable operation. Procedures outlined in the equipment manuals are the recommended
methods of performing operations and maintenance.
Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained on rig safety, tool
operation, and maintenance to ensure their safety.
Contact the National Oilwell Varco training department for more information about
equipment operation and maintenance training.
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose
described. The equipment manufacturer recommends that only those tools specified be
used when stated. Ensure that personnel and equipment safety are not jeopardized when
following service procedures and that personnel are not using tools that were not
specifically recommended by the manufacturer.
!
To avoid injury to personnel or equipment damage,
carefully observe requirements outlined in this section.
!
Personnel should wear protective gear during installation,
maintenance, and certain operations.
General Information
1
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General System Safety Practices
The equipment discussed in this manual may require or contain one or more utilities such
as electrical, hydraulic, pneumatic, or cooling water.
Isolate energy sources before beginning work.
Avoid performing maintenance or repairs while the equipment is in operation.
Wear proper protective equipment during equipment installation, maintenance, or
repair.
Replacing Components
Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
Replace failed or damaged components with original equipment manufacturer
certified parts. Failure to do so could result in equipment damage or injury to
personnel.
Routine Maintenance
Equipment must be maintained on a routine basis. See product-specific service manuals
for maintenance recommendations.
Proper Use of Equipment
National Oilwell Varco equipment is designed for specific functions and applications, and
should be used only for its intended purpose.
!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.
!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.
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Description
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. An 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 systems 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.
Description
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Figure 2-1. Typical Iron Roughneck Major Assemblies

SPINNER ROTATION
BOTTOM JAW
MAKE UP
FT LB
250
SPINNER
GRIP
COMPLETE MAKEUP
MAKEUP REPEAT
OFF
BREAK
OUT
3
START
OPEN
0
x100
SPIN
*
MAKEUPTORQUE
OUT
300
PSI
IRMOVE
WRENCH
ESTOP
2
CLOSE
1
DOWN
OUT
UP
IN
x10
SYSTEM PRESS
IN Remote Control
Console
Arm
Assembly
Spinner
Assembly
Torque Wrench
Assembly
Torque Setting
Panel
Hydraulic Enclosure
ERLS J-Box
RN 300018
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Description
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Table 2.1 Typical Iron Roughneck Major Assemblies
COMPONENT DESCRIPTION
Torque Wrench Assembly
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 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.
Spinner Assembly
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 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.
Column-Guide-Arm Assembly
The Automated Arm assembly is a folding arm that is used
for horizontal movement to extend and retract the
roughnecks Spinner/Wrench assemblies. The Automated
arm allows horizontal movement to the two 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.
Controls
Remote Control Console is used to remotely control the
Iron Roughneck.
Hydraulic Enclosure contains the electro- hydraulic
control valves. The electro hydraulic control system can be
remotely controlled from the remote console, or locally
controlled at the electro-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.
Hydraulic Power Unit
The Hydraulic Power Unit supplies hydraulic power at 3000
psi to the Roughneck.
Description
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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.
Table 2.2 Wrench Assembly Specifications
Table 2.3 Wrench Operational Parameters
DESCRIPTION MEASUREMENT
IR3080 IR30120
Length 36 36
Width 56-7/8 62-1/8
Height 27-1/8 27-18
Weight 3300 lbs 3600LBS
IR3080 IR30120
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
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Figure 2-2. Wrench Assembly
SPINNER ROTATION
BOTTOM JAW
MAKEUP
FT LB
250
SPINNER
GRIP
COMPLETE MAKEUP
MAKEUP REPEAT
OFF
BREAK
OUT
3
START
OPEN
0
x100
SPIN
*
MAKEUP TORQUE
OUT
300
PSI
IRMOVE
WRENCH
ESTOP
2
CLOSE
1
DOWN
OUT
UP
IN
x10
SYSTEM PRESS
IN Remote Control
Console
Arm
Assembly
Spinner
Assembly
Torque Wrench
Assembly
Torque Setting
Panel
Hydraulic Enclosure
ERLS J-Box
RN 300018
Description
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Figure 2-3. Bottom Wrench Assembly
BOTTOM WRENCH
ASSEMBLY
Front
Wear Block
View with
BW top plate
Rear
Wear Block
Die Holder
View without
BW top plate
Lock Plates
Cylinder
Stop Pin
Rod Pin
Bottom Jaw
Manifold
Jaw Dies
(WD4)
RN300022
Cylinder
Cylinder
Stop
BW
Body
Weldment
Torque Cylinder
Assembly
Front
Wear Block
Top Wrench
Assembly
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Spinner Assembly Description
Spinner Assembly
The Spinner is mounted above the Wrench Assembly (see Figure 2.1) 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 2.4), 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.
Table 2.6 Pipe Spinner Assembly Specifications
Table 2.7 Pipe Spinner Operational Parameters
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
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
Description
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Figure 2-4. Spinner and Support Assembly
Balance Spring
Wrench Frame
Interlock
Pin Hole
Head Support
RN300023
Spring Assembly
Lower Pin
Spinner Assembly
Spring Suspesion
Assembly Spring Assembly
Upper Pin
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Column-Guide-Arm Assembly
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 Assembly; 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.
Description
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Figure 2-5. Typical Column/Guide/Arm Assembly General Arrangement

Description
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Figure 2-6. Typical Column Assemblies
Description
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Major Component Description
Column Assembly
The column assembly provides four key functions to the operations of the Iron Roughneck:
1. The Iron Roughneck's column base assembly is mounted into the drill floor socket,
which provides structural support for the Iron Roughneck.
2. The column structure lower end provides an attachment point for the guide
assembly lift cylinder.
3. 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 travel.
4. 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
2.6). 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.
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2
Figure 2-7. Arm Assembly

Description
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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 horizontally and vertically 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 2-8. Automated Arm Retract and Extend Positions

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Description
2
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 2-9. Typical Guide Fram Assembly
Description
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Hydraulic Circuit Components
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.
i i
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.
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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.
Description
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IR3080 with 88 Arm Assembly
Automated Arm Assembly
Figure 2-10. Automated Arm Assembly

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2
Automated Arm Assembly
The Iron Roughneck Automated Arm Assembly consists of the following main assemblies
and components: Link Assembly; Guide Assembly; Vertical Track Assembly, and hydraulic
components.
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.
Figure 2-11. Automated Arm Retract and Extend Positions

Description
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Link Assembly
The Iron roughneck's Link Assembly is a group of linking arms that are connected in a
parallel linking arrangement consisting of five link arms that are joined to a center
connecting weldment that hold the link arms parallel with a common axis. The Link
Assembly allows the Iron Roughneck's wrench and spinner assemblies to reach maximum
extension distance and rotation points between well center, mousehole, and parking
positions.
The Link Assembly allows the Iron Roughneck's arm assembly to travel in a linear
direction parallel to the drill floor, and allows the link assembly to retract into a compact
envelope to park the Iron Roughneck wrench and spinner assemblies during drilling
operations.

Figure 2-12. Link Assembly
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Description
2
Link Assembly with Tilting Feature
The Link Arm Assembly with titling feature (if equipped) enables the lower right link
assembly to pivot the Iron Roughneck's wrench and spinner assemblies from the vertical
position to tilted axis angle position, for mousehole alignment.
The tilting hydraulic circuit consists of two hydraulic tilting cylinders that are mounted to the
lower right link assembly that are hydraulic energized when the hydraulic limit valve is
triggered. The hydraulic flow to the tilting cylinders is maintained and regulated by an
upstream mounted needle valve.
The pivot axis angle of the automated arm's titling system is controlled by the mechanical
positioning target bracket that is mounted on the automated arm assembly to target and
trigger the hydraulic limit valve. The hydraulic limit valve is triggered when the Iron
roughneck's link arm is extended beyond the set point of the well center. The Iron
Roughneck's wrench and spinner assembly return to a vertical position when the
automated arm assembly is retracted to the set point of well center, or when the
automated arm is retracted to the parking position.
Figure 2-13. Link Assembly with Tilting Feature

Description
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Guide Assembly
The Guide Assembly provides two key functions to the operation of the Iron Roughneck.
First, the Guide Assembly guides the Iron Roughneck vertically, and in addition also
transfers the Iron Roughneck load to the vertical track assembly. The Guide Assembly
uses four cam followers and four guide pads dimensionally spaced against the vertical
track assembly, which allows the guide assembly to guide the Iron roughneck along the
vertical tracks. Second, the Guide Assembly provides the pivotal connection points for the
Automated Arm Links and hydraulic cylinders. Attached to the Guide Assembly are two
hydraulic manifold assemblies (See Figure 2.19) the cross-port relief and the move in-out
relief manifolds.
Figure 2-14. Guide Assembly

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Vertical Track Assembly
The Vertical Track Assembly provides four key functions to the operations of the Iron
Roughneck. First, the Iron Roughneck's vertical track assembly's base is mounted into the
drill floor socket, which provides structural support for the Iron Roughneck. Second, the
vertical track assembly's rotating bearing allows the Iron Roughneck to be positioned
easily between orientation points of well center, mousehole, and parking positions. Third,
the Vertical Track Assembly provides attachment points for the Guide Assembly lift
cylinders. Four, the Vertical Track Assembly is fitted with four corner track rails, which allow
the cam follower to move in a smooth and linear travel.
Figure 2-15. Vertical Track Assembly

Description
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Automated Arm Hydraulic Circuit Components
Figure 2-16. Hydraulic Circuit Components

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Description
2
Automated Arm Hydraulic Circuit Components
Inline Hydraulic High-Pressure Filter
Mounted on the guide assembly weldment 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.
Lift Cylinder
Mounted on the guide assembly weldment is a Lift Cylinder, which is used to lift the guide
assembly vertically to position the Iron Roughneck wrench and spinner assemblies.
Mounted on the lift cylinder on the "UP" side is a counterbalance valve. The primary
function of the counterbalance valve is to prevent an "over running" load from moving the
cylinder. The counterbalance valve is factory set and normally no further adjustment is
required unless the lift cylinder and /or the valve has been serviced or repaired.
Lift Cylinder Cross Port Relief Valve (if equipped)
Mounted down stream from the lift cylinder is a cross over port relief valve, which is used
to set the up and down pressure setting of the hydraulic lift cylinder.
Linkage Cylinders
Mounted on the guide assembly weldment are two hydraulic cylinders, which are used to
extend or retract the automated arm assembly.
Move In-Out Cylinders and Manifold Valve (if equipped)
The hydraulic valve connected to the move in-out cylinders is a relief valve, which is used
to set the retract pressure setting of the hydraulic move in-out cylinders. Mounted on the
move in-out cylinders on the "MOVE-IN" side are counterbalance valves. The primary
function of the counterbalance valve is to prevent an "over running" load from moving the
cylinder. The counterbalance valve is factory set and normally no further adjustment is
required unless the move in-out cylinders and/or the valves has been serviced or repaired.
Description
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Remote Control Console Description
The remote control console (RCC) shown in Figure 2.20 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.
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.
i i
Jaw pressure setting is controlled from the torque setting
panel.
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Figure 2-17. Remote Control Console

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Technical Specifications
Iron Roughneck Technical Specifications
Table 2.11 Iron Roughneck Products
IRON ROUGHNECK WRENCH PACKAGE ARM LENGTH AUTO-ROTATION
TOP LEVEL NUMBER 3080 30120 55 88 YES NO
1100005 x x x
1100006 x x x
1100011 x x x
1100012 x x x
1100014 x x x
1100016 x x x
1100017 x x x
1100018 x x x
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IR3080 with 55 Arm
General Specifications
Table 2.12 80K / 55" IR3080 Components
Utility Requirements
Table 2.13 80K / 55" IR3080 Utility Requirements
Weight 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 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)
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IR3080 / 55 Size Specifications
Maximum Extend, Side Dimensions
ALL DIMENSIONS ARE IN INCHES.
ALL DIMENSIONS IN BRACKETS ARE IN CENTIMETERS,
UNLESS OTHERWISE SPECIFIED.
Figure 2-18. IR3080 / 55 Maximum Extend, Side Dimensions
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Maximum Extend, Maximum Lift, Side Dimensions
Figure 2-19. IR3080 / 55 Maximum Extend, Maximum Lift, Side Dimensions

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Maximum Extend, Top Dimensions

Figure 2-20. IR3080 / 55 Maximum Extend, Top Dimensions

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Maximum Retract, Side Dimensions
Figure 2-21. IR3080 / 55 Maximum Retract, Side Dimensions

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IR3080 with 88 Arm
Table 2.14 80K / 88" IR3080 Components
Weight 10,000 (4,536 kg)
Spin Speed (5" pipe dia.) 80 rpm
Spin Torque 2,250 ft / lbs (3,050 N-m)
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) 73.5" (186.8cm) maximum
Connection Height (minimum) 35.5" (90.2cm) minimum
Horizontal Travel 88.4" (224.6cm)
UTILITY MEASUREMENT
Hydraulic System Pressure 3000 psi
Hydraulic System Flow rate 40 gpm
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IR30120 with 55 Arm
Table 2.16 120K / 55" IR30120 Component Capacities
Weight 8,000 lbs (3,629 kg)
Spin Speed (5" pipe diameter) 80 rpm
Spin Torque 2,250 ft-lbs (3,050 N-m)
Makeup Torque (maximum) 100,000 ft-lbs (135,582 N-m)
Breakout Torque (maximum) 120,000 ft-lbs (162,699 N-m)
Connection Height (maximum) 68" (172.7cm) maximum
Connection Height (minimum) 30" (76.2cm) minimum
Horizontal Travel 55.4" (141cm)
UTILITY MEASUREMENT
Description
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IR30120 with 88 Arm
Table 2.17 120K / 88" IR30120 Component Capacities
Weight 10,400 lbs (4,536 kg)
Spin Speed (5" pipe diameter) 80 rpm on 5 Pipe OD
Spin Torque 2,250 ft-lbs (3,050 N-m)
Makeup Torque (maximum) 100,000 ft-lbs (135,582 N-m)
Breakout Torque (maximum) 120,000 ft-lbs (162,699 N-m)
Connection Height (maximum) 73.75" (186.8 cm) maximum
Connection Height (minimum) 35.75" (90.8 cm) minimum
Horizontal Travel 88.4" (244.6 cm)
UTILITY MEASUREMENT
Electrical Control Requirements 24VDC, 10A & 120VAC, 2A
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Figure 2-30. IR30120 / 88 Maximum Extend Dimensions
Description
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Figure 2-33. IR30120 / 88 Maximum Retract, Side & Top Dimensions
Description
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Installation
Pre-installation Procedures
Requirements and Procedures
The following assumes that all pre-installation planning and rig-up has been accomplished
prior to installation of the Iron Roughneck.
General Requirements
Although many installation layouts arrangements are possible critical preparation and
installation consideration must be preformed before attempting to install the Iron
roughneck.
Before installing the 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 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.
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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 for the intended purpose 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 with the electrical
schematics, as well as the equipment power and voltage requirements
When performing 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.
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Special Tools
The following table lists special tools and support equipment required to install and
commission an Iron Roughneck.
Table 3.1 Special Tools and Support Equipment
Equipment Motion Hazards
The IR3080 equipment travels either horizontally or vertically.
DESCRIPTION SUPPLIER& MODEL ACCURACY RANGE
Fluke Various <1% FS N/A
Hydraulic Pressure Test Gauge Various 3-5%-FS
0-3000 psi
(0-206 Bar)
Avoid placing objects in or near the path of motion for
this 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 personnel.
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Installation Procedures
Installing The Iron Roughneck
Figure 3-1. Typical IR3080 Iron Roughnecks
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Lifting the Iron Roughneck
Locate the Iron Roughneck and lift the assembly to the drill floor as follows.
Figure 3-2. Typical Iron Roughneck stored in Lifting Skid
1. Release and remove the ratchet strap from the lifting skid
2. Attach equipment used to lift the Iron Roughneck from lifting skid to drill floor using
the lifting assembly.
3. Lift Iron Roughneck and position perpendicular to the drill floor, then out of column
socket
4. Attach lifting devices to the lifting lugs and hoist the Iron Roughneck to hang over
the drill floor mount socket.
!
Always use lifting equipment, supports, and chains with a
minimum capacity of one and a half times that of the object
being lifted or supported. Serious injury or death can result
from falling or swinging equipment.

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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.
Mount the Iron Roughneck at the drill floor as follows:
1. Insert base into drill floor mount socket.
2. Check Column for vertical alignment, shim as necessary.
3. Disengage lifting device and remove lifting link and turnbuckle from lugs.
4. Remove the shipping/parking lock pins.
Figure 3-3. Leveling IR Column Base

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Installing the 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.
Figure 3-4. Remote Control Console
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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.
2. Check the E-STOP buttons are pressed down on the RCC and the Torque setting
Panel.
3. Make electrical connections from HPU to RCC and from the RCC to the Iron
Roughneck.
!
Make sure the operator can see the roughneck area of the
rig 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 remote control console, it must be placed in a
non-hazardous or Division-2 / Zone-2 hazardous area
on the drill floor.
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Installing the Service Loops
Refer to following Hydraulic/Electrical System configurations:
1. Customer System Configuration.
2. NOV System Configuration.
3. Check that all circuit breakers at the HPU are OFF.
4. Locate the hydraulic service loops. Connect the hydraulic supply and return hose
from the HPU to the Iron Roughneck.
5. Locate the electrical power and controls cables.
6. Make electrical connections from SCR to HPU.
7. Make electrical connections from HPU to Remote Control Console and from
Remote Control Console to Roughneck.
!
All equipment should be shut down, isolated and tagged
"OUT OF SERVICE" before any maintenance procedure is
performed. Any unexpected start-up of equipment during
procedure can cause serious injury or death to personnel
and / or damage to the equipment.
!
Exercise extreme caution when performing maintenance
on the hydraulic system. Fluid escaping under pressure
can easily cause serious injury or death to personnel and /
or damage to the equipment.
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Installing the Hydraulic Power Unit
1. Locate HPU and isolate in coming power OFF.
2. 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.
3. Locate the HPU service loops. Connect the hydraulic supply and return from the
HPU to the IR.
!
i i
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 serious injury or death to personnel and /
or damage to the equipment.
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Customer System Configuration
Table 3.2 Customer Hydraulic/Electrical Connection Schedule
Figure 3-5. Customer System Configuration
Hydraulic Supply Pressure Connection 3,000 PSI, 40 GPM, 1-1/4" FJIC
Hydraulic Return Connection 1-1/2" FJIC
Electrical Supply Connection 24VDC 10A
Electrical Control Connection 37 Conductor Cable

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NOV System Configuration
Table 3.3 NOV Hydraulic/Electrical Connection Schedule
Figure 3-6. NOV System Configuration
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 10A
Electrical Control Connection 37 Conductor Cable

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3
Checkout Procedures
Installation Checkout Procedure
Make sure that the Iron Roughneck is fully inserted in the socket and column is
vertically aligned.
Grease all Iron 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 and properly secure the electrical cables.
Check the electrical cables for snag hazards, crimped or kinked cables, .
Check the location and installation of the 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.
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Startup Checkout Procedure
Before applying power to the Iron Roughneck remote control console (RCC), perform a
thorough inspection of the equipment. There is no need to set or adjust any control inside
RCC cabinet.
Check the E - STOP buttons is pressed on the Remote Control Console (see Figure
3.4) 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.
In order to comply with the hazardous area rating of
the IR remote control console, it must be placed in a
non-hazardous or Division-2 / Zone-2 hazardous area
on the drill floor.
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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 3-7. ERLS J-Box Limit Switches
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Operation
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 describe the Iron Roughneck control system's components.
Operation
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Remote Control Console (RCC)
Figure 4-1. Remote Control Console Panel
3
0
2
1
PRESS TO ROTATE
WELL
CENTER
OFF
SPINNER ROTATION
OUT
OPEN
MOUSE
SPINNER
GRIP
SPIN
HOLE
IR ROTATE
BOTTOM JAW
CLOSE
IN
E-STOP
MAKEUP TORQUE
IR MOVE
DOWN
XXX
RET
ARM
BEKA
WRENCH
UP
ARM
EXT
MAKEUP REPEAT/
SLIPS
REL SET
OUT
BREAK
START
MAKE UP
NATIONAL OILWELL VARCO
E-Stop
3
0
2
1
PRESS TO ROTATE
WELL
CENTER
OFF
SPINNER ROTATION
OUT
OPEN
MOUSE
SPINNER
GRIP SPIN
HOLE IR ROTATE
BOTTOM JAW
CLOSE
IN
E-STOP
MAKEUP TORQUE
IR MOVE
DOWN
XXX
RET ARM
BEKA
WRENCH UP
ARM
EXT
MAKEUP REPEAT/
SLIPS
REL
SET
OUT BREAK
START MAKE UP
NATIONAL OILWELL VARCO
Remote Control Console
(RCC)
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Operation
4
Table 4.1 Remote Console Panel Controls
CONTROL RESPONSE
BOTTOM JAW OPEN/CLOSE
Rotary Selector Switch
Controls opening and closing of Bottom Jaw of Torque
Wrench.
E-STOP
Pushing in shuts down hydraulic system. Pulling it out
allows hydraulic system to restart.
IR MOVE - OUT / IN
Three-position, return-to-center switch. Causes Iron
Roughneck to move in a horizontal direction either toward
or away from tubular, as desired.
MAKEUP REPEAT
Lamp
Lights red if the pr-set torque has not been reached for
completion of the make-up operation. When this happens,
the torque process must be repeated.
MAKEUP TORQUE
Digital Gauge
Allows operator to monitor the amount of torque being
applied by the Torque Wrench. Gauge reading is in Ft -
Lbs. Multiply reading by x100 to get actual torque being
applied.
MAKEUP/BREAKOUT Rotary
Selector Control
Allows operator to control the operation of the Torque
Wrenches.
SLIPS-SET-RELEASE VALVE
(if equipped)
Sets or releases slips.
SPINNER OFF / GRIP / SPIN
OFF position causes spinner to open up and disengage
from tubular. GRIP causes spinner to close onto tubular.
SPIN causes spinner to spin tubular in direction desired,
according to chosen selection of SPINNER ROTATION
switch (IN/OUT).
SPINNER ROTATION OUT/IN
Selects direction of rotation of spinner. Spinner will spin in
or out when SPINNER switch is placed in SPIN position.
WRENCH - UP / DOWN Rotary
Selector Switch
Sends Torque Wrench up or down to level desired.
Operation
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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.
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 6 below, and go to step 7.
6. 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.
7. 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.
To avoid possible personnel injury of equipment
damage, make sure the IR operational area is clear of
personnel and equipment during startup.
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Limit Switch J-Box
Extend / Retract Limit Switch J-Box
An ERLS (Extend / Retract Limit Switch) J-box (see Figure 4.2) 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 4-2. 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.

Operation
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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 4.2).
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.
i i
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 4.5), 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.
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Figure 4-3. Typical Iron Roughneck, Retracted/Park Postion
Figure 4-4. Typical Iron Roughneck, Extended Position

RN300005
Drill Floor
Drill Floor
RN300006
Operation
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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.
3. 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 4.5).
4. If Iron roughneck travels long or short see "Setting the Extend/Retract Limit Switch
(ERLS) J-Box".
Figure 4-5. Rotation Stop Ring

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Torque Setting Panel
Figure 4-6. Setting Panel Control
Table 4.2 Torque Setting Panel Controls
CONTROL RESPONSE
Torque Setting Control Used to set maximum makeup torque.
JAW Pressure Gauge
Indicates hydraulic pressure in the Upper and
Lower Torque Wrench jaw.
Torque Gauge
Indicates the amount of torque the system is
providing during makeup operation.
System Pressure Gauge
Indicates hydraulic pressure available within the
Iron Roughneck.
E-STOP
Causes hydraulic system to shut down
immediately after this control is pressed.
Operation
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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 4.6) 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.
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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.
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.
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.
Operation
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Hydraulic Enclosure
Figure 4-7. Hydraulic Enclosure Controls Details
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Table 4.3 Hydraulic Enclosure Controls
CONTROL RESPONSE
BOTTOM JAW VALVE
(Valve No. 5)
Hydraulic manual valve to clamp and unclamp the bottom
jaws on a drill pipe connection.
IR Rotate
(if equipped)
Roates tool clockwise or counter clockwise.
MOVE IN-OUT VALVE
(Valve No. 8)
Hydraulic manual valve to extend and retract to and from
well center or mousehole.
SLIPS-SET-RELEASE VALVE
(if equipped)
Sets or releases slips.
SPINNER GRIP VALVE
(Valve No. 6)
Hydraulic manual valve to engages and disengages the
spinner grips onto tubular.
SPINNER ROTATION VALVE
(Valve No.7)
Hydraulic manual valve to select spin rotation in or out.
TOP JAW VALVE
(Valve No. 4)
Hydraulic manual valve to clamp and unclamp the top jaws
on a drill pipe connection.
TORQUE VALVE
(Valve No. 2)
Hydraulic manual valve to make or break a connection.
WRENCH LIFT VALVE
(Valve No. 3)
Hydraulic manual valve to adjust the wrench assembly
vertical height.
Operation
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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.
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.
5. If Iron roughneck rotates past or rotates short of the rotation targets see "Setting the
Rotation Target Switches" in this section.
6. Extend and position Iron Roughneck tools over Well Center or Mouse Hole; once
the roughneck is in proper target position,
7. 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
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Rotate Column Assembly
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.
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 1/8"
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 service loops can cause
premature failure and/or damage to the equipment.
Operation
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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 4.8). 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 4-8. Rotation Manifold Valve Assembly

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Rotation Manifold Override 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-
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-
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.
5. When override operations have been completed. Return the 2-way manually
operated directional valves to the normal operation position. Twist Counter-
Operation
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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.
Start-Up Procedures
1. 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.
2. Provide all electrical connections from SCR to HPU to Remote Control Console and
from Remote Control Console to Roughneck.
3. Provide hydraulic pressure in accordance with the instructions provided for your
unit.
4. Check the "SYSTEM" pressure gauge on the Torque Setting Panel should indicate
3000 psi.
5. 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.
6. 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.
!
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.
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Making Connections
Makeup Initial Position
Ensure the following parts of the Iron Roughneck are in the indicated positions prior to
normal makeup operation:
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.
Operation
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Figure 4-9. Remote Control Console, Making Connections
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Normal Makeup Procedure
Unless stated otherwise, all controls mentioned below are those found on the Remote
Control Console (RCC) see Figure 4.9.
2. Starting with the IRON ROUGHNECK in the Makeup Initial Position (see Figure
4.9), 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 4.9.
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.
i i
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.
!
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.
Operation
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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.
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.
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.
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.
i i
Makeup sequences will be controlled by rotation of
Makeup / Breakout Selector switch in a CLOCKWISE
direction.
i i
If MAKEUP COMPLETE light (green light) remains
illuminated, no further makeup is required. If MAKEUP
REPEAT light (red light) illuminates, repeat steps 8-11.
i i
The IR MOVE OUT function (extend) will not work if
Bottom wrench, Top wrench or Spinner is closed.
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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.
Operation
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Figure 4-10. Remote Control Console, Breaking Connections
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Normal Breakout Procedure
Unless stated otherwise, all controls mentioned below are those found on the Remote
Control Console (RCC) see Figure 4.10.
2. Starting with the Iron Roughneck in the Makeup Initial Position (see Figure 4.10),
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 4.10.
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.
i i
Makeup sequences will be controlled by rotation of
Makeup / Breakout Selector switch in a CLOCKWISE
direction.
!
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.
Operation
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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
i i
Breakout sequences will be controlled by rotation of
Makeup / Breakout Selector switch in a COUNTER
CLOCKWISE direction.
i i
The IR MOVE IN function (retract) will not work if Bottom
wrench, Top wrench or Spinner is closed.
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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.
Operation
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Maintenance
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.
Maintenance
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Preventive Maintenance
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.
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.
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.

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Maintenance
5
Preventive / Periodic Maintenance
Table 5.1 Iron Roughneck Preventive / Periodic Maintenance
IRON ROUGHNECK
MAINTENANCE PROCEDURE SCHEDULE
Inspect equipment during operation, noting any abnormal sounds or
vibrations.
DAILY
Investigate any fluid leaks and take action as necessary. DAILY
Apply grease to all Zerk fittings per grease schedule chart, Figure 5.1. WEEKLY
Visually inspect pipe spinner rollers. Verify that they are still within their wear
limit.
DAILY
Table 5.2 Hydraulic Systems Preventive / Periodic Maintenance
HYDRAULIC SYSTEMS
MAINTENANCE PROCEDURES SCHEDULE
Monitor gauges for correct pressure. DAILY
Check all filters and / or screens. DAILY
Remove all water and / or foreign material, and replace fluid as necessary. DAILY
Check all lines and connections for any leaks, and repair as necessary. DAILY
Observe equipment during operation, noting any abnormal sounds or
vibrations. Adjust if necessary.
WEEKLY
Inspect main hydraulic reservoir for any indication of contamination. Clean
and renew as needed.
WEEKLY
Clean and flush all system filters, screens and traps. WEEKLY
Inspect and clean all connections and lines. WEEKLY
Replace system hydraulic fluid. YEARLY
Check, recalibrate and pressure test all system lines and instrumentation. YEARLY
Clean, adjust, and / or replace any components necessary. YEARLY
Maintenance
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Table 5.3 Hydraulic Systems Preventive / Periodic Maintenance
ELECTRICAL SYSTEM
MAINTENANCE PROCEDURE SCHEDULE
If calibration is needed for any aspect of the Iron Roughneck, Contact National
Oilwell.
6 MONTHS
Clean, adjust and / or replace any components necessary. 6 MONTHS
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Maintenance
5
Lubrication and Inspection
Lubrication Schedule
For Lubrication and Hydraulic Fluid Specifications, refer to the "Recommended Lubricants
and Fluids" section located in Maintenance section in this manual.
Figure 5-1. Typical Arm Mounted Iron Roughneck Lubrication Grease Points
NTHLY
remove
top and bottom clamp rings
to access grease pionts
4 places
h side
1 MONTH
WEEKLY
each side
WEEKLY
each side
WEEKLY
each side
WEEKLY
each side
3 MONTHS
brush surface under
cylinders with grease
2 each side
each side
WEEKLY
RN 300013
betwe
WE
4 p
each side
WEEKLY
WEEKLY
each side
WEEKLY
each side
WEEKLY
between rollers/
4 places
3 MONTH
between rollers/
4 places
WEEKLY
each side
1 MONTH
remove top and bottom
clamp rings / 4 places
MONTHLY
each side
WEEKLY
each side
Maintenance
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Wrench Lubrication
Always clean grease fittings before pumping grease to help prevent contaminants from
entering the system and to increase the life of the components.
Table 5.4 Wrench Lubrication Schedule
CHECK POINT PROCEDURE LUBRICATION SCHEDULE
1
Grease cylinder pin fittings with 1 - 3
strokes of a hand-operated grease
gun.
NLGI Multipurpose Grease DAILY
2
Brush all moving surfaces parts with
grease.
NLGI Multipurpose Grease WEEKLY
!
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Maintenance
5
Column-Guide-Arm Lubrication
Always clean grease nipples before pumping grease to help prevent contaminants from
entering the system and to increase the life of the components.
Figure 5-2. Lubrication Points and Inspection Points
Maintenance
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Table 5.5 Column-Guide-Arm Lubrication Schedule
3
Grease all linkage pin fittings.
(1 fitting/linkage pin each side) with
1 - 3 strikes of a hand-operated grease
gun.
4
Grease all cylinder pin fittings.
(1 fitting/cylinder pin each side) with
1 - 3 strokes of a hand-operated
grease gun.
5
Grease all vertical track cam followers.
(1-fitting/ cam follower 2 each side)
with 1 - 3 strokes of a hand-operated
grease gun.
6
Grease the Rotating Bearing on the
Vertical Track Assembly. Apply several
strokes of grease to the fittings, rotate
the Vertical Track Assembly, and apply
several more strokes. Repeat pumping
grease and rotating the Vertical Track
Vertical Track 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.
!
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Maintenance
5
Automated Arm Lubrication
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.
Table 5.6 Automated Arm Lubrication Schedule
7
Grease all linkage pin fittings.
(1 fitting/linkage pin each side) with
1 - 3 strikes of a hand-operated grease
gun.
8
Grease all cylinder pin fittings.
(1 fitting/cylinder pin each side) with
1 - 3 strokes of a hand-operated
grease gun.
9
Grease all vertical track cam followers.
(1-fitting/ cam follower 2 each side)
with 1 - 3 strokes of a hand-operated
grease gun.
NLGI Multipurpose Grease MONTHLY
10
Grease the Rotating Bearing on the
Vertical Track Assembly. Apply several
strokes of grease to the fittings, rotate
the Vertical Track Assembly, and apply
several more strokes. Repeat pumping
grease and rotating the Vertical Track
Vertical Track 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.
NLGI Multipurpose Grease MONTHLY
!
Maintenance
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Inspection Schedule
Perform Inspection at scheduled intervals as noted in inspection table.
Wrench Inspection
Table 5.7 Wrench Inspection Schedule
CHECK POINT PROCEDURE SCHEDULE
1 Visually inspect Jaw Dies. DAILY
2
Flush out any drill mud, which may accumulate around the jaw dies or
under the 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.
DAILY
3 Check all hose and fitting for hydraulic oil leakage. DAILY
4
Visually inspect for loose or missing retention hardware. Make sure that
all bolts, washers, and hex nuts are secured and secondary locking
device intact.
WEEKLY
5 Visually inspect that all pins and cotter pins are secured, and intact. WEEKLY
6
Inspect all hoses, fittings thoroughly for any evidence of chaffing or
hydraulic oil leakage. Replace if necessary.
MONTHLY
7
Inspect hydraulic cylinder thoroughly for hydraulic oil leakage or
damage, Repair or replace if necessary.
6 MONTHS
i i
Inspect jaw dies frequently and replace if worn or
damaged.
!
Keep hands clear of Jaw Dies while dies are extending.
!
Maintain the original security devises, such as; safety wire,
cotter pins lock nuts, retaining rings, loctite, ect. To prevent
parts from vibrating loose and falling.
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Maintenance
5
!
Maintenance
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Column-Guide-Arm Inspection
Table 5.8 Column-Guide-Arm Inspection Schedule
CHECK POINT PROCEDURE SCHEDULE
9
Check the inline hydraulic filter. Replace as necessary if the indicator
indicates is red.
DAILY
10
Visually inspect for loose or missing retention hardware. Make sure that
all bolts, washers, and hex nuts are secured and secondary locking
device intact.
WEEKLY
11 Visually inspect that all pins and cotter pins are secured, and intact. WEEKLY
12
Inspect all hoses, fittings thoroughly for any evidence of chaffing or
hydraulic oil leakage. Replace if necessary.
MONTHLY
13
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
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.
QUARTERLY
14
Inspect all hydraulic cylinders thoroughly for hydraulic oil leakage or
damage, Repair or replace if necessary.
6 MONTHS
15 Inspect for worn linkage bushings. YEARLY
16 Inspect for worn side guide pads. YEARLY
!
maintenance on the hydraulic system. Fluid escaping
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Maintenance
5
Automated Arm Inspection
Table 5.9 Automated Arm Inspection Schedule
INSPECTION PROCEDURE SCHEDULE
18
Check the inline hydraulic filter. Replace as necessary if the
indicator indicates is red.
DAILY
19
Visually inspect for loose or missing retention hardware. Make
sure that all bolts, washers, and hex nuts are secured and
secondary locking device intact.
WEEKLY
20
Visually inspect that all pins and cotter pins are secured, and
intact.
WEEKLY
21
Inspect all hoses, fittings thoroughly for any evidence of chaffing
or hydraulic oil leakage. Replace if necessary.
MONTHLY
22
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 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.
QUARTERLY
23
Inspect all hydraulic cylinders thoroughly for hydraulic oil
leakage or damage, Repair or replace if necessary.
6 MONTHS
24 Inspect for worn linkage bushings. YEARLY
25 Inspect for worn side guide pads. YEARLY
!
Maintenance
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Spinner Assembly Inspection
Table 5.10 Spinner Assembly Inspection Schedule
26 Visually inspect Drive Rollers. DAILY
27
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
DAILY
28
Use wire brush as needed to keep drive rollers clean of metal
shavings.
DAILY
30 Inspect hydraulic motors for hydraulic oil leakage. WEEKLY
31
Apply grease to each grease fittings between the drive rollers
(4 places) with 1-3 pumps of a hand-operated grease gun.
WEEKLY
32
Inspect for loose, missing, or unsecured fasteners and take
correction action to tighten and secure parts.
MONTHLY
33
Inspect all hoses, fittings thoroughly for any evidence of chaffing
or hydraulic oil leakage. Replace if necessary.
MONTHLY
34 Inspect drive rollers for wear or damage. Replace if necessary MONTLY
35
Inspect hydraulic motors thoroughly for hydraulic oil leakage or
damage. Repair or replace if necessary.
6 MONTHS
36
Inspect hydraulic cylinders thoroughly for hydraulic oil leakage or
damage. Repair or replace if necessary.
6 MONTHS
!
caution symbol.
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Maintenance
5
!
caution symbol.
i i
Inspect Drive Rollers frequently and replace if worn or
damaged.
!
Keep hands clear of Drive Rollers while Drive Rollers are
rotating.
Maintenance
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Remote Control Console Inspection
Perform the following maintenance procedures.
Table 5.11 Remote Control Console Inspection Schedule
37
Inspect the control panel for damaged knobs and lens caps.
Replace as required.
DAILY
38
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.
DAILY
39
With the IR shutdown, check the operation of the selector
switches for smooth and positive movement.
DAILY
40
Inspect the service loop power and control cables for any signs
of wear or damage.
WEEKLY
41 Check panel interiors for moisture, cleanliness, and damages. MONTHLY
42
Check all equipment for abnormal conditions, such as
discoloration due to high temperature, corrosion damage, etc.
MONTHLY
43 Check / tighten all switches and switch mountings. MONTHLY
44 Check all switches for signs of moisture, dirt, and damage. MONTHLY
45 Check/tighten all terminals, and plugs to avoid loose connections 6 MONTHS
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Maintenance
5
Day-to-Day Inspection
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.
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.Typical checks to include are (but are not limited to) in the following table:
Table 5.12 Automated Arm Inspection Schedule
1
Inspect all areas with moving parts. Ensure they are free and
clear of debris.
DAILY
2 Check all fluid levels. DAILY
3
Ensure all instrumentation and controls are in good working
order.
DAILY
4 Check and grease all fittings and bearings. DAILY
5 Ensure all safety equipment is present and functional. DAILY
6 Check and grease all fittings, bearings, and wear plates WEEKLY
7 Check panel interiors for moisture, cleanliness, and damages. MONTHLY
8
Check all equipment for abnormal conditions, such as
discoloration due to high temperature, corrosion damage,
etc.General Storage Guidelines
MONTHLY
Maintenance
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Safety Warnings And Precautions
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
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 manual. Failure to heed this warning could result
in injury to personnel and damage to equipment.
Leaking joints, fittings, and connections should only
be tightened when the pressure source is isolated and
cut off and the system is depressurized.
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Maintenance
5
!
Always use caution when inspecting equipment. Begin
only when equipment is shut down and isolated, and
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.
!
!
Always use lifting equipment, supports, and chains with a
minimum capacity of one and a half times that of the object
being lifted or supported. Serious injury or death can result
from falling or swinging equipment
!
The hydraulic tank RETURN connector MUST be
connected before any system is operated; failure to do so
could cause reservoir drain, fluid starvation and equipment
damage
!
Use only specified fluid types. Use only fresh fluids that are
free of contamination. DO NOT MIX FLUIDS. Failure to
follow this caution could result in equipment failure.
Maintenance
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i i
When cleaning, use only an approved solvent to prevent
damage and / or deterioration of the equipment.
i i
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.
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Maintenance
5
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.
Recommended Hydraulic Fluids, for minimum start-up and operating temperatures are as
follows:
Table 5.13 Recommended Hydraulic FluidsGeneral Lubricants
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 Grade 46
-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 Grade 32
Maintenance
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Recommended General Lubricants, for general preventive maintenance are as follows:
Table 5.14 Recommended General Lubricants
AMBIENT TEMPERATURE RANGE
Above -4 F (Above -20 C)
NLGI Grade Number 2 Lithium base, general-purpose, extreme pressure grease.
Above -4 F (Above -20 C)
NLGI Grade Number 2 Lithium base, general-purpose, extreme pressure grease.
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Maintenance
5
General Maintenance
Hazard Descriptions and Safeguards
Table 5.15 List of Common Hazards
AREA HAZARD SAFEGUARDS
Securing Equipment
Equipment chassis assemblies
and subassemblies should
always be inspected prior to
each operation. Undesirable
movement and / or
malfunctioning equipment can
cause serious injury or death
All truck, trailer or skid-mounted
pieces of equipment should be
secured with blocks and / or
moorings prior to operation. All
equipment should receive a
thorough inspection before any
operation.
Equipment Handling
Equipment that falls or swings
while being hoisted or lifted can
crush body parts or bodies
between itself and immovable
objects, causing serious injury
or death.
Keep all people from under and
around the machine or item
during hoisting or lifting
operations.
Drive Systems
Drive systems can cut off
fingers and hands. If clothing is
caught in a moving part, it can
drag the entire arm or body into
the main drive system, causing
serious injury or death.
Keep guards in place and in
good condition. Keep hands and
clothing clear of the drive
system cavity at all times when
the drive is in motion.
Hydraulic Systems
Hydraulic system parts and
connection lines can contain
high pressure that can cause
serious injury or death in certain
circumstances.
Avoid striking or puncturing any
of the component parts or
connections. When working in
the area, slowly bleed pressure,
disconnect and tag, prior to any
work on the system.
Electrical Systems
Some electrical system parts
and connection lines can
contain high voltage that may
cause serious injury or death
when grounded by you, most
metal objects, water, or any
other electrical conductor.
Ensure all electrical power is
turned off prior to any electrical
work. Avoid striking or
puncturing any component parts
or electrical connections.
Lubrication /
Filtration Systems
Failure to adequately maintain
lubrication and / or filtration
systems can result in various
types of catastrophic equipment
failure that can cause serious
injury or death.
Institute a complete lubrication
program at regular intervals and
thoroughly inspect all systems
prior to operation.
Maintenance
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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"
Major Repairs and Modifications
Major repairs and modifications should only be performed by National Oilwell technicians.
Contact National Oilwell for additional information.
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Maintenance
5
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.
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.
i i
Daily hydraulic line inspection should be a routine part of
all active, in-service hydraulic systems.
Maintenance
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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.LUBRICATION AND MAINTENANCE
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Maintenance
5
General Storage Guidelines
General Storage
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.
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.
!
to avoid personal injury due to combustible liquids and
vapors, follow manufacturer's recommended safety
precautions.
!
Replace any locking pins prior to storage and/or
transporting the Iron Roughneck. Failure to observe this
precaution can cause serious injury and / or damage to the
equipment.
Maintenance
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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.
i i
Care must be given to positioning of stored components to
allow periodic reapplication of rust inhibitors, rotating of
machinery, etc.
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Maintenance
5
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.
Table 5.16 Long Term Storage Procedure Schedule
INITIAL STORAGE PROCEDURE SCHEDULE
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 involved while applying rust preventative to ensure parts are fully
coated. Make sure that covers/guards are replaced after coating.
3 MONTHS
2
Grease all pins and grease points. Rotate parts while applying grease
to ensure parts are fully coated.
3 MONTHS
3 Add/replace desiccant packs inside each electrical box. 3 MONTHS
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 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.
3 MONTHS
5
Perform recommended Lubrication and Maintenance procedures as
indicated the National Oilwell Operation and Maintenance Manual.
3 MONTHS
6 Ensure that all connections and covers are tightly sealed. 6 MONTHS
7
Clean exterior of Iron Roughneck to remove all mud, dirt or other
foreign material. Remove any rust and then coat area with red oxide or
zinc rich primer.
6 MONTHS
Maintenance
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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/e0lastomer 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.
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.
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Maintenance
5
Major Component Maintenance
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 5.3).
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".
i i
During disassembly and reassembly of jaw dies removal of
lower lock plate is not necessary.
Maintenance
5
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Figure 5-3. Changing Jaw Dies

Jaw Die
WD4
RN300021
Wide Die Holder
Lock Plate
Lock Plate Pin
Retaining Pin
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Maintenance
5
Remote Control Console 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 this warning could result in injury to personnel
and damage to equipment.
Maintenance
5
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5-34
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 5.3).
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.
i i
During disassembly and reassembly of jaw dies removal of
lower lock plate is not necessary.
!
Maintenance
5
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Maintenance
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Troubleshooting
The following sections describe general troubleshooting methods, guidelines, and tables
for troubleshooting of Iron Roughneck problems or components.
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
Troubleshooting 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.
!
Be sure to read and follow the General Safety Precautions
before proceeding with troubleshooting or maintenance of
the Iron Roughneck:
Troubleshooting
6
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Troubleshooting Categories
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 electric
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.
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Troubleshooting
6
Troubleshooting Operation Problems
This section describes troubleshooting potential operating malfunctions for the IR3080
Iron Roughneck.
Operating Mode Problems
Table 6.1 Operating Mode Problems
SYMPTOM PROBABLE CAUSE CORRECTION
No DC control power
or hydraulics to Iron
Roughneck
E-Stop pushbutton tripped and
interrupting DC power to IR
controls and HPU.
Re-set E-Stop pushbutton switch
to restore IR controls and IR
HPU.
No DC remote control
power.
HE limit switch is not activated
and interrupting DC remote
power to IR controls.
Check HE door is closed
completely to ensure limit switch
activation.
Iron Roughneck runs
slowly.
Power unit return filter clogged/
dirty.
Replace filter element of HPU.
Iron Roughneck pressure filter
clogged/dirty.
Replace filter element of Iron
Roughneck.
Hydraulic quick-disconnect not
fully shouldered.
Check the quick-disconnect
couplings between the HPU and
the Iron Roughneck. Tighten until
fully shoulder to ensure that the
two units are properly connected.
Power Unit not delivering full
flow.
Check power supply flow. Refer
to utility requirements for GPM
minimum flow.
High oil viscosity and /or cold
ambient conditions.
Check oil and replace with
correct viscosity. Refer to the
"Recommend Lubricants and
Fluids" section located in this
manual.
No hydraulic
pressure.
Remove the pump pressure
line to determine if the pump is
delivering any fluid.
See if the suction strainer is
plugged or restricted in any way.
Determine whether the suction
line might be leaking.
See if the reservoir breather or air
vents are restricted.
Drive shaft or coupling failure.
Rotation incorrect.
Inspect and insure rotation.
Replace parts as necessary.
Troubleshooting
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Table 6.1 Operating Mode Problems (continued)
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
maladjustment and/or system
leakage.
Inspect, isolate and replace.
Hydraulic pressure is
too high.
Relief Valve failure or
maladjustment.
Clogged / dirty filter. Replace filter element.
High oil viscosity and /or cold
ambient conditions.
Check oil and replace with
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.
When operating the
Iron Roughneck, one
solenoid does not
function when
sequenced.
The Iron Roughneck has a
loose connection,
contaminated fluid or a
defective solenoid.
Place the IR to perform a
makeup/breakout sequence and
check the control operation.
Torque cylinder
remains engaged in
the retract position
causing fluid to heat
up.
Torque cylinder limit switch
failure or not adjusted properly.
Using a voltmeter, check to see if
signal changes during makeup/
breakout. Replace or adjust
depth of limit switch as
necessary.
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6
Move In-Out Positioning Problems
Table 6.2 Move In-Out Positioning Problems
Move In-Out
positioning assembly
moves in one
direction or does not
move at all.
Low or no System hydraulic
pressure.
Check hydraulic system output
and settings. Test pressures and
adjust as required.
Relief Valve on the manifold is
defective, contaminated or is
not adjusted properly.
Clean, repair, or adjust the valve.
Counterbalance valve on the
Move In-Out cylinder is
defective, contaminated, or is
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
extends but fails to
stop at the well
center position
WC limit switch is not adjusted
correctly or limit switch
defective.
Locate the ERLS J-box and
check WC limit switch trip plate
adjustment. Replace limit switch
if defective.
Move In-Out
extends but fails to
stop at the
mousehole position
MH limit switch is not adjusted
correctly or limit switch
defective.
check MH limit switch trip plate
if defective.
Move In-Out
retracts but fails to
stop at the full retract
position or runs into
the stops.
Retract limit switch is not
adjusted correctly or limit
switch defective.
check retract limit switch trip plate
if defective.
Troubleshooting
6
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Table 6.2 Move In-Out Positioning Problems (continued)
IR assembly does not
rotate to the left or
right.
Locking pin not removed or
rotation stop rings not loosen.
Remove locking pin and/or
loosen rotation stop rings.
Mechanical interference.
Make sure automated arm
assembly is not interfering with
the rig structure or other pieces
of equipment.
Move In-Out
moves in one
direction or does not
move at all.
pressure.
adjust as required.
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Troubleshooting
6
Vertical Positioning Problems
Table 6.3 Vertical Positioning Problems
Vertical positioning
assembly moves in
one direction or does
not move at all.
Power Supply not operating.
Check Power supply pressure
gauge for indication. Make sure
supply pressure remains at
system pressure set with the
operating valve energized.
pressure.
adjust as required.
manually; repair of replace if
defective.
Linkage cylinders damaged or
leak.
Binding of linkage arms.
moving parts on the Guide
Assembly and Vertical Track.
Vertical positioning
assembly does not
maintain vertical
position.
Lift Cylinder leaks. Check cylinder repair or replace.
manually; replace if defective.
Troubleshooting
6
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Troubleshooting Components
Troubleshooting Mechanical Components
This section describes troubleshooting procedures for the Iron Roughneck mechanical
components.
Wrench Assembly
Table 6.4 Wrench Assembly
Torque Cylinder does
not makeup
pressure.
and settings. Test pressures
and adjust as required.
Cylinder damaged. Seals
leaking.
Check cylinders repair or
replace.
Torque setting valve is not
operating.
Torque setting valve set too low. Increase torque setting
pressure as required.
Torque setting valve stuck close,
dirty, or defective.
Check torque setting valve,
clean or replace.
Torque cylinder reaches its end
of stroke before the torque set
point is reached.
Recycle the torque wrench
sequence for an additional
makeup stroke to fully make up
the tool joint.
Torque cylinder does
not breakout.
pressure.
and settings. Test pressures
and adjust as required.
Torque cylinder drifts
in makeup direction.
Sticking or worn solenoid DCV.
Inspect solenoid DVC for
contamination or wear, and
repair or replace.
Torque cylinder drifts
in 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 move or moves
slowly
Dirty return filter in HPU. Replace filter element.
leaking.
Check cylinders repair or
replace.
Relief valve is not operating. Inspect, isolate and replace.
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Troubleshooting
6
Table 6.4 Wrench Assembly (continued)
Top Jaw Wrench
does not close
pressure.
adjust as required.
leaking.
Check cylinders and repair or
replace.
Jaw pressure relief valve is not
operating. Stuck close, dirty, or
defective.
Check Jaw pressure relief valve,
clean, or replace.
Jaw pressure relief valve set
too low.
Increase jaw pressure setting as
required.
Top Jaw Wrench
does not open.
pressure.
adjust as required.
leaking.
replace.
Top Jaw Wrench
cylinder drifts in
close direction.
contamination or wear, and repair
or replace.
leaking.
Top Jaw Wrench
cylinder drifts in
open direction.
or replace.
leaking.
Top Jaw Wrench
cylinder does not
move or moves
slowly.
leaking.
Inspect cylinders repair or
replace.
Top Jaw Wrench
slips on tool joint.
Worn or broken dies. Replace dies.
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.
Troubleshooting
6
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Spinner Assembly
Table 6.5 Spinner Assembly
Loss of power or
torque.
Power supply is not operating.
adjust as required.
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
irregularly.
pressure.
adjust as required.
Contaminated motors.
Inspect, and clean motors or
replace.
Defective hydraulic motors.
Repair hydraulic motors or
replace.
Defective motor, solenoid DCV
or relief valves.
Inspect, isolate, and repair or
replace motors or valves.
Spinner motors stop
rotating while
spinning in or
spinning out.
Flow to the motors is
restricted.
correct.
Defective hydraulic motors.
replace.
Hydraulic motor drive shaft is
broken.
Repair hydraulic motor or
replace.
Spinner Grip wheels
do not rotate.
pressure.
adjust as required.
Flow restricted.
correct.
Spinner Rotation Solenoid
DCV is not operating. DCV is
stuck close, dirty, or defective.
Check Spinner Rotation Solenoid
DCV, clean or replace.
Sheared drive roller keys. Replace keys.
Defective hydraulic motors or
broken motor drive shaft.
replace.
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Troubleshooting
6
Table 6.5 Spinner Assembly (continued)
Spinner Grip Wheels
slip.
Insufficient clamping force.
adjust as required.
Coating on new drill pipe is
making the surface too
slippery.
Remove coating.
Contamination on spinner grip
wheels.
Remove contamination.
Spinner grip wheels are worn. Replace spinner grip wheels.
Spinner Grip cylinder
drifts in clamp or
unclamp position.
or replace.
Defective counterbalance
valve or counterbalance valve
is out of adjustment.
Replace or adjust CB valve to
maintain clamp positioning with
the operating valve in neutral.
Spinner Grip
assembly does not
clamp or unclamp.
pressure.
adjust as required.
Flow restricted.
correct.
leaking.
replace.
Spinner Grip Solenoid DCV is
not operating. DCV is stuck
close, dirty, or defective.
Check Spinner Grip Solenoid
DCV, clean or replace.
Spinner Grip
assembly does not
move in unison.
Lack of lubrication.
moving parts.
Defective bearings in the
cylinder end connection or
spinner arm.
Repair or replace.
Defective linkage.
Check the arm pins and bores
and repair or replace.
Spinner Grip cylinder
does not move or
moves slowly.
leaking.
Inspect cylinders and repair or
replace.
Power Supply is defective. Low
or no System hydraulic
pressure.
Check system output and
settings. Test pressures and
adjust as required.
Troubleshooting
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Table 6.5 Spinner Assembly (continued)
Spinner does not
shoulder pipe or
cannot spin pipe
after breakout
sequence.
Hydraulic pressure low.
adjust as required.
Bottom jaw is clamped too high
on the box end of drill pipe.
Unclamp the lower jaws, lower
the Iron Roughneck to the lowest
point on the box, re-clamp and
spin in/out.
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Troubleshooting
6
Troubleshooting Hydraulic Components
This section describes troubleshooting procedures for the IR3080 Iron Roughneck
hydraulic components.
Hydraulic Enclosure
Table 6.6 Hydraulic Enclosure
Solenoid Directional
Control Valve(s) Fail
to Operate. Valve
does not appear to
shift.
Valve inoperative.
Ensure Hydraulic Enclosure door
is closed completely; 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 leakage.
Check pilot pressure. See if the
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.
Troubleshooting
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Torque Setting Panel
Table 6.7 Torque Setting Panel
Relief Valve fail to
function properly
No hydraulic pressure.
adjust as required.
Hydraulic lines incorrectly
connected.
Check hydraulic lines are
connected properly.
Relief valve defective and/or
damaged.
Torque Gauge does
not return to zero.
Gauge not adjusted to zero.
Reset gauge and recheck torque
setting.
Defective gauge. Replace.
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Troubleshooting
6
Troubleshooting System Components
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.
Troubleshooting
6
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6-16

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