I

Part Number 26-80

lul..Totco-

1A Van=0 Company

INSTALLATION, OPERATION, AND MAINTENANCE

WITH
ILLUSTRATED PARTS BREAKDOWN

ROTARY TORQUE SYSTEMS

PART NUMBERS
212944
212945
212946
212947

Manufacturers of Precision Instruments

Printed in U.S.A. February 1,198l

 Manual 26-80 contains 44 pages as follows:

Cover.. ............................ ..Aprill99 8

ii thru vi .............................. .April 1998
1-l thru 1-4 ......................... February 1,198l
2-1 thru 2-6 ......................... February 1,198l
3-l thru 3-24 ........................ February 1,198l
4-l thru 4-2 ......................... February 1,198l

All product, brand, or trade names used in this publication are the trademarks or registered trade-
marks of their respective owners.

Information in this manual is subject to change without notice.

 IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all M/D TOTCO equipment.
The service procedures recommended by M/D TOTCO and described in the technical manuals are
recommended methods of performing service operations. When these service operations require
the use of tools specially designed for the purpose, those special tools should be used as recom-
mended. Warnings against the use of specific service methods that can damage equipment or
render it unsafe are stated in the manuals. These warnings are not exclusive, as M/D TOTCO
could not possibly know, evaluate and advise service people of all conceivable ways in which ser-
vice might be done or of all possible associated hazardous consequences. Accordingly, anyone
who uses service procedures or tools which are not recommended by M/D TOTCO must first sat-
isfy themselves thoroughly that neither personnel safety nor equipment safety will be jeopardized
by the method selected.

...
February 1,198l III
M/D TOTCO
 THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

Martin-Decker TOTCO (“Company”) warrants to Buyer (“Purchaser) of new products manufactured or

supplied by the Company that such products are, at the time of delivery to the Purchaser, free of material and
workmanship defects, subject to the following exceptions:

A. Any product which has been repaired or altered in such a way, in the Company’s judgement, as to affect
the product adversely, including any repairs, rebuilding, welding or heat treating outside of Company
authorized facility.

B. Any product which has, in the Company’s judgement, been subject to negligence, accident, or improper
storage.

C. Any product which has not been installed, operated and maintained in accordance with normal practice
and within the recommendations of the Company.

D. For all items of special order by Buyer which are not manufactured by Company, Buyer should submit
warranty claims directly to the manufacturer thereof.

The Company’s obligation under this warranty is limited to repairing, or at its option, replacing any products
which in its judgement proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted to authorized Company service facility shall be
borne by Buyer. Costs of return transportation to Buyer of products accepted for repair or replacement by
Company under the warranty provisions of the Sales Agreement shall be borne by the Company. Company
may, at its sole option elect to refund the purchase price of the products, and Company shall have no further
obligation under the Sales Agreement.

The cost of labor for installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the
product upon which installed to the same extent as if such parts were original components thereof.

The warranty periods for various products are:

A. Hydraulic, Mechanical, Electronic Equipment: one (1) year from date of installation or fifteen (15) months
from date of shipment from Company, whichever occurs first.

B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.

No deviations from the Company’s standard warranty terms or period as stated herein will be honored unless
agreed to in writing by an authorized Company representative prior to acceptance of the order.

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY. THE REMEDIES PROVIDED FOR IN THIS
WARRANTY SHALL CONSTITUTE THE SOLE RECOURSE OF BUYER AGAINST COMPANY FOR
BREACH OF ANY OF COMPANY’S OBLIGATIONS UNDER THE SALES AGREEMENT WITH BUYER,
WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT, INCLUDING CLAIMS BASED ON
WARRANTY, NEGLIGENCE, OR OTHERWISE.

IN NO EVENT SHALL COMPANY BE LIABLE FOR DIRECT, INDIRECT, INCIDENTAL OR

CONSEQUENTIAL DAMAGES, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT,
STRICT LIABILITY OR IN TORT (INCLUDING NEGLIGENCE), NOR FOR LOST PROFITS.

iv February 1,198l
M/D TOTCO
 INSTRUCTION MANUAL 26-80
TABLE OF CONTENTS

Section Page

I PURPOSE AND DESCRIPTION ...................... l-l

l-l Introduction ....................... l-l
l-3 Purpose..........................l- 1
l-5 Description ........................ l-l
l-6 . General ......................... l-l
1-7 . Idler Assembly ..................... l-2
l-8 . Indicating Gauge .................... l-2
l-9 . Hydraulic Hose ..................... l-2
l-10 . Filling Steeple ..................... l-3
l-11 Principle of Operation .................. l-3
1-12 .General.........................l- 3
II INSTALLATION AND ADJUSTMENT .................... 2-1
2-l General Information .................... 2-l
2-3 Installation and Adjustment ................ 2-l
2-5 . Idler Assembly Installation ............... 2-l
2-6 . Rotary Torque Gauge Installation (Bracket Mount) .... 2-3
2-7 . Filling Steeple Installation .............. 2-3
2-8 . Hydraulic Hose Installation (Bracket Mount) ....... 2-6
2-9 . Hydraulic Hose Installation (Panel Mount) ........ 2-6
Z-10 . Rotary Torque Gauge and Damper Installation ....... 2-6
(Panel Mount)
III PERIODIC INSPECTION, FIELD MAINTENANCE, SHOP MAINTENANCE ..... 3-1
AND CALIBRATION
3-l General..........................3- 1
3-3 Periodic Inspection .................... 3-l
3-5 Field Maintenance ..................... 3-2
3-6 .General.........................3- 2
3-7 . Idler Assembly Removal ................. 3-2
3-8 . Idler Assembly Installation ............... 3-2
3-9 . Rotary Torque Gauge Removal (Bracket Mount) ....... 3-4
3-10 . Rotary Torque Gauge Installation (Bracket Mount). .... 3-5
3-11 . Rotary Torque Gauge and Damper Removal (Panel ...... 3-5
Mount
3-12 . Rotary Torque Gauge and Damper Installation ....... 3-5
(Panel Mount)
3-13 . Filling Steeple Removal ................. 3-5
3-14 . Filling Steeple Installation .............. 3-6
3-15 . Hydraulic Hose Removal and Replacement ......... 3-6
(Bracket/Panel Mount)
3-16 . Rotary Torque System Reloading ............. 3-6
3-17 . Rotary Torque Gauge Filling (Bracket Mount/Panel .... 3-7
Mount)
3-18 Shop Maintenance ..................... 3-7
3-19 .General.........................3- 7
3-20 . Idler Assembly Disassembly ............... 3-7
3-21 . Idler Assembly Reassembly ................ 3-10
3-22 . Rotary Torque Gauge Disassembly (Bracket Mount) ..... 3-10
3-23 . Rotary Torque Gauge Reassembly (Bracket Mount). ...... 3-12
 INSTRUCTION MANUAL 26-80
TABLE OF CONTENTS (Cont’d)

Section Page

III 3-24 . Rotary Torque Gauge Disassembly (Panel Mount). ..... 3-13
(Cont'd) 3-25 . Rotary Torque Gauge Reassembly (Panel Mount) ...... 3-13
3-26 . Low Pressure Gauge Mount Damper Disassembly. ...... 3-16
3-27 . Low Pressure Gauge Mount Damper Reassembly ....... 3-16
3-28 . Low Pressure Panel Mount Damper Disassembly ...... 3-17
3-29 . Low Pressure Panel Mount Damper Reassembly ....... 3-17
3-30 . Linkage Disassembly. . . . ............... 3-17
3-31 . Linkage Reassembly . . . . ............... 3-19
3-32 . Cylinder Disassembly . . . ............... 3-19
3-33 . Cylinder Reassembly. . . . . . . . . . . . . . . . . . . 3-20
3-34 Calibration. . . . . . . . . ............... 3-21
3-35 . General. . . . . . . . . . ............... 3-21
3-36 . Indicating Gauge . . . . . ............... 3-21
IV TROUBLESHOOTING . . . . . . . . . . ............... 4-l
4-l General . . . . . . . . . . . . . . . . . . . . . . . . . 4-l

LIST OF I LLUSTRAT ‘IONS

Figure Page

l-l Rotary Torque System (Bracket/Panel Mount) ............ l-l

2-l Rotary Torque System (Bracket/Panel Mount) ............ 2-2
2-2 Rotary Torque System Installation Dimensions ........... 2-4
2-3 Idler Assembly Installation ................... 2-5
3-1 Rotary Torque System (Bracket Mount) ............... 3-3
3-2 Rotary Torque System (Panel Mount) ................ 3-4
3-3 Idler Assembly (With Wheel) ................... 3-a
3-4 Idler Assembly (Less Wheel) ................... 3-9
3-5 Gauge Assembly, Rotary Torque (Bracket Mount). .......... 3-11
3-6 Gauge Assembly, Rotary Torque (Panel Mount). ........... 3-14
3-7 Damper Assembly, Low Pressure (Gauge Mount). ........... 3-16
3-8 Damper Assembly, Low Pressure (Panel Mount). ........... 3-18
3-9 Linkage Assembly (Short) ..................... 3- 19
3-10 Cylinder Assembly ........................ 3-20
3-11 Six Inch Rotary Torque Gauge Calibration Flow Chart ....... 3-22

LIST OF TABLES

Table Page

l-l Leading Particulars ....................... l-2

3-l Periodic Inspection Table .................... 3-l
4-l Troubleshooting Table ...................... 4-l
 INSTRUCTION MANUAL 26-80
RELATED PUBLICATIONS

Publication
Number Title

29-03 Installation, Operation and Maintenance, High Pressure Test

Bench Assembly, PN 210986

29-05 Installation, Operation and Maintenance with Illustrated Parts

Breakdown, Vacuum Pump Assembly, PN 212818

RELATED TOOLS AND TEST EQUIPMENT

999727-001 Pointer Puller

18A/18AA Automatic Center Punch (STARRETT)
6063-5 Torque Wrench, Type P-60 (PROTO)
211075 Calibration Dial, Six Inch Gauge
210986 High Pressure Test Bench Assembly
212818 Vacuum Pump Assembly
968202-002 Hex Nipple
970621-005 Quick-Disconnect
968601-003 Elbow
210912 Master Test Gauge
APPROVED EXPENDABLE ITEM LIST

214358-101 Instrument Fluid (M-8)

214359-101 Instrument Fluid (M-15)
991201-009 High Performance Pipe Sealant
JT-6 Mystic Lubricant (Cato Oil and Grease Co.)
THIS PAGE INTENTIONALLY LEFT BLANK.
 INSTRUCTION MANUAL 26-80
SI UNIT CONVERSION FACTORS

ATMOSPHERES (atm) (standard sea level pressure)

x 101.325 = Kilopascals (kPa) absolute
x 29.92 = Inches of mercury (in Hg) at O'C

KILOPASCALS (kPa)
x 0.001 = Pascals (Pa)
x 0.001 = Newtons per square metre (N/m2)

POUNDS PER SQUARE INCH GAGE (PSIG)

= Pounds-force square inch (lbf/in2)
x 6.895 = Kilopascals (kPa)

BARRELS, PETROLEW (bbl)

x 0.1590 = Cubic metres (m3)
x 42 = U. S. gallons (U. S. gal) oil

BARRELS PER INCH, PETROLEUM (bbl/in)

x 0.626 = Cubic metres per centimetre (m3/cm)

INCHES (in.)
x 2.540 = Centimetres (cm)

SQUARE FEET (ft2)

x 0.0929 = Square metres (m2)

DEGREES FAHRENHEIT (OF)

('F-32) x 5/9 = 'C

DEGREES CENTIGRADE ('C)

("C x 9/5) + 32 = OF

POUNDS-FORCE (lbf av.)

x 4.448 = Newtons (N)
x 0.4448 = Decanewtons (daN)

POUNDS MASS PER U. S. GALLON (lb/gal)

x 119.826 = Kilograms per cubic metre (kg/m3)

ii
INSTRUCTION MANUAL 26-80
 INSTRUCTION MANUAL 26-80
SECTION I
PURPOSE AND DESCRIPTION

l-l INTRODUCTION

l-2 This manual contains installation, operating and maintenance instructions

for the Rotary Torque System manufactured by TOTCO. Information contained
in this manual is sufficient for maintenance technicians to install and satisfactorily
accomplish all operating and maintenance tasks.

l-3 PURPOSE

l-4 The TOTCO Rotary Torque System is designed to provide a relative torque
measurement on rotary drilling rigs which employ a chain drive as a means
of power transmission to the rotary table. It is designed to provide a continuous
readout of relative torque, displayed on a rotary torque gauge in units. The
standard dial on the indicating gauge is O-500 units or O-1000 units.

l-5 DESCRIPTION

l-6 GENERAL. The rotary torque system (Figure l-l) consists of the idler
assembly, indicating gauge, interconnecting hydraulic hose, filling steeple
and mounting hardware. The system is totally hydraulic and requires no electrical
connections. For leading particulars see Table l-l.

BRACKET MOUNT

PANEL MOUNT

.~ .--- --- ___- --_---_ I__. ^---- I- .---- .r^r-rr-\

FIGURE l-l. ROTARY TOKQUE SYS'I'EM (BKACXE'l'/FANEL MVUN'I')

l-l
 INSTRUCTION MANUAL 26-80

TABLE l-l. LEADING PARTICULARS

SYSTEM

Weight Total combined shipping weight approxi-

mately 160 lbs (72 kg)
System Fluid Filled with M-15 instrument fluid.
Operating Temperature -50' to +150°F (-45' to +65'C).

HYDRAULIC HOSE l/4-inch, double-wire braid, rubber

covered.
Pressure Rating Maximum operating, 5000 psig.
Minimum burst, 20,000 psig.

Bend Radius Minimum, 4 inches.

End Connections l/4-inch NPT.

Couplings Self-sealing quick-di sconnect.

IDLER ASSEMBLY Installs under secondary chain in draw-

works or under rotary drive chain.

INDICATING GAUGE 6-inch dial.

Zero adjust dial.
Adjustable pointer damper.
Fluid filled.

1 450° pointer travel.

l-7 IDLER ASSEMBLY. The idler assembly acts as a lever with a hard rubber
wheel deflecting the chain. This lever action puts pressure on a hydraulic
cylinder that is filled with hydraulic fluid, which transforms the applied force
into a pressure signal and transmits the signal to the indicating gauge through
the hydraulic hose.

l-8 INDICATING GAUGE. The indicating gauge (bracket mount/panel mount) is a

pressure sensing instrument, that uses a Bourdon tube to drive the pointer
through the movement assembly. It has a zero adjust knob (bracket mount, rear0
zero adjust knob; panel mount, front zero adjust knob), and a pointer with 450
travel. The gauge is fluid filled to reduce extreme pointer movement, to lubricate,
and to protect working parts. It incorporates an adjustable damper to regulate
pointer sensitivity (bracket mount, damper is gauge mounted; panel mount, damper
is mounted adjacent to gauge).

l-9 HYDRAULIC HOSE. The hydraulic hose is double-steel wire braid and rubber
covered. A self-sealing, quick-disconnect coupling is installed on the
end of the hose which connects to the idler assembly.

l-2
 INSTRUCTION MANUAL 26-80

l-10 FILLING STEEPLE. The filling steeple is connected in series between the
cylinder assembly and the indicating gauge. It is installed adjacent to
the indicating gauge and serves as a junction point for filling the system without
disconnecting the hydraulic hose.

1-11 PRINCIPLE OF OPERATION

1-12 GENERAL. With the idler assembly properly installed under the secondary
or rotary drive chain, the hydraulic pressure generated in the idler assembly
cylinder will be relative to the drill string torque. As torque builds in the
drilling string, the rotary drive and secondary drive chains become more taut,
placing a greater downward pressure on the idler wheel. The idler wheel mechanically
couples this pressure to the cylinder assembly. The cylinder displaces a pro-
portional amount of hydraulic fluid into the interconnecting hydraulic hose, which
transmits this hydraulic signal to the indicating gauge where torque is displayed
in relative units.

l-3/1-4
 INSTRUCTION MANUAL 26-80
SECTION Ii
INSTALLATION AND ADJUSTMENT

2-1 GENERAL INFORMATION

2-2 This section contains procedures for installing the rotary torque system
(See Figure 2-l). Components of the rotary torque system are weather-
resistant, and have been field tested for continuous operation in hot and cold
temperature extremes. They are shipped as complete units and simple installation
procedures are all that are necessary to complete an interconnected system. The
rotary torque system is packed in a special built container with separate compart-
ments for each unit, protected with foam rubber packing. The hydraulic hose is
serviced with hydraulic fluid, with one end connected to the filling steeple and
the other has a self-sealing, quick-disconnect coupling. The indicating gauge is
packed in a separate box protected with foam rubber padding and placed with the
other components inside the special sealed shipping container. Mounting dimensions
are shown in Figure 2-2.

2-3 INSTALLATION AND ADJUSTMENT

2-4 The rotary torque system is delivered as an operational system. When it

is received and unpacked, inspect for shipping damage before installation.
Inspect and check as follows:

a. Check hydraulic hose and filling steeple for loose fittings, leaks,
cracks, kinks, and bends.

b. Check the indicating gauge for evidence of leaks, broken glass, loose
pointer, binding or jammed zero adjust knob and freedom of dial
rotation.

C. Check the idler for bends, cracks, leaks, and security of wheel
assembly.

d. Replace or repair any damaged units as necessary.

2-5 IDLER ASSEMBLY INSTALLATION. The idler assembly should be installed under
the secondary drive chain in the drawworks, if possible (See Figure 2-3).
Secondary chain must stop when rotary table stops. As a second choice it may be
installed under the rotary drive chain. Survey the drawworks, determine the best
location and proceed as follows:

WARNING

DO NOT HANDLE IDLER ASSEMBLY BY THE FRAME

ASSEMBLY (B, FIGURE 2-l); THIS COULD CAUSE
SEVERE PERSONNEL INJURY.

Measure down 13 in. (minimum) from the tight

a. bottom chain, measure
equal distance between the sprockets. Fabricate a rigid base for
the idler, and weld it to the rig's substructure. Welding and rigid base are
customer furnished.

2-l
 -BB

P
PANEL MOUNT
29

DO NOT LIFT HERE. 27

+ A
KEEP FINGERS AWAY
FROM THIS AREA.

DAMPER
ASSEMBLY

B
19 16
‘CONSOLE MANIFOLD !!

IDLER HOSE
 INSTRUCTION MANUAL 26-80

LEGEND FOR FIGURE 2-1

1. Female Coupling 16. Hex Bolt

2. Dust Cap 17. Box Mount Bracket
3. Hose Assembly 18. Hex Bolt
4. Idler Assembly 19. Lockwasher
5. Hex Bolt 20. Elbow
6. Washer 21. Bushing
7. Dust Cap 22. Rotary Torque Gauge Assembly
8. Male Coupling 23. Tubing
9. Nipple 24. Damper Assembly
10. Male Connector 25. Hex Bolt
11. Tubing 26. Lockwasher
12. Filling Steeple 27. Stop Nut
13. Stop Nut 28. Screw
14. Hex Bolt 29. Rotary Torque Gauge Assembly
15. Stop Nut

b. Using mounting hardware (5,6, Figure 2-l), bolt the six inch mounting
foot pad to the idler base nearest the cylinder assembly; bolt the
four inch mounting foot pad under the open (opposite) end of the idler base.

C. Place the idler assembly on the rigid base, centered under the bottom
drive chain and equal distance between sprockets (when possible). Weld
mounting foot pads to the rigid base.

CAUTION

WELD THE MOUNTING FOOT PADS TO THE RIGID

BASE SO THAT THE DRIVE CHAIN TRAVELS ACROSS
THE IDLER WHEEL FROM THE CYLINDER END TO
THE OPEN END OF THE IDLER.

Check
d. the idler wheel for alignment; it should be centered on the
drive chain and equal distance between sprocket. If not, loosen
the mounting bolts and align the wheel for positive and parallel tracking. The
mounting holes in the base of the idler assembly are slightly larger for alignment
purposes. Tighten the four mounting bolts.

2-6 ROTARY TORQUE GAUGE INSTALLATION (BUCKET MOUNT). The rotary torque gauge
may be installed in a weight indicator cabinet or other locations convenient
to the driller. Secure gauge (22, Figure 2-l) to bracket (17), with washer (18),
screw (lq), and secure bracket in place with bolts (16) and nuts (15).

2-7 FILLING STEEPLE INSTALLATION. The filling steeple is normally supplied

with a bracket mount system. Install the filling steeple adjacent to the
rotary torque gauge and connect it to the gauge using the copper tubing supplied.

2-3
 INSTRUCTION MANUAL 26-80

7.50 DIA
I- (19.05 cm) 9.00
(22.86 cm)

(1.73 cm)

\45”
VW

I- 7.26
(18.44 cm) .50
(1.27 cm)

(18.44 cm)

PANEL MOUNT GAUGE

BRACKET MOUNT GAUGE

-6.5+

12.6 DIA
14:69
(30.04 cm
(37.31 cm)

(50.0 cm)
26-801-3
(54.61 cm) (12.7 cm)

FIGURE 2-2. ROTARY TORQUE SYSTEM INSTALLATION DIMENSIONS

2-4
 INSTRUCTION MANUAL 26-80

DRILLER’S CONSOLE
7 I SECONDARY
CHAIN DRIVE

BRAKE HANDLE- \,A ~--

-REFERRED MOUNTING

INSTALL UNDER THIS CHAIN \

MEASURE DOWN 13 INCHES FROMJ WHERE POSSIBLE
TIGHT BOTTOM CHAIN AND
FABRICATE A RIGID BASE FOR IDLER
ALTERNATE MOUNTING
NOTE
WHEN IDLER IS INSTALLED INTO A
TOTALLY ENCLOSED CHAIN GUARD,
A BULKHEAD HYDRAULIC FITTING
MUST BE INSTALLED

SIX INCH MOUNTING PAD

f
6.0-/d /\
(15.24 cm)

RIGID BASE MUST NOT

YIELD UNDER LOAD

FIGURE 2-3. IDLER ASSEMBLY INSTALLATION

2-5
 INSTRUCTION MANUAL 26-80

2-8 HYDRAULIC HOSE INSTALLATION (BRACKET MOUNT). Route the hydraulic hose
through a well protected area between the gauge location and the idler
assembly. Avoid areas where rig personnel are working. Clamp or tie hose clear
of water, mud and walkways where they may sustain damage. One end of the hydraulic
hose (3, Figure 2-l) is connected to the filling steeple (12) prior to shipping;
connect the other end to the idler assembly hose female coupling (1).

2-9 ROTARY TORQUE GAUGE AND DAMPER INSTALLATION (PANEL MOUNT). The panel mount
gauge is normally installed in a driller's console or similar panel. It
is a front mounting gauge with the damper assembly installed on the panel adjacent
to it; proceed as follows (See Figure 2-l):

a. Install the gauge (29) into space provided and secure with bolts (28)
and nuts (27).

b. Install the damper assembly (24) on the back side of the console
adjacent to the gauge. Secure it with washers (26) and bolts (25).

NOTE

The roll pin must be removed from damper stem

before installation and reinstalled after in-
stallation.

C. Connect the low pressure copper tubing (23) between the damper
assembly (24) and the rotary torque gauge (29).

d. Check the console's hook-up manifold, identify the rotary torque

input, follow its tubing and connect it to the damper assembly.

e. After installation of gauge, reload the system with instrument fluid

(Refer to Paragraph 3-16).

2-10 HYDRAULIC HOSE INSTALLATION (PANEL MOUNT). The hydraulic hose (3, Figure
2-l) for the panel mount system is equipped with two quick-disconnects.
Route the hose as per instruction in Paragraph 2-8. Connect one hose end to the
female coupling (1). Check driller's console hook-up manifold (or customer supplied
filling steeple) and identify rotary torque input. Connect the other end of the
hose to the proper rotary torque input connection.

2-6
 INSTRUCTION MANUAL 26-80
SECTION Ill
PERIODIC INSPECTION, FIELD MAINTENANCE,
SHOP MAINTENANCE AND CALIBRATION

3-l GENERAL

3-2 The Rotary Torque System is built to give long, trouble-free service with
mininum maintenance. To keep the system in best operating condition,
it is recommended that periodic inspection be carried out. Maintenance personnel
should establish a suitable inspection cycle based upon usage and operating en-
vironment of equipment. General inspections are given in this section.

3-3 PERIODIC INSPECTION

3-4 Carry out a general visual inspection of the entire rotary torque system,
checking for damage, wear, and loose parts. Replace all defective com-
ponents. Carefully check the following:

a. Idler hard rubber wheel for cracks, cuts, wear, deterioration, and
alignment.

b. Hydraulic hose(s) for cuts, cracks, kinks, and verify that all
connections are tight.

C. Check the gauge for evidence of leaks, broken glass, loose pointers,
knobs, etc. Refer to Table 3-l for periodic inspection requirement.

TABLE 3-l. PERIODIC INSPECTION TABLE

COMPONENT CLEANED PERIODIC INSP LUBRICATION SERVICED

Gauge During Checked at NA After any maintenance

maintenance six month or when gauge fluid
intervals level is below 3/4
full (M-8).*

Idler Residue Weekly (a, Check daily. Check daily. Service

Assembly build-up or Paragraph 3-4) Lubricate with with instrument fluid
during main- mistic lubricant (as required)(M-15).*
tenance (or equivalent)
as required.*

Hydraulic Residue Refer to b., NA Anytime connection

Hose build-up Paragraph 3-4 is broken, apply
pipe sealant.

*See Approved Expendable Item List

3-l
 INSTRUCTION MANUAL 26-80

3-5 FIELD MAINTENANCE

3-6 GENERAL. Field maintenance is limited to the removal and replacement of

rotary torque system gauge and hose assemblies and system servicing. Do
not disassemble/reassemble gauge or hose at field level maintenance. Remove and
replace gauge and hose assemblies and return to a TOTCO field shop for complete
overhaul, test and calibration.

3-7 IDLER ASSEMBLY REMOVAL. Stop rotary drive, relieve pressure; proceed as
follows (See Figure 3-l or 3-2):

WARNING

ROTARY DRIVE MUST BE STOPPED PRIOR TO PERFORMING

ANY MAINTENANCE ON THE IDLER ASSEMBLY. FAILURE
TO STOP ROTARY DRIVE COULD CAUSE SEVERE PERSONNEL
INJURY AND/OR EQUIPMENT DAMAGE.

a. Disconnect hydraulic hose at the quick-disconnect (1).

b. Remove four bolts (5), four flat washers (6) and the idler assembly (4).

3-8 IDLER ASSEMBLY INSTALLATION. To install the idler assembly; proceed as

follows (See Figure 3-l or 3-2):

WARNING

ROTARY DRIVE MUST BE STOPPED PRIOR TO PERFORMING

ANY MAINTENANCE ON THE IDLER ASSEMBLY. FAILURE
TO STOP ROTARY DRIVE COULD CAUSE SEVERE PERSONNEL
INJURY AND/OR EQUIPMENT DAMAGE. DO NOT HANDLE
IDLER ASSEMBLY BY THE FRAME ASSEMBLY (B, FIGURE 2-l).

a. Place idler assembly into position over mounting foot pads and
secure with four flat washers (6) and four hex bolts (5).

b. Connect hydraulic hose (3) to idler hose female coupling (1).

CAUTION

INSTALL THE IDLER ASSEMBLY SO THAT THE DRIVE

CHAIN TRAVELS ACROSS THE IDLER WHEEL FROM THE
CYLINDER END ~0 THE OPEN END OF THE IDLER (SEE
FIGURE 2-3).

C. Check idler assembly for proper alignment. The drive chain should
travel across the idler wheel in a straight line; if not, loosen idler
mounting bolts (5, Figure 3-l). Determine which end of the idler is not parallel
with the drive chain, and position that end of the idler so that it is properly
aligned with drive chain, and tighten mounting bolts (5).

3-2
 INSTRUCTION MANUAL 26-80

FIGURE 3-l. ROTARY TORQUE SYSTEM (BRACKET MOUNT)

LEGEND FOR FIGURE 3-l

1. Female Coupling 13. Stop Nut

2. Dust Cap 14. Hex Bolt
3. Hose Assembly 15. Stop Nut
4. Idler Assembly 16. Hex Bolt
5. Hex Bolt 17. Box Mount Bracket
6. Washer 18. Hex Bolt
7. Dust Cap 19. Lockwasher
8. Male Connector 20. Elbow
9. Nipple 21. Bushing
10. Male Connector 22. Rotary Torque Gauge Assembly
11. Tubing 23. Hydraulic Hand Pump
12. Filling Steeple 24. Instrument Fluid

CAUTION

IMPROPER ALIGNMENT OF THE IDLER ASSEMBLY WILL

CAUSE EXCESSIVE WEAR TO THE IDLER'S HARD RUBBER
WHEEL.

d. With the idler assembly reinstalled, system must be reloaded (Refer

to Paragraph 3-16).

3-3
 INSTRUCTION MANUAL 26-80

DAMPER ASSEMBLY

5
CONSOLE MANIFOLD
6

IDLER HOSE

FIGURE 3-2. ROTARY TORQUE SYSTEM (PANEL MOUNT)

LEGEND FOR FIGURE 3-2

1. Female Coupling 8. Damper Assembly

2. Dust Cap 9. Hex Bolt
3. Hose Assembly 10. Lockwasher
4. Idler Assembly 11. Stop Nut
5. Hex Bolt 12. Screw
6. Washer 13. Rotary Torque Gauge Assembly
7. Tubing

3-9 ROTARY TORQUE GAUGE REMOVAL (BRACKET MOUNT). To remove the bracket mount
gauge assembly, stop the rotary drive, proceed as follows (See Figure 3-l):

a. Disconnect female coupling (1) on hydraulic hose (3) from idler

hose; disconnect copper tubing (11) from gauge (22).

b. Remove the three stop nuts (15) and hex bolts (16) securing bracket'(l7).
Remove three hex bolts (18), three lockwashers (19) and gauge assembly (22).

3-4
 INSTRUCTION MANUAL 26-80

3-10 ROTARY TORQUE GAUGE INSTALLATION (BRACKET MOUNT). Before installing

gauge assembly, ensure that it is calibrated and filled to within 314
of inner ring diameter with instrument fluid (Refer to Approved Expendable Item
List) with gauge standing in upright position;:proceed as follows (See Figure 3-l):

a. Secure gauge (22) to bracket (17) with three lockwashers (19),

three hex bolts (18), and secure bracket (17) to previously selected
location with three hex bolts (16) and three stop nuts (15).

b. Connect copper tubing (11) between gauge assembly (22) and filling
steeple (12).

C. With gauge reinstalled, system must be serviced (Refer to Paragraph

3-16).

3-11 ROTARY TORQUE GAUGE AND DAMPER REMOVAL (PANEL MOUNT). To remove the panel
mount gauge and damper assembly, stop the rotary drive, relieve pressure;
proceed as follows (See Figure 3-2):

Disconnect
a. interconnecting tubing (not illustrated) between damper
assembly and drilling console manifold. Remove tubing (7) between
damper assembly (8) and gauge (13).

b. Remove roll pin (See 6, Figure 3-8), two hex bolts (9, Figure 3-2),
two lockwashers (10) and damper assembly (8). Remove four stop nuts
(ll), four screws (12) and gauge assembly (13).

3-12 ROTARY TORQUE GAUGE AND DAMPER INSTALLATION (PANEL MOUNT). Before installing
gauge assembly, ensure that it is calibrated and filled to within 3/4 of
inner ring diameter with instrument fluid (Refer to Approved Expendable Item List)
and with gauge standing in upright position;proceed as follows (See Figure 3-2):

Insert
a. gauge assembly (13) through front of driller's console and
secure it with four screws (12) and four stop nuts (11). With roll
pin removed, install damper assembly (8) from the rear of driller's console with
damper stem through the front. Secure damper (8) with two lockwashers (lo), two
hex bolts (9). Install roll pin (6, Figure 3-8).

b. Connect tubing (7) between damper assembly (8) and gauge (13). Connect
interconnecting tubing (not illustrated) between damper assembly and
drilling console manifold (customer furnished).

C. With gauge and damper reinstalled, system must be reloaded (Refer to

Paragraph 3-16).

3-13 FILLING STEEPLE REMOVAL. Before removing filling steeple, stop rotary
drive, relieve pressure; proceed as follows (See Figure 3-l):

a. Disconnect hydraulic hose (3) and tubing (11) from filling steeple (12).

b. Remove two stop nuts (13), two hex bolts (14) and filling steeple (12).

3-5
 INSTRUCTION MANUAL 26-80

3-14 FILLING STEEPLE INSTALLATION. Before installing filling steeple, ensure

that rotary drive is stopped; proceed as follows (See Figure 3-l):

a. Install filling steeple (12) into its mounting position and secure
with two hex bolts (14) and two stop nuts (13).

b. Connect tubing (11) between filling steeple (12) and gauge assembly
(22) ' Apply pipe sealant to pipe thread end of hydraulic hose (3)
and connect that end to filling steeple (12). Connect female coupling (1) to
idler hose.

C. With filling steeple reinstalled, system must be serviced (Refer to

Paragraph 3-16).

3-15 HYDRAULIC HOSE REMOVAL AND REPLACEMENT (BRACKET/PANEL MOUNT). To remove

and replace hydraulic hose, ensure that rotary drive is stopped, relieve
pressure, proceed as follows (See Figure 3-l or 3-2):

a. Disconnect female coupling (1, Figure 3-l)(bracket mount) and unscrew

hydraulic hose (3) from filling steeple (12).

b. Disconnect female coupling (1, Figure 3-2) and disconnect opposite

end of hydraulic hose (3) from manifold on driller's console.

C. Route new hydraulic hose (Refer to Paragraph 2-8); apply pipe sealant
(Refer to Approved Expendable Item List) to pipe threaded end of
hose; screw that end of hose (3, Figure 3-l)(bracket mount) into filling steeple
(12) and connect female coupling (1) to idler hose.

d. Route new hydraulic hose as per instructions in Paragraph 2-8;

connect either quick-disconnect (1, Figure 3-2)(panel mount) to
manifold of driller's console; connect other end with female coupling (1) to
idler hose.

e. With the hydraulic hose removed and replaced, system must be reloaded
(Refer to Paragraph 3-16).

3-16 ROTARY TORQUE SYSTEM RELOADING. After installation, the system should be
reloaded with (M-15) instrument fluid (Refer to Approved Expendable Item
List). Stop rotary drive and proceed as follows (See Figure 3-l or 3-2):

a. Remove hex plug (bleed)(4, Figure 3-7 or 3, Figure 3-8) located on top
of the damper assembly. Connect the hydraulic hand pump to the filling
steeple (quick-disconnect at manifold on driller's console for panel mount system),
and pump fluid into system until all entrained air is bled through the bleed plug.

NOTE

After all air has been removed, allow sufficient

fluid to escape until gauge indication returns
to zero.

3-6
 INSTRUCTION MANUAL 26-80

[Link] hex (bleed) plug and pump in additional fluid until gauge
indicates 50 units approximately (pointer at six o'clock position).
Remove hand pump and zero the gauge.

C. Start rotary drive; and observe the torque gauge. With normal weight
on bit and pipe rotating, gauge should indicate between 0 to 200 units.
If torque gauge indication is high, open hex (bleed) plug and bleed some fluid
from the system; tighten bleed plug. If gauge indication is low, stop rotary drive,
and pump additional fluid into system and repeat step c.

3-17 ROTARY TORQUE GAUGE FILLING (BRACKET MOUNT/PANEL MOUNT). To fill either
gauge with instrument fluid, proceed as follow (See Figure 3-5 or 3-6):

a. Remove screw (26, Figure 3-5) and seal (27) on bracket mount gauge;
or screw (44, Figure 3-6) and seal (45) on panel mount gague. Add
additional instrument fluid until gauge is filled to within 0.25 inch of inner
ring diameter with gauge standing in upright position.

b. Reinstall seal (27, Figure 3-5) and screw (26) or bracket mount gauge
or seal (45, Figure 3-6) and screw (44) on panel mount gauge.

3-18 SHOP MAINTENANCE

3-19 GENERAL. Unless overhaul of the rotary torque system components is to be

carried out, component disassembly should be carried out only to the extent
necessary for replacement of defective parts. Do not remove decals, nameplates,
gaskets, and parts bonded in place unless replacement is necessary. Parts that
are swaged, bonded, welded, riveted, peened, press-fitted, staked or soldered
together as assemblies, should not be separated; replace these items as subassemblies.
During reassembly, replace all o-rings, gaskets, piston rings, and seals. Dis-
assembly of components is accomplished by following the order of index numbers
assigned to the exploded views.

3-20 IDLER ASSEMBLY DISASSEMBLY. To disassemble the idler assembly; proceed

as follows (See Figure 3-3 and 3-4):

a. Remove safety wire (1, Figure 3-3), loosen two hex bolts (2), remove
eight hex bolts (3) two axle mount (4), and two hex bolts (2). Raise
idler frame and remove wheel (11).

[Link] normal conditions, do not disassemble wheel assembly (5 through

11). If necessary, remove grease zerk (5), eight hex bolts (6), eight
flat washers (7), two bearing retainers (8), two bearings (9), one wheel axle (10)
and wheel (11).

C. Remove four cotter pins (9, Figure 3-4), two pins (10) and frame
assembly (8). Remove hose (3), cylinder assembly (11) (Refer to
Paragraph 3-32 and 3-33 for Cylinder Maintenance), piston support (12), from
idler base assembly (17).

d. Clean all metal parts, taking care to remove all foreign material,
corrosion, etc. Replace all worn or defective parts.

3-7
 INSTRUCTION MANUAL 26-80

SEE DETAIL BELOW

FIGURE 3-3. IDLER ASSEMBLY (WITH WHEEL)

3-8
 INSTRUCTION MANUAL 26-80

LEGEND FOR FIGURE 3-3

1. Safety Wire 7. Lockwasher

2. Hex Bolt 8. Bearing Retainer
3. Hex Bolt 9. Bearing
4. Axle Mount 10. Wheel Axle
5. Grease Zerk 11. Wheel
6. Hex Bolt

LEGEND FOR FIGURE 3-4

1. Dust Cap 10. Pin

2. Male Coupling 11. Cylinder Assembly
3. Hose Assembly 12. Piston Support
4. Safety Wire (Ref) 13. Mounting Foot
5. Axle Mount (Ref) 14. Mounting Foot
6. Hex Bolt (Ref) 15. Hex Bolt
7. Hex Bolt (Ref) 16. Washer
8. Idler Frame 17. Idler Base
9. Cotter Pin

FIGURE 3-4. IDLER ASSEMBLY (LESS WHEEL)

3-9
 INSTRUCTION MANUAL 26-80

3-21 IDLER ASSEMBLY REASSEMBLY. To reassemble the idler, proceed as follows

(See Figures 3-3 and 3-4):

Place idler
a. base (17, Figure 3-4) on clean level work surface and
install piston support (12); apply pipe sealant (Refer to Approved
Expendable Item List) to pipe threads of hose (3) and connect hose to cylinder
assembly (11); install cylinder assembly (11); place frame assembly (8) into
position over cylinder assembly (11) and base assembly (17) and secure with two
pins (10) and four cotter pins (9).

b. If wheel assembly was disassembled, insert wheel axle (10, Figure 3-3)
into wheel (11) and install two bearing (9), two bearing retainers (8).
Secure with eight flat washers (7), eight hex bolts (6), and install grease zerk (5).

C. Raise idler frame (8, Figure 3-4), place reassembled wheel (11) into
position between slotted area of frame (8) and lower frame. Secure
wheel with two axle mounts (4), two hex bolts (2)(do not tighten), eight hex
bolts (3), tighten two hex bolts (2) and secure entire bolt pattern with safety
wire (1).

3-22 ROTARY TORQUE GAUGE DISASSEMBLY (BRACKET MOUNT). To disassemble the

bracket mount gauge, place it flat on clean work surface; proceed as
follows (See Figure 3-5):

a. Remove cap plug (l), four screws (3), case ring (2), glass (4), and
o-ring (5). Drain gauge instrument fluid into an approved waste
container.

LEGEND FOR FIGURE 3-5

1. Cap Plug 19. Nut

2. Case Ring 20. Washer
3. Screw 21. Movement Assembly
4. Glass 22. Screw
5. O-Ring 23. Tube Stop
6. Pointer 24. Screw
7. Snap Ring 25. Lockwasher
8. Dial 26. Screw
9. Dial Mount 27. Seal
10. Screw 28. Damper Assembly
11. Lockwasher 29. Bolt
12. Tubing 30. Lockwasher
13. Male Connector 31. Setscrew
14. Bourdon Tube 32. Drive Assembly
15. Tube Mount Screw 33. O-Ring
16. O-Ring 34. Housing Nut
17. Linkage Assembly 35. O-Ring
18. Shoulder Screw 36. Zero Adjust Gear
37. Case

3-10
4
 INSTRUCTION MANUAL 26-80

Use pointer
b. puller (Refer to Related Tools and Test Equipment) to
remove pointer (6); remove snap ring (7), dial (8), screw (lo), lock-
washer (11) and dial mount (9). Disconnect male connector (13) from Bourdon tube
(14), remove three screws (15), three o-rings (16) and Bourdon tube assembly (14).

Remove two screws (18), two nuts (19), linkage

C. assembly (17) (Refer to
Paragraph 3-30 for maintenance) and two washers (19). Remove screws
(22), movement assembly (21) from Bourdon tube (14). Remove screw (24), washer (24),
tube stop (23); screw (26), seal (27), two bolts (29), two washers (30) and damper
assembly (28)(Refer to Paragraph 3-26 for maintenance) disconnect male connector (13).

d. Remove set screw (31), drive assembly (32), o-ring (33); housing nut
(34), o-ring (35) and zero adjust gear (36) from gauge case (37).

WARNING

USE TRICHOROETHYLENE IN WELL VENTILATED AREA.

IT IS A FLAMMABLE LIQUID AND FUMES ARE HIGHLY
TOXIC.

e. Clean all metal parts with steel wool and trichoroethylene solvent,
taking care to remove all foreign material, corrosion, etc. Discard
all o-rings, seals, gaskets, and worn or defective parts.

3-23 ROTARY TORQUE GAUGE REASSEMBLY (BRACKET MOUNT). To reassemble the bracket
mount gauge assembly; proceed as follows (See Figure 3-5):

Insert
a. zero adjust gear (36) into gauge case (37), o-ring (35) over
housing nut (34) and screw housing nut into gauge case. Install
o-ring (33) onto drive assembly (32) and insert drive assembly (32) through housing
nut (34) and zero adjust gear (36). Secure zero adjust (36) to drive assembly (32)
with setscrew (31).

b. Secure tubing (12) to damper assembly (28) with connector (13). Place
damper gasket over damper mounting holes on top of gauge case (37)
and install damper (28) by inserting tubing (12) through top of gauge case (37)
and secure damper with two washers (30), two bolts (29); use torque wrench (Refer
to Related Tools and Test Equipment List) and torque bolts (29) 8-10 foot pounds.

Install
C. tube stop (23) secure with washer (25) and screw (24)(tube
stop will be adjusted and set during calibration). Prepare Bourdon
tube (14) for installation by installing movement assembly (21) onto Bourdon tube
(14) and secure with screws (22). Insert screws (18) through linkage assembly (17),
washers (20) and install linkage assembly (17) between slotted end of movement
assembly (21) and Bourdon tube tip (14), secure linkage assembly (17) with nuts
(19); install assembled Bourdon tube into gauge case (37), and secure with o-rings
(161, screws (15), then connect connector (13).

d. Place dial
mount (9) into mounting position on top of movement assembly
(21) ; secure
with washer (11) and screw (10). Place dial (8) over
dial mount (9) and secure with snap ring (7). Install pointer (6) onto pinion
shaft (pointer will be properly positioned and secured during calibration).

3-12
 INSTRUCTION MANUAL 26-80

e. Perform gauge calibration (Refer to Paragraph 3-36).

Install
f. o-ring (5), glass (4), case ring (2); secure with four screws
(3); install cap plug (1). Stand gauge in upright position and fill
to within l/4 in. of inner ring diameter with instrument fluid (Refer to Approved
Expendable Item List). Install seal (27) and screw (27).

3-24 ROTARY TORQUE GAUGE DISASSEMBLY (PANEL MOUNT). To disassemble the panel
mounted gauge, place on a clean flat work surface and proceed as follows
(See Figure 3-6):

a. Remove cap plug (8), male elbow (9), setscrew (ll), set knob (lo),
drive assembly (12), bearing sleeves (13), setscrew (14), zero adjust
gear (19), idler gear shaft (15), o-ring (16), housing nut (17), o-ring (18), four
screws (21), case ring (20), glass (22) and o-ring (23). Use pointer pullers to
extract pointer (24). Remove snap ring (25) and dial (26).

[Link] screw (28), washer (29) and dial mount (27). Disconnect
connector (31) from Bourdon tube (32); remove screws (33), o-rings
(34) and Bourdon tube (32) from gauge case (50). Remove screws (36), nuts (37),
linkage (35) (Refer to Paragraph 3-30 for maintenance) and washers (38); screws
(40) and movement assembly (39) from Bourdon tube (32).

C. Remove screw (42), washer (43) and tube stop (41); screw (44), seal
(45). Remove two bolts (47), two washers (48), junction block (46),
with tubing (30), disconnect connector (31) and remove gasket (49).

WARNING

USE TRICHOROETHYLENE IN WELL VENTILATED AREA.

IT IS A FLAMMABLE LIQUID AND FUMES ARE HIGHLY
TOXIC.

d. Clean all metal parts with steel wool and trichoroethylene solvent,
taking care to remove all foreign material, corrosion, etc. Discard
all o-rings, seals, gaskets and worn or defective parts.

3-25 ROTARY TORQUE GAUGE REASSEMBLY (PANEL MOUNT). To reassemble the panel
mount gauge assembly; proceed as follows (See Figure 3-6):

a. Insert zero adjust gear (19) into gauge case (50), o-ring (18) over
housing nut (17) and screw housing nut (17) into gauge case (50).
Install o-ring (16) onto idler gear shaft (15) and insert idler gear shaft (15)
through housing nut (17) and zero adjust gear (19). Secure zero adjust gear (19)
to idler gear shaft (15) with setscrew (14).

Secure tubing
b. (30) to damper assembly (46) with connector (31). Place
damper gasket (49) over damper mounting holes on top of gauge case
(50) and install damper (46) by inserting tubing (30) through top of gauge case
(50)and secure damper with two washers (48), two bolts (47); use torque wrench
(Refer to Related Tools and Test Equipment List) and torque bolts (47) 8-10 foot
pounds.

3-13
 INSTRUCTION MANUAL 26-80
FIGURE 3-6. GAUGE ASSEMBLY, ROTARY TORQUE (PANEL MOUNT)
3-14
 INSTRUCTION MANUAL 26-80

LEGEND FOR FIGURE 3-6

1. Tubing 26. Dial

2. Roll Pin 27. Dial Mount
3. Hex Bolt 28. Screw
4. Lockwasher 29. Lockwasher
5. Damper Assembly 30. Tubing
6. Stop Nut 31. Male Connector
7. Screw 32. Bourdon Tube Assembly
8. Cap Plug 33. Tube Mount Screw
9. Elbow 34. O-Ring
10. Knob 35. Linkage Assembly
11. Setscrew 36. Shoulder Screw
12. Drive Assembly 37. Nut
13. Bearing Sleeve 38. Washer
14. Setscrew 39. Movement Assembly
15. Idler Gear Assembly 40. Screw
16. O-Ring 41. Tube Stop
17. Housing Nut 42. Screw
18. O-Ring 43. Lockwasher
19. Zero Adjust Gear 44. Screw
20. Case Ring 45. Seal
21. Screw 46. Junction Block
22. Glass 47. Hex Bolt
23. O-Ring 48. Lockwasher
24. Pointer 49. Damper Gasket
25. Snap Ring 50. Case

[Link] tube stop (41), secure with washer (43) and screw (42)
(tube stop will be adjusted and set during calibration). Prepare
the Bourdon tube (32) for installation by installing movement assembly (39) onto
Bourdon tube (32) and secure with screws (40). Insert screws (36) through linkage
assembly (35), washers (38) and install linkage assembly (35) between slotted end
of movement assembly (39) and Bourdon tube tip (32), secure linkage assembly (35)
with nuts (37) (linkage assembly will be adjusted during calibration); install
assembled Bourdon tube (32) into gauge case (50), and secure with o-rings (34),
screws (33), then connect connector (31).

d. Place dial mount (27) on top of movement assembly (39) and secure with
washer (29) and screw (28). Install pointer (24) onto pinion shaft
(pointer will be properly positioned and secured during calibration).

e. Perform gauge calibration (Refer to Paragraph 3-36).

[Link] bearing sleeve (13) over drive assembly (12); insert drive
assembly (12) from the rear of gauge case (50), until gear teeth
mesh with gear teeth of idler shaft (15). Install o-ring (23), glass (22), case
ring (20) and secure with four screws (21). Place set knob (10) onto protruding
end of drive assembly (12) and secure with setscrew (11). Install male elbow (9)
and cap plug (8).

g. Stand gauge in upright position and fill to within l/4 in. of inner
ring diameter with instrument fluid (Refer to Approved Expendable Items
List), then install seal (45) and screw (44).

3-15
 INSTRUCTION MANUAL 26-80

3-26 LOW PRESSURE GAUGE MOUNT DAMPER DISASSEMBLY. To disassemble the gauge
mount damper (low pressure) proceed as follows (See Figure 3-7).

a. Remove gasket (3), hex plug (4), male connector (5) and low pressure
stem assembly (6 thru 9). Remove o-ring (6), roll pin (7), retainer
nut (8), from damper stem (9).

WARNING

USE TRICHOROETHYLENE IN WELL VENTILATED AREA.

IT IS A FLAMMABLE LIQUID AND FUMES ARE HIGHLY
TOXIC.

b. Clean all metal parts with steel wool and trichoroethylene solvent,
taking care to remove all foreign material, corrosion, etc. Replace
all seals, gaskets, o-rings, worn, damaged, or defective parts.

3-27 LOW PRESSURE GAUGE MOUNT DAMPER REASSEMBLY. To reassemble the gauge
mount damper (low pressure) proceed as follows (See Figure 3-7):

a. Install o-ring (6), retainer nut (8), onto low pressure stem assembly
(9), then install roll pin (7).

b. Insert stem assembly (9) into damper body (10) and secure with
retainer nut (8). Install male connector (5), hex plug (4) and
gasket (3).

FIGURE 3-7. DAMPER ASSEMBLY, LOW PRESSURE (GAUGE MOUNT)

3-16
 INSTRUCTION MANUAL 26-80

LEGEND FOR FIGURE 3-7

1. Hex Bolt 6. O-Ring

2. Lockwasher 7. Roll Pin
3. Damper Gasket 8. Retainer Nut
4. Hex Plug 9. Damper Stem
5. Male Connector 10. Damper Body

3-28 LOW PRESSURE PANEL MOUNT DAMPER DISASSEMBLY. To disassemble the panel
mount damper (low pressure) proceed as follows (See Figure 3-8):

a. Remove hex plug (3), male connector (4), remove stem assembly (5 thru
8). Remove o-ring (5), roll pin (6), retainer nut (7), from damper
stem (8).

WARNING

USE TRICHOROETHYLENE IN WELL VENTILATED AREA.

IT IS A FLAMMABLE LIQUID AND FUMES ARE HIGHLY
TOXIC.

b. Clean all metal parts with steel wool and trichoroethylene solvent,
taking care to remove all foreign material, corrosion, etc. Replace
all o-rings, worn, damaged or defective parts.

3-29 LOW PRESSURE PANEL MOUNT DAMPER REASSEMBLY. To reassemble panel mount
damper (low pressure), proceed as follows (See Figure 3-8):

a. Install o-ring (5), retainer nut (7) onto damper stem (8), then
install roll pin (6). Install damper body (9) into console and
secure with two washers (2), and two bolts (1).

b. Insert stem assembly (5 thru 8) into damper body (9) and secure
with retainer nut (7).

3-30 LINKAGE DISASSEMBLY. To disassemble the linkage assembly; proceed as

follows (See Figure 3-9):

a. Remove two nuts (l), two shoulder screws (3,4), two washers (2), two
nuts (5), two washers (6) and slide bar (7).

WARNING

USE TRICHOROETHYLENE IN WELL VENTILATED AREA.

IT IS A FLAMMABLE LIQUID AND FUMES ARE HIGHLY
TOXIC.

b. Clean all parts with steel wool and trichoroethylene solvent, taking
care to remove all foreign material, corrosion, etc. Discard all
worn, damaged or defective parts.

3-17
 INSTRUCTION MANUAL 26-80

FIGURE 3-8. DAMPER ASSEMBLY, LOW PRESSURE (PANEL MOUNT)

LEGEND FOR FIGURE 3-8

1. Hex Bolt 6. Roll Pin

2. Lockwasher 7. Retainer Nut
3. Hex Plug 8. Damper Stem
4. Male Connector 9. Damper Body
5. O-Ring

LEGEND FOR FIGURE 3-9

1. Nut 6. Washer
2. Washer 7. Linkage Slide Bar
3. Shoulder Screw 8. Linkage Bar
4. Shoulder Screw 9. Screw
5. Stop Nut

3-18
 INSTRUCTION MANUAL 26-80

FIGURE 3-9. LINKAGE ASSEMBLY (SHORT)

3-31 LINKAGE REASSEMBLY. To reassemble the linkage assembly; proceed as follows

(See Figure 3-9):

a. Place slide bar (7) on top of linkage (8) with slotted end over ad-
justing weldment screws (9); secure with two washers (6), and two
nuts (5). Install washers (2), shoulder screws (3)(4) and nuts (1).

3-32 CYLINDER DISASSEMBLY. To disassemble the cylinder, proceed as follows

(See Figure 3-10):

WARNING

DO NOT APPLY MORE THAN 20 PSIG HYDRAULIC PRESSURE

TO CYLINDER. IF FRICTION SHOULD BREAK LOOSE TOO
RAPIDLY, PISTON COULD CAUSE PERSONNEL INJURY OR
EQUIPMENT DAMAGE.

[Link] piston (3), o-ring (5), seal (4), pipe plug (1) and elbow (2).
If piston (3) is extremely difficult to remove, connect idler hose
(3, Figure 3-4) to cylinder elbow (2, Figure 3-10); connect hydraulic hand pump
to idler hose and apply approximately 20 psig to cylinder to extract piston. Re-
move the hose. If piston (3) cannot be extracted with 20 psig, replace cylinder
assembly.

[Link] all metal parts with steel wool or a wire brush, taking care not
to damage any moving parts. Remove all foreign material, corrosion,
etc. Replace all o-rings, seals, and worn, damaged or defective parts.

3-19
 INSTRUCTION MANUAL 26-80

FIGURE 3-10. CYLINDER ASSEMBLY

LEGEND FOR FIGURE 3-10

1. Pipe Plug 5. O-Ring

2. Elbow 6. Pin
3. Piston 7. Cylinder Body
4. Seal

3-33 CYLINDER REASSEMBLY. To reassemble the cylinder, proceed as follows

(See Figure 3-10):

a. Lubricate and install o-ring (5), presfit seal (4) (tapered end of
seal must be to the bottom end of piston), elbow (2); stand piston (3)
in an upright position; fill with red instrument fluid (Refer to Approved Expendable
Items List). Press cylinder body (7) over piston (3). Install pipe plug (1).

b. With cylinder repaired and serviced, it must be purged. Connect

idler hose (3, Figure 3-4) to elbow (2, Figure 3-10); connect hy-
draulic hand pump to idler hose and install pipe plug (1) but do not tighten.
Apply hydraulic pressure with hand pump until air free hydraulic fluid escapes
from pipe plug (1). Tighten pipe plug (1) and remove hand pump.

3-20
 INSTRUCTION MANUAL 26-80

3-34 CALIBRATION

3-35 GENERAL. If equipment or components are suspected of being out of

tolerance or operating imporperly, testing, adjustment and/or calibra-
tion may be required to ensure proper operation. There is no complete system
calibration required for the rotary torque system; however, the gauges must be
calibrated. Calibration procedures given in this section are applicable to both
rotary torque gauges (Bracket and Panel Mount).

3-36 INDICATING GAUGE. To calibrate the rotary torque indicating gauge, place
on a clean work bench; proceed as follows:

[Link] case ring screw (3, Figure 3-5), case ring (2), glass (4),
and o-ring (5). Using pointer puller (Refer to Related Tools
and Test Equipment) remove pointer (6). Remove snap ring (7), dial (8), and drain
gauge dampening fluid into an approve waste container. Loosen screws (23) securing
maximum stop (22); loosen linkage attaching nuts (13).

b. Remove setscrews (11, Figure 3-6), front zero adjust knob (lO)(panel
mount gauge only), case ring screws (21), case ring (20), glass (22),
and o-ring (23). Using pointer pullers (Refer to Related Tools and Test Equipment),
remove the pointer (24). Remove snap ring (25), dial (26), and drain instrument
fluid into an approved waste container. Loosen screws (35) securing maximum stop
(34); loosen linkage attaching nuts (31).

C. Install elbow, hex nipple and/or male quick-disconnect (Refer to

Related Tools and Test Equipment) into damper assembly (27, Figure
3-5)(bracket mount gauge) or junction block (46, Figure 3-6)(panel mount gauge).
On bracket mount gauge, turn damper stem to full open. Remove plug (1, Figure 3-5)
from damper (27) of bracket mounted gauge; remove elbow (9, Figure 3-6) from
junction block (46) of panel mounted gauge. Connect vacuum pump assembly (Refer
to Related Tools and Test Equipment) to damper (27, Figure 3-5)(bracket mounted
gauge) or junction block (46, Figure 3-6)(panel mounted gauge). Evacuate all
entrained air from the Bourdon tube; then reload it. Once the Bourdon tube has
been evacuated and loaded, remove the gauge from the vacuum pump assembly and
place it on a clean work bench; proceed as follows (See Figure 3-11).

d. Center the linkage (13) on the slotted end of the Bourdon tube tip (11)
and on the slotted end of the movement quadrant, (14). Adjust the
linkage so that the quadrant arm (9) is parallel with top plate of the movement
assembly. Tighten linkage slide nuts (10) and attaching screws (15).

e. Install test dial (2) and center it over mounting holes (do not install
dial mounting hardware). Check pointer pinion shaft; it should be
in the exact center of the hole in the dial face (1). If not centered, remove
dial (2). Loosen movement mounting screws (6) and position the movement (8) to
a position that will center pointer pinion shaft (7) when the dial (2) is installed.
Repeat the above procedure until pointer pinion shaft is centered.

f. Connect the gauge to the high pressure test bench (Refer to Related
Publications) using the special hardware supplied (elbow, hex nipple or
male quick-disconnect)(Refer to Related Tools and Test Equipment). Check the damper
assembly on the bracket mount gauge (not required on panel mount gauge); it should
be in the full open position.

3-21
 WITH N O PRESSURE O N TEST SYSTEM
SPOT POINTER 2’ BEHIND ZERO. 1358’1
NOTE THAT ZERO STOP IS LOOSE.
I I

-58 DEGREES
MOVE QUADRANT NO MOVE QUADRANT
END OF LINKAGE
TO START CALIBRATION TOWARD GAUGE
CENTER LOW
CENTER LINKAGE ON TUBE TIP
STEP 1 STEP 2
CENTER LINKAGE ON QUADRANT YES
WITHIN 0 5% FS
ADJUST LINKAGE LENGTH SO
THAT QUADRANT ARM IS
PARALLEL WITH TOP PLATE

NOTE
ENSURE THAT MOVEMENT PINION
SHAFT IS AT CENTER OF GAUGE

0 \ ++PARALLEL TO STAR T
SHORTEN LINKAGE
L O R MOVE TUBE END
OF LINKAGE AWAY
i FROM GAUGE CENTER

STEP 3

NEVER USE SOLDER

/
TO START
CENTER LINKAGE
x1 13
Tb START
CENTER LINKAGE
ON BOURDON TUBE
ON MOVEMENT QUADRANT ” TIP
 INSTRUCTION MANUAL 26-80

LEGEND FOR FIGURE 3-11

1. Dial Face Center 9. Movement Quadrant Arm

2. Dial 10. Linkage Slide Nuts
3. Pointer 11. Bourdon Tube Tip
4. Case 12. Maximum Stop
5. Case Ring Mounting Screw 13. Linkage
Holes 14. Slotted End of Movement
6. Movement Mounting Screws Quadrant
7. Pointer Pinion Shaft 15. Linkage Attaching Screws
8. Movement Assembly

NOTE

If damper is not fully open, gauge will give

incorrect readings.

g. Ensure that a calibrated master test gauge is installed on the high

pressure test bench and zeroed. Check gauge under test for full
scale range and determine calibration pressure.

NOTE

Calibration pressure for rotary torque gauge

equals full scale range of the dial. Example:
gauge dial inidcates O-500 units, calibration
pressure equals 500 psig for full scale in-
dication.

h. Install calibration dial (Refer to Related Tools and Test Equipment)

with zero at the extreme bottom of the gauge (six o'clock position),
and install the pointer (3) 2' behind zero.

NOTE

Any time the linkage is moved after step h.

has been completed, reset the calibration
dial so that the pointer remains 2' behind
zero; do not reset the pointer.

1. Once calibration pressure has been determined, divide it into four

equal parts and determine calibration pressure at 90° (l/4 scale),
180° (l/2 scale), 270' (3/4 scale) and 360° (full scale). Apply calibration
pressure for 90' (l/4 scale) indication and compare master test gauge indication
with gauge under test indication; now apply calibration pressure for 180° (l/2
scale) indication. If the indication is less than 88' (l/4 scale) and 178O (l/2
scale), release the pressure and loosen screw (15) that attaches the linkage (13)
to the movement quadrant (14); move that end of the linkage (13) toward gauge
center. If the indication is above 92' (l/4 scale) and 182' (l/2 scale), move
that end of the linkage away from gauge center. Tighten screw (15), recheck
calibration at 90° (l/4 scale) and 180° (l/2 scale).

3-23
 INSTRUCTION MANUAL 26-80

NOTE

After any adjustment, check to ensure that

linkage is not binding.

j. Apply calibration pressure for 270° (3/4 scale) indication and compare
master test gauge indication with gauge under test indication; now
apply calibration pressure for 360' (full scale) indication. If the indication
is less than 268' (3/4 scale) and 358O (full scale)(Step 3, Figure 3-ll), release
the pressure and loosen the linkage slide nuts (10) and shorten the linkage (13).
If the indication is above 272' (3/4 scale) and 362O (full scale)(Step 4, Figure
3-U), lengthen the linkage (13). Tighten linkage slide nuts (10) and recheck
calibration.

k. Gauge accuracy must be within + l/2 of full scale indication. Example,

full scale reading equals 1,000 units of torque, +1/Z% of 1,000 equals
50, gauge must indicate between 950-1050 units. If gauge accuracy is not within
tolerance, repeat calibration procedures.

1.
Release the pressure, remove pointer (3), and with zero pressure
applied, reinstall the pointer (3) 45' behind zero position (pointer
tip should be at the four o'clock position), aligned with case ring mounting screw
hole (5); press pointer down un;il snug. Apply pressure until pointer (3) makes
one complete revolution plus 90 (450° of pointer travel). The pointer should
stop 45 ahead of the six o'clock position. Set the maximum stop (12) at this
position.

m. Release the pressure, remove calibration dial and pointer (3). Install
the gauge dial (2) and secure with snap ring; install the pointer (3)
45' behind zero (pointer tip should be at the four o'clock position); aligned with
case ring mounting screw hole (5); press pointer down until snug. Use automatic
center punch (Refer to Related Tools and Test Equipment) to stake pointer (3) on
pinion shaft. Pointer hub should be flush with pinion end, not to exceed 0.03 in.
maximum. Recheck calibration; remove special hookup connections and complete gauge
reassembly (Refer to Paragraph 3-23, f.).

3-37 Rotary torque gauge has been repaired, tested, adjusted, calibrated, re-
loaded, and now it is ready for reinstallation.

3-24
 INSTRUCTION MANUAL 26-80
SECTION IV
TROUBLESHOOTING

4-l GENERAL. The indicating gauge serves as a good troubleshooting device.

No indication, or erroneous indications on the gauge, will define the
major trouble areas. A list of probable causes for the troubles is given in
Table 4-l. Under normal operating conditions, and with proper care, few troubles
will be encountered with the rotary torque system.

NOTE
If troubleshooting reveals that there is in-
sufficient hydraulic fluid in the system, before
reloading the system, check that all system com-
ponents are free of damage. This will ensure that
fluid loss will not continue after reloading.

TABLE 4-l. TROUBLESHOOTINGTABLE

TROUBLE PROBABLE CAUSE

No indication on gauge. Obstruction in hose.

Loss of hydraulic fluid.
Idler assembly improperly positioned.
Gauge internal mechanism damaged.
Damper closed.

Gauge indication too high. Idler assembly improperly positioned.

Incorrect zero dial setting.
Excessive hydraulic fluid.
Gauge internal mechanism damaged.

Gauge indication too low. Idler assembly improperly positioned.

Incorrect zero dial setting.
Insufficient hydraulic fluid.
Gauge internal mechanism damaged.

Erratic or sluggish gauge indication. Improper pointer damper adjustment.

Pointer rubbing glass or dial.
Insufficient hydraulic fluid.
Sticky gauge movement.
Gauge internal mechanism damaged.
Air in system.

Rapid deterioration of idler wheel. Improper alignment of idler assembly.

Excessive fluid preload.
Defective chain.

4-l/4-2