PM-3000 Pragma Pipe-Matic 3000 Assembly Manual Rev 01

PRAGMA PIPE-MATIC 3000
ASSEMBLY MANUAL
1.0
TABLE OF CONTENTS
1.0 TABLE OF CONTENTS........................................................................................ 3 2.0 INTRODUCTION .................................................................................................. 6 3.1 CATWALK......................................................................................................... 8 3.1.1 INDEXERS................................................................................................. 9 3.1.1.1 INDEXER PREPERATION WORK................................................... 11 3.1.1.2 INDEXER ASSEMBLY....................................................................... 11 3.1.2 PIPE RACKS ............................................................................................ 14 3.1.2.1 PIPE RACK ARM PREPARATION WORK ...................................... 16 3.1.2.2 PIPE RACK ARM ASSEMBLY.......................................................... 16 3.1.3 STAIRS..................................................................................................... 20 3.1.3.1 SHORT LANDING DECK STAIRS.................................................... 21 3.1.3.1.1 SHORT LANDING DECK ASSEMBLY ...................................... 22 3.1.3.2 PIVOTING DECK STAIRS ................................................................. 24 3.1.3.2.1 PIVOTING DECK STAIRS ASSEMBLY..................................... 24 3.1.4 REAR POSTS.......................................................................................... 25 3.1.4.1 REAR POST ASSEMBLY................................................................... 26 3.1.5 VERTICAL GUIDE STRIP ..................................................................... 27 3.1.5.1 VERTICAL GUIDE STRIP ASSEMBLY ........................................... 27 3.1.6 GORETRAC ............................................................................................. 28 3.1.6.1 GORETRAC ASSEMBLY................................................................... 30 3.1.7 SPEAR ...................................................................................................... 34 3.1.7.1 SPEAR ASSEMBLY............................................................................ 35 3.1.8 LASER EYE GUARD.............................................................................. 36 3.1.8.1 LASER EYE GUARD ASSEMBLY.................................................... 38 3.1.9 HYDRAULIC POWER PACK ............................................................... 39 3.1.9.1 HYDRAULIC POWER PACK ASSEMBLY ..................................... 41 3.1.10 ELECTRICAL BOX................................................................................ 44 3.1.10.1 ELECTRICAL BOX ASSEMBLY .................................................. 46 3.1.11 RESERVOIR ............................................................................................ 47 3.1.11.1 RESERVOIR ASSEMBLY .............................................................. 50 3.1.12 ELECTRICAL CONTROL BOX............................................................. 61 3.1.12.1 ELECTRICAL CONTROL BOX ASSEMBLY .............................. 62 3.1.13 RESERVOIR CASING ............................................................................ 63 3.1.13.1 RESERVOIR CASING ASSEMBLY .............................................. 64 3.1.14 HYDRAULIC COOLER .......................................................................... 65 3.1.14.1 HYDRAULIC COOLER ASSEMBLY............................................ 66 3.1.15 HIGH PRESSURE FILTER ..................................................................... 67 3.1.15.1 HIGH PRESSURE FILTER ASSEMBLY....................................... 68 3.1.16 HYDRAULIC VALVE BANK ................................................................ 69 3.1.16.1 HYDRAULIC VALVE BANK ASSEMBLY.................................. 70 3.2 CARRIER ......................................................................................................... 71 3.2.1 KICKERS ................................................................................................ 72 3.2.1.1 KICKER PREPERATION WORK ...................................................... 74 3.2.1.2 KICKER ASSEMBLY ......................................................................... 74
3.2.2 SAFETY PINS.......................................................................................... 76 3.2.2.1 SAFETY PIN PREPERATION WORK.............................................. 78 3.2.2.2 SAFETY PIN ASSEMBLY................................................................. 78 3.2.3 FLANGE ROLLER WHEELS ................................................................. 82 3.2.3.1 FLANGE ROLLER WHEEL ASSEMBLY......................................... 83 3.2.4 SHEAVE................................................................................................... 84 3.2.4.1 SHEAVE ASSEMBLY ....................................................................... 86 3.2.5 LIFET ARM PILLOW BLOCKS............................................................. 89 3.2.5.1 LIFET ARM PILLOW BLOCKS ASSEMBLY .................................. 91 3.2.6 SKATE...................................................................................................... 92 3.2.6.1 SKATE ASSEMBLY ........................................................................... 94 3.2.7 CABLE BLOCK....................................................................................... 97 3.2.7.1 CABLE BLOCK ASSEMBLY............................................................ 98 3.2.8 ROPE DEFLECTOR .............................................................................. 100 3.2.8.1 ROPE DEFLECTOR ASSEMBLY.................................................... 102 3.2.9 OVERSHOOT DOGS ............................................................................ 103 3.2.9.1 OVERSHOOT DOGS ASSEMBLY .................................................. 105 3.2.10 TAPERED ROLLERS............................................................................ 106 3.2.10.1 TAPERED ROLLERS ASSEMBLY ............................................. 107 3.2.11 V-ROLLER............................................................................................. 108 3.2.11.1 V-ROLLER ASSEMBLY .............................................................. 109 3.2.12 CABLE GUIDE ...................................................................................... 110 3.2.12.1 CABLE GUIDE ASSEMBLY........................................................ 111 3.2.13 SKATE STOPS...................................................................................... 112 3.2.13.1 SKATE STOP ASSEMBLY........................................................... 113 3.2.14 HYDRAULIC VALVE BANK .............................................................. 114 3.2.14.1 HYDRAULIC VALVE BANK ASSEMBLY............................... 115 3.2.15 SKATE DRIVE MOTOR ....................................................................... 116 3.2.15.1 SKATE DRIVE MOTOR ASSEMBLY......................................... 118 3.2.16 SKATE WINCH ..................................................................................... 121 3.2.16.1 SKATE WINCH ASSEMBLY....................................................... 123 3.2.17 SKATE DRIVE CABLE ........................................................................ 131 3.2.17.1 SKATE DRIVE CABLE ASSEMBLY .......................................... 132 3.3 LIFT ARM ..................................................................................................... 135 3.3.1 POCKET ROLLERS .............................................................................. 136 3.3.1.1 POCKET ROLLER ASSEMBLY ...................................................... 136 3.3.2 PILLOW BLOCKS................................................................................ 137 3.3.2.1 PILLOW BLOCK ASSEMBLY......................................................... 137 3.3.3 BREARING PADS................................................................................. 138 3.3.3.1 BREARING PAD ASSEMBLY......................................................... 138 3.4 RAMP ............................................................................................................. 139 3.4.1 LIFT WINCH.......................................................................................... 140 3.4.1.1 LIFT WINCH ASSEMBLY ............................................................... 141 3.4.2 SHEAVE................................................................................................. 146 3.4.2.1 SHEAVE ASSEMBLY ..................................................................... 148 3.4.3 TOP CARRIER ROLLER ...................................................................... 150
3.4.3.1 TOP CARRIER ROLLER ASSEMBLY............................................ 152 3.5 FINAL ASSEMBLY ...................................................................................... 154 3.5.1 LIFT ARM CARRIER......................................................................... 155 3.5.1.1 LIFT ARM CARRIER ASSEMBLY .............................................. 156 3.5.2 LIFT ARM CATWALK ...................................................................... 157 3.5.2.1 LIFT ARM CATWALK ASSEMBLY............................................ 158 3.5.3 RAMP CATWALK ............................................................................. 159 3.5.3.1 RAMP CATWALK ASSEMBLY................................................... 160 3.6 ELECTRICAL COMPONENTS ................................................................... 161 3.6.1 ELECTRICAL SYSTEM PARTS LIST ............................................... 162 3.6.1.1 600V PARTS LIST............................................................................. 162 3.6.1.2 480V PARTS LIST............................................................................. 164 3.6.2 ELECTRICAL SCHEMATICS............................................................. 166 3.7 HYDRAULIC SYSTEM ............................................................................... 183 3.7.1 HYDRAULIC CYLINDERS.................................................................. 184 3.7.2 HYDRAULIC BULKHEADS................................................................ 185 3.7.3 PIPE RACK ARM HYDRAULICS ....................................................... 186 3.7.4 HOSE CLAMPS ..................................................................................... 187 3.7.5 HYRDRULIC SCHEMATICS................................................................. 2
2.0
INTRODUCTION
The PRAGMA PIPE-MATIC 3000 is a power catwalk used to move tubulars and tools between the pipe rack area and the drilling floor. This manual has been prepared to help assemble the PIPE-MATIC 3000. It consists of four sub assemblies including the CATWALK, RAMP, CARRIER and LIFT ARM. Step by step procedures of each sub assembly will explain how to install mechanical, hydraulic, and electrical components. Furthermore, this manual will explain how to connect these four sub-assemblies into a final and complete assembly of the PIPE-MATIC 3000.
Fig. 2.0.0.1 PIPE-MATIC 3000
The CATWALK is the base of the PIPE-MATIC 3000 and is the largest of the subassemblies. Its major components include six sets of hydraulic pipe racks, six sets of indexers, hydraulic reservoir, hydraulic valve bank, hydraulic cooler, control box, pump and motor. The CATWALK also consists of a large portion of hydraulic plumbing, electrical wiring and many smaller components. The CARRIER is used to carry tubulars and tools to and from the drill floor. The major components of the CARRIER include six kickers, six safety pins, the V-roller axle, sheave, skate drive motor, skate winch, skate cable and the skate. The CARRIER also consists of many smaller components, along with a hydraulic system, electrical system and control box.
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The RAMP is hinged to the CATWALK and rotates up to rest on the drilling floor during operation. The major component is the carrier lift winch mounted on the back side of the RAMP. It is used to drive the CARRIER during operation. The ramp also includes the top carrier roller, sheave, along with hydraulic and electrical components. The LIFT ARM connects the CARRIER to the CATWALK, supporting the flare end of the CARRIER during operation. The LIFT ARM consists of pocket rollers, the hinge pin, bearing pads, slide plate and hydraulic hinges. Three tubes run the length of the lift arm. These are used for the hydraulic and electrical systems, however, they are not hooked up until the sub assemblies are being connected.
3.1
CATWALK
The catwalk is the base of the PIPE-MATIC 3000 and is the largest of the sub assemblies. Its major components include six sets of hydraulic PIPE RACKS, six sets of INDEXERS, HYDRAULIC RESERVOIR, HYDRAULIC VALVE BANK, ELECTRICAL BOX, PUMP and MOTOR. The catwalk also consists of a large portion of hydraulic plumbing, electrical wiring and many smaller components.
Fig. 3.1.0.1 CATWALK
The CATWALK houses the CARRIER when the CARRIER is in the down position. The INDEXERS and PIPE RACKS are used to move and store pipes. The HYDRAULIC RESERVOIR, MOTOR, PUMP, ELECTRICAL BOX and HYDRAULIC VALVE BANK are all housed within the CATWALK on the drillers side flare end.
3.1.1 INDEXERS
There are six INDEXERS located on the CATWALK, three on the drillers side and three on the off drillers side. Each is attached to two hydraulic cylinders and these cylinders are attached to the base of the CATWALK. One hydraulic cylinder attaches to the outside of the CATWALK while the other is attached to the inside of the CATWALK. These INDEXERS are used to move pipes from the PIPE RACKS to the CARRIER and vice versa.
Fig. 3.1.1.1 INDEXER
ITEM 1 2 3 4 5 6 7 8
DESCRIPTION INDEXER INDEXER CYLINDER HYDRAULIC RAM BLOCK PIN INDEXER PIN 1.0" FLAT WASHER 1/8" COTTER PIN 5/16"-18x2.25" HEX BOLT 5/16"-18 NYLON LOCK NUT NUT
PART# 131100046 PPM-0201003 161100012 161100075 FW 1.0 COTTER PIN 0.125 HBOLT 0.312518x2.25x0.875-N NYLOK 0.3125-18-D-N
QUANTITY PER UNIT 1 2 1 3 2 2 3 3
TOTAL QUANTITY 6 12 6 18 12 12 18 18
Fig. 3.1.1.2 INDEXER EXPLODED
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3.1.1.1
-
INDEXER PREPERATION WORK

Clean all grooves and holes, be sure to remove all paint and debris. Wipe clean with rag. Test fit all INDEXER PINS and HYDRAULIC RAM PINS, make sure PINS fit firmly into their proper holes. Once PINS are properly fit, test fit INDEXERS. Grind off any slight contact or rubbing. If contact is large or abnormal, alert supervisor and wait for instruction. Once all components are test fitted, dismantle all assemblies.
3.1.1.2
INDEXER ASSEMBLY
There are six INDEXERS for each PIPE-MATIC, therefore this assembly must be carried out six times. 1. Insert two INDEXER PINS, each through the INDEXER and the top of each INDEXER CYLINDER. Be sure that INDEXER CYLINDER are attached so that the hydraulic caps point towards the outside of the catwalk. 2. Align and insert a 5/16-18 x 2 Bolt with each SET COLLAR. Attach a 5/16-18 Nylon Lock Nut to the end of each bolt and tighten.
Fig. 3.1.1.3 INDEXER WITH CYLINDERS

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3. Place INDEXERS with attached Hydraulic Pistons into proper location on CATWALK base. 4. Align outer Hydraulic Cylinder with CATWALK, insert INDEXER PIN through Cylinder and CATWALK base. 5. Align a 5/16-18 x 2 1/4 Bolt with SET COLLAR and insert. Attach a 5/16-18 Nylon Lock Nut and tighten appropriately.
Fig. 3.1.1.4 OUTER HYDRAULIC CYLINDER
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6. Align inner Cylinder with CATWALK; insert HYDRAULIC RAM BLOCK PIN through CATWALK and Cylinder. 7. Slip 1 Flat Washer over each end of the HYDRAULIC RAM BLOCK PIN.
8. Insert Cotter Pins through each end of HYDRAULIC RAM BLOCK PIN.
Fig. 3.1.1.5 INNER HYDRAULIC CLYLINDER
9. Grease each PIN in the KICKER assembly using a grease gun.
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3.1.2
PIPE RACKS
There are six PIPE RACKS which are attached to the base of the CATWALK, three on the drillers side and three on the off drillers side. They are attached with a ball joint and are able to swing outwards at a 90 from the base of the CATWALK while in use. The main component of the PIPE RACK is the PIPE RACK ARM. On the tip of the PIPE RACK ARM, a Hydraulic Cylinder is attached to a round flat JACK PAD. The JACK PAD is to be rested on the ground while the Cylinder moves the tip of the PIPE RACK ARM up and down. The PIPE RACK is used to store pipe while not in use. The movement of the piston changes the slope of the PIPE RACK ARMS allowing pipe to roll towards or away from the base of the CATWALK depending on the current application.
Fig. 3.1.2.1 PIPE RACK ARM
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ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
DESCRIPTION JACK PAD 5/16" - 16 x 4 1/2" HEX BOLT 3/8" FLAT WASHER 3/8"-16 NYLON LOCK NUT FOOT CYLINDER 1.5OD 1.25ID X 2" OILITE BUSHING 3/4" FLAT WASHER CYLINDER MOUNT SPACER 3/4"-10 X 8" THREADED ROD 3/4"-10 NYLON LOCK NUT 3/4" LOCK WASHER PIPE RACK PIN 5/16" - 18 X 2 1/4" HEX BOLT 5/16" - 18 NYLON LOCK NUT PIPE RACK ARM 1/8" GREASE FITTING 5/8"-11 X 2 1/4" HEX BOLT 5/8" LOCK WASHER ARM RETAINING PLATE 5/8" FLAT WASHER 5/8"-11 NYLON LOCK NUT
PART# 131100057 HBOLT 0.750-16x4.5x1-N FW 0.375 NYLOK T 0.3750-16-D-N PPM-02-I004 55-4048-32 FW 0.75 152100024 .75 INCH THREADED ROD NYLOK .7500-10-D-N LW 0.75 161100016 HBOLT 0.3125-18x1x0.875-N NYLOK 0.3125-18-D-N 131100050 GREASE FITTING 0.125 HBOLT 0.6250-11-D-N LWASHER 0.625 131100087 FW 0.625 NYLOK 0.6250-11-D-N
QUANTITY PER UNIT 1 2 4 2 1 2 2 1 1 2 1 1 1 1 1 1 6 6 1 6 6
TOTAL QUANTITY 6 12 24 12 6 12 12 6 6 12 6 6 6 6 6 6 36 36 6 36 36
Fig. 3.1.2.2 PIPERACK ARM EXPLODED
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3.1.2.1
-
PIPE RACK ARM PREPARATION WORK

Clean off ball joints and sockets including CATWALK-PIPE RACK ARM joint as well Hydraulic- JACK PAD joints. Clean out all pin holes. Be sure to remove all paint and debris, then wipe clean with rag. Use grease to lubricate sockets thoroughly.
3.1.2.2
PIPE RACK ARM ASSEMBLY
1. Using crane, lift PIPE RACK ARM into place, connecting the socket joint of the ARM to the ball on the CATWALK base. 2. Align arm retainer plate with pipe rack arm. Bolt into place using six 5/8-11 x 2 Hex Bolt with 5/8 Lock Washers, while using a 5/8 Flat Washer and 5/8-11 Nylon Lock Nut on the end of each Bolt.
Fig. 3.1.2.3 PIPE RACK ARM - CATWALK
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3. Screw in a 1/8 Grease Nozzle to the ball and socket joint connecting the PIPE RACK ARM to the base of the CATWALK. 4. Attach Hydraulic Pistons to JACK PADS by aligning ball and socket. Insert two 3/8-16 x 3 Bolts with 3/8 Flat Washers into the two parallel holes provided in the jack pad. Insert 3/8-16 Nylon Lock Nuts and 3/8 Flat Washers onto the end of the Bolts, tighten appropriately. 5. Insert two 1.5OD 1.25ID X 2 OILITE BUSHINGS inside the pin hole of each Hydraulic Foot Cylinder.
Fig. 3.1.2.4 JACK PAD AND CYLINDER
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6. Using the crane for support, rotate the attached pipe rack arm away from the CATWALK base and lower the unattached end. Place Hydraulic Cylinder with JACK PAD on the ground and align with PIPE RACK ARM. Be sure that the plugs on the Hydraulic Piston point out towards the tip of the PIPE RACK ARM.
Fig. 3.1.2.5 CLYINDER ALIGNED WITH PIPE RACK ARM 7. Insert PIPE RACK PIN. Use a 5/16-18 x 2 Bolt to hold in place and tighten with 5/16-18 Nylon Lock Nut. Lift pipe rack arm back into upright position adjacent to the CATWALK onto ledges and remove crane support.
Fig. 3.1.2.6 CYLINDER PIN
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8. Align CYLINDER MOUNT SPACER with PIPERACK ARM and insert THREADED ROD. On the outer side, attach a Flat Washer; Lock Washer and Nylon Lock Nut to the THREADED ROD along with a Washer and Nut to the inner side of the THREADED ROD. Tighten accordingly.
Fig. 3.1.2.7 CYLINDER MOUNT SPACER
9.
Grease each pin and ball joint using a grease gun.
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3.1.3
STAIRS
There are two sets of STAIRS that connect to the CATWALK, the SHORT LANDING DECK STAIRS and the PIVOTING DECK STAIRS. The SHORT LANDING DECK STAIRS are attached to the drillers side at the ramp end of the catwalk while the PIVOTING DECK STAIRS are attached to the off drillers side at the flare end of the CATWALK.
Fig. 3.1.3.1 SHORT LANDING STAIRS
Fig. 3.1.3.2 PIVOTING DECK DECK STAIRS
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3.1.3.1
SHORT LANDING DECK STAIRS

QUANTITY PER UNIT 1 4 12 2 4
ITEM 1 2 3 4 5
DESCRIPTION SHORT LANDING DECK STAIR HEX BOLT 3/4"-10 X 3 1/2" FLAT WASHER 3/4" STAIR IDLER PLATE NYLON LOCK NUT 3/4"-10
PART# 131100169 HBOLT 0.750010x3.5x1.75-N FW 0.75 141100387 NYLOK 0.7500-10-D-N
Fig. 3.1.3.3 SHORT LANDING DECK STAIRS EXPLODED
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3.1.3.1.1
SHORT LANDING DECK ASSEMBLY
The SHORT LANDING DECK STAIRS are attached to the CATWALK on the drillers side at the ramp end. 1. Lift the SHORT LANDING DECK STAIRS onto the CATWALK and so that the STAIRS are upside down. 2. Align the STAIR IDLER PLATE with the STAIRS along with a Flat Washer in between. Slide a Flat Washer over a x Bolt and insert through the stair side, adding a Flat Washer and -10 Nylon Lock Nut to the exterior end. Repeat this step with an IDLER PLATE on the opposite side of the STAIRS.
Fig. 3.1.3.4 IDLER PLATE
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3. Align the STAIR IDLER PLATE with the CATWALK with a Flat Washer between the two. Slide a Flat Washer over a x Bolt and insert through the IDLER PLATE side, adding a Flat Washer and Nylon Lock Nut to the exterior end. Repeat this step to attach the opposite side of the stairs.
Fig. 3.1.3.5 SHORT LANDING STAIRS - CATWALK
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3.1.3.2
PIVOTING DECK STAIRS

QUANTITY PER UNIT 1 2 4
ITEM 1 2 3
DESCRIPTION PIVOTING DECK STAIR STAIR HINGE PIN 1/8 COTTER PIN
PART# 131100326 161100035 COTTER PIN 0.125
Fig. 3.1.3.6 PIVOTING DECK STAIRS EXPLODED
3.1.3.2.1
PIVOTING DECK STAIRS ASSEMBLY
The PIVOTING DECK STAIRS are attached to the CATWALK on the off drillers side at the flare end. 1. Align the PIVOTING DECK STAIRS with the CATWALK. Insert the two STAIR HINGE PINS through the CATWALK and Stairs. Insert four 1/8 COTTER PINS, two through each of the STAIR HINGE PINS to hold assembly together.
2.
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3.1.4
REAR POSTS
There are two posts which must be attached to the flare end of the CATWALK, the REAR BUMPER POST and the PULLER POST.
QUANTITY PER UNIT 1 1 2 2 4 2
ITEM 1 2 3 4 5 6
DESCRIPTION REAR BUMPER POST PULLER POST 3/4"-10 X 7 1/4" HEX BOLT 3/4" LOCK WASHER 3/4" FLAT WASHER 3/4"-10 NYLON LOCK NUT
PART# 131100047 131100143 HBOLT 0.7500-10x7.25x2-N LW 0.75 FW 0.75 NYLOK 0.7500-10-D-N
Fig. 3.1.4.1 REAR POSTS EXPLODED
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3.1.4.1
REAR POST ASSEMBLY
Each post is assembled similarly with the REAR BUMPER POST on the off drillers side and the PULLER POST on the drillers side as shown in figure 3.1.4.1. Repeat the following steps for each post. 1. Raise POST into place with crane and insert into the correct hole at the flare end of the CATWALK base. The proper orientation of the POST can be seen from figure 3.1.4.1. Align the bolt holes in the POST with the bolt holes in the base of the CATWALK. 2. Slide a Lock Washer, then a Flat Washer over the threads of a -10 x 7 Bolt. Insert Bolt through the CATWALK and POST to hold POST into place. The Bolt should be slid in from the outer side of the POST. 3. Slide a Flat Washer and -10 Nylon Lock Nut over the end of the Bolt. Tighten appropriately.
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3.1.5
VERTICAL GUIDE STRIP

The VERTICAL GUIDE STRIP is attached to the CATWALK near the ramp end. The STRIP is a plate of UHMW plastic which serves as a bumper for the GORETRAC and SPEAR to prevent contact between them and the CATWALK.
ITEM 1 2 3 4
DESCRIPTION VERTICAL GUIDE STRIP 3/8"-16 X 1 1/14" SOCKET HEAD COUNTER SUNK SCREW 3/8"-16 NYLON LOCK NUT 3/8" LOCK WASHER
PART# 141500005 SCHCSCREW 0.375-16x1.25x1.25-HX-N NYLOCK 0.3750-16-D-N LW 0.375
QUANTITY PER UNIT 1 10 10 10
Fig. 3.1.5.1 VERTICAL GUIDE STRIP EXPLODED
3.1.5.1
1.
VERTICAL GUIDE STRIP ASSEMBLY
Align the VERTICAL GUIDE STRIP with the CATWALK. Insert ten 3/8-16 x 1 1/14 Counter Sunk Screws through the VERTICAL GUIDE STRIP side, holding the GUIDE STRIP in place on the CATWALK. Slip a 3/8 Lock Washer and 3/8-16 Nylon Lock Nut over the end of each Screw and tighten appropriately.
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3.1.6
GORETRAC
The GORETRAC connects to the SPEAR and the CATWALK base. It is used to house Hydraulic Hoses and Electrical Wires, allowing them to move flexibly, yet provides protection. They are able to move along the length of the CATWALK as the CARRIER is in motion while preventing them from becoming tangled or snagged. The Hose and Wires connect through the hollow SPEAR and to the LIFT ARM, eventually attaching to the Hydraulics on the CARRIER.
Fig. 3.1.6.1 GORETRAC
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ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13
DESCRIPTION GORETRAC GORETRAC MOUNT A GORETRAC MOUNT B GORETRAC INSERT GORETRAC SNAP RING GORTRAC UHMW SLIDE 1/4"-20 X 1" SOCKET HEAD COUTERSUNK SCREW 1/4" FLAT WASHER 1/4"-20 NYLON LOCK NUT 3/8"-16 X 1" HEX BOLT 3/8" FLAT WASHER 3/8" LOCK WASHER 3/8"-16 NYLON LOCK NUT
PART# 12140001 GORETRAC MOUNT A GORETRAC MOUNT B GORETRAC INSERT GORETRAC SNAP RING 14110302 SCHCSCREW 0.25-20x1.25x1.25HX-N FW 0.25 NYLOK 0.2500-20-D-N HBOLT 0.3750-16x1x1-N FW 0.375 LW 0.375 NYLOK 0.3750-16-D-N
QUANTITY PER UNIT 1 2 2 8 8 12 48 48 48 4 4 4 4
Fig. 3.1.6.2 GORETRAC EXPLODED
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3.1.6.1
GORETRAC ASSEMBLY
The first step is to attach the GORETRAC MOUNTS to the GORETRAC. The GORETRAC MOUNTS, GORETRAC INSERTS and GORETRAC SNAP RINGS come delivered with the GORETRAC. 1. Slide the MOUNTS into the slot located at the ends of the GORETRAC. The center hole in the GORETRAC has a grove and the MOUNT will snap into place once aligned properly, ensuring a good fit.
Fig. 3.1.6.3 GORETRAC MOUNTS
Make sure that the angled side of the mounts are on the same side of the GORETRAC if the GORETRAC were to be outstretched.
Fig. 3.1.6.4 GORETRAC MOUNTS 2

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2.
Slide the GORETRAC INSERTS through the ends of the GORETRAC and GORETRAC MOUNTS. The INSERTS should come through the inside walls of the GORETRAC from the inside, and the SNAP RINGS be attached to the INSERTS on the outside of the GORETRAC. This must be repeated for all four GORETRAC MOUNTS.
Fig. 3.1.6.5 GORETRAC INSERTS
3. The GORETRAC UHMW SLIDEE PLATES are attached to every second link on one side of the GORETRAC. Pick a side of the GORETRAC and have it face upwards. The SLIDE PLATES have 4 holes with countersinks at each corner on one side, and on the other side, the holes have counterbores along with four grooves. The side with the counter bores faces downwards on the link of the GORETRAC.
Fig. 3.1.6.6 SLIDE PLATES
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4.
The slide plates are attached to every second GORETRAC LINK on the outside of one side. They start being attached on the second outer link, the one directly beside GORETRAC MOUNT and end at the second last outside link, the one beside the other GORETRAC MOUNT. This results in a total of 11 slide plates.
Fig. 3.1.6.7 SLIDE PLATES 2 5. Place a -20 x 1 Countersunk Screw through each of the four corners of the SLIDE PLATE. Use a Flat Washer and -20 Hex Bolt tighten the slide plate to the GORETRAC.
Fig. 3.1.6.8 SLIDE PLATES 3
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6. Lift GORETRAC to the floor of the CATWALK and place into the carrier groove. The SLIDE PLATES should be face down between the GORETRAC and the floor of the CATWALK. Align the GORETRAC MOUNTS to attach to the CATWALK BASE on the drillers side of the CATWALK. Slide 3/8 Flat Washers over 3/8-16 x 1 Hex Bolts and insert from CATWALK side. Use a 3/8 Lock Washer and 3/8-16 Nylon Lock Nut to tighten into place.
Fig. 3.1.6.9 GORETRAC CATWALK 1
Fig. 3.1.6.10 GORETRAC CATWALK 2
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3.1.7
SPEAR
The SPEAR attaches to the GORETRAC and the LIFT ARM. It houses Hydraulic Hoses and Electrical Wires which run the length of the SPEARS hollow midsection. Essentially, the SPEAR is used to keep these Hydraulic Hoses and Electrical Wires protected and untangled during the operational movement of the PIPE-MATIC 3000 while serving as a link between the CARRIER and CATWALK Hydraulic and Electrical systems.
ITEM 1 2 3 4 5
DESCRIPTION SPEAR PLUMBING SPEAR UHMW SOCKET HEAD COUNTER SUNK SCREW 3/8"-16 X 1" FLAT WASHER 3/8" NYLON LOCK NUT 3/8"-16
PART# 131100077 141500001 SCHCSCREW 0.37516x1x1-HX-N FW 0.375 NYLOK 0.3750-16-D-N
Fig. 3.1.7.1 SPEAR EXPLODED
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3.1.7.1
1.
SPEAR ASSEMBLY
Align the PLUMBING SPEAR UHMV with the SPEAR. Insert four 3/8-16 x 1 Counter Sunk Screws and tighten into place.
Fig. 3.1.7.2 PLUMBING SPEAR UHMV
2.
Lift the SPEAR onto the CATWALK using crane support. Align GORETRAC MOUNTS with the SPEAR. Insert four 3/8-16 x 1 Counter Sunk Screws through the SPEAR side, then add a 3/8 Flat Washer and 3/8 Nylon Lock Nut to each Screw and tighten appropriately.
Fig. 3.1.7.3 GORETRAC SPEAR
35
3.1.8
LASER EYE GUARD

The LASER EYE GUARD is a casing which is used to add protection the Photoelectric Sensors. There are four Photoelectric Sensors on the CATWALK, one at each corner, however, only three need LASER EYE GUARDS, both of the off drillers side Photoelectric Sensors and the ramp end drillers side Photoelectric Sensor. The fourth one is located within the RESEVOIR casing.
Fig. 3.1.8.1 LASER EYE GUARD
36
ITEM 1 2 3 4
DESCRIPTION LASER EYE GUARD FLAT WASHER 1/4" LOCK WASHER 1/4" HEX BOLT 1/4"-20 X 5/8"
PART# 141100082 FW 0.25 LW 0.25 HBOLT 0.250020x0.625x0.625-N
TOTAL QUANTITY 3 12 12 12
Fig. 3.1.8.2 LASER EYE GUARD EXPLODED
37
3.1.8.1
LASER EYE GUARD ASSEMBLY

There are three LASER EYE GUARDS and the following assembly must be followed for each LASER EYE GUARD. The GUARDS are located one each of the RAMP HINGE POSTS as well as one on the REAR BUMPER POST. The LASER EYE GUARDS cannot be installed until the Photoelectric Sensors are already attached to the CATWALK
Fig. 3.1.8.3 LASER EYE GUARD LOCATIONS
1.
Align the LASER EYE GUARD with the CATWALK. Slide a Lock Washer and Flat Washer over four -20 x 5/8 Hex Bolts. Insert the Bolts through the LASER EYE GUARD and tighten to the CATWALK.
38
3.1.9
HYDRAULIC POWER PACK
The HYDRAULIC POWER PACK consists of a PUMP and MOTOR which are attached in one unit. The MOTOR is an electric powered three phase motor and is used to run the PUMP which is used to pressurize the hydraulic fluid, therefore providing the force for all hydraulic systems on the PIPE-MATIC 3000. A PUMP-MOTOR adapter connects the two sections.
Fig. 3.1.9.1 HYDRAULIC POWER PACK
39
ITEM 1 2 3 4 5 6
DESCRIPTION HYDRAULIC POWER PACK NYLON LOCK NUT 1/2"-13 LOCK WASHER 1/2" FLAT WASHER 1/2" HEX BOLT 1/2"-13 X 2 3/4" HYDRAULIC POWER PACK PAD
PART# 121100002 NYLOK 0.5000-13-D-N LW 0.5 FW 0.5 HBOLT 0.5000-13x2.75x1.25-N HYDRAULIC POWER PACK PAD
Fig. 3.1.9.2 HYDRAULIC POWER PACK EXPLODED
40
3.1.9.1
HYDRAULIC POWER PACK ASSEMBLY
1.
The PIPE-MATIC 3000 is built and distributed nationally and internationally. Depending on a PIPE-MATICS final destination, the electrical system must be setup differently depending on the power supply used on drilling rigs in different countries. The power supply is either 230V or 460V.
On the side of the MOTOR there is an electrical box which unscrews to expose the wiring. There are nine wires in total. Wires 1,2,3 are the input, output and ground wires. The rest of the wires must be configured for the specified voltage. For 230V Wires 4,5,6 must be attached together. For 460V Wires 4,7 must be attached, wires 5,8 attached and wires 6,9 attached.
Figure 3.1.9.3 shows the wiring for a 460V unit.
Fig. 3.1.9.3 MOTOR WIRES
41
2.
Unbolt and remove the PUMP. Slide the MOTOR COUPLING over the shaft of the MOTOR. Tighten set screw to hold in place. Insert FLEXIBLE SPLINE COUPLING next to MOTOR COUPLING. Slide the PUMP COUPLING over the shaft of the PUMP. Tighten set screw to hold in place loosely. Re-attach PUMP to the MOTOR. Make sure that the MOTOR COUPLING, FLEXIBLE SPLINE COUPLING, and the PUMP COUPLING are aligned as well as ensure that the PUMP COUPLIN Set Screw is accessible through the PUMP-MOTOR ADDAPTER. Leave a small gap between the couplings to allow for heat expansion. Tighten set screw on PUMP COUPLING to hold firmly in place.
Fig. 3.1.9.4 COUPLINGS
42
3.
Align the four HYDRAULIC POWER PACK PADDINGS with the CATWALK.
Fig. 3.1.9.5 HYDRAULIC POWER PACK PADDING
4.
Using crane support, lower HYDRAULIC POWER PACK to hover and align with CATWALK. Slide a Flat washer over four -13 x 2 Hex Bolts and insert from below the CATWALK. Slip a Flat Washer, Lock Washer and Nylon Lock Nut over the end of each Bolt. Drop the motor to become fully rested on the CATWALK. Tighten Nuts appropriately.
5.
6.
43
3.1.10
ELECTRICAL BOX
The ELECTRICAL BOX is used to control the functions of the PIPE-MATIC, converting human input into physical operations including all hydraulic and winch operations. The ELECTRICAL BOX also controls all sensors, alerting the operator of any malfunctions. The ELECTRICAL BOX is located next to the HYRDRAULIC POWER PACK on the drillers side, flare end of the CATWALK.
Fig. 3.1.10.1 ELECTRICAL BOX
44
ITEM 1 2 3 4
DESCRIPTION 5/16" - 18 X 1" HEX BOLT 5/16" FLAT WASHER ELECTRICAL BOX 5/16"-18 NYLON LOCK NUT
PART# HBOLT 0.312518x1x0.875-N FW 0.3125 ELECTRICAL BOX 3 NYLOK 0.3125-18-D-N
Fig. 3.1.10.2 ELECTRICAL CONTROL BOX EXPLODED
45
3.1.10.1 ELECTRICAL BOX ASSEMBLY

1. Using crane support, lower the ELECTRICAL BOX to a hover over the CATWALK. Place four 5/16 - 18 x 1" Hex Bolts with 5/16 Flat Washers through holes in ELECTRICAL BOX and through the holes in the CATWALK. 2. Lower ELECTRICAL BOX to be resting on the CATWALK. Use 5/16 - 18 Nylon Lock Nuts with 5/16 Flat Washers to tighten into place.
46
3.1.11
RESERVOIR
The RESEVOIR is used to store and filter hydraulic fluid for all of the PIPEMATIC hydraulic systems. The fluid is pumped out of the RESEVOIR by the HYDRAULIC POWER PACK and is returned after use.
Fig. 3.1.11.1 HYDRAULIC RESERVOIR
47
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
DESCRIPTION HYDRAULIC RESERVOIR REMOVABLE BAFFLE 3/4" NPT HOLE PLUG RESERVOIR PADDING CLOSE NIPPLE 3" NPT 3" BALL VALVE 3" HOSE BEAD TO 3" MNPT 3-8 PIPE COUPLING 3/4" BALL VALVE RESISTANCE TEMP DETECTOR HEATER 2" NPT HOLE PLUG 5/8" FLAT WASHER 5/8" LOCK WASHER 5/8-11 NYLON LOCK NUT OIL FLITER 8-8 JIC x NPT STRAIGHT OIL FILTER MOUNT 2103-6-6 90 ELBOW 8-8 JIC x FJIC 90 ELBOW 1 1/4" NPT HOLE PLUG 5/8"-11 X 1 3/4" BOLT TEMPERATURE GUAGE O-RING LV/E1-TEMP GAUGE TEMPERATURE VISUAL INDICATOR LVE1-254-M HOLLOW BOLT 3/4" x 19 1/2" HYDRAULIC HOSE 1/2" x 19 1/2" HYDRAULIC HOSE 1" x 44 3/4" HYDRAULIC HOSE RESERVOIR GASKET RESERVOIR TOP PANEL 3/8" FLAT WASHER 3/8" LOCK WASHER 3/8"-16 NYLON LOCK NUT FILTER BREATHER FILTER PRESSURE GUAGE 3/8"-16 X 1 1/4" BOLT ADJUSTABLE PRESSURE SWITCH FILTER MAIN FITTING RESERVOIR OIL FILTER
PART# 131100020 141100384 RESERVOIR 0.75 NPT CAP RESERVOIR PADDING CLOSE NIPPLE 3 IN NPT BALL VALVE 3 IN GREEN LINE HOSE 3 IN TO 3 IN NPT 3-8 PIPE COUPLING BALL VALVE 0.75 IN B-3 RESISTANCE TEMP DETECTOR 4000 SERIES CALORITECH CXFT215P225R81 HEATER RESERVOIR 2.0 NPT CAP FW 0.625 LWASHER 0.625 NYLOK 0.6250-11-D-N STAUFF SF-6520 8-8 JIC x NPT STR STAUFF SAF-07-25HD-1 2103-6-6 8-8 JIC x FJIC 90 ELBOW RESERVOIR 1.25 NPT CAP HBOLT 0.6250-11x1.75x1.5-N LVE1-254-M O-RING LVE1-254-M HOLLOW BOLT LVE1 - 254 -M12 - CHANGE LVE1-254-M HOLLOW BOLT 3/4" x 19 1/2" HYDRAULIC HOSE 1/2" x 19 1/2" HYDRAULIC HOSE 1" x 44 3/4" HYDRAULIC HOSE 141500011 141100373 FW 0.375 LW 0.375 NYLOK 0.375-16-D-N MP FILTRI_CSG MP FILTRI V1 HBOLT 0.3750-16x1.25x1.25-N PMLA-2-4M-B-SP MP FILTRI MAIN FITTING MPF 400 3 A GB
QUANTITY PER UNIT 1 1 2 2 1 1 1 1 1 1 1 1 8 4 4 1 4 1 3 1 1 4 4 1 1 2 1 1 1 1 1 32 20 16 1 1 20 1 1 1
48
Fig. 3.1.11.2 HYDRAULIC RESERVOIR EXPLODED
49
3.1.11.1 RESERVOIR ASSEMBLY

1. Clean out the inside of the RESERVOIR, use a vacuum and be sure to rid of all debris. 2. Attach Stauff SF 6520 Oil Filter to a 8-8 JIC FJIC 90 Elbow Hydraulic fitting. Insert Elbow to top drillers side hole on RESERVOIR. Align the Elbow to be pointing towards the off drillers side and the oil filter is level and hanging downwards. 3. INSERT 1 NPT HOLE PLUG in the middle hole on the drillers side at the top section of the RESERVOIR. 4. Attach a 2103-6-6 90 Elbow Hydraulic fitting to the middle off-drillers side hole to top section of the RESERVOIR. Be sure that the elbow points directly down. 5. Attach 8-8 JIC NPT Straight Hydraulic Fitting to top left hole on RESERVOIR.
Fig. 3.1.11.3 FITTINGS AND FILTER
50
6. Screw the 3 Close Nipple, 3 Ball Valve and 3 Hose Bead together. Next, attach the Close Nipple end to the bottom drillers side of the RESERVOIR. Tighten to a point so that the valve lever is faced upwards.
Fig. 3.1.11.4 3 BALL VALVE 7. Attach the BALL VALVE to the center bottom hole and ensure that the valve lever is on the upper side of the BALL VALVE. 8. Attach heater to the bottom left of the RESEVOIR.
Fig. 3.1.11.5 HEATER AND BALL VALVE

51
9. Attach the RESISTANCE TEMPERATURE DETECTOR to the tank just above the 3 VALVE. 10. Insert a 2 NPT HOLE PLUG into the hole which is just left of the sensor.
Fig. 3.1.11.6 RESISTANCE TEMP. DETECTOR AND NPT HOLE PLUG 11. On drillers side of box, attach the VISUAL INDICATOR AND ELECTYRICAL LEVEL SWITCH. Remove the original Hollow Bolt from the lower end of the VISUAL INDICATOR. Insert the Place O-RINGS over holes, insert TEMPERATURE GUAGE and tighten accordingly.
Fig. 3.1.11.7 TEMPERATURE GUAGE

52
12. On the inside of the HYDRAULIC RESERVOIR, attach x 19 Hydraulic Hose to connect on the top drillers side. The hose should have a 90 Elbow Fitting and the hose should point downwards. 13. Attach x 19 Hydraulic Hose inside the RESEVOIR to connect to the middle off drillers side with the 90 Elbow Fitting pointing the Hose downwards.
Fig. 3.1.11.8 INSIDE RESERVOIR 14. Drop REMOVABLE BAFFLE into slots provided within the RESERVOIR. The PANEL should be parallel to the existing panel and have the missing corner located on the bottom of the off drillers side of the RESERVOIR, facing the full corner of the existing panel.
53
Fig. 3.1.11.9 REMOVABLE BAFFLE 15. Attach a Hydraulic Hose with a Straight Fitting inside the box on the off drillers side. Guide the loose end of the hose over the two internal plates so that it rests atop the grate at the far end of the box.
Fig. 3.1.9.12 RESERVOIR INTERNALS
54
16. Screw in sixteen 3/5-16 x 1 Bolts in all the holes located along the top of the box. The Bolts should screw in from below the ledge so that the threads are pointed upwards. 17. Apply grease to one side of RESERVOIR GASKET. Lay the GASKET, grease side down, around the top edge of the RESERVOIR aligning the Bolts through their respective holes.
Fig. 3.1.11.10 RESERVOIR GASKET 18. Apply grease to topside of RESERVOIR GASKET, align RESERVOIR TOP PANEL over 3/8 Bolts so that the large hole on top is located at the back left of the box. Insert a 3/8 Lock Washer and 3/8-16 Nylon Lock Nut over the end of each bolt. Tighten appropriately.
Fig. 3.1.11.11 RESERVOIR GASKET EXPLODED

55
19. The RESERVOIR OIL FILTER must be dismantled and a hole must be drilled in the RESERVOIR OIL FILTER COLLAR in order to attach the ADJUSTIBLE PRESSURE SWITCH. The PRESSURE SWITCH is to be parallel to the large hole on the side of the COLLAR and should be located on the flat plane adjoining the large hole. First a pilot hole must be drilled near the approximate center of the curve located on the flat plane. Place the COLLAR in a vice so that the drilling surface is perpendicular to the ground. Put a cloth between the collar and the vice to avoid damage to the COLLAR. Take steps to ensure that the pilot hole is to be perfectly level. The hole is to be 7/16 with a tap. Be sure to lube drill bits before drilling.
Fig. 3.1.11.12 OIL FILTER COLLAR 20. Screw ADJUSTABLE PRESSURE SWITCH into the hole in the RESERVOIR OIL FILTER COLLAR 21. Place OIL FILTER inside COLLAR. The filter fits in freely. 22. Align the OIL FILTER CAP with COLLAR. Bolt together the OIL FILTER BOLTS that come with the RESERVOIR OIL FILTER ASSEMBLY. 23. The FILTER PRESSURE GUAGE gets attached inserted in the top of the OIL FILTER CAP so that the readout meter points towards the drillers side of the RESERVOIR. 24. Attach the FILTER MAIN FITTING to the hole in the side of the OIL FILTER COLLAR.
56
Fig. 3.1.11.13 RESERVOIR OIL FILTER EXPLODED 25. Align RESERVOIR OIL FILTER with the large flange located on the top panel. The FILTER should be aligned with the holes in the top panel so that the pressure sensor and side hole of the FILTER should point out towards the off drillers side of the RESERVOIR. The FILTER then should be bolted to flange on the top panel with four 3/8-16 x 1 Bolts and 3/8 Lock Washer.
57
Fig. 3.1.11.14 FILTER INSTALLATION
26. Attach FILTER BREATHER by screwing it on to the threaded pipe on top of the RESERVOIR TOP PANEL.
Fig. 3.1.11.15 RESERVOIR FILTER BREATHER
58
27. Lay out Rubber Padding on the base of the CATWALK where the tank box will be sitting. Ensure that the wire for the electrical box is placed in to groove along the right side frame of the CATWALK before lowering RESERVOIR into place.
Fig. 3.1.11.16 RESERVOIR PADDING
28. Using crane support, lift the RESERVOIR onto the base of the CATWALK. Lower to a hover. Align with the holes in the base of the CATWALK. Slide a 5/8 Flat Washer over four bolts and insert each bolt through the CATWALK and RESERVOIR to hold the RESERVOIR in place. Insert a 3/8 Flat Washer, 3/8 Lock Washer and 3/8 Nylon Lock Nut over each Bolt. Drop the box onto the CATWALK and tighten the Nuts.
Fig. 3.1.11.17 RESERVOIR INSTALLATION

59
29. Insert NPT HOLE PLUG into bottom of RESERVOIR
Fig. 3.1.11.18 RESERVOIR - CATWALK
60
3.1.12 ELECTRICAL CONTROL BOX

The ELECTRICAL CONTROL BOX is located on the Drillers Side of the HYDRAULIC RESERVOIR. The ELECTRICAL CONTROL BOX contains buttons for human input along with a digital display which outputs whether the system is running fine or if there is an error in the system.
Fig. 3.1.12.1 ELECTRICAL CONTROL BOX
61
ITEM 1 2 3 4
DESCRIPTION ELECTRICAL CONTROL BOX HINGE ELECTRICAL CONTROL BOX 3/8" LOCK WASHER 3/8"-16 X 1" HEX BOLT
PART# ELECTRICAL CONTROL BOX HINGE ELECTRICAL CONTROL BOX LW 0.375 HBOLT 0.3750-16x1x1-N
Fig. 3.1.12.1 ELECTRICAL CONTROL BOX EXPLODED
3.1.12.1
1.
ELECTRICAL CONTROL BOX ASSEMBLY

Insert ELECTRICAL CONTROL BOX hinges through the slotted bars on the outside of the HYDRAULIC RESERVOIR.
2. Align ELECTRICAL CONTROL BOX with HINGES. Insert four 3/8"-16 x 1 Hex Bolts along with 3/8 Lock Washers through the ELECTRICAL CONTROL BOX and HINGES. Tighten appropriately.
62
3.1.13 RESERVOIR CASING

The RESERVOIR CASINGS includes a set of panels and bars surrounding the HYDRAULIC RESERVOIR in order to provide protection.
Fig. 3.1.13.1 RESERVOIR CASING EXPLODED

ITEM 1 2 3 4 5 6 7 8 9 10 11 DESCRIPTION 1/2"-13 X 1 1/2" HEX BOLT 1/2" FLAT WASHER RESERVOIR SIDE GUARD 1 RESERVOIR SIDE GUARD 2 1/2" LOCK WASHER 1/2"-13 NYLON LOCK NUT CONTROL BOX GUARD 1/4" FLAT WASHER 1/4"-20 X 1 1/4" HEX BOLT 1/4" LOCK WASHER 1/4"-20 NYLON LOCK NUT PART# HBOLT 0.5000-13x1.5x1.25N FWASHER 0.5 141100065 141100064 LWASHER 0.5 NYLOK 0.5000-13-D-N 153100057 FW 0.25 HBOLT 0.250020x1.25x0.75-N LW 0.25 NYLOK 0.2500-20-D-N QUANTITY PER UNIT 15 15 1 1 15 15 2 4 4 4 4
63
3.1.13.1 RESERVOIR CASING ASSEMBLY

1. Align RESERVOIR SIDE GUARD 1 with the posts on the CATWALK on the Off-Drillers side of the HYDRAULIC RESERVOIR. Insert nine 1/2"-13 x 1 1/2" Hex Bolts with Flat Washers through the RESERVOIR SIDE GUARD 1 and tighten onto CATWALK using -13 Nylon Lock Nuts with Lock Washers. Align RESERVOIR SIDE GUARD 2 with the posts on the CATWALK on the Ramp End of the HYDRAULIC RESERVOIR. Insert six 1/2"-13 x 1 1/2" Hex Bolts with Flat Washers through the RESERVOIR SIDE GUARD 2 and tighten onto CATWALK using -13 Nylon Lock Nuts with Lock Washers. Align the two CONTROL BOX GUARDS with the posts on the CATWALK on the Drillers Side of the HYDRAULIC RESERVOIR. Insert four 1/2"-20 x 1 1/4" Hex Bolts with 1/4 Flat Washers through the CONTROL BOX GUARDS and tighten onto CATWALK using -20 Nylon Lock Nuts with 1/4 Lock Washers.
2.
3.
64
3.1.14
HYDRAULIC COOLER
The HYDRAULIC COOLER is located on the drillers side of the CATWALK between the ELECTRICAL BOX and the HYDRUALIC VALVE BANK. The HYDRAULIC COOLER is used to cool hydraulic fluid.
Fig. 3.1.14.1 HYDRAULIC COOLER

ITEM 1 2 3 4 5 DESCRIPTION HYDRAULIC COOLER 3/8"-16 X 3/4" HEX BOLT 3/8" FLAT WASHER 3/8" LOCK WASHER 3/8"-16 NYLON LOCK NUT PART# HYDRAULIC COOLER HBOLT 0.3750-16x0.75x0.75-N FW 0.375 LW 0.375 NYLOK 0.3750-16-D-N QUANTITY PER UNIT 1 2 4 2 2
Fig. 3.1.14.2 HYDRAULIC COOLER EXPLODED
65
3.1.14.1 HYDRAULIC COOLER ASSEMBLY

1. Align HYDRAULIC COOLER with CATWALK. Insert two 3 /8"-16 x 3/4" Bolts with 3 /8" Flat Washers through the top two corners of the HYDRAULIC COLLER and CATWALK. Attach a 3 /8"-16 Nylon Lock Nut with a 3 /8" Lock Washer and 3 /8" Flat Washer to the end of each bolt. Tighten appropriately.
66
3.1.15 HIGH PRESSURE FILTER

The HIGH PRESSURE FILTER is located on the drillers side of the CATWALK near the HYDRAULIC COOLER and the ELECTRICAL BOX. The HIGH PRESSURE FILTER is used to filter the HYDRAULIC FLUID.
Fig. 3.1.15.1 HIGH PRESSURE FILTER

ITEM 1 2 3 4 5 6 DESCRIPTION 1/2"-13 X 1 1/2" HEX BOLT 1/2" LOCK WASHER 1/2" FLAT WASHER HIGH PRESSURE FILTER HIGH PRESSURE FILTER FITTING HIGH PRESSURE FILTER INDICATOR PART# HBOLT 0.5000-13x1.5x1.25-N LW 0.5 FW 0.5 HIGH PRESSURE FILTER HIGH PRESSURE FILTER FITTING HIGH PRESSURE FILTER INDICATOR QUANTITY PER UNIT 4 4 4 1 2 1
Fig. 3.1.15.2 HIGH PRESSURE FILTER EXPLODED
67
3.1.15.1 HIGH PRESSURE FILTER ASSEMBLY

Insert the two HIGH PRESSURE FILTER FITTININGS into each side of the HIGH PRESSURE FILTER. Insert the HIGH PRESSURE FILTER INDICATOR into the appropriate hole in the HIGH PRESSURE FILTER. Align HIGH PRESSURE FILTER with the four holes on the inside drillers side beam of the CATWALK. Insert four -13 x 1 Bolts with Lock Washers and Flat Washers through the CATWALK and into the back of the HIGH PRESSURE FILTER. Tighten appropriately.
Fig. 3.1.15.3 EXTERIOR BOLTS
68
3.1.16 HYDRAULIC VALVE BANK

The HYDRAULIC VALVE BANK is used to direct the hydraulic fluid to and from the HYDRAULIC PISTONS, controlling their movement and operation.
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION 8-8 JIC x NPT STR 20-20 JIC x NPT STR 20 - T SECTION 16-16 JIC x NPT STR 16 - T SECTION HYDRAULIC VALVE BANK 1/2" FLAT WASHER 1/2" LOCK WASHER 1/2"-13 X 1" HEX BOLT 1/4" FLAT WASHER 1/4" LOCK WASHER 1/4"-20 X 7/8" HEX BOLT PART# 8-8 JIC x NPT STR 20-20 JIC x NPT STR 20 - T SECTION 16-16 JIC x NPT STR 16 - T SECTION PIPE MASTER COMBO VALVE FWASHER 0.5 LW 0.5 HBOLT 0.5000-13x1x1-N FW 0.25 LW 0.25 HBOLT 0.250020x0.875x0.75-N QUANTITY PER UNIT 20 1 1 3 1 1 2 2 2 2 2 2
Fig. 3.1.16.1 HYDRAULIC VALVE BANK

69
3.1.16.1 HYDRAULIC VALVE BANK ASSEMBLY

1. Insert twenty 8-8 JIC x NPT Straight Fittings into the HYDRAULIC VALVE BANK. Insert 20-20 JIC x NPT Straight Fitting into the HYDRAULIC VALVE BANK. Insert 20 T SECTION onto the 20-20 JIC x NPT Straight Fitting. Insert the three 16-16 JIC x NPT Straight Fittings into the HYDRAULIC VALVE BANK. Insert a 16 T SECTION onto the 16-16 JIC x NPT Straight Fitting closest to the edge of the HYDRAULIC VALVE BANK. Align the HYDRAULIC VALVE BANK with the CATWALK. Insert two -13 x 1 Hex Bolts with Flat Washers and Lock Washers into the two holes at the flare end of the HYDRAULIC VALVE BANK. Tighten appropriately. Insert two 1/4-20 x 7/8 Hex Bolts with 1/4 Flat Washers and 1/4 Lock Washers into the two holes at the flare end of the HYDRAULIC VALVE BANK. Tighten Appropriately.
2.
3.
4.
5.
70
3.2
CARRIER
The CARRIER is used to carry tubulars and tools to and from the drill floor. The major components of the CARRIER include six KICKERS, six SAFETY PINS, the VROLLER AXLE, SHEAVE, SKATE DRIVE MOTOR, SKATE WINCH, SKATE CABLE and the SKATE. The CARRIER also consists of many smaller components, along with a HYDRAULIC SYSTEM, ELECTRICAL SYSTEM and CONTROL BOX.
Fig. 3.2.0.1 CARRIER
A winch on the RAMP attaches cables to the CARRIER and pulls it up towards the drilling floor. The ramp end of the CARRIER has a set of TAPPERED ROLLERS which allow the CARRIER to roll up the RAMP towards the drilling floor. The LIFT ARM attaches to the flare end of the CARRIER and lifts the flare end of the CARRIER during the operation.
71
3.2.1
KICKERS
There are six KICKERS located on the CARRIER, three on the drillers side and three on the off drillers side. Each is attached to a Hydraulic KICKER CYLINDER and the CYLINDER is attached to the base of the CARRIER. These KICKERS are used to move pipes from the CARRIER to the CATWALK by simply pushing the pipe from the groove in the center of the CARRIER.
Fig. 3.2.1.1 KICKERS
72
ITEM 1 2 3 4 5 6
DESCRIPTION KICKER KICKER CYLINDER 90 ELBOW GREASE FITTING 5/16"-18 NYLON LOCK NUT UNIVERSAL KICKER PIN 5/16"-18 X 2 1/4" BOLT
PART# 131100108 PPM-02-I002 GREASE FITTING 90 ELBOW O.125 NYLOK 0.3125-18-D-N 161100092 HBOLT 0.3125-18x2.25x0.875-N
TOTAL QUANTITY 6 6 6 18 18 18
Fig. 3.2.1.2 KICKERS EXPLODED
73
3.2.1.1
-
KICKER PREPERATION WORK

Clean all grooves and holes, be sure to remove all paint and debris. Wipe clean with rag.
3.2.1.2
KICKER ASSEMBLY
This assembly is for each KICKER. There are six sets of KICKERS for each PIPE-MATIC, therefore this assembly must be carried out six times.
1.
Due to the location of the KICKER CYLINDER, it is impossible to grease the KICKER PIN which connects to the CARRIER. Installing a 90 GREASE FITTING allows access to grease this pin. Detach STRAIGHT GREASE FITTING from the end of the KICKER CYLINDER that attaches to the base of the carrier. Replace this with a 90 GREASE FITTING, having it face the same direction as the closest plug on the KICKER CYLINDER.
Fig. 3.2.1.3 GREASE FITTING
74
2. Align KICKER with CARRIER, insert KICKER PIN to hold in place. 3. Align KICKER CYLINDER with KICKER, make sure that the inside hydraulic plug faces away from the KICKER which is located next to it. This way the hydraulic plumbing will not interfere with the adjacent KICKER. Insert KICKER PIN to hold in place. 4. Test piston and KICKER alignment, make sure that there is no interference with the base of the CARRIER. 5. Align hydraulic KICKER CYLINDER with CARRIER, insert KICKER PIN to hold in place. 6. Once all KICKER PINS are inserted, use a 5/16-18 x 2 1/4 Bolt, and 5/16 Nylon Lock Nut to tighten each into place. 7. Grease each KICKER assembly using a grease gun.
75
3.2.2
SAFETY PINS
There are six sets of SAFETY PINS located along the side of the CARRIER. There are three on the drillers side and three on the off drillers side. The SAFETY PINS are used to prevent pipes from accidentally rolling off of the CARRIER. They can be manually turned on using the wireless remote and are also automatically engaged when the CARRIER is not at rest on the CATWALK.
Fig. 3.2.2.1 SAFETY PIN

76
ITEM 1 2 3 4 5 6 7 8 9
DESCRIPTION SAFETY PIN SAFETY PIN ARM SAFETY PIN CYL. PIN SAFETY PIN CYL. BASE PIN SLOTTED SPRING PIN 0.1875 X2 SAFETY PIN CYLINDER GREASE FITTING 1/8 COTTER PIN 3/4" FLAT WASHER
PART# 161100005 141100319 161100089 161100091 SSPIN 0.1875 PPM-02-I001 GREASE FITTING 0.125 COTTER PIN 0.125 FWASHER 0.75
QUANTITY PER UNIT 1 2 3 1 1 1 1 3 3
TOTAL QUANTITY 6 12 18 6 6 6 6 18 18
Fig. 3.2.2.2 SAFETY PIN EXPLODED
77
3.2.2.1
-
SAFETY PIN PREPERATION WORK

Clean all grooves and holes; be sure to remove all paint and debris. Wipe clean with rag.
3.2.2.2
SAFETY PIN ASSEMBLY
This assembly is for each SAFETY PIN. There are six sets of SAFETY PINS for each PIPE-MATIC, therefore this assembly must be carried out six times.
10. Align SAFETY PIN CYLINDER with CARRIER and ensure that the nozzles on the CYLINDERS are pointing towards the Flare end of the CARRIER. 11. Insert SAFETY PIN CYLINDER BASE PIN to hold CYLINDER in place on the CARRIER. 12. Insert SLOTTED SPRING PIN through SAFETY PIN CYLINDER BASE PIN.
Fig. 3.2.2.3 SAFETY PIN ALIGNMENT
78
13. Align the two SAFETY PIN ARMS with the SAFETY PIN CYLINDER. Insert SAFETY PIN CYL. PIN from the inside of the CARRIER through the two ARMS and the HYDRAULIC CYLINDER. Slide a Flat Washer over the end of the CYLINDER PIN and insert a 1/8 Cotter pin to hold in place.
Fig. 3.2.2.4 SAFETY PIN CLY. PIN
79
14. Align the two SAFETY PIN ARMS with the base of the CARRIER. Insert SAFETY PIN CYLINDER PIN from the outside. Slide a Flat Washer over the end of the CYLINDER PIN and insert a 1/8 Cotter Pin to hold in place. 15. Align the two SAFETY PIN ARMS with the SAFETY PIN. Insert CYLINDER PIN from the inside of the CARRIER. Slide a Flat Washer over the end of the CYLINDER PIN and insert a 1/8 Cotter Pin to hold in place.
Fig. 3.2.2.5 SAFETY PIN PINS
80
16. Insert GREASE FITTING into Safety Pin Guide on the CARRIER
Fig. 3.2.2.6 GREASE FITTING
17. Grease each SAFETY PIN assembly using a grease gun.
81
3.2.3
FLANGE ROLLER WHEELS
The FLANGE ROLLER WHEELS are located on the bottom at the flare end of the CARRIER. They allow the flare end of the CARRIER to roll along the length of the CATWALK before the flare end is lifted off of the CATWALKS surface.
Fig. 3.2.3.1 FLANGE ROLLER WHEELS
82
ITEM 1 2 3 4 5 6
DESCRIPTION TRUARC EXTERNAL SNAP RING 5100-250 2.50" SD FLANGE WHEEL 3x2.5x2" OILITE BUSHING SPACER RING SOCKET SET SREW 0.5 X 0.5 FLANGE ROLLER AXLE
PART# TRUARC ZST-30 121300004 SS8096-32 141100320 SSSREW 0.5 161100090
Fig. 3.2.3.2 FLANGE ROLLER WHEELS EXPLODED
3.2.3.1
1. 2. 3. 4.
FLANGE ROLLER WHEEL ASSEMBLY

Insert an OILITE BUSHING into each FLANGE WHEEL. Insert FLANGE ROLLER AXLE though CARRIER. Slide a SPACER RING over each end of the FLANGE ROLLER AXLE. Slide the FLANGE WHEEL with the OILITE BUSHING over each end of the FLANGE ROLLER AXLE. Slide a SNAP RING over each end of the AXLE and insert the SNAP RING into the FLANGE WHEEL until it slips into the groove on the end of the FLANGE ROLLER AXLE, holding each WHEEL in place. Grease the FLANGE ROLLER WHEEL using a grease gun.
5.
6.
83
3.2.4
SHEAVE
The SHEAVE is used as a pulley in the SKATE DRIVE system. The SKATE CABLE comes from underneath, driven by the SKATE WINCH, then wraps around the SHEAVE, runs along the upper length of the CARRIER and attaches to the SKATE. The SHEAVE is located at the flare end of the CARRIER and has the ability to slide horizontally along the CARRIER which allows the adjustment of tension in the SKATE CABLE.
Fig. 3.2.4.1 SHEAVE
84
ITEM 1 2 3 4 5 6 7 8 9 10 11 12
DESCRIPTION SHEAVE AXLE SHEAVE SLIDER 1"-8-D-N NUT SHEAVE BUSHING SHEAVE BEARING SHEAVE WHEEL THREADED ROD RR1-8GR8X24 1" FLAT WASHER SKATE SHEAVE ADJUSTMENT PLATE 1-8 UNC NUT 3/8" LOCK WASHER 3/8"-16 x 1 1/4" BOLT
PART# 161100079 161100056 HNUT 1.0000-8-D-N 161100080 BEARING - 4.3125 X 1.9375 X 1.0625 161100081 RR1-8-GR8X24 FWASHER 1.0 141100321 NUT 1-8UNC LWASHER 0.375 HBOLT 0.3750-16x1.25x1-N
QUANTITY PER UNIT 1 2 2 2 2 1 2 2 1 2 1 1
Fig. 3.2.4.2 SHEAVE EXPLODED
85
3.2.4.1
1. 2. 3.
SHEAVE ASSEMBLY
Press the SHEAVE BEARINGS into each side of the SHEAVE WHEEL. Insert the SHEAVE PIN though the center of the SHEAVE BEARINGS. Slide a SHEAVE SPACER over each end of the SHEAVE PIN.
Fig. 3.2.4.3 SHEAVE WHEEL
86
4.
Slide SHEAVE SLIDERS over each end of SHEAVE PIN and insert the assembly into the sheave track on the CARRIER.
Fig. 3.2.4.4 SHEAVE TRACK 5. Insert the two THREADED RODS though the SHEAVE SLIDERS and the CARRIER. Slide a 18 Nut over the SLIDER end of each THREADED ROD.
Fig. 3.2.4.5 THREADED RODS
87
6.
Slide a 1 Flat Washer on the end of each THREADED ROD which is sticking out of the CARRIER. Align the SKATE SHEAVE ADJUSTMENT PLATE with the hole in the CARRIER that is centered between the THREADED RODS. Align a 3/8 Lock Washer with the hole, insert a 3/8"-16 x 1 1/4" Bolt and tighten to hold ADJUSTMENT PLATE in place. Slide a 1- 8 UNC Nut over the end of each THREADED ROD which is sticking out of the CARRIER.
7.
8.
Fig. 3.2.4.6 SHEAVE-SKATE ADJUSTMENT PLATE
88
3.2.5
LIFET ARM PILLOW BLOCKS

The LIFT ARM PILLOW BLOCKS located on the bottom flare end of the CARRIER and are used to hold the LIFT ARM to the CARRIER. Each PILLOW BLOCK has four vertical and one horizontal bolt. The horizontal bolt allows the pillow blocks to be slightly adjusted allowing proper alignment of the LIFT ARM.
Fig. 3.2.5.2 PILLOW BLOCKS
89
ITEM 1 2 3 4 5 6 7
DESCRIPTION RETAINER BLOCK LIFT ARM PILLOW BLOCK WITH BEARING 3/4" FLAT WASHER 3/4"-16 X 5" HEX SOCKET HEAD CAP SCREW 3/4"-16 X 7" HEX SOCKET HEAD CAP SCREW 1"-12 NUT 1"-12 X 4" BOLT
PART# 161100039 161100037 FW 0.75 HX-SHCS 0.7516x5x2-S HX-SHCS 0.7516x7x2-S HNUT 1.0000-12-B-N HBOLT 1.000012x4x4-S
QUANTITY PER UNIT 2 2 8 4 4 2 2
Fig. 3.2.5.2 PILLOW BOLCKS EXPLODED
90
3.2.5.1
1.
LIFET ARM PILLOW BLOCKS ASSEMBLY

Align RETAINER BLOCK and PILLOW BLOCK with the CARRIER. Slide a 1 Flat Washer over each Socket Head Cap Screw and insert Socket Head Cap Screws through the PILLOW BOCK and into the RETAINER BLOCK. The 3/4"-16 X 7" Socket Head Cap Screw long Screws should be inserted into the center two holes while the 3/4"-16 X 5" Socket Head Cap Screw are to be inserted into the outside holes. Insert a 1-12 Nut over each 1-12 x 4 Bolt and insert into the pivot blocks on the CARRIER located next to the PILLOW BLOCK.
2.
All Screws and Bolts must be adjusted when the LIFT ARM is being attached to the CARRIER as these Screws and Bolts are used to align the PILLOW BLOCK, therefore aligning the LIFT ARM.
91
3.2.6
SKATE
The SKATE sits on the top surface of the CARRIER, it moves horizontally along the length of the CARRIER and follows a groove in the center of the CARRIER known as the skate track. The SKATE is driven by the SKATE CABLE which is wrapped around the SKATE WINCH that is driven by the SKATE WINCH MOTOR. The SKATE is used to cradle pipes, and it can move them up and down the length of the CARRIER.
Fig. 3.2.6.1 SKATE
92
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13
DESCRIPTION 3/4"-24 X 2 1/2 FINISHED BOLT FLAT WASHER 3/8" SKATE RETAINER SKATE BODY SKATE SLIDE 3/8"-16 X 3/4" SOCKET HEAD COUTNERSUNK SCREW 3/8"-24 NYLON LOCK NUT 3/4" X 4" MCMASTER HITCH PIN SKATE CAGE 3/4"-10 NYLON LOCK NUT 3/4" FLAT WASHER 3/4" X 2 1/4" SLEEVE 3/4"-10 X 3 1/2" FINISHED HEX BOLT
PART# HFBOLT 0.375-24x2.5x1-C FW 0.375 131100257 131100154 141500004 SCHCSCREW 0.375-16x0.75x0.75HX-N NYLOK 0.3750-24-D-C 98497A664 131100155 NYLOK 0.7500-10-D-N FW 0.75 PI0.75x2.25 HFBOLT 0.75-10x3.5x1.75-C
Fig. 3.2.6.2 SKATE EXPLODED
93
3.2.6.1
1.
SKATE ASSEMBLY
Align SKATE SLIDES with SKATE BODY. Insert six 3/8"-16 x 3/4" Socket Head Countersunk Screws for each SKATE SLIDE and tighten.
Fig. 3.2.6.3 SKATE SLIDES 2. With the CARRIER upside down, center the SKATE underneath the CARRIER. Slip a lifting strap between the skate track that runs the length of the CARRIER. Attach the strap to the SKATE and lift with crane. This will lift the SKATES bottom blade through the rail on the CARRIER. Lift until the strap is tight and the SKATE is flush with the carrier.
Fig. 3.2.6.4 SKATE INSTALLATION

94
3.
Align SKATE RETAINERS with the SKATE BODY. Insert a 3/4"-24 x 2 Finished Bolt with a Flat Washer from the off drillers side of the SKATE. The Bolt should go through both SKATE RETAINERS as well as the SKATE itself. On the drillers side, slide a Flat Washer and a 3/8"- 24 Nylon Lock Nut over each Bolt. Once all four SKATE RETAINERS are attached, the crane may be released as these SKATE RETAINERS will keep the skate snug.
Fig. 3.2.6.5 SKATE RETAINERS The rest of the SKATE ASSEMBLY must wait for the CARRIER to be flipped right side up. Before being flipped, the CARRIER is lowered to rest on wood supports which prevent it from being scratched while being flipped. These wood supports are low to the ground and when the CARRIER is rested on these wood supports, the SKATE CAGE will contact the ground if it is installed before flipping. Once CARRIER is right side up, the rest of the SKATE can be assembled.
95
4.
Align SKATE CAGE with SKATE BODY. In the upper hole, insert a x 2 Sleeve. Insert a Finished Hex Bolt 3/4"-10 X 3 1/2" with a Flat Washer though the sleeve. Slide a Flat Washer with a -10 Nylon Lock Nut and tighten.
Fig. 3.2.6.6 SKATE CAGE
96
3.2.7
CABLE BLOCK
The CABLE BLOCK is located within the midsection of the CARRIER. It has two EYE BOLTS where the cables from the RAMP connect to the CARRIER. These cables attach to a large WINCH on the RAMP which pulls the CARRIER up the RAMP and slackens tension to allow the CARRIER to slide back down to rest in the CATWALK.
Fig. 3.2.7.1 CABLE BLOCK

ITEM 1 2 3 4 5 6 7 8 9 10 DESCRIPTION EYE BOLT 1.25-7-8 X 2 1/2-13 X 1 1/2" HEX BOLT 1/2" LOCK WASHER 1/2" FLAT WASHER EYEBOLT CAPTURE CABLE BLOCK 1" FLAT WASHER COTTER PIN 1/8" 1 -13" NUT CABLE BLOCK PIN PART# EYE BOLT 1.25-7-8 X 2 HBOLT 0.500013x1.5x1.5-N LW 0.5 FW 0.5 153100056 131100147 FWASHER 1.0 COTTER PIN 0.125 HNUT 1.25 161100095 QUANTITY PER UNIT 2 1 1 1 1 1 2 8 4 2
Fig. 3.2.7.2 CABLE BLOCK EXPLODED
97
3.2.7.1
1. 2.
CABLE BLOCK ASSEMBLY

Slide CABLE BLOCK onto CARRIER and align holes. Insert the two CABLE BLOCK PINS. Slip a 1 Flat Washer over the exiting end and use a COTTER PIN to hold each CABLE BLOCK PIN in place.
Fig. 3.2.7.3 CABLE BLOCK 3. Align EYEBOLT CAPTURE with CABLE BLOCK. Insert a 1/2-13 x 1 1/2" Hex Bolt with a Lock Washer and Flat Washer through EYBOLT CAPTURE and CABLE BLOCK. Tighten appropriately.
Fig. 3.2.7.4 EYEBOLT CAPTURE
98
4.
Insert EYEBOLTS so that the loop end is facing the ramp end of the CARRIER. Slide two 1 Nuts onto the end of each EYEBOLT. Insert 1/8 COTTER PINS through the end of each EYEBOLT.
5. 6.
Fig. 3.2.7.4 EYEBOLTS
Fig. 3.2.7.5 EYEBOLT NUTS
99
3.2.8
ROPE DEFLECTOR
The ROPE DEFLECTOR is located on the bottom of the CARRIER directly to the flare end of the CABLE BLOCK. The ROPE DEFLECTOR is a roller which used to push the SKATE CABLE out from CARRIER while keeping it cantered, preventing it from interfering with the other systems in the CARRIER.
Fig. 3.2.8.1 ROPE DEFLECTOR
100
ITEM 1 2 3 4 5 6 7
DESCRIPTION 3/8" -16x2" BOLT ROLLER BRACKET 3/8" LOCK WASHER 3/8"-16 NYLON LOCK NUT ROLLER AXLE ROLLER SET SCREW ROPE DEFLECTOR ROLLER
PART# HBOLT 0.375 131100150 LWASHER 0.375 NYLOK 0.375 161100085 ROLLER SET SCREW 161100084
QUANTITY PER UNIT 3 1 3 3 1 2 1
Fig. 3.2.8.2 ROPE DEFLECTOR EXPLODED
101
3.2.8.1
1.
ROPE DEFLECTOR ASSEMBLY

Align ROPE DEFLECTOR ROLLER with the ROLLER BRACKET. Insert ROLLER AXLE and tighten into place with ROLLER SET SCREWS. Align ROLLER BRACKET with CARRIER WELDMENT. Insert three 3/8-16 x 2 Bolts. Attach a 3/8 Lock Washer and 3/8-16 Nylon Lock Nut to the end of each Bolt, tighten accordingly.
2.
102
3.2.9
OVERSHOOT DOGS
The OVERSHOOT DOG, located towards the ramp end of the CARRIER, is used to stop the CARRIER from moving a further distance up the RAMP. The OVERSHOOT DOG PLATES pivot up into the CARRIER when the CARRIER is at rest on the CATWALK. Once the CARRIER is lifted, gravity drops the OVERSHOOT DOG PLATES, allowing them to hang down from the CARRIER like hooks. These OVERSHOOT DOG PLATES hook onto the TOP CARRIER ROLLER at the top of the RAMP, preventing the CARRIER from moving any further forward.
Fig. 3.2.9.1 OVERSHOOT DOGS
103
ITEM 1 2 3 4 5 6 7 8
DESCRIPTION OVERSHOOT DOG OVERSHOOT DOG PLATE 5/8"-11 x 1 3/4" BOLT 5/8" LOCK WASHER 5/8"-11 NYLON LOCK NUT 3/4-10 X 2 1/2" BOLT 3/4" LOCK WASHER 3/4"-10 NYLON LOCK NUT
PART# 131100152 141100315 HBOLT 0.625011x1.75x1.5-N LWASHER 0.625 NYLOK 0.625 HBOLT 0.750010x2.5x1.75-N LW 0.75 NYLOK 0.7500-10-D-N
Fig. 3.2.9.2 OVERSHOOT DOGS EXPOLDED
104
3.2.9.1
1.
OVERSHOOT DOGS ASSEMBLY

Align OVERSHOOT DOG PLATES with OVERSHOOT DOG. Insert a -10 x 2 Bolt to hold each PLATE in place. Attach a Lock Washer and a -10 Nylon Lock Nut to the back of each Bolt. Tighten accordingly. Align the OVERSHOOT DOG with the CARRIER. Insert eight; four per each side; 5/8"-11 x 1 3/4" Bolts from the inside of the OVERSHOOT DOG into the CARRIER. Attach a 5/8 Lock Washer and 5/8"-11 Nylon Lock Nut onto the end of each bolt on the outside of the CARRIER. Tighten accordingly.
2.
Fig. 3.2.9.3 EXTERNAL BOLTS
105
3.2.10
TAPERED ROLLERS
The TAPERED ROLLERS are located on the bottom of the ramp end of the CARRIER. They are simply wheels which allow the ramp end of the CARRIER to roll up the RAMP.
Fig. 3.2.10.1 TAPPERED ROLLERS
106
ITEM 1 2
DESCRIPTION EXTERNAL SNAP RING 5100-200 2.00" SD TAPERED ROLLER
PART# TRUARC ZST30 121300006
QUANTITY PER UNIT 2 2
Fig. 3.2.10.2 TAPPERED ROLLERS EXPLODED
3.2.10.1
1. 2.
TAPERED ROLLERS ASSEMBLY

Slide TAPERED ROLLER over axle located on the CARRIER. Press SNAP RING into place, holding the TAPERED ROLLER to the CARRIER. Grease the TAPERED ROLLERS using a grease gun.
3.
107
3.2.11
V-ROLLER
The V-ROLLER is located at the RAMP END of the CARRIER and it the first part of the CARRIER to contact the CABLE. The V-ROLLER is used to direct the CARRIER CABLE underneath the CARRIER where it connects with the EYEBOLTS on the RAMP BLOCK.
Fig. 3.2.11.1 V-ROLLER
108
ITEM 1 2 3 4 5
DESCRIPTION V-ROLLER AXLE 3/8"-16 X 4.5" BOLT V-ROLLER SPACER V-ROLLER 1/8 GREASE FITTING
PART# 161100004 HBOLT 0.3750-16x4.5x1-N 152100026 161100094 GREASE FITTING 0.125
Fig. 3.2.11.2 V-ROLLER EXPLODED
3.2.11.1
1. 2.
V-ROLLER ASSEMBLY
Insert two 1/8 Grease Fittings into the V-ROLLER. Align the V-ROLLER and two V-ROLLER SPACERS with the CARRIER. Insert V-ROLLER AXLE through the V-ROLLER and SPACERS. Insert a 3/8"-16 x 4 through each collar and V-ROLLER AXLE located on either side on the outside of the CARRIER. Tighten accordingly.
3.
4.
Grease the V-ROLLER using a grease gun.
109
3.2.12
CABLE GUIDE
The CABLE GUIDE, located at the ramp end of the CARRIER, is a protective grooved plate which helps direct the CARRIER CABLE underneath the CARRIER while allowing the CABLE to rub against the CABLE GUIDE, protecting the CARRIER from damage.
Fig. 3.2.12.1 CABLE GUIDE
110
ITEM 1 2
DESCRIPTION CABLE GUIDE 1/2"-13 X 1 1/2" HEX SOCKET HEAD CAP SCREW
PART# 161500002 HX-SHCS 0.5-13x1.5x1.5-N
Fig. 3.2.12.2 CABLE GUIDE EXPLODED
3.2.12.1
1.
CABLE GUIDE ASSEMBLY

Align CABLE GUIDE with CARRIER. Insert six 1/2"-13 X 1 1/2" Hex Socket Head Cap Screws and tighten accordingly.
111
3.2.13
SKATE STOPS
The SKATE STOPS are used to prevent to the SKATE from moving any further to the flare end of the CARRIER.
Fig. 3.2.13.1 SKATE STOPS
112
ITEM 1 2 3 4
DESCRIPTION 5/8"-11x2 1/2" HX-C SBHC SCREW SKATE STOP 5/8" LOCK WASHER 5/8"-11 NYLON LOCK NUT
PART# SBHCSCREW 0.625-11x2.5HX-C 141100322 LW 0.625 NYLOK 0.6250-11-D-N
Fig. 3.2.13.2 SKATE STOPS EXPLODED
3.2.13.1
1.
SKATE STOP ASSEMBLY

Align SKATE STOPS with CARRIER. The pointed end of the SKATE STOP should point towards the ramp end of the CARRIER and towards the outside of the CARRIER as shown in fig. 3.2.13.2 Insert two 5/8"-11 x 2 1/2" HX-C SBHC SCREWS through the CARRIER and each SKATE STOP from the outside top of the CARRIER. Attach a 5/8 Lock Washer and a 5/8-11 Nylon Lock Nut to the other end of the bolt. Tighten accordingly.
2.
113
3.2.14
HYDRAULIC VALVE BANK

The HYDRAULIC VALVE BANK is located at the flare end of the CARRIER. It is used to direct the hydraulic fluid to and from the HYDRAULIC CYLINDERS, controlling their movement and operation.
ITEM 1 2 3 4 5 6
DESCRIPTION 8-8 JIC x NPT STR 16 C5OX-S 90 ELBOW HYDRAULIC VALVE BANK 5/16" FLAT WASHER 5/16" LOCK WASHER 5/16"-18 X 3/4" HEX BOLT
PART# 8-8 JIC x NPT STR 12_C5OX-S PVG 32 DIRECTIONAL VALVECARRIER FW 0.3125 LW 0.3125 HBOLT 0.3125-18x0.75x0.75-N
Fig. 3.2.14.1 HYDRAULIC VALVE BANK
114
3.2.14.1
1.
HYDRAULIC VALVE BANK ASSEMBLY

Insert ten 8-8 JIC x NPT Straight Fittings into the HYDRAULIC VALVE BANK. Insert two C5OX-S 90 Elbow Fittings into the HYDRAULIC VALVE BANK. Align HYDRAULIC VALVE BANK with CARRIER. Insert four 5/16-18 x Bolts with Lock Washers and Flat Washers. Tighten appropriately.
2.
3.
115
3.2.15
SKATE DRIVE MOTOR

The SKATE DRIVE MOTOR is located near the ramp end of the CARRIER. It is used to drive the SKATE WINCH which moves the SKATE along the Skate Track.
Fig. 3.2.16.1 SKATE DRIVE MOTOR
116
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13
DESCRIPTION 3/8"-16x1x1-N HEX BOLT 3/8" LOCK WASHER ACCESS COVER MOTOR SPROCKET SNAP RING MOTOR MOUNT COTTER PIN JAW & JAW TURNBUCKLE, CROSBY # 1032812 CLEVIS PIN SKATE DRIVE MOTOR 1/2" LOCK WASHER 1/2"-20 X 1 1/2 HEX BOLT DRIVE CHAIN
PART# HBOLT 0.3750-16x1x1-N LWASHER 0.375 141100323 161100202 Truarc 5100-315 - S3.156 141100314 COTTER PIN 0.125 TURNBUCKLE CLEVIS PIN OMT FH 400 LW 0.5 HBOLT 0.5000-20x1.5x1.25-N DRIVE CHAIN
Fig. 3.2.15.2 SKATE DRIVE MOTOR EXPLODED
117
3.2.15.1 SKATE DRIVE MOTOR ASSEMBLY

1. Align and insert MOTOR MOUNT with CARRIER. Attach the SNAP RING into the Snap Ring Groove on the CARRIER to hold MOTOR MOUNT in place.
Fig. 3.2.15.3 MOTOR MOUNT 2. Align and insert four 1/2"-20 x 1 Hex Bolts with Lock Washers with SKATE DRIVE MOTOR. Align SKATE DRIVE MOTOR with Bolts to the MOTOR MOUNT and tighten Bolts to hold SKATE DRIVE MOTOR in place.
Fig. 3.2.15.4 MOTOR AND MOUNT
118
3.
Align JAW & JAW TURNBUCK with the CARRIER and the MOTOR MOUNT. Insert a CLEVIS PIN into each end of the TURNBUCKLE to hold in place. Insert COTTER PINS into each CLEVIS PIN.
Fig. 3.2.15.6 TURNBUCKLE The following steps of ASSEMBLY must not be carried out until the SKATE WINCH is installed. 4. Once the SKATE WINCH is installed, use the TURNBUCKLE to raise motor so it aligns with service hole. Heat the MOTOR SPROCKET and insert onto the SKATE WINCH MOTOR. Align MOTOR SPROCKET tread with tread of WINCH MOUNT GEAR. Use a straight edge to ensure that the sprockets line up correctly. The heated SPROCKET will then shrink and adhere to the MOTOR shaft.
Fig. 3.2.15.7 MOTOR SPROCKET
119
5. Lower SKATE DRIVE MOTOR and wrap DRIVE CHAIN around the MOTOR SPROCKET and WINCH MOUNT GEAR. The DRIVE CHAIN should start and end on the MOTOR SPROCKET as the location of the service hole will allow more room to attach the ends of the DRIVE CHAIN together. Attach the ends of the DRIVE CHAIN and using the TURNBUCKLE, raise the SKATE DRIVE MOTOR until the DRIVE CHAIN become tight. Allow a little bit of flex in DRIVE CHAIN.
Fig. 3.2.15.7 CHAIN 6. Align ACCESS COVER with CARRIER. Insert four 3/8"-16x1x1-N Hex Bolts with 3/8 Lock Washers and tighten appropriately.
Fig. 3.2.15.8 ACCESS COVER

120
3.2.16 SKATE WINCH

The SKATE WINCH is located near the ramp end of the CARRIER. It is driven by the SKATE WINCH MOTOR and is used to pull the SKATE forwards and backwards along the skate track.
Fig. 3.2.16.1 SKATE WINCH
121
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
DESCRIPTION CAP PLATE INTERNAL SNAP RING BEARING SPHERICAL SB-22216 1/2"-13 X 1" HEX BOLT 1/2" LOCK WASHER 1/2" FLAT WASHER BEARING FLANGE 1/2"-13 X 1 1/2" HEX BOLT FLOATING END SKATE MOUNT 5/8"-11 X 4 1/2" GR.8 BOLT 5/8" LOCK WASHER TB WOODS SURE-GRIP BUSHING SKATE WINCH DRUM SKATE DRIVE SHAFT DRUM KEY GEAR BUSHING GEAR BUSHIN SET SCREW SKATE WINCH GEAR MOUNT ENTRANCE CAP 1/4" LOCK WASHER 1/4"-20 X 7/8" HEX BOLT GREASE FITTING
PART# 141100152 TRUARC N5000-550-55.5 BEARING SPHERICAL SB-22216 HBOLT 0.5000-13x1x1-N LW 0.5 FW 0.5 161100087 HBOLT 0.5000-13x1.5x1.25-N 161100097 HBOLT 0.6250-11x4.5x1.5-N LW 0.625 J312 161100032 161100033 KS0.875X0.875X3.5 GEAR BUSHING GEAR BUSHIN SET SCREW 600.75P2ST45T45SO6H2.9375L3.5000R1 161100096 LW 0.25 HBOLT 0.2500-20x0.875x0.75-N GREASE FITTING 0.125
QUANTITY PER UNIT 2 2 2 15 27 24 2 12 1 3 3 1 1 1 1 1 1 1 1 8 8 2
Fig. 3.2.16.2 SKATE WINCH EXPLODED
122
3.2.16.1 SKATE WINCH ASSEMBLY

1. Insert TB Woods Sure-Grip BUSHING over the SKATE DRIVE SHAFT so that the smaller diameter is facing the end of the shaft with the Snap Ring groove. Pry the bushing open by inserting a screwdriver in the slit along the bushing, allowing the BUSHING to slide on the SHAFT. Align so that when the SKATE WINCH DRUM is inserted, that the wall of the drum is approximately 6 from the end of the SHAFT without the groove. Remember that the DRUM will move slightly when tightened, so consider this when the BUSHING is being lined up. Once the BUSHING is the proper distance, remove the screw driver, allowing the BUSHING to fit tightly around the SKATE DRIVE SHAFT.
Fig. 3.2.16.3 SKATE DRIVE SHAFT
123
2. Insert DRUM onto SKATE DRIVE SHAFT and slide over BUSHING so that Bolt holes align. 3. Blow air into Bolt holes to remove any debris. Insert three 5/8"-11 x 4 1/2" GR.8 Bolts with 5/8 Lock Washers and tighten into place.
Fig. 3.2.16.4 WINCH AND SHAFT 4. Insert GEAR BUSHING into SKATE WINCH GEAR. Insert three -13 x 1 Bolts with Lock Washer through the GEAR BUSHING and GEAR. Only tighten lightly.
124
Fig. 3.2.16.5 SPROCKET PRYED OPEN 5. Pry open insert with screw driver and insert over the end of the SKATE DRIVE SHAFT with the Snap Ring groove so that the GEAR BUSHING is facing out. The outside of the face of the gears should be approximately 3 5/8 from the end of the SKATE DRIVE SHAFT. Note that when the bolts are tightened between the GEAR BUSHING and the GEAR, that the distance will change slightly and this must be accounted for. Once the proper location is determined, remove the screw driver allowing the GEAR BUSHING to tighten over the SKATE DRIVE SHAFT. Insert GEAR BUSHING SET SCREW and tighten. 6. Tighten the -13 x 1 Bolts that connect the bushing to the gears. Be sure to tighten each one evenly so that the GEAR is not crooked. Check the 3 5/8 distance from the GEAR to the end of the SKATE DRIVE SHAFT. If distance is off, loosen bolts and re-align GEAR BUSHING until an accurate alignment is made.
125
Fig. 3.2.16.6 SPROCKET ON SHAFT
7. Pre-Fit the each SPERICAL BEARINGS with its designated BEARING FLANGE. By performing this step now, it prevents debris from entering the exposed internals of the BEARING in case modifications need to be made. 8. Remove Snap Rings from the one side of bearing which will be facing the outside of the CARRIER. Remove the Bearing Seal from that one side and re-attach the Snap Ring to keep the inner spheres in place. Removing this cover allows the bearings to be greased once the unit is constructed while the Snap Ring keeps the bearings internals intact. 9. Remove the snap ring on the opposite side. Puncture the seal, making small inserts with scissors along the path which the snap ring usually covers. Replace the snap ring. These holes allow grease to flow out of the bearing if the pressure becomes too high. By puncturing them along the path of the snap ring, the snap ring will help prevent any debris from entering the bearing internals through these holes. 10. Press the BEARINGS into their respective BEARING FLANGE so that the side of the BEARING without the Bearing Seal will be facing towards to outside of the CARRIER.
126
Fig. 3.2.16.7 BEARING IN BEARING FLANGE 11. On the off drillers side of the CARRIER, align the FLOATING END SKATE MOUNT to the inside of the CARRIER. Insert six 1/2"-13 x 1 1/2" Bolt with Flat Washer and Lock Washer from the outside of the CARRIER and tighten FLOATING END SKATE MOUNT into place.
Fig. 3.2.16.8 FLOATING END SKATE MOUNT
127
12. Insert smaller diameter end of BEARING FLANGE through the outer side of the CARRIER and into the FLOATING END SKATE MOUNT. Align and bolt together from the outside of the CARRIER using six 1/2"-13 x 1" Bolts with Flat Washer and Lock Washer. 13. Align CAP PLATE with the BEARING FLANGE and bolt together using four 1/4"-20 x 7/8" Bolts with Lock Washers. 14. Insert a Grease Fitting into the center of the CAP PLATE.
Fig. 3.2.16.9 BEARING FLANGE ASSEMBLY 15. Using crane support, attach a strap to the SKATE WINCH DRUM, GEAR and SHAFT assembly. Lift through the skate mount entrance with the SKATE WINCH DRUM entering first and the GEAR end in last. Push as far inward as possible. Remove the crane support, reattach strap to SKATE WINCH DRUM from between the inside walls of the CARRIER. Attach to crane and lift. This should hold the SKATE WINCH DRUM inside the CARRIER walls, allowing easy installation. 16. Slip SKATE DRIVE SHAFT through Bearing in the FLOATING END SKATE MOUNT.
128
Fig. 3.2.16.10 SKATE WINCH-CARRIER 17. Align the second BEARING FLANGE with the MOUNT ENTRANCE CAP and bolt together using six 1/2"-13 x 1" Bolts with Flat Washer and Lock Washer. 18. Align second CAP PLATE with the BEARING FLANGE and bolt together using four 1/4"-20 x 7/8" Bolts with Lock Washers. 19. Insert a Grease Fitting into the center of the CAP PLATE.
Fig. 3.2.16.11 MOUNT ENTRANCE CAP
129
20. Insert SKATE DRIVE SHAFT into Bearing and align MOUNT ENTRANCE CAP with the CARRIER. Bolt the MOUNT ENTRANCE CAP to the CARRIER using six 1/2"-13 x 1 1/2" Bolts with Flat Washer and Lock Washer.
Fig. 3.2.16.12 MOUNT ENTRACE CAP - CARRIER 21. Grease the SKATE WINCH using a grease gun.
130
3.2.17 SKATE DRIVE CABLE

The SKATE DRIVE CABLE is attached to both ends of the SKATE and is used to pull the SKATE both directions along the CARRIER. The SKATE DRIVE CABLE is driven by the SKATE WINCH at the ramp end of the CARRIER and is wrapped around a SHEAVE at the flare end of the CARRIER.
Fig. 3.2.17.1 SKATE DRIVE CABLE
ITEM 1 2 3
DESCRIPTION SKATE DRIVE CABLE CLEVIS PIN COTTER PIN
PART# SKATE DRIVE CABLE CLEVIS PIN COTTER PIN 0.125
131
3.2.17.1
SKATE DRIVE CABLE ASSEMBLY
1. Wrap one end of SKATE DRIVE CABLE around SKATE WINCH four and a half times. The end of the SKATE DRIVE CABLE that exits through the bottom of the CARRIER should be fed from the off-driller side of the SKATE WINCH and leave though the driller side of the SKATE WINCH with no tangles in between.
Fig. 3.2.17.2 CABLE ON WINCH 2. One person pulls the end of the CABLE along the internal top of the CARRIER until it reaches the SKATE while another feeds the CABLE to the WINCH, holding it tight as to not tangle. Align the end of the CABLE with the front hole of the SKATE and insert the CLEVIS PIN with the COTTER PIN to hold the CABLE to the SKATE.
Fig. 3.2.17.3 CABLE ATTACHED TO RAMP END OF SKATE
132
3. The other end of the CABLE must now be run along the bottom of the CARRIER, around the SHEAVE at the flare end
Fig. 3.2.17.4 CABLE WRAPPED AROUND SHEAVE 4. The CABLE then gets run along the top of the CARRIER and attached to the flare end of the SKATE. Insert the CLEVIS PIN with the COTTER PIN to hold the CABLE to the SKATE
Fig. 3.2.17.5 CABLE ATTACHED TO FLARE END OF SKATE
133
5. The SHEAVE is than adjusted, adding tension to the CABLE. These Bolts should be tightened evenly so that the SHEAVE is kept straight and should be tight enough so that the CABLE is raised to be touching only the ROPE DEFLECTOR. Once the PIPE-MATIC is setup and running, the proper amount of tension in the SKATE DRIVE CABLE will be calibrated and adjusted.
Fig. 3.2.17.6 CABLE TENSION ADJUSTMENT
134
3.3
LIFT ARM
The LIFT ARM attaches to the SPEAR and rests inside the CATWALK. The LIFT ARM travels inside the CATWALK as the CARRIER is pulled up the RAMP. The LIFT ARM enters a pocket at the ramp end of the CATWALK, which causes the flare end of the CARRIER to lift out of the CATWALK. This allows the CARRIER to extend across the drilling floor.
Fig. 3.3.0.1 LIFT ARM
135
3.3.1
POCKET ROLLERS
There are two POCKET ROLLERS located at the Ramp End of the LIFT ARM. These POCKET ROLLERS slide along the CATWALK into the pocket blocks on the CATWALK. This is the pivot point and allows the LIFT ARM to raise the Flare End of the CARRIER out of the CATWALK.
Fig. 3.3.1.1 POCKET ROLLER
ITEM 1 2
DESCRIPTION POCKET ROLLER RETAINING RING
PART# 161100053 WST-250
3.3.1.1
POCKET ROLLER ASSEMBLY
1. Slide the POCKET ROLLER onto the LIFT ARM and spin it to make sure it moves freely. 2. Lock the POCKET ROLLER in place with the RETAINING RING.
136
3.3.2
PILLOW BLOCKS
The PILLOW BLOCKS, located at the Ramp End of the LIFT ARM, are the connecting point between the SPEAR and the LIFT ARM, allowing the LIFT ARM to pivot as the SPEAR lays flat on the CATWALK..
Fig. 3.3.2.1 PILLOW BLOCKS

ITEM 1 2 3 4 DESCRIPTION NTN PILLOW BLOCK 1/4" NPT COUPLING MALE 1/4" NPT ELBOW 90 DEGREE FEMALE 1/8" GREASE FITTING PART# P207N1D1_UC207-107D1 NPT 0.250 MALE COUPLING FEMALE ELBOW 0.250 NPT90 GREASE FITTING 0.125 QUANTITY PER UNIT 2 2 2 2
3.3.2.1
1.
PILLOW BLOCK ASSEMBLY

Remove the old Grease Fitting from the inside of the pin on the LIFT ARM. Replace by attaching Grease fitting to a 90 Female Fitting with a NPT coupling that connect to the LIFT ARM. This allows clearance for the grease guns to lubricate the joint regularly during service and maintenance. Slide the bearing over the pin make sure it moves freely.
2.
137
3.3.3
BREARING PADS
The BEARING PADS, located at the Ramp End of the LIFT ARM, are replaceable pads the take all the wear of sliding across the CATWALK and the CARRIER.
Fig. 3.3.3.1 BEARING PADS

ITEM 1 2 3 DESCRIPTION 1/4"-20 X 1 1/4" SOCKET HEAD COUTERSUNK SCREW GORTRAC UHMW SLIDE LIFTING ARM BEARING PAD PART# SCHCSCREW 0.25-20x1.25x1.25HX-N 141100302 141100305 QUANTITY PER UNIT 4 1 2
3.3.3.1
BREARING PAD ASSEMBLY
1. Using the -20 counter sunk screws attach the pads to the catwalk as shown in figure 3.3.4.1 and tighten accordingly.
138
3.4
RAMP
The RAMP is hinged to the CATWALK and rotates up to rest on the drilling floor during operation. The major component is the CARRIER LIFT WINCH which mounted on the back side of the RAMP. It is used to drive the CARRIER during operation. The RAMP also includes the TOP CARRIER ROLLER which is used as a stopper to prevent the CARRIER from moving any further up the RAMP, a SHEAVE which is used to direct the CARRIER CABLE from the CARRIER LIFT WINCH from the underbelly of the RAMP to the top surface allowing it to connect with the CARRIER. Along with these components, the RAMP also has hydraulic and electrical components.
Fig. 3.4.0.1 RAMP
139
3.4.1
LIFT WINCH
The LIFT WINCH is attached to the underside of the RAMP. It is the LIFT WINCH which drives the CARRIER CABLE, producing the force to move the CARRIER up and down the RAMP during operation.
Fig. 3.4.1.1 LIFT WINCH

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 DESCRIPTION LIFT WINCH WINCH ROLLER AXLE END CAP AXLE ARM END CAP WINCH ROLLER SPRING THREADED ROD HYDRAULIC HOSE WINCH CABLE GUARD 3/8"-16 X 1 1/4" HEX BOLT 3/8" LOCK WASHER 3/8" FLAT WASHER 1 1/4"-7 X 3 3/4" HEX BOLT 1 1/4" FLAT WASHER 2 1/4" LOCK WASHER 1 1/4"- 7 NYLON LOCK NUT 3/4-10 X 2 1/4" HEX BOLT 3/4" FLAT WASHER 3/4" LOCK WASHER 3/4"-10 NYLON LOCK NUT PART# 205418T WINCH ROLLER AXLE END CAP AXLE ARM END CAP WINCH ROLLER SPRING THREADED ROD HYDRAULIC HOSE 131100122 HBOLT 0.3750-16x1.25x1.25-N LW 0.375 FW 0.375 HBOLT 1.2500-7x3.75x2.75-N FW 1.25 LW 1.25 HNYLOK 1.2500-7-D-N HBOLT 0.7500-10x2.25x1.75-N FWASHER 0.75 LW 0.75 NYLOK 0.7500-10-D-N QUANTITY PER UNIT 1 1 1 1 1 1 3 1 4 4 4 4 8 4 4 2 4 2 2
140
3.4.1.1
LIFT WINCH ASSEMBLY
The LIFT WINCH comes pre-manufactured, however, some alterations must be made with the LIFT WINCH 1. A WINCH ROLLER must be inserted into the LIFT WINCH. Un-bolt and remove the WINCH CASING. Remove the pre existing ROLLER AXLE which comes as part of the WINCH. Strip the paint of off of the ROLLER AXLE where it will make contact with the ROLLER HOLDERS. The ROLLER HOLDERS are part of the WINCH ROLLER. Align the AXLE with the ROLLER HOLDERS and insert. Bolt the ROLLER HOLDERS to the ROLLER AXLE.
Fig. 3.4.1.2 WINCH ROLLER
141
2.
Align AXLE END CAP with AXLE. Insert Bolt with Flat Washer and tighten with Nylon Lock Nut and Lock Washer.
Fig. 3.4.1.3 AXLE END CAP 3. Align AXLE ARM END CAP with AXLE. Insert Bolt with Flat Washer and tighten with Nylon Lock Nut and Lock Washer.
Fig. 3.4.1.4 AXLE ARM END CAP
142
4.
Attach WINCH ROLLER SPRING to the end of the AXLE ARM END CAP. Attach the THREADED BAR to the end of the WINCH ROLLER SPRING. Insert the THREADED BAR through the BAR GUIDE PLATE on the side of the WINCH. Put a Nut on the bottom of the THREADED BAR to prevent the THREADED BAR form moving up through the BAR GUIDE PLATE.
Fig. 3.4.1.5 WINCH ROLLER SPRING
143
5. 6.
Replace the WINCH CASING and bolt back together. Attach the Hydraulic hoses to the side of the LIFT WINCH
Fig. 3.4.1.6 WINCH SIDE VIEW 7. Align the WINCH CABLE GUARD with the CARRIER LIFT WINCH. Insert four 3/8"-16 x 1 1/4" Bolts with 3/8 Lock Washers and 3/8 Flat Washers to hold the CABLE GUARD to the WINCH. Tighten the appropriately.
Fig. 3.4.1.7 WINCH CABLE GUARD

144
8.
Align the LIFT WINCH with the RAMP. Insert four 1 1/4"-7 x 3 3/4" Bolts with 1 Flat Washers through the RAMP side and bolt together with 1 1/4"-7 Nylon Lock Nuts, 1 Flat Washers and 1 Lock Washers. Align the WINCH CABLE GUARD with the RAMP. Insert four -10 x 2 1/4" Bolts with Flat Washers from the outer side and bolt together with -10 Nylon Lock Nuts, Flat Washers and Lock Washers.
9.
Fig. 3.4.1.8 WINCH INSTALLATION
145
3.4.2
SHEAVE
The RAMP SHEAVE is used to direct the CARRIER CABLE from the WINCH on the underbelly of the RAMP to the upper surface of the RAMP where it then attaches to the CARRIER.
Fig. 3.4.2.1 SHEAVE
146
ITEM 1 2 3 4 5 6 7 8 9 10 11
DESCRIPTION 1/2"-13 X 1 1/2" HEX BOLT 1/2" LOCK WASHER 1/2" FLAT WASHER RAMP SHEAVE SHAFT END CAP RAMP SHEAVE SPACER B RAMP SHEAVE SHAFT RAMP SHEAVE RAMP SHEAVE SPACER A RAMP SHEAVE SPACER 1/8" GREASE FITTING RAMP SHEAVE LOCK
PART# HBOLT 0.5000-13x1.5x1.25N LWASHER 0.5 FWASHER 0.5 141100220 161100061 161100062 MCKISSICK SHEAVE 4300312 161100060 161100059 GREASE FITTING 0.125 141100221
QUANTITY PER UNIT 5 5 5 1 1 2 2 1 1 2 1
Fig. 3.4.2.2 SHEAVE EXPLODED
147
3.4.2.1
1.
SHEAVE ASSEMBLY
Align and insert a 1/8 Grease Fitting to each end of the RAMN SHEAVE SHAFT.
Fig. 3.4.2.3 GREASE FITTINGS
2. 3. 4.
Align and insert the RAMP SHEAVE SPACER A into the RAMP. Align and insert the RAMP SHEAVE SPACER B into the RAMP. Align the RAMP SHEAVE SPACER and both RAMP SHEAVES with the RAMP. Align and insert the RAMP SHEVE SHAFT through all three SPACERS and RAMP SHEAVES.
5.
Fig. 3.4.2.4 SHEAVE, SPACERS AND SHAFT

148
6.
Align RAMP SHEAVE SHAFT END CAP with RAMP SHEAVE. Insert three 1/2-13 x 1 Hex Bolts with Flat Washers and Lock Washers. Tighten Bolts to hold RAMP SHEAVE END CAP to the RAMP SHEAVE.
Fig. 3.4.2.5 END CAP 7. Align the RAMP SHEAVE LOCK with the Bolt holes in the RAMP as well as the groove in the end of the RAMP SHEAVE SHAFT. Insert two 1/2-13 x 1 Hex Bolts with Flat Washers and Lock Washers. Tighten Bolts to hold RAMP SHEAVE LOCK to the RAMP.
Fig. 3.4.2.6 RAMP SHEAVE LOCK 8. Grease the SHEAVE using a grease gun.
149
3.4.3
TOP CARRIER ROLLER

The TOP CARRIER ROLLER is a bar that sits at the top of the RAMP; it is used as a stopper, catching onto the OVERSHOOT DOGS located on the CARRIER, preventing the CARRIER from moving any further up the RAMP.
Fig. 3.4.3.1 TOP CARRIER ROLLER
150
ITEM 1 2 3 4 5 6 7 8
DESCRIPTION 3/4"-10 X 3" HEX BOLT 3/4" FLAT WASHER BEARING BLOCK 1/8" GREASE FITTING TOP CARRIER ROLLER 4.5" BORE SPLIT COLLAR 3/4"-10 NYLON LOCK NUT 3/4" LOCK WASHER
PART# HBOLT 0.7500-10x3x1.75-N FWASHER 0.75 832100001 GREASE FITTING 0.125 161100058 H2C-450 NYLOK 0.7500-10-D-N LW 0.75
Fig. 3.4.3.2 TOP CARRIER ROLLER EXPLODED
151
3.4.3.1
1.
TOP CARRIER ROLLER ASSEMBLY

Align TOP CARRIER ROLLER with RAMP. Slide a SPLIT COLLAR over each end of the TOP CARRIER ROLLER. Align the two BEARING BLOCKS with the RAMP and the TOP CARRIER ROLLER. Insert four 3/4-10 x 3" Hex Bolts with Flat Washers through each of the BEARING BLOCKS and the RAMP. Slide a Flat Washer, Lock Washer and a -10 Nylon Lock Nut over the end of each Bolt and tighten appropriately. Tighten the Set Screws on the SPLIT COLLARS.
2.
3.
Fig. 3.4.3.3 TOP CARRIER ROLLER ASSEMBLY
152
4. 5.
Align and insert a 1/8 GREASE NOZZLE on each BEARING BLOCK. Grease the TOP CARRIER ROLLER using a grease gun.
Fig. 3.4.3.4 GREASE FITTINGS
Fig. 3.4.3.5 TOP CARRIER ROLLER END
153
3.5
FINAL ASSEMBLY
The FINAL ASSEMBLY is where we attach the four sub-assemblies together; the CATWALK, CARRIER, LIFT ARM, and RAMP; to a one final unit. First the LIFT ARM is attached to the CARRIER, then the other end of the LIFT ARM gets attached to the CATWALK. Finally, the RAMP gets connected to the CATWALK.
Fig. 3.5.0.1 FINAL ASSEMBLY
154
3.5.1
ITE M 1 2 3 4 5
LIFT ARM CARRIER

DESCRIPTION HYDRAULIC CLAMP HYDRAULIC CLAMP CAP 3/8"-16 X 1 1/2" BOLT 1/8" GREASE FITTING LIFTING ARM HINGE PIN PART# 220200003 220200002 HBOLT 0.3750-16x1.5x1-N GREASE FITTING 0.125 161100009 QUANTITY PER UNIT 1 1 2 2 1
Fig. 3.5.1.1 LIFT ARM -CARRIER
155
3.5.1.1
LIFT ARM CARRIER ASSEMBLY

1. Insert 1/8 GREASE FITTINGS into either end of LIFT ARM HINGE PIN. 2. Using Crane support, lower the LIFT ARM onto the CARRIER when the CARRIER is upside down. Align the LIFT ARM with the PILLOW BLOCKS on the CARRIER. 3. Align and insert the LIFT ARM HINGE PIN through the LIFT ARM and PILLOW PLOCKS. Tighten the four Set Screws on the LIFT ARM to hold it firmly around the LIFT ARM HINGE PIN. 4. Adjust both vertical and horizontal Bolts on the PILLOW BLOCK in order to align the LIFT ARM with the CARRIER. 5. Grease the LIFT ARM HINGE PIN using a grease gun. 6. Attach the Hydraulic Hoses from the CARRIER to the two HYDRAULIC PIPES on the LIFT ARM. 7. Attach the HYDRAULIC CLAMP, holding the Hydraulic Hose closest to the Drillers Side.
156
3.5.2
LIFT ARM CATWALK

Attaching the LIFT ARM to the CATWALK consists of lowering the LIFT ARM (attached to the CARRIER) into the center groove of the CATWALK. The LIFT ARM then gets attached to the SPEAR on the CATWALK along with all of the hydraulic and electrical components. Next the LIFT ARM and CARRIER get lowered into place on the CATWALK.
Fig. 3.5.2.1 LIFT ARM - CATWALK
157
ITEM 1 2 3
DESCRIPTION 1/2"-20 X 1 1/2" HEX BOLT 1/2" LOCK WASHER 1/2" FLAT WASHER
PART# HBOLT 0.500020x1.5x1.25-N LW 0.5 FW 0.5
Fig. 3.5.2.2 LIFT ARM - SPEAR
3.5.2.1
1.
LIFT ARM CATWALK ASSEMBLY

Align the PILLOW BLOCKS on the LIFT ARM with the SPEAR on the CATWALK. Insert four -20 x 1 Hex Bolts along with Lock Washers and Flat Washer, tighten appropriately. Lower CARRIER and LIFT ARM into place in the CATWALK. Make sure the ROLLERS on the CARRIER and LIFT ARM align with the CATWALK. The SKATE CAGE can be installed now that the CARRIER is right side up. See SKATE ASSEMBLY in section 3.2.5.1 for further instructions. Connect the Hydraulic Hoses and Electrical Wires from the LIFT ARM to the CATWALK by running them through the three pipes which run the length of the LIFT ARM and through the hollow center of the SPEAR.
2.
3.
4.
158
3.5.3
RAMP CATWALK
The RAMP is attached to the CATWALK by aligning the PIVOT POSTS on the CATWALK with the PIVOT POSTS on the RAMP. Two RAMP-CATWALK PINS are inserted to hinge the two together, allowing the RAMP to be folded down for storage and transportation, then rotate upwards to attach to the drilling rig.
ITEM 1 2 3 4 5 6
DESCRIPTION RAMP-CATWALK PIN RETAINING RING 1/8" GREASE FITTING 3/8"-16 NYLON LOCK NUT 3/8" LOCK WASHER 3/8"-16 X 4 1/2"
PART# 161100006 WST-250 GREASE FITTING 0.125 NYLOK 0.3750-16-D-N LW 0.375 HBOLT 0.3750-16x4.5x1-N
Fig. 3.5.3.1 RAMP - CATWALK
159
3.5.3.1
1. 2.
RAMP CATWALK ASSEMBLY

Insert 1/8 GREASE FITTINGS into each RAMP-CATWALK PIN. Align the PIVOT POSTS on the RAMP with the PIVOT POSTS on the CATWALK. Insert RAMP-CATWALK PIN to hole the RAMP to the CATWALK. Insert the RETAINING RING over RAMP-CATWALK PIN. Align and insert a 3/8-16 x 4 Bolt through the collar on each of the CATWALK PIVOT POSTS. Slip a 3/8-16 Nylon Lock Nut and 3/8 Lock Washer over the end of each Bolt. Tighten Appropriately.
3. 4.
Fig. 3.5.3.2 RAMP-CATWALK PIN IN PIVOT POST 5. Connect the Hydraulic Hoses and Electrical Wires from the RAMP to the CATWALK.
160
3.6
ELECTRICAL COMPONENTS
The PIPEMATIC 3000 needs to be configured for either 600V or 480V depending on the power supply used by the customer. The electrical system has a large ELECTRICAL BOX which is located near the Flare End on the Drillers Side of the CATWALK. A smaller ELECTRICAL CONTROL BOX is located on the Drillers Side of the Hydraulic Reservoir, and it contains buttons for manual input as well as a display screen, showing the status of the system.
Along with these two ELECTRICAL BOXES, another small ELECTRICAL BOX is located on the Drillers Side towards the Ramp End of the CATWALK. From this box, the wires are diverted to the Goretrac and become connected to the CARRIER. We have provided set of Electrical Schematics as well as a list of all the components used for the 600V and 480V configurations.
161
3.6.1
ELECTRICAL SYSTEM PARTS LIST 3.6.1.1 600V PARTS LIST
QUANTITY 1 1 1 2 2 1 1 1 2 1 3 1 1 1 1 1 1 1/2 1 1 2 12 40 4 1 60 10 16 8 1 1 3 1 3 1 30
ITEMS CJIW - PD025 POWER SUPPLY NT2S-SF121BEV2 INTERFACE 2 LINE SCREEN 1CJIG - CPU42H CPU CJIW- ID211 16 PT. INPUT CJIW- OC211 16 PT. OUTPUT CJIW - AD08VI 8 ANALOG IN CJIW - DA041 4 ANALOG OUT CJIW - CT021 HIGH SPEED COUNTER E3S-CT11 PHOTO CONTROL S8VS - 03012 120- 12 VDC P.S. 2.5A OUTPUT P2RF - 05- "E" RELAY BASEand relay gzr-1-s 24vdc E2E- X10F1-M1 DISCONNECTABLE PROX. SW. RKT R13 - 632 / 5mm PROX CABLE 3RU1041-4LAIO 70-90 AMP MANUAL MOTOR STARTER 3RT1046-1A 75 HP. @ 460-VOLT STARTER c/w 120V COIL 3RT1016-1AK61 3PHASE CONTACTOR 3RH1921-1FA22 AUXILLARY TOP MOUNT CONTACTS 3RA1943-2A REVERSING CONTACTOR KIT ( 1 EACH JOB) 24 pole wieland 90 deg. Hood to panel mount c/w bushing DAH 4001B PANEL HEATER QUINT P.S. 120-240-VOLT~ 24VDC. @ 10-AMP UKK5-MTK 2 TIER DISCONNECT BLOCKS UKKB5 2 TIER TERMINAL BLOCKS D-UKKB 3 / 5 DP-UKK B 3 / 5 END PLATE UK5N TERMINAL BLOCKS D-UK 4 / 10 END PLATE ULSKG GROUND BLOCKS UK6 - FS I /C FLAT TYPE FUSE HOLDER TCP 10.0 AMP 250-VOLT CIRCUIT BREAKER TCP 6.0 AMP 250-VOLT CIRCUIT BREAKER TCP 4.0 AMP 250-VOLT CIRCUIT BREAKER TCP 3.0 AMP 250-VOLT CIRCUIT BREAKER TCP 1.0 AMP 250-VOLT CIRCUIT BREAKER SD-US / SC / LA/ GY DIN RAIL RECEPTACLE GGM 2 2AMP FUSESand fuse holders 3004126
Manufacturer Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Siemens Siemens Siemens Siemens Siemens Wieland Hoffman Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix
162
QUANTITY 1 1 1 1 1 1 1 1 2 3 1 1 20 10 7 2 1 1 1 1 1 6' 6' 6' 6'
ITEMS S222 K3A 2 POLE 3AMP 600-VAC BREAKER K6A 3 POLE 6 AMP 600VAC BREAKER 10250t PILOT LIGHT 10250TC2N GREEN LENS 24 VDC GREEN LED 10250TB 11 2 POSITION SELECTOR SWITCH 10250TB ED1080 E STOP 10250TB 63 RED EMERGENCY STOP BUTTON 10250 T1 1- N/O 1- N/C CONTACT BLOCK 14-2 / 0 - 1 ILSCO POWER DISTRIBUTION BLOCK MO1ISP 1500-VA 600 ~ 120 / 240 VOLT MARCUS 24-VDC AMBER PIPE MOUNT STROBE FEDERAL SIGNAL 2532 STRAIN RELIEF CONNECTOR T & B 2521 STRAIN RELIEF CONNECTOR T & B 3/4' STEEL MYERS HUB T& B 1'' - 3/4'' THREADED REDUCER STEEL HO300 3'' MYERS HUB STEEL 1-1/4'' THREADED REDUCER STEEL 72' - 16 conductor over all sheilded amphenol to panel mount 35'- 3 pair encoder cable + amphenol 35' - 2 conductor "raw" cable > no ends< F 3'' X 3'' LG6 PANDUIT GREY F 3'' LG6 PANDUIT GREY COVER F- 1.5'' X 3'' G6 PANDUIT GREY F- 1.5'' G6 PANDUIT GREY
Manufacturer ABB ABB Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS Varisystems Inc. Varisystems Inc. Varisystems Inc. PANDUIT PANDUIT PANDUIT PANDUIT
163
3.6.1.2
480V PARTS LIST
QUANTITY 1 1 1 2 2 1 1 1 2 1 3 1 1 1 1 1 1/2 1 2 12 40 4 1 60 10 16 8 1 3 1 3 1 30
ITEMS CJIW - PD025 POWER SUPPY NT2S-SF121BEV2 INTERFACE 2 LINE SCREEN 1CJIG - CPU42H CPU CJIW- ID211 16 PT. INPUT CJIW- OC211 16 PT. OUTPUT CJIW - AD08VI 8 ANALOG IN CJIW - DA041 4 ANALOG OUT CJIW - CT021 HIGH SPEED COUNTER E35-CT11 PHOTO CONTROL S8VS - 03012 120- 12 VDC P.S. 2.5A OUTPUT P2RF - 05- "E" RELAY BASE E2E2 X1081 DISCONNECTABLE PROX. RKT R13 - 632 / 5mm PROX CABLE 3RU1041-4LAIO 70-90 AMP MANUAL MOTOR STARTER 3RT1046-1A 75 HP. @ 460-VOLT STARTER c/w 120V COIL 3RH1921-1FA22 AUXILLARY TOP MOUNT CONTACTS 3RA1943-2A REVERSING CONTACTOR KIT ( 1 EACH JOB) 24 pole wieland 90 deg. Hood to panel mount c/w bushing QUINT P.S. 120-240-VOLT~ 24VDC. @ 10-AMP UKK5-MTK 2 TIER DISCONNECT BLOCKS UKKB5 2 TIER TERMINAL BLOCKS D-UKKB 3 / 5 DP-UKK B3 / 5 END PLATE UK5N TERMINAL BLOCKS D-UK 4 / 10 END PLATE ULSKG GROUND BLOCKS UK6 - FS I /C FLAT TYPE FUSE HOLDER TCP 6.0 AMP 250-VOLT CIRCUIT BREAKER TCP 4.0 AMP 250-VOLT CIRCUIT BREAKER TCP 3.0 AMP 250-VOLT CIRCUIT BREAKER TCP 1.0 AMP 250-VOLT CIRCUIT BREAKER SD-US / SC / LA/ GY DIN RAIL RECEPTACLE GGM 2 2AMP FUSES
MANUFACTURER Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Omron Siemens Siemens Wieland Wieland Hoffman Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix Phoenix
164
QUANTITY 1 1 1 1 1 1 1 2 3 1 1 20 10 7 1 2 1 1 70' 35' 35' 6' 6' 6' 6'
ITEMS S222 K3A 2 POLE 3AMP 600-VAC BREAKER 10250t PILOT LIGHT 10250TC2N GREEN LENS 24 VDC GREEN LED 10250TB 11 2 POSITION SELECTOR SWITCH 10250TB ED1080 E STOP 10250TB 63 RED EMERGENCY STOP BUTTON 10250 T1 1- N/O 1- N/C CONTACT BLOCK 14-2 / 0 - 1 POWER DISTRIBUTION BLOCK ~ ILSCO MO1ISP 1500-VA (480) ~ 120 / 240 VOLT ~ MARCUS 24-VDC AMBER PIPE MOUNT STROBE ~ FEDERAL SIGNAL 2531 STRAIN RELIEF CONNECTOR ~ T & B 2521 STRAIN RELIEF CONNECTOR ~ T & B HO50 1/2'' STEEL MYERS HUB ~ T& B 1-1/4'' - 1'' THREADED REDUCER STEEL 1'' - 3/4'' THREADED REDUCER STEEL HO300 3'' MYERS HUB STEEL ~ T & B 3'' TO 1-1/4'' THREADED REDUCER STEEL 16 conductor over all sheilded amphenol to panel mount 3 pair encoder cable + amphenol 2 conductor "raw" cable > no ends< F 3'' X 3'' LG6 PANDUIT GREY F 3'' LG6 PANDUIT GREY COVER F- 1.5'' X 3'' G6 PANDUIT GREY F- 1.5'' G6 PANDUIT GREY
MANUFACTURER ABB Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer Cutler Hammer MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS MISCELANEOUS Varisystems Inc. Varisystems Inc. Varisystems Inc. PANDUIT PANDUIT PANDUIT PANDUIT
165
3.6.2
ELECTRICAL SCHEMATICS
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
3.7
HYDRAULIC SYSTEM
An extensive amount of hydraulics are used in the PIPE-MATIC 3000, they are used to power all forms of motion from the PIPE RACKS, INDEXERS, KICKERS, SAFETY PINS to the WINCHES that drive the SKATE and CARRIER. In order to achieve these operations, a complex configuration of Hydraulic Components are used. A pump draws the Hydraulic Fluid from the Hydraulic RESERVOIR, transferring it to set of Hydraulic Valves located in the CATWALK and CARRIER. These Valves are grouped together in the HYDRAULIC VALVE BANKS, however, each valve works independently. The VALVE BANK CATWALK being much larger than the one on the CARRIER as it controls all Hydraulics on the PIPE-MATIC minus the ones on the CARRIER. The CARRIER needs its own HYDRAULIC VALVE BANK to reduce the amount of hoses that need to be used to carry Fluid from the CATWALK to the CARRIER. From these VALVE BANKS, two sets of hydraulic hoses run to each hydraulic sub-system, one hose pushes fluid into the system, raising an INDEXER for example, while the other hose allows fluid to leave the sub-system, therefore lowering the INDEXER. These motions are all controlled by the VALVE for that particular sub-system. This section will provide information on how to attach the Hydraulic Components as well as a set of schematics which will further detail the location of these Hydraulic Components on the PIPEMATIC.
183
3.7.1
HYDRAULIC CYLINDERS
There are 30 Hydraulic Cylinder located on the PIPE-MATIC 3000, 18 on the CATWALK controlling the PIPE-RACKS and the INDEXERS, while 12 Cylinders control the SAFETY PINS and KICKERS on the CARRIER. Two Hydraulic Hoses must be attached to each Cylinder, one for inflow and one for outflow. Which hose goes in what hole on the Cylinder is determined by where the hoses attach to the VALVE BANK. 1. Remove the Plugs from the Hydraulic Cylinder by simply using a screw driver to unscrew the Plugs. Screw on Hydraulic Fitting. This may be a straight, elbow or a T-section fitting depending on the specific Hydraulic Cylinder. The hoses are simply screwed onto the end of each Hydraulic Fitting. Be sure to keep protective plastic covering on Hydraulic Fitting until hoses are attached to prevent dirt and debris from entering into the hydraulic system.
2.
3.
Figure 3.7.1.1 CYLINDER FITTINGS
184
3.7.2
HYDRAULIC BULKHEADS
Hydraulic Bulkheads are used to connect Hydraulic Hoses between the walls of the CATWALK or CARRIER for example. These Bulkheads come with Straight, Elbow or T-Section fittings depending on what is needed in a given situation. 1. Insert Bulkhead though pre-drilled hole. Screw nut over the opposite end and tighten nut to hold Bulkhead into place. Hoses are then simply screwed onto the end of each Hydraulic Fitting.
2.
Fig 3.7.2.1 BULKHEADS
Fig. 3.7.2.2 HOSES ATTACHED TO BULKHEADS

185
3.7.3
PIPE RACK ARM HYDRAULICS
The Hydraulics on each PIPE RACK ARM contains a Pressure Reducer along with a set of Hydraulic Pipes that run the length of the ARM. 1. Remove the plastic caps for the Pressure Reducer. Insert two straight fittings into the top side of the Reducer with 90 Elbows on either side pointing away from the straight fittings.
Fig. 3.7.3.1 PRESSURE REDUCER CONFIGURATION
2.
Screw a Hydraulic Pipe into each end of the Straight Fittings on the Pressure Reducer. Using two sets of Hydraulic Clamps and the holes provided in the Pipe Rack Arm, clamp the Hydraulic Pipes onto the Arm. The Pipes should be on the outside of the Arm when the Arm is folded inward and the Pressure Reducer located towards the base of the Arm.
Fig. 3.7.1.2 PRESSURE REDUCER
Fig 3.7.3.3 HYDRAULIC CLAMP
186
3.7.4
HOSE CLAMPS
Hose Clamps are used to organize and tidy up Hydraulic Hoses as they run throughout the CARRIER and CATWALK. This helps prevent entanglement and helps speed up any service or troubleshooting that may have to be done one the system. There are two types of Hose Clamps, the one shown previously on the Pipe Rack Arms along with straps which simply hold a bundle of hoses together for organizational purposes. Both types of Clamps are very basic and easy to install by simply inserting a Bolt through the Clap and anchor such as the CATWALK or CARRIER. Simply use a Nut on the other end of the bolt and tighten.
Fig. 3.7.4.1 HOSE CLAMP
Fig. 3.7.4.2 TIE CLAMP
187
3.7.5
HYRDRULIC SCHEMATICS

PM-3000 Pragma Pipe-Matic 3000 Assembly Manual Rev 01

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What are the main components of the Pipe-Matic 3000 assembly?

What are the main components of the Pipe-Matic 3000 assembly?

What are the steps to assemble the hydraulic cylinders?

What are the steps to assemble the hydraulic cylinders?

PRAGMA PIPE-MATIC 3000

Fig. 2.0.0.1 PIPE-MATIC 3000

Fig. 3.1.0.1 CATWALK

Fig. 3.1.1.1 INDEXER

QUANTITY PER UNIT 1 2 1 3 2 2 3 3

Fig. 3.1.1.2 INDEXER EXPLODED

INDEXER PREPERATION WORK

Fig. 3.1.1.3 INDEXER WITH CYLINDERS

Fig. 3.1.1.4 OUTER HYDRAULIC CYLINDER

Fig. 3.1.1.5 INNER HYDRAULIC CLYLINDER

9. Grease each PIN in the KICKER assembly using a grease gun.

Fig. 3.1.2.1 PIPE RACK ARM

QUANTITY PER UNIT 1 2 4 2 1 2 2 1 1 2 1 1 1 1 1 1 6 6 1 6 6

Fig. 3.1.2.2 PIPERACK ARM EXPLODED

PIPE RACK ARM PREPARATION WORK

PIPE RACK ARM ASSEMBLY

Fig. 3.1.2.3 PIPE RACK ARM - CATWALK

Fig. 3.1.2.4 JACK PAD AND CYLINDER

Fig. 3.1.2.6 CYLINDER PIN

Fig. 3.1.2.7 CYLINDER MOUNT SPACER

Grease each pin and ball joint using a grease gun.

Fig. 3.1.3.1 SHORT LANDING STAIRS

Fig. 3.1.3.2 PIVOTING DECK DECK STAIRS

SHORT LANDING DECK STAIRS

PART# 131100169 HBOLT 0.750010x3.5x1.75-N FW 0.75 141100387 NYLOK 0.7500-10-D-N

Fig. 3.1.3.3 SHORT LANDING DECK STAIRS EXPLODED

SHORT LANDING DECK ASSEMBLY

Fig. 3.1.3.4 IDLER PLATE

Fig. 3.1.3.5 SHORT LANDING STAIRS - CATWALK

PIVOTING DECK STAIRS

PART# 131100326 161100035 COTTER PIN 0.125

Fig. 3.1.3.6 PIVOTING DECK STAIRS EXPLODED

PIVOTING DECK STAIRS ASSEMBLY

PART# 131100047 131100143 HBOLT 0.7500-10x7.25x2-N LW 0.75 FW 0.75 NYLOK 0.7500-10-D-N

Fig. 3.1.4.1 REAR POSTS EXPLODED

REAR POST ASSEMBLY

VERTICAL GUIDE STRIP

PART# 141500005 SCHCSCREW 0.375-16x1.25x1.25-HX-N NYLOCK 0.3750-16-D-N LW 0.375

QUANTITY PER UNIT 1 10 10 10

Fig. 3.1.5.1 VERTICAL GUIDE STRIP EXPLODED

VERTICAL GUIDE STRIP ASSEMBLY

Fig. 3.1.6.1 GORETRAC

QUANTITY PER UNIT 1 2 2 8 8 12 48 48 48 4 4 4 4

Fig. 3.1.6.2 GORETRAC EXPLODED

Fig. 3.1.6.3 GORETRAC MOUNTS

Fig. 3.1.6.4 GORETRAC MOUNTS 2

Fig. 3.1.6.5 GORETRAC INSERTS

Fig. 3.1.6.6 SLIDE PLATES

Fig. 3.1.6.8 SLIDE PLATES 3

Fig. 3.1.6.9 GORETRAC CATWALK 1

Fig. 3.1.6.10 GORETRAC CATWALK 2

PART# 131100077 141500001 SCHCSCREW 0.37516x1x1-HX-N FW 0.375 NYLOK 0.3750-16-D-N

QUANTITY PER UNIT 1 1 8 4 4

Fig. 3.1.7.1 SPEAR EXPLODED

Fig. 3.1.7.2 PLUMBING SPEAR UHMV

Fig. 3.1.7.3 GORETRAC SPEAR