Service Manual

ST-120 Iron Roughneck

Reference Reference Description

This document contains proprietary and confidential

information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only National Oilwell Varco
and remains the property of NOV. Reproduction, in whole or in RIG SOLUTIONS
part, or use of this design or distribution of this information to
others is not permitted without the express written consent of
11000 Corporate Centre Drive
NOV. This document is to be returned to NOV upon request or Houston, TX 77041
upon completion of the use for which it was loaned. This
document and the information contained and represented
herein is the copyrighted property of NOV.
© National Oilwell Varco
Document Number Rev.
D811000557-MAN-001 04

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Form D811001123-GEN-001/06
 D811000557-MAN-001
Revision 04

Revision History

04 Fourth Issue M. Taylor A. Sharma A. Jones

05.09.2013

03 06.03.2010 Third Issue P. Solovyov A. Jones J. Walker

02 16.01.2009 Second Issue P. Solovyov J. Walker J. Walker

01 09.12.2008 First Issue P. Solovyov A. Jones B. Winter

Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved

Change Description

Revision Change Description

01 First Issue

• Added Section: Making Connections (Page 4-4).

02 • Updated Arm Assembly Control plaque throughout document:
From: Lever LEFT SLEW RIGHT To: CW SLEW CCW

• Update from “User Manual” to “Service Manual” throughout document and use current template.
03 • Replaced figures with latest model.
• Updated and added new procedures in Chapters 2 through 7.

• Updated to the current template.

• Added five steps under the General System Safety Practices section (Page 1-4).
• Added Safety Alert Advisory on page 5-16.
• Updated Maintenance Operation Warning Plate (page 5-1).
04 • Added Safety Alert Advisory (page 5-26) and updated illustration (page 5-27).
• Updated procedure for Removing Torque Wrench Assembly (page 5-18), added Safety Alert Advisory,
and changed Figure 5-8 (page 5-19).
• Removed Service Center information, Chapter 7, since it is in Chapter 1.

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Table of Contents

Chapter 1: General Information

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 2: Overview
Tool Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Iron Roughneck Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Tool Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Socket Mounted Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Floor Base Mounted Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Floor Socket Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Floor Mount Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Floor Socket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Hydraulic Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Control Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Auxiliary Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Bit Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Pinch Point Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Chapter 3: Installation
ST-120 Iron Roughneck Installation Procedures Manual . . . . . . . . . . . . . . . . . . . . . . 3-1

Chapter 4: Operation
Operating the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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Normal Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Normal Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Positioning and Adjusting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Adjusting Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Moving the Grounding Links to the Upper Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Setting up the Bit Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Using the Bit Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Locking Out the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Hydraulic Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Slew Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Opening Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Opening Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Moving Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Securing the Iron Roughneck 
on a Floating Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Transport Skid Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Transport Skid Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Transport Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Transporting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Storing the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Return to Service After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Chapter 5: Maintenance
Maintenance Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Recommended Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Inspecting Hardware and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Lubricating the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Inspection, Lubrication, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
ST-120 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Head Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Arm Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Replacing Wrench Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Removing Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Replacing Spin Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Removing the Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Part Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

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Changing Intensifier Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Changing Inlet Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Changing Oil Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Changing Brake and Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Changing Brake and Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Changing System Hydraulic Expansion Tanks Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Chapter 6: Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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General Information 1

Conventions
This manual is intended for use by field engineering, installation, operation, and repair personnel.
Every reasonable effort has been made to ensure the accuracy of the information contained
herein. National Oilwell Varco® (NOV) will not be held liable for errors in this material, or for
consequences arising from misuse of this material.

Advisories
Graphic symbols and bracketed text indicate advisories for a specific topic. This information
provides the reader with additional details and may advise the reader to take a specific action to
protect personnel from potential injury or lethal conditions. These advisories may also inform the
reader of actions necessary to prevent equipment damage.

Note

The note symbol indicates that additional information is

provided about the current topic.

Caution

!
The caution symbol indicates that potential damage to
equipment, or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.

Warning

The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
follow safe work procedures could result in serious or
fatal injury to personnel, significant equipment
damage, or extended rig down time.

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Conventions
Advisories
Hot Surfaces

The hot surface symbol indicates the presence of a

hot surface or component. Touching this surface
could result in bodily injury. To reduce the risk of
injury from a hot component, allow the surface to cool
before touching.

Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts, or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your rig configuration, see the technical drawings included
with your NOV documentation.

Safety Requirements
The NOV equipment is installed and operated in a controlled drilling rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
outlined in the equipment manuals are the recommended methods of performing operations and
maintenance.

!
To avoid injury to personnel or equipment damage,
carefully observe requirements outlined in this section.

Proper Use of Equipment

NOV equipment is designed for specific functions and applications, and should be used only for its
intended purpose.

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General Information 1

Safety Requirements
Safe Lifting
When lifting and handling NOV equipment, use approved lifting procedures and safe methods.

Always follow all federal, state and local rules, codes, and
rig-specific safety guidelines when lifting and handling
NOV equipment. Operators and maintenance personnel
should be properly trained in safe lifting procedures and
the inspection of material handling equipment and lifting
components. Safe lifting recommendations provided in this
manual do not take precedence over local safety rules and
regulations, OSHA regulations, or instructions issued by
the manufacturers of rig hoisting equipment and other tools
on the rig.

Lifting equipment improperly creates a hazardous

working environment. To avoid lifting hazards, only lift
equipment with material handling equipment rated for
the expected load and only from the designated lift
points. Failure to follow safe lifting guidelines may
result in serious or fatal injury to personnel,
significant equipment damage, and extended rig down
time.

Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained in rig safety, tool operation,
and maintenance to ensure their safety.

!
Personnel should wear protective gear during installation,
maintenance, and certain operations.

Contact the NOV training department for more information about equipment operation and
maintenance training.

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Safety Requirements
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
The equipment manufacturer recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures and that personnel are not using tools that were not specifically recommended by the
manufacturer.

General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities such as
electrical, hydraulic, pneumatic, or cooling water.

!
Read and follow the guidelines below before installing
equipment or performing maintenance to avoid
endangering exposed persons or damaging equipment.

 Isolate energy sources before beginning work.

 Avoid performing maintenance or repairs while the equipment is in operation.
 Wear proper protective equipment during equipment installation, maintenance, or
repair.
 Read and understand the manual before operation of the equipment.
 Ensure that personnel are clear of the operating path of the equipment before
operation.
 Shut down the equipment when not in use.
 When restarting the equipment, ensure that all personnel are clear of the equipment
before use. If tool moves unexpectedly, shut down and lock out equipment
immediately and inspect equipment for damage.
 Do not, for any reason, place hands or limbs in any portion of the roughneck while
the equipment is enabled or operating.

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General Information 1

Safety Requirements
Replacing Components
 Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installment.
 Replace failed or damaged components with original equipment manufacturer
certified parts. Failure to do so could result in equipment damage or injury to
personnel.

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Safety Requirements
Routine Maintenance
Equipment must be maintained on a routine basis. See product-specific service manuals for
maintenance recommendations.

During operation, surfaces may become hot enough to

cause bodily injury. To reduce the risk of injury from
hot components, allow the surface to cool before
touching.

!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.

Service Centers
For a directory of NOV Service Centers, see document number D811001337-DAS-001, titled
“Service Center Directory.” This document is located in the User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
www.nov.com/contact_us/24hr_EmergencyList.asp

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Overview 2

Tool Description
The ST-120 Iron Roughneck is a drill floor tool used for make-up and break-out of drilling tubular
connections. Designed for use on offshore and large land rigs, the durable Iron Roughneck
features a manually operated extend/retract scissor-arm system. The Iron Roughneck allows
clearance around the Well Center and the Mousehole during use or when placed in the parked
position.
The Iron Roughneck can make or break all tool connections from 4" – 10" outside diameter, and
can handle nominal drill pipe from 3-1/2" up to 7". The Iron Roughneck can also make and break
stabilizers, spiral collars, and other Bottom Hole Assembly (BHA) components with sufficient
connection length.

For safe operating conditions, place the Iron Roughneck in

the parked position when it is not in use.

This document describes the day-to-day care and

operation of the Iron Roughneck. It is essential that the
operators have the required knowledge, education, and
training before using the tool and related equipment and
systems.

Head Assembly and Arm Assembly Controls are used to operate the Iron Roughneck. Refer to
section titled "Control Console Assembly" on page 2-24. For convenient operation, the Control
Console Assembly can be mounted on the front left or right side of the Iron Roughneck Head
Assembly. The hydraulic control components safely and quickly provide up to 100,000 ft.-lbs.
makeup torque and 120,000 ft.-lbs breakout torque.
The Iron Roughneck works at Well Center and at the Mousehole. When the Iron Roughneck is not
in use, personnel can operate a control valve to rotate the tool around the column into the storage
position.
The ST-120 Iron Roughneck can be installed on the drill floor by either of the two following
methods:
 Single, floor-mounted socket with no hanging cable (see to Figure 2-14).
 Floor mount assembly with an upper tie back assembly to secure the Iron
Roughneck to the rig structure (see Figure 2-15).

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Iron Roughneck Components

Table 2-1. Iron Roughneck Components

Assembly Description

Head Assembly The Head Assembly includes Spin Wrench and Torque
Wrench Assemblies. 
The Head Assembly is connected to the Arm Assembly. The
Control Console support is located on the front of the Head
Assembly. For details, refer to section titled "Head
Assembly" on page 2-20.

• Spin Wrench Assembly The Spin Wrench rollers grip the connection and spins with a
torque of 3000 ft.-lb. For details, refer to section titled "Spin
Wrench Assembly" on page 2-22.

• Torque Wrench Assembly The Torque Wrench can make up the connection with a
maximum torque of 100,000 ft.-lb, and break out connections
with a maximum torque of 120,000 ft.-lb.
For details, refer to section titled "Torque Wrench
Assembly" on page 2-21.

Control Console Assembly The Iron Roughneck operator-controlled control console is

installed on the front of the Iron Roughneck. The control
console can be mounted on the front left or front right side,
depending on the space requirements of the rig floor. For
details, refer to section titled "Control Console Assembly"
on page 2-24.

Arm Assembly Capable of extending and retracting, the Arm Assembly

supports and provides horizontal travel of the Head Assembly
for positioning at the Well Center, Mousehole, and Parked/
Standby positions. For details, refer to and section titled
"Arm Assembly" on page 2-19.

Column Assembly The Column Assembly, which is mounted either on a floor

socket or on the drill floor, provides vertical and rotational
travel for the Iron Roughneck for alignment with either the
Mousehole or Well Center as required. For details, refer to
section titled "Column Assembly" on page 2-18.

Mounting Assemblies

• Iron Roughneck -  The Column Assembly is attached to the Floor Socket

Floor Socket Mount Model assembly to secure the Iron Roughneck to the drill floor. For
details, refer to section titled "Floor Socket Assembly
Installation" on page 2-15.

• Iron Roughneck -  The Column Base Assembly is welded to the drill floor and a
Floor Mount Model Tie-Back structure secures the Iron Roughneck to the Mast.
For details, refer to section titled "Floor Mount Assembly
Installation Options" on page 2-16.

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Overview 2

Iron Roughneck Components

Table 2-1. Iron Roughneck Components (cont.)

Assembly Description

Hydraulic Assembly The Hydraulic Assembly provides operations functions for

movable components of the Iron Roughneck. For details,
refer to section titled "Hydraulic Assemblies" on page 2-
23.

Bit Breaker Assembly The Bit Breaker Assembly is auxiliary equipment used for
making or breaking tubing to drill bit connections. See section
titled "Bit Breaker Assembly" on page 2-25.

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Tool Orientation
The Iron Roughneck Head Assembly can be positioned over Well Center or Mousehole for tubular
makeup and breakout procedures. Refer to Chapter 4, titled "Positioning and Adjusting the Iron
Roughneck.
Left Rear

Front Right
Front View

Right Front

Rear Left
Rear View

Figure 2-1. Iron Roughneck - Orientation

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Overview 2

Tool Orientation

Arm
Spin Wrench Assembly
Assembly

Torque Gage

Torque Wrench
Assembly
Head Assembly
Controls

Arm Assembly
Controls

Front
Front View

Column

Arm Assembly
Extend/Retract
Cylinder

Arm Function
Manifold
(Behind Guard)

Guard

Rear Rear View

Figure 2-2. Iron Roughneck - General Description

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Specifications
Hydraulic Requirements

Required Operating Pressure 2,500 psi (172 bar)

Required Flow Rate 45 gpm (170 lpm)

Maximum Input Pressure 3,000 psi (206 bar)

Minimum Input Pressure 2,500 psi (172 bar)

Maximum Flow Rate 65 gpm (246 lpm)

Supply Connections 1" pressure, 1 1/4" tank, and 1/2" drain

Spin Wrench

Speed 80 rpm on 5" OD Tubular

Torque 3,000 ft-lb (4,067 N-m) on 5" OD Tubular

Torque Wrench

Make-up Torque 100,000 ft-lb (135,582 N-m)

Break-out Torque 120,000 ft-lb (162,698 17)

Connection Range 3 1/2" - 10"

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Overview 2

Specifications
Socket Mounted Option
The Iron Roughneck is flexible for positioning as required according to rig floor specifications.

Fully Retracted
Top View
Numbers in brackets are millimeters [mm].
89.64
[22]
62.42
[1585]
Tool
Outline R66.94
[R1700] *Maximum slew angle is ± 90° as shown.
For deviation, consult National Oilwell
Varco Engineering.
51.20
4.50 [1300] ±90° *
[1638]

P34.77 90°
[R883]
Control
Assembly
Center of Rotation 47.03
[1195]

47.03
Fully Retracted [1195] Fully Retracted
and Lowered 20.42 and Lowered
Side View [519]
Front View

Center
of Center of Spin
Gravity Wrench Rollers

104.32
[2650]

*59.15
47.03 [1502]
[1200] *31.40
[798]
Connection
Height

Drill Floor
Floor Socket *Vertical dimensions vary by ± 0.85"
as the arm extends/retracts.

Figure 2-3. Socket Mounted Option - Range of Operation (1 of 4)

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Specifications
Socket Mounted Option

Numbers in brackets are millimeters [mm].

Fully Extended Top View

237.20
[6025]
190.85
[4848]

5800
[1473]
64.50
[1638]

Fully Extended and Fully Lowered Side View

112.36
[2854]

Socket Mounted
42.00
Column
Spin [1067]
Arm Assembly
Wrench
Center
Guide of Gravity Center of Spin
Wrench Rollers

105.22
[2673]

6037 60.86
[1533] 46.76 [1546]
79.95 [1188] 33.10
26.55
[2031] 15.70 [841]
[674]
[399]

Torque Connection
Floor Socket Height
Wrench
Assembly
Socket
Center Line

Figure 2-4. Socket Mounted Option - Range of Operation (2 of 4)

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Overview 2

Specifications
Socket Mounted Option

Fully Retracted Top View

Numbers in brackets are millimeters [mm].

93.39
[2372]
R39.23
62.42 R66.94
[R996] [1585] [R1700]

64.50 51.20
[1638] [1300]

47.03
Center of [1195]
Rotation

Fully Retracted and Fully Raised Front View

Fully Raised Side View
47.06
[1195]

Center of
Gravity
Center of Spin
Wrench Rollers

145.63
[3699]

Connection *101.15
85.60 Height [2569]
[2174] 20.42 *73.40
[519] [1864]

*Vertical dimensions vary by ± 0.85"

as the arm extends/retracts.

Figure 2-5. Socket Mounted Option - Range of Operation (3 of 4)

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Specifications
Socket Mounted Option

Numbers in brackets are millimeters [mm].

Fully Extended Top View

233.46
[5930]
190.85
[4848]

58.00 64.50
[1473] [1638]

Fully Extended and Fully Raised Side View

112.36
[2854]
42.00
[1067]

Center
of Gravity Center of Spin
Wrench Rollers

145.63 147.22
[3699] [3739]
121.95
102.37
73 [3097] 102.86
[2600] Connection [2613]
85.02
[2061] 68.55 Height
75.10
60.52 55.86 [1908]
[1741]
[1537] [1419]

Socket Center Line Rig Floor

Figure 2-6. Socket Mounted Option - Range of Operation (4 of 4)

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Overview 2

Specifications
Floor Base Mounted Option

Fully Retracted and Lowered Top View

138.42 Numbers in brackets are millimeters [mm].
[3516]
89.64
Column [2277]
62.42 R66.94
Tie-Back
[3516] [R1700]
To Rig

51.20
[1300]

34.77
[R883]
Center of Rotation
76.00 47.03
[1930] [1195]
Fully Retracted and Fully Lowered Side View Fully Retracted and Fully Lowered Front View

47.03
[1195]

20.42
[519]

Center
of Gravity

155.75
Center of Spin
[39.65]
Wrench Rollers

*60.15
48.33 [1528]
[1228] *32.40
[823]
Connection Height

These areas should Drill Floor

be kept clear for Floor mount option
tool operation. only available with *Vertical dimensions vary by ± 0.85"
tie-back to rig. as the arm extends/retracts.

Figure 2-7. Floor Mount Assembly Option - Range of Operation (1 of 4)

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Specifications
Floor Base Mounted Option

Fully Extended Top View Numbers in brackets are millimeters [mm].

233.46
[5930]
190.85
[4848]

58.00
[1473]
64.50
[1638]

Fully Extended Side View

Column Extension
for Upper Tie-Back

112.36
[2854]
Floor Base*
Mounted Column 42.00
Center Spin [1067]
Arm Assembly Wrench
of Gravity
Guide Center of Spin
Wrench Rollers
106.22
[2698]

61.37 61.86
[1559] 47.76 [1571]
80.95 [1213] 34.10
27.55
[2056] 19.52 [866]
[700]
[496]

14.86
Torque Connection
[377]
Wrench Height

Figure 2-8. Floor Mount Assembly Option - Range of Operation (2 of 4)

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Overview 2

Specifications
Floor Base Mounted Option
Fully Retracted and
Fully Raised Top View
138.42 Numbers in brackets are millimeters [mm].
[3516] 89.64
Column [2277]
62.42 R66.94
Tie-Back
[1585] [R1700]
to Rig

51.20
[1300]

R34.77
[R883]
Center or Rotation
76.00 47.03
[1930] [1195]

Fully Retracted and Fully Retracted and

47.03
Fully Raised Side View [1195] Fully Raised Front View
20.42
[519]

Center
of Gravity

Center of Spin
Wrench Rollers

146.63
[3724]

*102.15
86.60 Connection [2595]
[2200] Height *74.40
[1890]

Column Base Rig Floor

*Vertical dimensions vary by ± 0.85"
as the arm extends/retracts.

Figure 2-9. Floor Mount Assembly Option - Range of Operation (3 of 4)

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Specifications
Floor Base Mounted Option

Fully Extended and Fully Raised Top View

Numbers in brackets are millimeters [mm].

233.46
[5930]
190.85
[4848]

58.00
[1473]
64.50
[1633]

Fully Extended and Fully Raised Side View

112.36
[2854]

42.00
Center [1067]
of Gravity
Center of Spin
Wrench Rollers

5148.22
[3765]
122.95
103.37 [3123] 103.86
[2626] 86.02 Connection [2638]
[2185] Height 76.10
69.55
[1767] 61.52 56.86 [1933]
[1563] [1444]

Figure 2-10. Floor Mount Assembly Option - Range of Operation (4 of 4)

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Overview 2

Installation Options
The ST-120 Iron Roughneck can be installed on the drill floor by either a single, floor-mounted
socket, or a floor-base assembly with a tie back assembly. See Figure 2-11 and Figure 2-12.

Floor Socket Assembly Installation

Socket Mounted Spin Wrench
Column Assembly
Arm Assembly

Guide

Torque Wrench
Assembly

Floor Socket Drill Floor

Assembly

Figure 2-11. Floor Socket Assembly Installation Options

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Installation Options
Floor Mount Assembly Installation
Upper Tie-back

Column Extension
for Upper Tie-Back

Base Spin Wrench

Mounted Assembly
Column Arm Assembly

Guide

Torque Wrench
Assembly

Floor Mount
Assembly Drill Floor

Figure 2-12. Floor Mount Assembly Installation Options

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Overview 2

Assembly Description
Floor Socket Assembly
The Iron Roughneck is installed on the drill floor using a single, floor-mounted socket. The Socket
Assembly enables the Iron Roughneck to be rotated for proper alignment over the Well Center or
Mousehole.

Hydraulic Motor

Hydraulic Brake

Idler Shaft
(2 places)

Column Lock Pin

(4 places)

Column Base

Turntable
Bearing

Idler Gear

Pinion Gear

Figure 2-13. Floor Socket Assembly

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Assembly Description
Column Assembly
The Column Assembly, which is mounted on the drill floor, provides vertical and rotational travel for
the Iron Roughneck for alignment with either the Mousehole or Well Center as required.

!
If air is introduced into the duplex extend cylinder, use extreme
caution when extending the arm for the first time.

As the arm extends, the air will compress causing the arm to
extend rapidly. Support unit with tugger and stand to the side
until air is purged.

Column Assembly

Hydraulic
Service Loop
(Drag Chain)

Column
Assembly
Lift Cylinder

Arm Assembly

Arm Assembly
Extend/Retract
Duplex Cylinder

Drain Line
Return Line Supply Line

Figure 2-14. Column Assembly

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Overview 2

Assembly Description
Arm Assembly
Center Support
Weldment

Cylinder Assembly
(2)
Rear

High Pressure
Hydraulic
Filter

Hydraulic
Shut Off Arm Assembly
Valve Function
Manifold

Figure 2-15. Arm Assembly

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Assembly Description
Head Assembly
The Iron Roughneck Head Assembly attaches to the scissor-arm which provides horizontal travel
to align the Iron Roughneck with Well Center or Mousehole. The Head Assembly contains the spin
wrench and torque wrench assemblies.

The control console can be installed on the left or right side

of the Iron Roughneck carriage. Refer to ST-120
Installation Procedure, included in the User Manual.

Spin Wrench
Hydraulic Service Loop
Drag Chain

Spin Wrench
Clamp Manifold
Assembly

Intensifier
Hydraulic Filter
with Ball Valve

Spin Wrench
Assembly

Torque Wrench
Assembly

Front
Figure 2-16. ST-120 Head Assembly

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Overview 2

Assembly Description
Torque Wrench Assembly
The Torque Wrench can make up connections up to a maximum torque of 100,000 ft.-lb. The
Torque Wrench can break out connections up to a maximum torque of 120,000 ft.-lb. Follow
general safety precautions when working around the Torque Wrench. Failure to follow the
precautions in these warnings may result in serious injury to personnel and/or damage to
equipment.

Ensure power is OFF to the Torque Wrench before

touching or performing repairs and maintenance.
The Torque Wrench presents pinching hazards.

Torque Cylinder
(4)
Torque Wrench
Assembly Plate

Clamp Cylinder
(6)
Upper Dies
(3)

Right

Left

Lower Dies
(3)

Front
Isometric View

Figure 2-17. Torque Wrench Assembly

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Assembly Description
Spin Wrench Assembly
The Spin Wrench rollers grip the connection and spins with a torque of 3,000 ft.-lbs, on 5" OD
tubulars.
Motors
(4)

Ensure power is OFF to the Spin Wrench before

touching or performing repairs and maintenance.
Spin rollers present pinching hazards.

Spin rollers can become hot during operation.

Ensure spin rollers are allowed to cool before
touching or performing repairs and maintenance.

Spin Rollers
(4)

Front Isometric View Ensure tools, clothing, or personal equipment

Front
do not come in contact with the spin rollers during
Guard operation. Objects can become tangled in the
spin rollers and lead to serious personal injury or
equipment damage.
Hydraulic
Manifold

Clamp
Cylinder

Rear Isometric View

Rear
Figure 2-18. Replace Spin Rollers

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Overview 2

Assembly Description
Hydraulic Assemblies
Spin Wrench
Assembly

Arm Assembly

Inlet
High Pressure
Hydraulic
Filter

Head Unit
Function Manifold Control Console
Torque Assembly
Wrench
Assembly

Hydraulic Arm Assembly

Shut Off Function
Valve Manifold

Rear

Figure 2-19. ST-120 Hydraulic Assemblies

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Assembly Description
Control Console Assembly
The Iron Roughneck Control Console can be installed on the right or left side of the Head Assembly
and adjusted out 90°. Refer to Figure 2-5 on page 2-9. The ST-120 Iron Roughneck Control Console
includes Head Assembly and Head Assembly controls.

UNCLAMP BREAK CENTER OUT UNCLAMP UP

TW TW MODE SW SW SW
CLAMP MAKE SW IN CLAMP DOWN
M364000424 Rev -

Head Assembly Control Plaque

UP RETRACT CW RETRACT
CARRIAGE DEPLOY SLEW ADJUST
DOWN EXTEND CCW EXTEND
M364000425 Rev -

Arm Assembly Control Plaque

Torque
Adjustment
Knob

Torque
Gauge

UNCLAMP
SW
UNCLAMP UNCLAMP BREAK CENTER OUT UNCLAMP UP CLAMP
TW TW
CLAMP
TW
MAKE
MODE
SW
SW
IN
SW
CLAMP
M364000424 Rev -
SW
DOWN

CLAMP OUT
SW
CENTER IN
MODE
SW
BREAK UP
TW SW
MAKE DOWN
UP RETRACT CW RETRACT
CARRIAGE DEPLOY SLEW ADJ
DOWN EXTEND CCW EXTEND

Head Assembly M364000425 REV 02

Controls

UP
CARRIAGE RETRACT
DOWN ADJUST
EXTEND
RETRACT
DEPLOY CW
EXTEND SLEW
CCW
Control Console - Front View)
Arm Assembly
Control Console - Rear View
Controls

Figure 2-20. Control Console Views

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Overview 2

Auxiliary Equipment
Bit Breaker Assembly

Uniform holes in the side panels can be

used to adjust the height of the guide plates,
Bit Breaker Frame lock plates, and adapter plates.
Top Open Area

Torque Wrench
Connection
(4 places)

Bit Breaker
Clevis Pin
Support
(1 each side)

Cotter Pin

Bit Breaker
Frame

Lock Plate
(1 each side)
Retaining
Glider Bar
Bar
(1 each side)

Guide Plate
(1 each side)

PDC Bit
Quick Release Pin Adapter Plate
with Safety Chain
Tri Cone
Adapter Plate

Figure 2-21. Bit Breaker Carrier

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Pinch Point Hazards

Keep all body parts clear

of pinch point hazards.

Figure 2-22. Iron Roughneck Pinch Point Hazards

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Installation 3

ST-120 Iron Roughneck Installation

Procedures Manual
A separate, custom installation manual is required for the ST-120 Generation 2 Iron Roughneck
models. Please refer to the ST-120 Installation Procedures Manual in the Technical Drawing
Package included in the ST-120 Shipping Package.

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Operation 4

Operating the Iron Roughneck

Control Console
The Control Console levers operate the Head Assembly (Torque Wrench and Spin Wrench) and
the Arm Assembly. For operating procedures, refer to section titled "Positioning and Adjusting the
Iron Roughneck" on page 4-3.

UNCLAMP BREAK CENTER OUT UNCLAMP UP

TW TW MODE SW SW SW
CLAMP MAKE SW IN CLAMP DOWN
M364000424 Rev -

Head Assembly Control Plaque

UP RETRACT CW RETRACT
CARRIAGE DEPLOY SLEW ADJUST
DOWN EXTEND CCW EXTEND
M364000425 Rev -

Arm Assembly Control Plaque

Torque
Adjustment
Knob

Torque
Gauge
UNCLAMP
SW
UNCLAMP CLAMP
TW UNCLAMP BREAK CENTER OUT UNCLAMP UP

CLAMP
TW
CLAMP
TW
MAKE
MODE
SW
SW
IN
SW
CLAMP
M364000424 Rev -
SW
DOWN OUT
SW
IN
CENTER
MODE
SW

BREAK UP
TW UP
CARRIAGE
RETRACT
DEPLOY
CW
SLEW
RETRACT
ADJUST
SW
MAKE
DOWN EXTEND CCW
M364000425 REV 02
EXTEND
Down

Head Assembly Controls

UP RETRACT
CARRIAGE ADJUST
DOWN EXTEND
CW
RETRACT SLEW
DEPLOY CCW
EXTEND
Arm AssemblyControls
Control Console (Front View)

Figure 4-1. Head Assembly and Arm Assembly Control Console

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Operating the Iron Roughneck

Normal Sounds
Sounds in the following list may occur during normal operation.
 Ticking: Ticking noise occurs when jaws have made contact with pipe and the intensifier
is building pressure.
 Whining: The torque wrench clamp flow dividers make a whining noise when the jaws are
being clamped prior to making contact with pipe. The torque wrench also makes a whining
noise when the output torque is set in the lower range.
 Humming: Humming noise occurs from the slew system when slewing.

Normal Occurrences
Activity described in the following list may occur during normal operation:
 Torque Wrench may cycle left or right slowly when operating other functions.*
 Spin Wrench may move up and down when operating other functions.*
 Spin Wrench may drift down when raised above the first stage of the telescopic cylinder.*
 Torque gage drops to ZERO when going to full make position.*
 Spin Wrench rollers may rotate very slowly when operating other functions.*
*Component motion that occurs when operating other functions is due to high return
pressure.Operating the Iron Roughneck

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Operation 4

Positioning and Adjusting the Iron Roughneck

!
Before operating the ST-120 for the first time, be Special attention is necessary if hard banding
sure to remove the storage pin and place it in is present. Do not grip on hard banding.
a secure location. Do not operate the ST-120
Iron Roughneck when the storage pin is installed.

UP RETRACT CW RETRACT
CARRIAGE DEPLOY SLEW ADJUST
DOWN EXTEND CCW EXTEND
M364000425 REV 02

Arm Assembly Control Plaque

Procedure Left Right Right

Hand Hand Hand
4 5 1
Use Arm Assembly Control Levers for the following steps:1
1 Hold the SLEW lever until the tool aligns
with either the well center or the mousehole
UP RETRACT CW RETRACT
as required. CARRIAGE DEPLOY SLEW ADJUST
DOWN EXTEND CCW EXTEND

2
M364000425 REV 02

Hold the DEPLOY lever in the EXTEND

position until the cylinders reach full extension.
3 Hold the ADJUST lever in the EXTEND
position until the torque wrench and spin
wrench are aligned properly with the drill pipe.

!
Wrench and Proper
Pipe Alignment 2 3
Right Right
Center drill pipe in wrench opening within ½" Hand Hand
of center before clamping to avoid damage
to drill pipe and/or the ST-120. Arm Assembly Controls

4 Hold the CARRIAGE lever in the UP or DOWN

position to align the torque wrench vertically
with the drill pipe.
5 During operation, use the DEPLOY lever
for consistent alignment with the drill pipe.

Figure 4-2. Positioning and Adjusting the Iron Roughneck

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Operating the Iron Roughneck

Positioning and Adjusting the Iron Roughneck

Use control levers to align the Numbers in brackets are millimeter [mm].
iron roughneck with the tubular.

Spin Rollers
(4 Places)

Connection
Pin End
Torque
Gage Upper Dies
(3 Places)

Box
UNCLAMP
TW
CLAMP
BREAK
TW
MAKE
CENTER
MODE
SW
OUT
SW
IN
UNCLAMP
SW
CLAMP
M364000424 Rev -
UP
SW
DOWN
Shoulder
Range

UP RETRACT CW RETRACT
CARRIAGE DEPLOY SLEW ADJ
DOWN EXTEND CCW EXTEND

Head Assembly
M364000425 REV 02

Controls

Arm Assembly
Controls
4.69"
[119]
Connection
Box End
Lower Dies
(3 Places)

Figure 4-3. Positioning the Iron Roughneck

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Operation 4

Operating the Iron Roughneck

Making Connections

UNCLAMP BREAK CENTER OUT UNCLAMP UP

TW TW MODE SW SW SW
CLAMP MAKE SW IN CLAMP DOWN
M364000424 Rev -

Head Assembly Control Plaque

Procedure Left Right Right Right Right

Hand Hand Hand Hand Hand
Use the Head Assembly Control Levers for the following steps: 9 6 10 5 2
1 Hold MODE lever in SW position and activate TW
lever in CLAMP position until the lower jaws make
contact on the drill pipe. Release.
2 Hold SW lever in UP position until the spin wrench raises UNCLAMP
TW
BREAK
TW
CENTER
MODE
OUT
SW
UNCLAMP
SW
UP
SW
approximately 6 inches. CLAMP MAKE SW IN CLAMP DOWN

3 Hold the SW lever in the CLAMP position.

4 While holding SW-CLAMP lever, hold SW lever
in the IN position until the drill pipe shoulders. Release.
5 Hold SW lever in the UNCLAMP position to retract
the roller carriers.
6 Hold TW lever in the BREAK position until
the upper wrench is aligned in the MAKE position.
Release.
7 Hold TW lever in the CLAMP position until the
upper jaws make contact with the drill pipe. 1 8 1 4 3
8 While holding TW-CLAMP, move TW lever to the
MAKE position until the required torque is reached. 7 Right Right Left Right
Hand Hand Hand Hand
Left
Hand
If the wrench does not reach the required
torque value in one stroke, unclamp and Head Assembly Controls
repeat steps 6, 7, and 8.

9 Hold TW lever in the UNCLAMP position to retract jaws.

Release.
10 Hold MODE lever in CENTER position until the upper
wrench is centered. Release.

Figure 4-4. Head Assembly Controls - Making Connections

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Operating the Iron Roughneck

Breaking Connections

UNCLAMP BREAK CENTER OUT UNCLAMP UP

TW TW MODE SW SW SW
CLAMP MAKE SW IN CLAMP DOWN
M364000424 Rev -

Head Assembly Control Plaque

Left Right Right Left Right Right

Procedure Hand Hand Hand Hand Hand Hand

Use the Head Assembly Control Levers for the following steps: 9 3 10 7 8 5
1 To place the upper Torque Wrench in the “break-out”
position, hold TW lever in MAKE position until the
wrench stops rotating. Release.
UNCLAMP BREAK CENTER OUT UNCLAMP UP
2 Hold TW lever in CLAMP position. TW
CLAMP
TW
MAKE
MODE
SW
SW
IN
SW
CLAMP
SW
DOWN

3 While holding TW-CLAMP, move TW lever to

the BREAK position until the connection is broken.

If connection is not broken in one

stroke, repeat steps 1, 2, and 3.

4 Hold MODE lever to SW position until the

upper jaws retract from the pipe. Release.
5 Hold SW lever in UP position until the spin wrench
raises approximately 6 inches. 2 1 4 6 11
6 Hold SW lever in CLAMP position. Left Right Left Right Right
Hand Hand Hand Hand Hand
7 While holding SW-CLAMP lever, move SW lever to
the OUT position until the connection is unthreaded. Head Assembly Controls
Release.
8 Move SW lever to UNCLAMP to retract the jaws and
the roller carriers respectively.
9 Move TW lever to UNCLAMP to retract jaws. Release.

10 Hold the MODE lever in the CENTER position

until the upper Torque Wrench is centered. Release.

Figure 4-5. Head Assembly Controls - Breaking Connections

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Operation 4

Operating the Iron Roughneck

Adjusting Makeup Torque

National Oilwell Varco offers an additional gage

kit that can be installed in the driller’s cabin
(Remote Torque Gage kit, PN M364000562.)

Torque
Adjustment
Knob

Torque
Gauge
P/N M364000423 REV-
UNCLAMP BREAK CENTER OUT UNCLAMP UP
TW TW MODE SW SW SW
CLAMP MAKE SW IN CLAMP DOWN

Torque Gage Display Detail M364000424 Rev -

Procedure

Perform the following steps to adjust the torque:

Head Assembly
1. Turn the adjustment knob located on the main control Controls UP RETRACT CW RETRACT

panel counterclockwise (decrease) until it stops. CARRIAGE

DOWN
DEPLOY
EXTEND
SLEW
CCW
M364000425 REV 02
ADJ
EXTEND

2. Verify that the torque gage reads zero.

3. Position the reference indicator (red needle) on the
torque gage at the desired torque value.
4. Actuate the TW lever in the BREAK position until it stops.
While holding the TW lever in the BREAK position, turn Arm Assembly
the torque adjustment knob clockwise until the desired Controls
torque is set.

!
If torque cylinders reach end of stroke during Control Console
a makeup cycle, and the gage reads zero, (Front View)
recycle the jaws and retorque.

Figure 4-6. Adjusting Makeup Torque

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Operating the Iron Roughneck

Moving the Grounding Links to the Upper Jaw
For bit breaking function, the upper jaw stays stationary while the lower jaw rotates. To achieve
this, the grounding links are transferred from the lower jaw to the upper jaw.

Procedure

Before performing any hydraulic or mechanical work on the

tool, ensure the hydraulic ball valve located on the rear of
the ST-120 Iron Roughneck is off and control levers are
actuated to bleed system pressure.

1. Uninstall the bolt securing the frame retaining pin to the grounding frame.

!
Restrain the frame retaining pin before completely
removing this bolt. Once the bolt is removed, the frame
retaining pin could fall out the bottom of the torque wrench.

2. Remove the frame retaining pin from the grounding frame and the torque wrench frame.

3. Uninstall the jaw retaining pin securing the anti-rotation link to the lower jaw.

Jaw retaining pin is retained by a cotter pin that can be

removed through the side of the torque wrench frame. The
jaw retaining pin can subsequently be removed
downwards from beneath the torque wrench.

4. Remove the anti-rotation link from the lower jaw.

5. Turn the anti-rotation link up-side-down and install in the upper jaw.
6. Install the jaw retaining pin to secure the anti-rotation link to the upper jaw.
7. Install the frame retaining pin through the torque wrench frame, grounding frame and the 
anti-rotation link.
8. Re-install the bolt securing the frame retaining pin to the grounding frame.

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Operation 4

Operating the Iron Roughneck

Moving the Grounding Links to the Upper Jaw
9. Perform steps 1-8 for both sides of the torque wrench.

Due to inverting the grounding frame from the lower

wrench to the upper wrench, make-up and break-out
function will be backwards on the control console.

10. Torque all bolts to NOV torque specification.

!
During operation, surfaces may become hot
Lock out hydraulics to disable equipment
enough to cause bodily injury. To reduce the
operation and avoid personal injury
risk of injury from a hot component,
and equipment damage.
allow the surface to cool before touching.

Front

Frame Retaining
Pin Torque Wrench
Frame
Anti-Rotation
Link
Bolt Jaw Retaining
Grounding Pin
Frame

Figure 4-7. Moving Grounding Links to the Upper Jaw

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Operating the Iron Roughneck

Setting up the Bit Breaker Assembly
Procedure
To perform this procedure, refer to Figure 4-8, Figure 4-9, and Figure 4-10.
1. Adjust the guide plate on the side panel to accommodate the bit.
2. Position the bit breaker such that the drill bit is in the bit breaker frame top open area.
3. Slide the PDC bit adapter plate through the guide plate on the side panel of the bit breaker.
4. Index the PDC bit adapter plate to the drill bit.
5. Position the ST-120 above the bit and the Bit Breaker Assembly.
6. Index the bit breaker to the ST-120 Torque Wrench frame.

Using the Bit Breaker Assembly

For bit connecting and breaking procedures, refer to section titled "Making Connections" on page
4-5 and section titled "Breaking Connections" on page 4-6.

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Operation 4

Operating the Iron Roughneck

Setting Up the Bit Breaker Assembly

Drill Pipe Connecting

Threads

Drill Bit

Glider Bar
(1 each side)

Guide Plate
(1 each side)
Torque Wrench
Assembly Retaining Bar
Support
(2 places)
Lock Plate

PDC Bit
Bit Breaker
Adapter Plate
Frame

Tri Cone Bit

Adapter Plate

Quick Release Pin

Safety Chain

Figure 4-8. Bit Breaker Set Up

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Operating the Iron Roughneck

Using the Bit Breaker Assembly

Spin Wrench
Assembly

Head Assembly

Torque Wrench
Assembly

Torque Wrench
Assembly
Support
(2 places)

Bit Breaker Assembly

Figure 4-9. Torque Wrench Assembly Interface with Bit Breaker Assembly (1 of 2)

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Operation 4

Operating the Iron Roughneck

Using the Bit Breaker Assembly

Spin Wrench
Assembly

Torque Wrench
Assembly

Torque Wrench
Assembly
Support
(2 places)

Bit Breaker
Assembly

Figure 4-10. Torque Wrench Assembly Interface with Bit Breaker Assembly (2 of 2)

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Operating the Iron Roughneck

Locking Out the Arm Assembly
Use the control console features to operate the Iron Roughneck during installation procedures.
See figure Figure 4-11.
Procedure
1. Once the hydraulic service loop has been installed, turn the ball valve on the rear of
the ST-120 to the ON position.
2. Extend the arm, by activating the DEPLOY EXTEND lever on the control console, to
the point where the Arm Assembly Lock Plate can be installed.
3. Install the Arm Assembly Lock Plate.
4. Turn the ball valve on the rear of the ST-120 to the OFF position.
5. Actuate the Spin Wrench INlever on the control console to bleed any residual
pressure in the hydraulic system.

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Operation 4

Operating the Iron Roughneck

Locking Out the Arm Assembly

Arm Lockout Plate

View showing arm retracted to a position close enough to rotate the locking arm.

Arm Lockout Plate

View showing the locking arm rotated into the locked position.

Figure 4-11. Arm Assembly Lockout

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Hydraulic Failure Operation

Safety Precautions
Before performing hydraulic failure manual operation, see the following safety sections:
 See “Safety Requirements,” page 1-2.
 See See “Pinch Point Hazards,” page 2-26.
 See “Safety Precautions,” page 4-16.
If the hydraulic system fails, shut off the hydraulic supply and perform the appropriate actions to
enable manual operation of components. Some procedures may be required to repair and 
stabilize hydraulic system functions.

During operation, surfaces may become hot enough to

cause bodily injury. To reduce the risk of injury from a
hot component, allow the surface to cool before
touching.

!
Procedures described in this section will result in hydraulic
fluid leaks, that can exposes personnel to possible slip-
and-fall injuries. Lubricants that are not contained or
cleaned up immediately can cause environmental
contamination. Therefore, personnel must immediately
collect and cleaned up any spilled or escaping oil.
Personnel must dispose of excess hydraulic fluids and
lubricants, and cleaning materials appropriately.

Before performing hydraulic failure procedures, ensure the

hydraulic ball valve, located on the rear of ST-120 Iron
Roughneck, is off and control levers are actuated to bleed
system pressure.

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Operation 4

Hydraulic Failure Operation

Safety Precautions

Manual iron roughneck operating procedures must

only be performed in emergency conditions. Manual
operation includes procedures that slow production
and may cause personal injury and equipment
damage. Perform manual operation procedures with
extreme caution.

Release all hydraulic oil pressure before

disconnecting hydraulic lines. Hydraulic oil
under pressure can penetrate skin and cause
serious injury.

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Hydraulic Failure Operation

Slew Base Assembly
Procedure
If the socket base assembly needs to be rotated during hydraulic failure, please do the following:
1. Extend the arm, if necessary, to allow access to the column.
See section titled "Moving Arm Assembly" on page 4-21.
2. Disconnect lines A and B of the hydraulic slew motor from the connection to the hoses in the
column.
3. Connect lines A and B of the hydraulic slew motor. These lines are equipped with quick
disconnect connections and should couple together. See Figure 4-12.
4. Next, using a hydraulic power source of no more than 500 psi, connect to the brake release
line C (#6 male JIC fitting) and release the brake.
5. Once the brake is released, the socket base assembly should be able to rotate. Rotate into the
position desired and release hydraulic pressure to the brake.
6. Next, disconnect the A and B lines of the hydraulic motor and reconnect each to the
appropriate hose in the column. Disconnect hydraulic power source from the brake and
replace hose.

Figure 4-12. Manual Slew Hydraulic Connection

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Operation 4

Hydraulic Failure Operation

Opening Torque Wrench
Procedure
If the torque wrench clamp cylinders need to be retracted during a hydraulic failure, please do the
following:
1. To deactivate torque wrench clamp cylinders, locate and slowly remove the plugs in port “P” on all four
forward clamp cylinders to gradually release hydraulic pressure.
2. Once all residual pressure is relieved, use a pry-bar to retract clamp cylinders from drill pipe.

!
If the clamp cylinder plug is released quickly, it will be
projected by extreme hydraulic pressure and cause a hazard
for personnel. Hydraulic pressure should be relieved very
slowly to ensure safety. Hydraulic oil under pressure can
penetrate skin and cause serious personal injury.

Torque Wrench
Assembly

Front

Lower Jaw Assembly

“P”
Hydraulic Drain Plug

Figure 4-13. Open Torque Wrench If Hydraulic Failure Occurs

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Hydraulic Failure Operation

Opening Spin Wrench
Procedure
If the spin wrench clamp cylinders need to be retracted during a hydraulic failure, please do the
following:

1. Slowly and carefully loosen fittings on spin wrench clamp cylinder.

!
If the clamp cylinder plug is released quickly, it will be
projected by extreme hydraulic pressure and cause a
hazard for personnel. Hydraulic pressure should be
relieved very slowly to ensure safety. Hydraulic oil
under pressure can penetrate skin and cause serious
personal injury.

2. Once any residual pressure is relieved, remove hydraulic connections from the spin wrench
clamp cylinder.
3. Use a pry-bar to move rollers away from drill pipe.

Clamp
Cylinder

Hydraulic
Fittings
Rear
Rear Isometric View

Figure 4-14. Open Spin Wrench if Hydraulic Failure Occurs

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Operation 4

Hydraulic Failure Operation

Moving Arm Assembly

!
Hydraulic fluid will be expelled from test fitting ports as the
Extend Cylinders extend or retract. Take measures to
contain spills.

Procedure
If the Arm Assembly needs to be extended or retracted during a hydraulic failure, please do the
following:
1. Use a Stauff test coupling to bleed pressure from Extend Cylinders. Slowly screw the test coupling
onto each test fitting (4 fittings per cylinder) until all hydraulic pressure is relieved.
2. Once all pressure has been relieved, remove all test fittings from the Extend Cylinders.
 Optional Procedure
Once all pressure has been relieved, remove all test fittings from Extend Cylinders.
As an option, open-ended hoses can be connected to test fitting ports where open
ends can be placed in a container to minimize hydraulic fluid spilling.
3. Extend or retract the ST-120 Arm Assembly by pushing or pulling the Head Assembly in the
required direction.

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Hydraulic Failure Operation

Moving Arm Assembly

Arm Assembly Extend Cylinder Detail

Test Fittings
(4 on each cylinder)

Figure 4-15. Arm Assembly Extend Cylinder

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Operation 4

Securing the Iron Roughneck 

on a Floating Vessel
Floating vessels are subject to the actions of waves and wind, resulting in unpredictable floor
motions. Such motions can cause an iron roughneck to make sudden and unexpected
movements. When this begins to occur, operations should cease and the iron roughneck should be
secured at standby position. Refer to section titled "Storing the Iron Roughneck" on page 4-28.
NOV offers a special kit (PIN M364000413) for use on floating vessels. The kit allows securing the
iron roughneck at well center, mousehole, and standby positions.
Procedure
When conditions exceed the parameters listed under Operational Environment:
1. Immediately stop operation.
2. Retract the Iron Roughneck fully, install the storage pin, and secure the Iron
Roughneck in a standby position. See Table 4-1 and Table 4-2 for maximum
operational/survival conditions on floating vessels.

For dynamic conditions in excess of the values listed in

Tables 4-1 and 4-2, please consult NOV Engineering.

Table 4-1. Operational Environment

Condition Parameter

 4° pitch, single amplitude on 10 second period

Roll/Pitch
 50 ft. roll center below rig floor
Heave 2% Acceleration force
Wind No wind assumed on rig floor during operation
Design Temp -20°C Min. to 40°C Max.
Ice Thickness None

Table 4-2. Survival Environment 

(ST-120 Iron Roughneck must be stored with storage pin installed.)

Condition Parameter

 20° pitch, single amplitude on 10 second period

Roll/Pitch  50 ft. roll center below rig floor (ST-120 in secured parked
position)
Heave 30 ft. on 10 second period (ST-120 in secured parked position)
Wind No wind assumed on rig floor during operation
Design Temp -20°C Min. to 40°C Max.
Ice Thickness None

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Transport Skid Installation and Removal

NOV recommends using the supplied wire rope sling

(NOV PN M364000518) with master link when lifting
the iron roughneck.

Always keep the iron roughneck in an upright position

to avoid equipment damage and personal injury or
death.

!
When transporting the iron roughneck, always use the iron
roughneck lifting lugs and lifting shackles. No other part is
rated for, nor intended to support the full weight of the iron
roughneck.

!
For stability, always transport the iron roughneck with the
Transport Frame Installed. For added security, straps can
be attached to major structural components as required.

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Operation 4

Transport Skid Installation and Removal

Transport Skid Installation
Procedure
The following steps assume the ST-120 is being removed from its service location on the rig and
being placed on the shipping skid.
1. Ensure the iron roughneck is in the fully retracted position, and all hydraulic lines
connecting the column to the base assembly have been disconnected.
2. Ensure the storage pin is installed.
3. Place the transport skid on a strong surface.
4. Attach ST-120 Iron Roughneck wire rope sling to lifting shackles.
5. Remove the column lock pins connecting the column to the base assembly.
6. Hoist and move the iron roughneck and center it on the transport skid:
a. Align the Iron Roughneck column base support with the transport skid base
supports.
b. Align the bottom of the torque wrench base plate with the transport skid lower
support.
7. Insert the column lock pins to connect the column support to the transport skid base
supports.
8. Insert hairpin cotter pins.
9. Place the transport skid support cap on the inside edge of the torque wrench top
plate.
10. Insert top lock washers and hex nuts on the top ends of each 8" threaded rods.
11. Insert threaded rods through the transport skid support cap and transport skid lower
support.
12. Install lock washers and hex nuts on the bottom end of the threaded rods.
13. Tighten hex nuts securely to the transport frame support column. Tighten to
appropriate torque.
14. Attach wire rope sling to ST-120 Iron Roughneck lifting shackles and hoist and move
the iron roughneck and transport skid to the proper location.

Transport Skid Removal

Procedure
1. Use the lifting shackles to hoist the iron roughneck.
2. Remove the column lock pins and transport skid support cap.
3. Attach ST-120 Iron Roughneck wire rope sling to lifting shackles and hoist the iron
roughneck to the required location.
4. Retain all transport skid components and move the transport skid to storage.

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Transport Skid Installation and Removal

ST-120 Iron Roughneck and Transport Skid

ST-120 Lifting
Storage Pin
Shackles
(2 places)

Hex Nut (4 places)

Threaded Bar
(2 places)

Transport Skid
Support Cap

Torque Wrench
Top Plate
Column Lock
Pin
(2 places)

Torque Wrench
Bottom Plate

Transport Skid
Transport Lower Support
Skid

Front

Figure 4-16. Transport and Skid Installation

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Operation 4

Transporting the Iron Roughneck

When transporting the iron roughneck, ensure the unit remains vertical and is stable. Always
transport the iron roughneck with the transport skid installed to increase stability. See “Transport
Skid Installation and Removal,” page 4-24.

!
Always keep the iron roughneck in an upright position.
Never place the iron roughneck on it’s sides or back.
Failure to heed this caution will cause damage to the
equipment.

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Storing the Iron Roughneck

Long Term Storage
 Palletize the ST-120 Iron Roughneck and store it in indoor storage. A cargo container
would be appropriate for indoor/outdoor storage.
 Avoid wide variations in temperature and high humidity. The preferred environment is
clean and dry at 60°F (16°C) ambient temperature. If high humidity is unavoidable, 70°F
(21°C) ambient temperature is recommended.
 All exposed unpainted metal surfaces are coated with a rust preventive at the factory prior
to shipment. Coat all unpainted metal surfaces with rust preventative prior to storage or
transport.
 The recommended rust preventive (slushing compound) for bare metal surfaces is Kendall
Grade 5 (GE-D6C6A1) or equivalent.
 All openings should be covered to prevent water or dust from entering. Ensure cover
allows for air circulation around equipment. NOV does not recommend using a silica gel or
a dehydrating agent.
 During storage, lubricant drains from the top half of the roller bearings, allowing corrosion
on the exposed areas. To prevent corrosion, periodically rotate the column to slew to
distribute lubricant over the top of the bearings. Perform this at three-month intervals if the
iron roughneck is stored indoors, and at monthly intervals if stored outdoors.

Return to Service After Storage

Before placing the Iron Roughneck back into service, the following tasks should be completed and/
or verified.
 Remove all rust preventative and any corrosion, taking special care with all load-carrying
components.
 Blow out all dust and dirt from equipment as required with clean, dry air.
 A complete system test and adjustment should be performed as detailed in the ST-120
Iron Roughneck Commissioning Procedure. 

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Maintenance 5

Maintenance Warning
Anytime before shutting down the tool for maintenance, follow this precautions:

Figure 5-1. Maintenance Operation Warning Plate

During Operation, surfaces may become hot enough

to cause bodily injury. To reduce the risk of injury from
a hot component, allow the surface to cool before
touching.

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Recommended Lubricants
Hydraulic Fluids
Minimum start-up and operating temperatures are as follows:

Table 5-1. Arctic Service Lubricant Criteria

Non-Arctic Service: -10°F to 125°F / -29°C to 52°C

First Choice Hydraulic Oil - premium grade with anti-wear and anti-rust additives

Viscosity = 48-55 SUS @ 210°F (6.8 - 8.9 cSt @ 100°C)

Viscosity Index = 132

Pour Point = -30°F (-34°C)

ISO/ASTM Viscosity Grade = 46

Second Choice Automatic Transmission Fluid

Type “F” meeting Ford Motor Company specification ESW-M2C33-F

Third Choice Hydraulic Transmission Oil.

Viscosity = Typically 49 SUS @ 210°F (7 cSt @ 100°C

Viscosity Index = 100 minimum

Pour Point = -35°F (-37 C)

ISO/ASTM Viscosity Grade = 46

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Maintenance
5

Recommended Lubricants
Hydraulic Fluids

Arctic Service Lubricant Criteria (continued)

Arctic Service: -50°F to 0°F / -45°C to -18°C

First Choice Hydraulic Oil - premium shear stable high VI anti-wear hydraulic oil

Viscosity = 46.6 SUS @ 210°F (6.1 cSt @ 100°C)

Viscosity Index = 153

Pour Point = -58°F (-50°C)

ISO/ASTM Viscosity Grade = 32

Second Choice Automatic Transmission Fluid - Dextron III

Viscosity = 51 SUS @ 210°F (7.5 c0.St @ 100°C)

Viscosity Index = 172

Pour Point = -54°F (-48°C)

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Recommended Lubricants
Gear Oil
The following charts give the recommended grades for various temperatures surrounding the
reservoirs.
Table 5-2. Temperature Criteria

Temperature Recommended Grade

50°F to 125°F (10°C to 52°C) AGMA NO. 7 EP, ISO/ASTM VG 460

15°F to 60°F (9°C to 16°C) AGMA NO. 6 EP, ISO/ASTM VG 320

-20°F to 25°F (-29°C to -4°C AGMA NO. 4 EP, ISO/ASTM VG 150

-50°F to 0°F -45° (C to -18°C) AGMA NO. 3 EP, ISO/ASTM VG 100

For additional wear protection, the use of Dow Corning

Molykote-M Gear Guard (5% to 10% by volume) is
recommended.

Table 5-3. General Temperature Criteria

General Lubricants Recommended Grade

Above 20°F (-7°C) NLGI Gr. No. 2, lithium base, general-purpose, extreme pressure
grease.

Below 20°F (-7°C) NLGI Gr. No. 1, lithium base, general-purpose, extreme pressure
grease.

!
When adding to or changing lubricants (gear oil or
hydraulic oil), every precaution should be taken to prevent
any contamination of the lubricants. Do not mix different
types of fluids.

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Maintenance
5

Recommended Lubricants
Table 5-4. Lubricant Chart

Component/ Environment Lube Type ASTM / NLGI AGMA Viscosity Viscosity Pour
Lube ISO-VG Index Point°
Description Grade

Hydraulic Hydraulic Oil1 46 --- --- 48-55 SUS @ 210°F 132 -30°F
Fluids 6.8-8.9 cST @ 100°C (-34°C

-20°F –125°F Automatic Transmission Fluid - Type “F” meeting Ford Motor Co. Spec. ESW-M2C33-F
(-29°C – 52°C)
Hydraulic 46 --- --- 48-55 SUS @ 210°F 100 MIN. -35°F
Transmission 6.8-8.9 cST @ 100°C (-37°C
Oil

Synthetic 32 --- --- 47 SUS @ 210°F 140 -55°F

Hydraulic Oil2 6.1 cST @ 100°C (-48°C
-50°F – 0°F
(-46°C – 18°C)
Automatic Transmission Fluid - --- 51 SUS @ 210°F 172 -54°F
Dexron III 7.5 cST @ 100°C (-48°C

Gearbox and 15°F to 60°F EP Gear Oil3 460 --- #7 EP 150 SUS @ 210°F 95 20°F
Swivel Bearing (10°C to 52°C) 30.3 cST @100°C (-7°C

-20°F to 25°F EP Gear Oil3 320 --- #6 EP 120 SUS @ 210°F 95 0°F
(10°C to 52°C) 24.0 cST @100°C (-18°C

50°F to 125°F EP Gear Oil3 150 --- #4 EP 78.1 SUS @ 210°F 95 -10°F
(10°C to 52°C) 14.5 cST @100°C (-23°C

-50°F to 0°F Synthetic  100 --- --- 77.1 SUS @ 210°F 149 -50°F
(10°C to 52°C) Gear Oil 14.4 cST @100°C (-46°C

General Above 20°F --- #2 ---

Lubricants (-7°C) EP Grease4 --- --- ---

EP Grease4 --- #1 --- --- --- ---

Footnotes:
1. Must be Premium Grade with Anti-Rust and Anti-Wear Additives.
2. Must be Premium Shear Stable High VI Anti-Wear hydraulic oil.
3. For additional wear protection, the use of Dow-Corning Molykote-M Gear Guard (5% -
10% by volume is recommended.
4. Lithium base, general-purpose, extreme pressure grease.
5. Lithium soap base grease, per motor manufacturer’s specifications.
6. Fluids and Lubricants must pour freely at minimum operating temperature. If machine is
started when the temperature is near or below the pour point of a lubricant, the lubricant
may be congealed and incapable of providing a lubricating film, resulting in metal-to-metal
friction; which can cause sparks or hot spots.

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Inspection and Lubrication

Inspecting Hardware and Fittings
1. Visually inspect the Iron Roughneck for loose or missing hardware and fittings daily. Make
sure all lock safety wire is undamaged.
2. Check intensifier hydraulic indicator filter weekly. Replace as necessary if the indicator is
red during operation.
3. Check inlet high pressure hydraulic filter indicator weekly. Replace as necessary if the
indicator is red during operation.
4. Inspect all hoses for wear or damage. Replace as necessary.
5. Tighten any fittings that appear to be leaking.

All hoses are clearly labeled. Consult hose kit drawings for
proper routing and hose specification and always label when
replacing hoses on the Iron Roughneck.

When changing hydraulic cartridge valves, refer to the

hydraulic schematic for proper settings.

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Maintenance
5

Inspection and Lubrication

Lubricating the Iron Roughneck
The lubrication intervals described in this manual are based on lubricant supplier
recommendations. Severe conditions such as extreme loads or temperature, corrosive
atmosphere, etc., may require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more
frequent lubrication is necessary.
Inspect all grease fittings daily as shown on the following page, and apply grease as needed or
weekly.

!
During inspection and lubrication, lock out hydraulics to
disable equipment operation to avoid personal injury or
equipment damage.

!
Clean any grease which falls to the floor to prevent
personal injury due to slipping.

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Maintenance Schedule
Inspection, Lubrication, and Maintenance

Power down the Iron Roughneck and allow hot

surfaces to cool before performing inspection and
maintenance procedures.

Table 5-5. Maintenance Schedule by Component

Major Components

Item Inspection Lubrication Maintenance

General

1. Hardware Weekly N/A  Tighten to proper torque.

 Replace if missing.

2. Hoses and Connectors Weekly N/A  Tighten connections if loose.

 Replace if damaged, leaking, or kinked.

3. Cleanliness:  Daily N/A  Remove corrosives and contaminants:

Equipment and Work Areas salt, sand, mud, oil, and grease.
 Dispose of components properly.

4. Intensifier Filter Monthly N/A See “Changing Intensifier Hydraulic Filter,”

page 5-23.

Head Assembly

Spin Wrench Assembly

1. Grease Fittings - behind Weekly Weekly See “Lubrication (1 of 5),” page 5-10.
cover

2. Grease Fittings behind spin Weekly Weekly See “Lubrication (2 of 5),” page 5-11.
wrench

3. Spin Wrench General Weekly Weekly See “Lubrication (4 of 5),” page 5-13.
Maintenance

4. Spin Rollers Weekly N/A Replace if worn or damaged. See

“Replacing Spin Rollers,” page 5-20.

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Maintenance
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Maintenance Schedule
Inspection, Lubrication, and Maintenance
Table 5-5. Maintenance Schedule by Component (continued)

Major Components (continued)

Item Inspection Lubrication Maintenance

Torque Wrench Assembly

1. Grease Fittings Weekly Weekly See “Lubrication (3 of 5),” page 5-12.

See “Lubrication (4 of 5),” page 5-13.

2. Replace Dies Daily N/A See “Replacing Wrench Dies,” page 5-17.

Arm Assembly

1. Structure Fittings Weekly Weekly See “Lubrication (5 of 5),” page 5-14.

2. System Hydraulic Filter Monthly N/A See “Changing Inlet Hydraulic Filter,”
page 5-24.

3. Arm Pin Fittings Weekly Weekly See “Lubrication (2 of 5),” page 5-11.
See “Lubrication (4 of 5),” page 5-13.
See “Lubrication (5 of 5),” page 5-14.

Column Assembly

1. Break and Gearbox Weekly  6 Months See “Changing Oil,” page 5-28.
Expansion Oil Tank (Oil Level)

Column Base

2. Slew Bearing Grease Fittings Weekly Monthly See “Lubrication (4 of 5),” page 5-13.

3. Slew Idler Gear Grease Weekly Weekly See “Lubrication (5 of 5),” page 5-14.
Fittings

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Maintenance Schedule
ST-120 Iron Roughneck

During operation, surfaces may become hot Each grease fitting is to be greased until
enough to cause bodily injury. To reduce the clean grease is seen extruding from the
risk of injury from a hot component, related component.
allow the surface to cool before touching.

Instructions

• Inspect all marked areas daily.

• Grease areas as indicated.

Spin Wrench
Grease Fitting
Weekly Spin Wrench
Roller Bearings
Weekly

UNCLAMP BREAK CENTER OUT UNCLAMP UP

TW TW MODE SW SW SW
CLAMP MAKE SW IN CLAMP DOWN
M364000424 Rev -

UP RETRACT CW RETRACT
CARRIAGE DEPLOY SLEW ADJ
DOWN EXTEND CCW EXTEND
M364000425 REV 02

Weekly
Spin Wrench
Grease Fitting
(Behind Spin Wrench
2 each side)

Weekly
Weekly
Column Base
Column Base
Grease Fitting
Grease Fitting Monthly (Behind plate)
(Behind plate)
Slew Bearing
(4 Places)
Front View

Figure 5-2. Lubrication (1 of 5)

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Maintenance
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Maintenance Schedule
ST-120 iron Roughneck

During operation, surfaces may become hot

enough to cause bodily injury. To reduce the
risk of injury from a hot component, allow
the surface to cool before touching.

Each grease fitting is to be greased until

clean grease is seen extruding from the
related component.

Grease Fitting
System Hydraulic (4 places)
Filter Weekly
Weekly

ST-120 Top View (extended) Front

Figure 5-3. Lubrication (2 of 5)

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Maintenance
5

Maintenance Schedule
Torque Wrench Assembly
Top View of Torque Wrench Assembly

During operation, surfaces may become hot Rocker Arm Pin

enough to cause bodily injury. To reduce the Grease Fittings
risk of injury from a hot component, allow (Both Sides)
the surface to cool before touching. Weekly
Torque Wrench
Upper Jaw
Rocker
Arm
Each grease fitting is to be greased until
clean grease is seen extruding from the
related component.

Instructions

• Inspect all marked areas daily.

• Grease areas as indicated.

Rocker Arm Pin

Grease Fittings
(Both Sides) Lower Jaw
Weekly
Torque Wrench
Lower Jaw
Front
Rocker
Arm

Front

Upper Jaw

Bottom View of Torque Wrench Assembly

Figure 5-4. Lubrication (3 of 5)

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Maintenance
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Maintenance Schedule
Head Assembly Lubrication

Each grease fitting is to be greased until During operation, surfaces may become hot
clean grease is seen extruding from the enough to cause bodily injury. To reduce the
related component. risk of injury from a hot component, allow
the surface to cool before touching.
Hanger Link Pins
Grease Fittings
(3 places)
Weekly
ST-120 Head Unit
Spin Wrench Intensifier Filter
Assembly Inspect Weekly
and change annually.

Weekly
Spin Wrench
Torque
Grease Fittings
Wrench
(4 places)
Housing

Die Holder Guide Ring Torque Spring Torque Wrench

(Extend jaws) (2 places) Wrench Outer Housing
Housing Diameter Inner
(2 places) Diameter
Weekly (Anti-Seize)

Rotate the upper jaw to apply grease to the inner diameter of

the torque Wrench Housing and outer diameter of the spring.

Figure 5-5. Lubrication (4 of 5)

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Maintenance Schedule
Arm Lubrication

During operation, surfaces may become hot Each grease fitting is to be greased until
enough to cause bodily injury. To reduce the clean grease is seen extruding from the
risk of injury from a hot component, allow related component.
the surface to cool before touching.

Instructions

• Inspect all marked areas daily.

• Grease areas as indicated.

Cylinder Pin
(Both Sides
(Both Sides)
Arm Pin Fittings
Weekly (Both Sides) Arm Pin Fittings
Arm Pin Fittings (Both Sides)
Weekly
(Both Sides) Weekly
Guide Roller Weekly
(4 Places)
Weekly

Arm Pin
Fittings
(Both Sides)
Weekly

Weekly
Arm Pin Weekly
Fittings Arm Pin Fittings
(Both Sides) (Both Sides) Weekly
Weekly
Torque Cylinder
Weekly Arm Pin Fittings Grease Fittings
6 Months (Both Sides) (Located behind plate)
Slew Idler Gear
Grease Fitting Slew Gear Box
(In column base - Gear Oil)

ST-120 Side View (extended)

Figure 5-6. Lubrication (5 of 5)

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Maintenance
5

Disassembly and Assembly

Precautions

!
Transport hydraulic components to a safe, clean, dust-free
service area before disassembling.

Disassembly procedures are performed when replacing damaged components that are causing a
tool function to fail. Whenever performing a disassembly, practice preventive maintenance as
follows:
 Clean and inspect all disassembled parts.
 Replace all worn and damaged parts before they can cause another failure.
 Install thread protectors on exposed threads.

!
Torque all fasteners to the limits given in DS00008, Design
Specification Design Torque Standard, unless an
alternative torque value is given in the procedure.

Do not re-use nord-lock washers after removing a bolt.

Replace with properly assembled new nord-lock washer.
See graphic below for assembly.

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Disassembly and Assembly

Precautions

Release all hydraulic oil pressure before

disconnecting hydraulic lines. Hydraulic oil under
pressure can penetrate skin and cause serious injury.

Before opening the hydraulic system, thoroughly clean
the work area. Maintain system cleanliness by
promptly capping all disconnected lines. Dirt is
extremely harmful to hydraulic system components
and can cause equipment failure and subsequent
injury to personnel.

Ensure all hydraulic lines are isolated and the ball
valve is closed before any work is performed on the
Iron Roughneck.

If air is introduced into the duplex extend cylinder, use
extreme caution when extending the platform for the
first time. As the load moves over the well center, the
air will compress causing the support arm to extend
rapidly. Support the unit with a tugger and a stand to
the side until air is purged.

Maintenance should not be performed on the ST-120

Iron Roughneck while it is in an elevated position,
even with the hydraulic power unit shut off and
residual pressure bled from the system.

!
During operation, surfaces may become hot enough to
cause bodily injury. To reduce the risk of injury from a hot
component, allow the surface to cool before touching.

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Maintenance
5

Disassembly and Assembly

Replacing Wrench Dies
Procedure
ST-120 Head Unit

• Install new dies in all die carriers.

• Replace screws with new ones if necessary.
• Clean and inspect parts and hardware for damage
and wear. Replace damaged parts and hardware.
Spin Wrench
Assembly !
Once screws are removed die may slip out of die carrier.
Secure die to avoid personal injury or equipment damage.

Wrench 1. Actuate the torque wrench lever to extend the

Assembly clamp cylinders.
!
Lock out hydraulics to disable equipment operation
to avoid personal injury or equipment damage.

2. Remove hydraulic power.

3. Clean the area around die and die carriers.
4. Remove upper die retention screw and remove die. If die is
stuck, remove the lower retention screw
(and Center Die retaining plate) and drive die out.
Center Dies 5. Use a wire brush to clean die carrier.
Side Dies (2 places) 6. Inspect and lightly grease die carrier.
(4 places) See “Recommended Lubricants,” page 5-3.
7. Install new die, and apply center die retaining plate.
Apply antiseize compound to retention screw and replace
the retaining screw.
8. Torque screws to 57-81 ft.-lbs.
Side Dies (4 places) Center Dies (2 places)

Die
Die Carrier (2 places)
(4 places)
Center Die
Screw, Die Carrier
Carrier (2 places)
(4 places)
Center Die
Retaining
Plate
(2 places)
Screw, Retention Die Screw, Die Screw, Retention
(8 places) (4 places) Carrier (2 places)
(2 places)

Figure 5-7. Replacing Wrench Dies

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Disassembly and Assembly

Removing Torque Wrench

Lock out hydraulics to disable equipment operation to

avoid personal injury and damage to the Iron
Roughneck.

To remove the Torque Wrench, complete the following steps

1. Disconnect all hydraulic lines to all 4 torque cylinders.
2. Remove the pin keeper from the torque cylinders and remove the pivot pin to disengage
the torque cylinder from the rocker arm.
3. Carefully follow these steps to bleed residual hydraulic pressure prior to maintenance of
the torque wrench.
a. Remove the pressure-bleed-fitting from Port Z of the Clamp Cylinder Manifold, which
is located on the top of the Upper Jaw Assembly. Proceed in small increments of 1/2
turn counter clockwise at a time. (See Figure 5-8, Torque Wrench Assembly Top
View).
b. Wipe away any fluid and do not continue until overflow has stopped.
c. After completely relieving the trapped pressure, close the port with the pressure bleed
fitting.
d. Ensure that the bleed fitting is properly torqued prior to resuming maintenance on the
Iron Roughneck.
4. Disconnect the hydraulic lines from the swivel fittings located on the top of the upper jaw
and beneath the lower jaw.
5. Remove the grounding frames.
6. Attach a lifting eye to the top of the upper jaw and lift slightly with a crane.
7. Slide out the upper jaw from the torque wrench frame.
8. Attach a lifting eye to the top of the lower jaw and lift slightly with a crane.
9. Slide out the lower jaw from the torque wrench frame.

Safely release hydraulic pressure from Port Z

of the hydraulic circuit in the Torque
Wrench’s Upper Jaw Assembly prior to
performing maintenance on the Torque
Wrench Assembly. Carefully follow step 3 of
this procedure, using caution to ensure that
the pressure is completely released.

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Maintenance
5

Disassembly and Assembly

TOP VIEW
Torque Wrench Assembly
Torque Wrench Rocker Torque Cylinder
Upper Jaw Arm Pivot Pin
Pressure Bleed
Fitting

Lower Jaw
Torque
Wrench
Cylinder
Front
Grounding Frame
BOTTOM VIEW
Torque Wrench Assembly

Torque Wrench Passive Spring

Lower Jaw (4 places)
Rocker
Arm Pin
Rocker
Arm

Torque Upper Jaw

Wrench
Cylinder
Grounding ST1200099
Frame Front

Figure 5-8. Removing the Torque Wrench

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Replacing Spin Rollers

Front Isometric View Motors
(4)
• Minimum allowable Spin Roller diameter is 6.9"
Front (equates to 1/8" radial wear).
• Replace Spin Rollers with all new rollers at the
same time.
• Replace screws with all new screws if necessary.
• Clean and inspect parts and hardware for damage
and wear. Replace damaged parts and hardware.

!
Parts may slip from the Spin Wrench Assembly
once they are loosened. Secure parts and place
in a clean, safe location to avoid personal
injury or equipment damage.
Spin Rollers
(4 sets)
!
Lock out hydraulics to disable equipment operation
Roller Torque and avoid personal injury and equipment damage.
Tool

Procedure

1. Remove the Plug from the lower cover plate.

2. Use the Roller Torque Tool to keep rollers from turning.
3. Remove the large support screw inside the cover plate.
Rear Isometric View 4. On the bottom of the Cover Plate, remove screws to
release and remove the Cover Plate, Lower Drive Hub,
Guard and Lower Bearing Assembly.
5. Remove Spin Rollers.
Hydraulic 6. Clean the Spin Wrench Assembly.
Manifold 7. Install new Rollers interlaced as shown. Rollers
must interlace with opposing Roller Assembly.
8. Use Roller Torque tool to keep rollers from turning.
Clamp 9. Install Cover Plate, Lower Drive Hub, and Lower
Cylinder Bearing Assembly.
10. Slightly oil washer, and install it and the large support
screw in the bottom of the Lower Bearing Assembly.
11. Torque bolt to 430 ft.-lbs.

While the Spin Rollers are disassembled, worn or

damaged Bearing Assemblies and other Spin Wrench
Assembly parts should be replaced.
Rear
Figure 5-9. Replacing Spin Rollers

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Maintenance
5

Disassembly and Assembly

Replacing Spin Roller

Retaining Ring
Hydraulic Motor

Ball Bearing
(3 places)

Upper Bearing
Housing Ring Seal

Upper Drive
Hub

Upper Bearing
Assembly
Grease Port
(2 places) Grooved Roller
(4 places) Lower Drive
Hub

Ring Seal
Carrier,
Grease Port Roller
Ball Bearing
(2 places)
(2 places)

Lower Bearing Retaining Ring

Cover Plate Screw Housing

(4 places) Lower Bearing
Cover Plate Assembly

Plug Large Support

Screw To replace ball bearings, ensure
bearings align as shown below:

Seal

Ball
Bearing
Frame

Figure 5-10. Spin Wrench Assembly - Disassembled

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Disassembly and Assembly

Removing the Spin Wrench
ST-120 Spin Wrench Procedure
Assembly Rear View

Hanger !
Link Lock out hydraulics to disable equipment
Pressure, Tank,
and Drain Ports operation and avoid personal injury
and equipment damage.

1. Disconnect the hydraulic connections to the

spin wrench manifold.
2. On the bottom of the spin wrench assembly,
remove the spring and the spring perch from
the spin wrench hinge pin.
Rear 3. Using a crane, support the weight of the
spin wrench.
Spin Wrench 4. Disconnect the spin wrench hanger link from
Hydraulic Manifold the hanger.
5. Lift and remove the spin wrench.

ST-120 Spin Wrench Hanger Link

Front Isometric View

Spring

Spring
Spring Perch

Front

Figure 5-11. Removing the Spin Wrench

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Maintenance
5

Part Maintenance
Changing Intensifier Hydraulic Filter

!
Lock out hydraulics to disable equipment
operation and avoid personal injury
and equipment damage.

Procedure

1. Turn off main ball valve and bleed residual pressure.

2. Turn off intensifier ball valve.
3. Remove hydraulic filter cap.
4. Replace filter element.
5. Install hydraulic filter cap.

Intensifier
Hydraulic
Filter
Spin Wrench
Assembly

Torque
Wrench
Housing

Intensifier
Intensifier
Hydraulic
Ball Valve
Filter Cap

Front

Figure 5-12. Changing Intensifier Hydraulic Filter

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Part Maintenance
Changing Inlet Hydraulic Filter
!
Lock out hydraulics to disable equipment
operation and avoid personal injury
and equipment damage.
Arm Assembly Hydraulic
Inlet Manifold

Procedure

1. Turn off main ball valve and bleed residual pressure.

2. Remove hydraulic filter cap.
3. Replace filter element.
4. Install hydraulic filter cap.

Hydraulic Inlet Manifold Detail Inlet

Hydraulic
Filter Cap

Rear

Main Ball Valve

Figure 5-13. Changing Inlet Hydraulic Filter

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Maintenance
5

Changing Oil

!
Before performing any hydraulic or mechanical work on the
tool, ensure the hydraulic ball valve located on the rear of
the ST-120 Iron Roughneck is in the OFF position and
bleed residual pressure by actuating SW lever in either
SPIN IN or SPIN OUT.

Changing Oil Guidelines

 Gear oil must be drained and changed after the first 50/100 hours of operation and
subsequently after every 2500 hours or in any case each year. The following list provides
oil change information.
 Oil changes must be carried out after first 50/100 hours of operation and subsequently
after every 2500 hours or at least every 12 months.
 Oil change intervals may be modified, depending on actual operating conditions.
 During oil change, we recommend that the inside of the gear case is flushed out with
flushing fluid recommended by lubricant manufacturer.
 Pay attention to oil and gear temperature during oil change, to avoid the risk of scalding.
 Oil should be changed when hot to prevent build up of sludge deposit.
 It is advisable to check oil level at least once per month. If more than 10% of total oil
capacity has to be added, check hydraulic hoses and connections for oil leaks.
 Do not mix oils of different types even if they are from the same manufacturer.
 Never mix mineral oil and synthetic oils.
 Be conscious of the pollution hazard due to oil.

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Changing Oil
Changing Brake and Gearbox Oil
.

Never perform maintenance on the ST-120

Iron Roughneck while it is in an elevated
position, even with the hydraulic power unit
shut off and the residual pressure bled from
the system. Failure to adhere to this warning
may lead to severe personal injury or death.

Lock out hydraulics to disable equipment

operation and avoid personal injury and
damage to the equipment.

To change brake and gearbox oil, complete the following steps:

1. Ensure that the ST-120 Iron Roughneck is fully lowered and the Arm Assembly is locked
out. For detailed information, see Locking Out Arm Assembly procedure, page 4-14.

The drain and fill ports can be easily accessed from the front
of the column with the unit fully lowered.

2. To ease oil drainage, remove the constant vented breather from both oil expansion tanks
located in the column assembly.
3. Turn the hydraulic ball valve located on the rear of the ST-120 to the OFF position.
4. Bleed residual pressure by actuating SW lever in either SPIN IN or SPIN OUT.
5. Carefully remove Plug A from the gearbox and Plug A from the brake,
6. Once all the oil is drained and the gear case is flushed, install the gearbox Plug A and the
brake Plug A.
7. Remove the gearbox Plug B and brake Plug B and fill with recommended oil. See
"Recommended Lubricants" on page 5-3.
For illustrated view of this procedure, see Figure 5-14, Changing Brake and Gearbox Reservoir Oil.

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Changing Brake and Gearbox Oil

When changing brake and gearbox reservoir oil in the ST-120 Iron Roughneck, it is very important to refer
back to the proper procedure for locking out the Arm Assembly. See “Locking Out the Arm Assembly,”
page 4-14.

Brake Plug B
Brake Brake Plug A

Gearbox Plug B

Gear Box Gearbox Plug A

This page is intentionally blank.

Figure 5-14. Changing Brake and Gearbox Reservoir Oil

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Maintenance
5

Changing Oil
Changing Brake and Gearbox Oil
Changing System Hydraulic Expansion Tanks Oil

Procedure (Continued)

When adding oil to expansion tank, allow

time for fluid to make it’s way to the gearbox
and brake.

8. Fill expansion tanks with oil until the specified height.

(See top sight glass on side of the expansion tank.)
9. Install the breather plug on the tanks.

Constantly
Vented Breather

Sight Glass

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Sight Glass

Extension Pipe
Lock Nut
Column Rear View
System Hydraulic Expansion Oil Tank
(Cross Section)

Figure 5-15. Brake and Gear Box Expansion Oil Tanks Maintenance

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Troubleshooting 6

Troubleshooting
This section describes general troubleshooting methods and provides tables for troubleshooting
specific problems or components.

!
Make sure all hydraulic lines are isolated and the inlet ball
valve is closed before any work is performed on the Iron
Roughneck.

!
Whenever hoisting, lowering and operating the iron
roughneck, ensure all personnel and equipment are clear
of the operating area. Failure to follow this warning may
result in personal injury or equipment damage.

When troubleshooting the Iron Roughneck, make sure the hydraulic pressure is 2,500 psi at the
inlet of the manifold. Check the back pressure of the tank line and ensure it does not exceed 
100 psi.
1. Ensure that all hoses and QDs are properly connected.
2. Check manifold, fittings, QDs, and hoses for leaks or damage.
3. Ensure the tool is lubricated per Chapter 5, titled “Maintenance,” section “Lubricating
the Iron Roughneck” on page 5-8.
Mandatory things to check prior to operating the Iron Roughneck include the following:
1. Ensure that the Iron Roughneck is fully inserted in the floor socket or the floor base
as appropriate.
2. Ensure all QDs are fully engaged.
3. Ensure the operating pressures are correct.
4. Verify the condition of the filter.
5. Check all fittings for leaks.
Lubricate entire Iron Roughneck and check the condition of the filter per Chapter 5, titled
"Maintenance, “Lubricating the Iron Roughneck” on page 5-8.

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Troubleshooting the Iron Roughneck

Troubleshooting Tables

Symptom Probable Cause Remedy

Hydraulic quick
disconnect on supply or
Tool runs slowly. Tighten until fully shouldered.
return lines not fully
shouldered

Check power supply flow while spin out

Power unit not delivering
valve is actuated. Flow should be 45 GPM
full flow
minimum.

Power unit return line filter

Replace filter element of HPU.
dirty

Pressure filter dirty Replace filter element of ST-120.

Vertical positioning
Power supply not
assembly moves in one
operating, or pressure too Re-establish hydraulic power.
direction only or does not
low
move at all.

Lift cylinder damaged or

Clean or repair cylinder.
dirty

Binding of carriage guide

Lubricate or replace side rollers.
in column

Pilot pressure is set too

Check pressure and adjust.
low

Does not maintain vertical Counterbalance valve out Replace, or adjust counterbalance valve to
position of adjustment maintain vertical position.

Lift cylinder leak Replace seals.

Base assembly quick

Tool does not rotate Fully connect all base assembly quick
disconnect couplings are
(slew). disconnect couplings.
not connected

Ensure storage pin is removed.

Tool does not extend Obstruction
Ensure arm lock plate is not locking the arm.

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Troubleshooting 6

Troubleshooting the Iron Roughneck

Troubleshooting Tables

Symptom Probable Cause Remedy

Torque cylinders do not

Torque valve set too low Increase setting.
makeup.

Torque valve or pressure

reducing valve stuck closed, Check valves, clean or replace.
dirty, or damaged

Torque cylinders already at end

Recycle the upper jaw for another bite.
of stroke

Torque valve damaged Check, clean, or replace.

Torque setting pressure

Torque cylinders do not
reducing valve stuck closed, Check valves, clean, or replace.
breakout.
dirty or damaged

Torque setting is too low Increase torque setting.

Disassemble valve, inspect for

Torque cylinders drift in Sticking or worn main operating
contamination or wear, and repair or
makeup direction. valve
replace.

Torque cylinder does not Dirty return filter in power

Replace filter element.
move or moves slowly. supply

Torque gage does not

indicate pressure during Dirty inlet port or gage Clean inlet port or replace gage.
makeup

Torque cylinders reached end

of stroke and actuated dump Reset for additional stroke.
valve

Open damper located on top front of

Gage damper closed
gage (rotate counterclockwise).

Torque gage does not Rotate zero adjust knob on back of

Gage not adjusted to zero
return to zero. gage case. Recheck torque setting.

High tank line pressure Check and correct.

Defective gage Replace.

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Troubleshooting the Iron Roughneck

Troubleshooting Tables

Symptom Probable Cause Remedy

Jaws slip on tool joint. Worn or broken dies Replace dies.

Make sure the pressure at the

Hydraulic pressure too low
manifold is set to 2,500 psi.

Ensure the intensifier ball valve is on

Intensifier not operating
and inspect and replace as necessary.

Dirty intensifier filter Check and/or replace.

Check that intensifier is doubling

Defective intensifier
pressure to the clamp circuit.

Upper torque wrench

body lifts while cycling in Interference between upper
Check and remove interference.
makeup or breakout and lower body sets
mode.

Torque wrench clamp

Check valves on manifold
cylinders too slow or Clean, repair, or adjust valves.
contaminated or defective
uneven.

Lack of lubrication Lube all grease fittings.

Flow Divider not operating Check for damaged line and/or flow
properly divider and replace as necessary.

Symptom Probable Cause Remedy

Spin Wrench assemblies

Locate cause or restriction and
do not clamp or unclamp Flow restricted
correct.
and/or motors do not run.

Power supply defective Check power supply.

Return valve to center position

Spin Wrench Assemblies
manually. If problem persists, inspect
or motor creep with valve Leaking or sticky valve
valve spool for wear or contamination.
in neutral position.
Repair or replace.

High tank line pressure Check and correct.

Motor runs irregularly. Contaminated motor Repair motor or replace.

Bent shaft Repair motor or replace.

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Troubleshooting 6

Troubleshooting the Iron Roughneck

Troubleshooting Tables

Symptom Probable Cause Remedy

Spin rollers do not turn with

motor running, or have Damaged motor spline Check motor spline.
insufficient power.

Motor seal blown Replace motor seals.

Flow restricted to motor Locate cause of restriction and correct.

Defective roller bearings Replace bearings.

Defective motor Repair motor.

Motor Drive shaft broken Replace motor.

Check power supply pressure gage for

indication. Ensure that supply pressure
Loss of power, torque. Power supply not operating
remains high with operating valve
energized.

Check for pinched, clogged, or

Restricted hydraulic lines otherwise obstructed hydraulic lines.
Clear obstruction.

Worn cylinder seals Replace seals.

Drill pipe or collars rub

Spin rollers worn
against Spin Wrench motor Replace spin rollers.
excessively
during spinning.

Check pressure at manifold set to

Insufficient clamping
Spin rollers slip. 2,500 psi. Check for leaks in clamping
pressure
lines and replace as required.

Defective seal on spin clamp

Replace seal.
cylinder piston

Slippery connection Clean connection.

Spin rollers worn Replace spin rollers.

Grease on Spin Rollers.

Spin Wrench clamp should Remove grease.
be held while spinning

Check nitrogen pre-charge on

Spin Wrench does not thread
Accumulator pre-charge accumulator.
compensate.
Add nitrogen as required to 100 psi.

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