ST 80 Iron Roughneck

Iron Roughneck ST-80C
Generation 1 Tall Column without Reach Extender

Shipping Package: 30181800-ASM
Configuration: 30181800-510|511
User Manual
Customer References
Document Number: 10977529-MAN
Revision: 02
Volume: 1
www.nov.com
Document number 10977529-MAN
Revision 02
Page 2
REVISION HISTORY
02 19.03.2015 For Information I. Vargas L. Krajenbrink J. Walker

01 04.09.2014 For Information I. Vargas L. Krajenbrink J. Walker
Rev Date (dd.mm.yyyy) Reason for issue Prepared Checked Approved
CHANGE DESCRIPTION
Revision Change Description

01 Initial Release
02 Documentation Updates as Follows: Updated cover page to remove the description.
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Document Number: 10977529-MAN TOC
TABLE OF CONTENTS
Revision: 02
Page: 1
Vol. Chapter/ Title Remarks

Section
1 1 General Information
1 2 Installation, Operation, & Maintenance
1 2.1 Procedures
1 2.2 Spare Parts List
1 3 Technical Documents & Drawings
1 3.1 General/Mechanical Drawings
1 3.2 System /Process Diagrams
1 3.3 Electrical/Instrument Section Not Applicable
1 3.4 Performance Data Section Not Applicable
1 4 Vendor Documentation Chapter Not Applicable
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Document Number: 10977529-MAN TOC 1
TABLE OF CONTENTS
Revision: 02
Page: 1
Vol. Chapter/ Title Document Number Rev.

Section
1 1 General Information
Functional Design Specification, ST-80C D364000206-FDS-001 01

FUNCTIONAL DESIGN
SPECIFICATION
ST-80C
This document contains proprietary and confidential information which belongs to National-Oilwell
Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in
part, or use of this design or distribution of this information to others is not permitted without the
express written consent of NOV. This document is to be returned to NOV upon request and in any
event 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 TITLE
CURRENT INITIAL FUNCTIONAL DESIGN
DRAWN
E. AXELSON SPECIFICATION, ST-80C
CHECKED
J. WALKER SIZE DWG NO REV
APPVD
J. WALKER A D364000206-FDS-001 01
DATE
03/09/2010 SCALE NONE WT LBS SHEET 1 OF 2
D7DCF0045_FMT_AV-TPL-001/C
Functional Requirements: Iron Roughnecks
Unit Name: ST- 80C
Compact Iron Roughneck for highly portable installations. Pedestal

mounted unit with all hydraulic, manual controls mounted on the tool.
Unit combines spinning and torque functions into one wrench for safe,
Description
fast, and controlled make-up and break-out of drilling tubular
connections. The spinner rollers and torque wrench dies work directly
on the tool joint.
The control console mounted on the tool provides for spinner and
torque wrench clamp/unclamp, spin in and out, and torque functions,
as well as positioning controls. A single operator adjusts the position
of the tool both vertically and horizontally in either the storage or
Operator Controls working positions. The controls are designed such that a fine
adjustment is set to position the ST-80C precisely at either well center
or the mousehole, and the tool can consistently be positioned at either
location on a repetitive basis. The tool includes a rotating pedestal
which can rotate a full 360 degrees and can be locked at any position.
Specs/Features:
Pedestal mounted, drag up v-door, insert into socket installed in rig
Installation Method floor, connect hydraulic P&T. Requires socket to be structurally
supported in rig floor.
Connection Range 4-1/4” to 8-1/2" OD connection
Max Make-up Torque 60,000 ft lbs
Max Break-out Torque 80,000 ft lbs
Spin Speed 85 RPM typical on 6-5/8” OD connection
Spin Torque 1,550 ft lbs typical on 6-5/8” OD connection
Drill Pipe 3-1/2” to 6-5/8” nominal
Drill Collars from 4-1/2” to 8-1/2” OD
Bit Breaking No
Casing/tubing No
Operates at Mousehole Yes
Horizontal Adjustment 60”
Rotational Adjustment 360 degrees
Overall Vertical Travel 72” (Tall Column) / 36” (Short Column)
Nominal Connection Height 23” to 59”
Weight, Total 7800 lbs (Tall Column) / 7400 lbs (Short Column)
Required Hydraulic Supply 40 GPM max / 2500 PSI max
Local Controls Left side mount
Remote Controls No
Automated Feature No
Cycle Time 20 sec.
Optional Items None
Compatible with PS-21/30, PS-15/16/20
SIZE DWG NO REV
A D364000206-FDS-001 01
SCALE NONE WT LBS SHEET 2 OF 2
TABLE OF CONTENTS
Revision: 02
Page: 1
Vol. Chapter/ Title

Section
1 2 Installation, Operation & Maintenance
1 2.1 Procedures
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Document Number: 10977529-MAN TOC 2.1
TABLE OF CONTENTS
Revision: 02
Page: 1

Section
1 2.1 Procedures
Commissioning Procedure ST-80 Gen 3 & ST-80C 3TS00688 B
The Use of and Application of Safety Wire for Secondary ASP00019 A

Retention
Service Manual ST-80C Iron Roughneck D811000124-MAN-001 03
Recommended Lubricants Guide D811000719-PRO-001 06
Design Torque Standard DS00008 F
Hydraulic Fluid Cleanliness SM00081 C
www.nov.com
3TS00688
ST-80 GEN 3 & ST-80C
COMMISSIONING PROCEDURE
Serial Number: ____________________________
Part Number: ____________________________
Date: ____________________________
This document contains proprietary and confidential information which belongs to National-Oilwell
Varco, L.P., its affiliates or subsidiaries (all collectively referred to hereinafter as "NOV"). It is
loaned for limited purposes only and remains the property of NOV. Reproduction, in whole or in
part, or use of this design or distribution of this information to others is not permitted without the
express written consent of NOV. This document is to be returned to NOV upon request and in any
event 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 TITLE
CURRENT INITIAL COMMISSIONING PROCEDURE
DRAWN
A HASTINGS B. DE JONG ST-80 GEN 3 & ST-80C
CHECKED
S KARAJAGI N. WEST SIZE DWG NO REV
APPVD
J ADKINS N. WEST A 3TS00688 B
DATE
30 JANUARY 14 15 OCTOBER 03 SCALE NONE WT LBS N/A SHEET 1 OF 6
1. Pre-installation checklist:
1.1. Run hydraulic supply lines to installation position on rig floor. Pressure line to be 1.0”
diameter minimum (.75” if hose shorter than 8 ft, 1.25” if hose longer than 25 ft.) Tank line to
be 1.25” diameter minimum (1” if hose shorter than 8 ft, 1.5” if hose longer than 25 ft.) Hose
end fittings are to be compatible with connections on column of ST-80.
________________.
1.2. Hydraulic supply pressure is 2000-2500 PSI and supply capacity is 30 GPM minimum.
________________.
1.3. ST-80 support socket is installed plumb and within a margin of 71-89” from each connection
location according to General Arrangement drawing 30171616 or General Arrangement
drawing 30176031 for the ST-80C.
________________.
2. ST-80 physical condition checklist:
2.1. Inspect ST-80 for damage. Bores for base attachment to be clean and greased. Structure to
be true and free of defects.
________________.
2.2. Inspect Socket Flange and Base Assembly for damage.
________________.
2.3. Inspect all hydraulic lines and fittings for kinks, abrasions, and cuts.
________________.
SIZE DWG NO REV
A 3TS00688 B
3. ST-80 installation checklist:
3.1. Apply a coating of grease to the bore of the floor socket. (Socket already installed according
to GA-drawing 30171616 or 30176031).
________________.
3.2. Clean and apply a coating of grease to the tube of the Socket Flange and insert Flange/Base
assembly into the floor socket.
________________.
3.3. Verify the support post is fully seated; the bottom of the flange should be approximately one
inch above the top of the socket.
________________.
3.4. Remove pins from the Base Assembly and hoist ST-80 onto it. Make the connection by
inserting the 2 pins and hairpins (Note, pins must be inserted from designated side).
________________.
3.5. Close the shut-off valve on the ST-80 and attach the hydraulic lines to the pressure and tank
lines of the ST-80.
________________.
3.6. Energize the hydraulic supply and open the shut-off valve on the ST-80 (top of support
column). Inspect the hydraulics for leaks.
________________.
3.7. Remove transport pin to stored position and extend the tool and raise the carriage using the
control panel to verify sufficient clearances. Safety note: When first extending the tool, air in
the extend cylinder can cause the tool to move rapidly as the wrench passes over the support
arm pivot. Stand safely to one side of the ST-80 until a full extend/retract cycle has been
completed.
________________.
SIZE DWG NO REV
A 3TS00688 B
3.8. Operate each hydraulic valve, starting with the spin control, to purge any air from the system
and verify function.
________________.
3.9. Rotate and extend the tool to both the mouse hole and well center position to verify reach.
________________.
3.10. With a connection in well center (mouse hole optional), position the ST-80 toward the
connection.
________________.
3.11. With the Adjust lever (located on top of wrench), move the carriage full back. Extend the
Carriage with the In-Out lever until it reaches end of stroke. Check that the ST-80 is hanging
true, loosen swing damper at back/left of frame if necessary. Using the Adjust lever, position
the ST-80 forward until the bottom support plate just touches the pipe connection (adjust
height as necessary). This is best done with another person viewing below the ST-80 until
you are comfortable what to look for. Keep hands clear of the pipe!
________________.
3.12. Adjust the height until the connection box shoulder is located above the lower clamp dies,
and below the spin rollers.
________________.
3.13. Adjust the torque pressure valve (on top of wrench, next to Adjust lever) to full counter
clockwise, then one turn clockwise.
________________.
3.14. Make the connection in the following sequence:

- Use the Make/Break lever to cycle the jaws to Break (ready to Make).
- Clamp using the Clamp/Unclamp lever, release.
- Put in Spin Wrench (SW) mode using the TW/SW lever, hold.
- Spin-in using the Spin lever, hold until pipe stops spinning.
- Put in Torque Wrench (TW) mode using the TW/SW lever, hold.
- Make the connection using the Make/Break lever, hold.
- While holding the Make lever, adjust the torque pressure valve to the desired torque by
watching the torque gage on top of the control console (you may release the TW/SW
lever while making this adjustment).
- Unclamp.
________________.
SIZE DWG NO REV
A 3TS00688 B
3.15. Break the connection in the following sequence:
- Use the Make-Break lever to cycle the jaws to Make (ready to Break).
- Clamp using the Clamp/Unclamp lever, release.
- Put in Torque Wrench (TW) mode using the TW/SW lever, hold.
- Break the connection using the Make-Break lever (torque pressure adjustment has no
effect), hold until end of stroke.
- Put in Spin Wrench (SW) mode using the TW/SW lever, hold.
- Spin-out using the Spin lever.
- Unclamp.
________________.
3.16. Verify if ST-80 meets the timing table presented below.

1) Deployment with ST-80 Check ST-80 to this table working under the following condition
a) Fully up (with ST-80 extended to work position): < 13 sec.
b) Fully down (with ST-80 extended to work position): < 12 sec.
c) Fully forward (with adjust cylinder half extended): < 2.5 sec.
d) Fully backwards (with adjust cylinder half extended): < 2.5 sec.
1) Jaws Open & Close
a) Jaws from fully open to fully close: < 5 sec.
b) Jaws from fully close to fully open: < 5 sec.
1) Spinners
a) Spinning IN a 6.3/8” tool joint: > 100 RPM
b) Spinning OUT a 5.1/2” tool joint: > 115 RPM
Note: Calculate own expected RPM when size tool joint is different. Spinning is a linear
function going from 150 RPM to 75 RPM if diameter is going from a 4.25” tool joint to a
8.50” tool joint.
1) Torque Cylinders (torque setting at 20,000 ft-lbf).
a) Make Up, full stroke: < 3 sec.
b) Break Out, full stroke: < 3.5 sec
1) Total cycle time for a semi experienced operator (including to the pipe, clamp, spin,
torque, unclamp & return to standby position):
a) Make Up cycle: < 20 sec.
b) Break Out cycle < 19 sec.
________________.
SIZE DWG NO REV
A 3TS00688 B
The undersigned representatives hereby acknowledge that all
checkout and testing work, as listed herein, has been successfully
completed for this ST-80:
______________________________.
Varco Representative
______________________________.
Customer Representative
______________________________.
ST-80 Serial Number
______________________________.
Date
SIZE DWG NO REV
A 3TS00688 B
PROCEDURE
THE USE OF AND APPLICATION OF

SAFETY WIRE FOR SECONDARY
RETENTION
National Oilwell Varco

This document contains proprietary and confidential information
which belongs to National Oilwell Varco; it is loaned for limited Rig Solutions
RIG/PLANT
purposes only and remains the property of National Oilwell.
Reproduction, in whole or in part; or use of this design or 11000 Corporate Centre Dr.
distribution of this information to others is not permitted without the
ADDITIONAL CODE SDRL CODE TOTAL PGS
express written consent of National Oilwell Varco. This document is Houston TX 77041 USA
to be returned to National Oilwell Varco upon request and in any Phone +1 (281) 854-0647
REMARKS event upon completion of the use for which it was loaned. Fax +1 (281) 854-0508
 National Oilwell Varco
MAIN TAG NUMBER DISCIPLINE
DOCUMENT NUMBER REV
CLIENT PO NUMBER
ASP00019 A
CLIENT DOCUMENT NUMBER
Client Document Number

Document number ASP00019
Revision A
Page 2
REVISION HISTORY
A 15/04/2011 SEE ECN C. SILVA T. GORMSEN T. GORMSEN

- 10/03/1995 First Issue KTK K DAW JES
CHANGE DESCRIPTION

- First Issue
A SEE ECN
Revision A
Page 3
TABLE OF CONTENTS
1 SCOPE .............................................................................................................................. 3
2 APPLICABLE DOCUMENTS ........................................................................................... 4
3 REQUIREMENTS ............................................................................................................. 4
3.1 MATERIAL AND SIZE ............................................................................................ 4
3.2 GENERAL REQUIREMENTS ................................................................................. 5
3.3 LOCK-WIRING METHODS..................................................................................... 6
3.4 OTHER APPLICATIONS ........................................................................................ 7
3.5 ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION .................................. 8
4 QA PROVISIONS.............................................................................................................. 9
5 NOTES .............................................................................................................................. 9
1 SCOPE
Revision A
Page 4
This procedure establishes the method for the selection and application of safety wire.
Lock wiring is the application of wire to prevent relative movement of structure or other
critical components subject to vibration, tension, torque, etc.
This procedure is intended to help eliminate the risk of dropped objects in

components or parts manufactured.
Bolts, Nuts and Screws are the common type of fasteners used on NOV
equipment. They need to be locked (secondary retention) against loss of torque / pre-
tension.
Use of safety wire to prevent rotation of fasteners is a safe and primarily

recommended secondary retention method for fasteners. It is the most preferred
method because it not only prevents fasteners from loosening but also keeps them from
falling in case of primary retention failure (bolt head Breaks off) and effectively prevents
dropped objects.
Note that the secondary retention will work only if the primary retention method is
properly in place, i.e. bolts and screws are tightened and torqued as per specifications,
and there is no play between the mating elements. Secondary retention methods aim in
preventing any compromise in primary retention, loss of pre-tension in assembled
fasteners, loosening and backing out.
Definitions:
Secondary Retention – The means of effectively retaining a fastener/joining component

such that the operating loads do not compromise the integrity of the primary fastening
component.
2 APPLICABLE DOCUMENTS
DS00008-DES DESIGN TORQUE STANDARDS

Machinery’s Handbook 27th Edition
3 REQUIREMENTS
3.1 MATERIAL AND SIZE
3.1.1 Material
Lock wire must be aircraft quality stainless steel 302/304 condition A.
3.1.2 Lock-wire sizes

Revision A
Page 5
a. 0.5080 mm (0.020 inch) diameter

b. 0.8128 mm (0.032 inch) diameter NOV P/N Z6000.8
c. 1.1938 mm (0.047 inch) diameter NOV P/N Z6000.9
d. 1.2950 mm (0.051 inch) diameter NOV P/N Z6001
e. 3.1750 mm (0.125 inch) diameter NOV P/N Z6002
3.2 GENERAL REQUIREMENTS
3.2.1 Safety wire shall be new upon each application.
3.2.2 Parts shall be lockwired in such a manner that the lockwire shall be put in tension
when the part tends to loosen.
3.2.3 The lockwire should always be installed and twisted so that the loop around the
head stays down and does not tend to come up over bolt head and leave a slack loop.
3.2.4 Care shall be exercised when installing lockwire to ensure that it is tight but not
over stressed.
3.2.5 Properly twisted lockwire will have 7-12 twists per inch for .032 wire and 6-8 turns
for .052 wire. More twists will over stress the wire and cause fatigue and breakage.
3.2.6 A pigtail should be ½” to 5/8” in length (4-8 twists) at the end of the wiring. This
pigtail shall be bent back or under to prevent it from becoming a snag.
3.2.7 As per the Machinery’s Handbook 27th edition the following rules apply:
a) No more than three (3) bolts may be tied together.

b) Bolt heads may be tied as shown only when the female thread receiver is
captive.(see figure 1)
c) Lockwire must fill a minimum of 50% of the drilled hole provided for the
use of lockwire.
d) Diameter of lockwire is determined by the thread size of the fastener to be
lockwired.
1) Thread sizes of 6 mm (0.25 inch) and smaller use 0.508mm (0.020
inch) wire.
2) Thread sizes of 6 mm (0.25 inch) to 12 mm (0.5 inch) use 0.8128 mm
(0.032 inch) wire.
3) Thread sizes > 12 mm (0.5 inch) use 1.1938 mm (0.047 inch) OR
1.295mm (0.051) wire.
The larger wire may be used in smaller bolts in cases of convenience, but smaller
wire must not be used in larger fastener sizes.
Revision A
Page 6
Figure 1: Safety Wire / Lock Wire
3.3 LOCK-WIRING METHODS
3.3.1 The method involves threading a wire through holes in the fastener to lock it
against being rotated loose. The wire is twisted before being threaded and is locked to
next bolt. Safety wire should be placed in and around bolt head to maintain the pre-load.
The use of safety wire ties is illustrated in figure 1 above. The illustrations assume the
use of right-hand threaded fasteners.
3.3.2 The double-twist method:

The double-twist method of lock-wiring shall be used as the common method of
lock-wiring.
CAUTION: screws in closely spaced geometric which secure hydraulic or air seals, hold
hydraulic pressure, or used in critical areas of clutch mechanism should use double twist
method of lock-wiring. Make sure that the wire is so installed that it can easily be broken
when required in an emergency situation.
3.3.3 Lock-wiring widely spaced multiple groups by the double twist method.
a) When the multiple fasteners are from 4-6 inches apart, three (3) fasteners
shall be the maximum number in a series that can be safety wired
together.
b) When the multiple fasteners are spaced more than 6 inches apart, the
multiple fastener application specified in Figure 1 shall not be used unless
tie points are provided on adjacent parts to shorten the span of the wire to
less than 6 inches.
c) One end of the safety wire shall be inserted through one set of lockwire
holes in the head of the bolt. The other end of the safety wire shall be
looped around the bolt head in the tightening direction.
Revision A
Page 7
d) The strands, while taut, shall be twisted until the twisted part is just short of
the nearest hole in the next bolt. The twisted portion shall be within 1/8” of
the holes in each bolt as shown in figure 1 above.
e) After wiring the last bolt, the wire shall be twisted to form a pigtail of 2-4
twists. The excess wire shall be cut off. The pigtail shall be bent back or
under the part to prevent it from becoming a snag.
3.3.4 Single wire method:

The single wire method may be used in a closely spaced, closed geometrical
pattern (triangle, square, circle, etc.) on parts in an electrical system, and in places that
would make the single-method more advisable as shown in figure 2 below. Closely
spaced shall be considered a maximum of two inches between centers. Maximum length
of wire shall not exceed 24” in total length.
Figure 2: Safety Wire / Lock Wire Single
3.4 OTHER APPLICATIONS

Revision A
Page 8
3.4.1 Hollow head bolts are safety wired in the manner prescribed for regular bolts.
3.4.2 Drain plugs and cocks may be wired to a bolt, nut, or other part having a free lock
hole in accordance with the general instructions contained herein.
3.4.3 External snap rings may be locked if necessary in accordance with the general
locking principles contained herein.
3.4.4 Internal snap rings shall never be lockwired.
3.4.5 Bolts and hardware may be wired using SAFE-T-Cable. Follow procedure
D744000087-PRO-001.
Safe-T-Cable® can be used similar to Safety/Lock wire to secure Fasteners. The safety
cable installation procedure is shown in Figure. The safety cable comes in pre-cut
lengths with stubs on one end. After sewing through the holes in the fasteners they are
tightened and crimped using a ferrule cartridge and crimping tool.
They are more convenient to use and take only a fraction of the time to secure fasteners
as compared to safety wire as no wire twisting is required. However additional tools like
ferrule cartridge and crimping tool are required. For additional information refer Safe-T-
Cable® (website http://www.dmctools.com/Catalog/safe_t_cable.htm).
Figure 3: Safety Cable Installation Procedure
3.5 ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION

Revision A
Page 9
4 QA PROVISIONS
5 NOTES
Service Manual
ST-80C
Iron Roughneck
Reference Reference Description

Iron Roughneck, ST-80C
This document contains proprietary and confidential information which
belongs to National Oilwell Varco; it is loaned for limited purposes only
and remains the property of National Oilwell Varco. Reproduction, in National Oilwell Varco
whole or in part; or use of this design or distribution of this information to 12950 West Little York
others is not permitted without the express written consent of National Houston, TX 77041
Oilwell Varco. This document is to be returned to National Oilwell Varco Phone: 713-937-5000
upon request and in any event upon completion of the use for which it was Fax: 713-856-4138
loaned.
© National Oilwell Varco
Document Number Rev.
D811000124-MAN-001 03
www.nov.com
D811000124-MAN-001
Revision 03
Revision History
Changed manual type to Service Manual. Removed

03 16.06.2010 the Recommended Lubricant section. Added note in C. Rodriguez E. Axelson E. Axelson
chapter 5. Removed chapter 7.
1. Add General Specifications
02 08.07.2008 P. Solovyov E. Axelson B. Winter
2. Correct technical data
01 11.05.2007 First Issue P. Solovyov K. Schmidt B.Winter
Change Description
01 First Issue
02 1. Add General Specifications.

2. Correct technical data.
Changed “User Manual” to “Service Manual” in title page.
Made the follwing changes to Chapter 5:
- Removed section titled “Recommended Lubricants”,
03
- added a statement referring to the Lubricants and Hydraulic Fluids document,
- added a note related to lubrication intervals and severity of use.
Removed Chapter 7: Service Locations.
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D811000124-MAN-001
Revision 03
Page 3 of 6
Table of Contents
Chapter 1: General Information

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Note, Caution, Warning, and Hot Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Chapter 2: Overview
Tool Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Iron Roughneck Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
ST-80C Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
ST-80C Tall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
ST-80C Range of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pinch Point Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Allowable Tool Joint Differentials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Tool Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Socket Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Controls Positioning Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Hoist/Lower Kit (ST-80C Tall) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Chapter 3: Installation
Pre-Installation and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Customer Verification of Hydraulic Fluid Cleanliness . . . . . . . . . . . . . . . . . . . . . . . 3-1
Equipment Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Pre-Installation Requirements and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Equipment Motion Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
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Floor Socket Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Floor Socket Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Reach Extender Plate (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Use of Optional Reach Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Lifting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removing Transport Frame and Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Iron Roughneck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Installing the Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Positioning the Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Installing the Service Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Installing the Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Iron Roughneck Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
HPU Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Controls Installation Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Storing the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Using an Iron Roughneck on Floating Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Chapter 4: Operation
Operating the ST-80C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Checking System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Hoist/Lower Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Positioning ST-80C for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Making and Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Adjusting the Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Adjusting Torque Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Securing the ST-80C on a Floating Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Chapter 5: Maintenance
Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Inspecting Hardware and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Lubricating the ST-80C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
MPI Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Changing Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Replacing Spin Rollers and Slide Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Adjusting Torque Gauge Responsiveness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
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Chapter 6: Troubleshooting
Troubleshooting the ST-80C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
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Chapter 1: General Information
Overview
Intended Audience
This manual is intended for use by field engineering, installation, operation, and repair personnel.
Every effort has been made to ensure the accuracy of the information contained herein. National
Oilwell Varco® (NOV), will not be held liable for errors in this material, or for consequences arising
from misuse of this material.
Conventions
Note, Caution, Warning, and Hot Surface
Notes, cautions, warnings and hot surfaces safety messages provide readers with additional
information to advise the reader to take specific action to protect personnel from potential injury or
lethal conditions. They may also inform the reader of actions necessary to prevent equipment
damage. Please pay close attention to these advisories.
Note
i
The note symbol indicates that additional information is provided about the
current topics.
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 observe and follow proper procedures
could result in serious or fatal injury to personnel, significant
property loss, or significant equipment damage.
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Conventions
Note, Caution, Warning, and Hot Surface
Hot Surface
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 Drawing
Package included with your NOV documentation.
Safety Requirements
National Oilwell Varco equipment is installed and operated in a controlled drilling rig environment
involving hazardous situations. Proper maintenance is important for safe and reliable operation.
Procedures outlined in NOV 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.
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 Drilling Equipment training department for more information about equipment
operation and maintenance training. Refer to the Service Location document listed in the User
Manual.
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General Information
3
Safety Requirements
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
NOV recommends that only those tools specified be used when stated. Ensure that personnel and
equipment safety are not jeopardized when following service procedures or using tools not
specifically recommended by NOV.
General System Safety Practices

The equipment discussed in this manual may require or contain one or more utilities, such as
electric, 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.
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.
 Isolate energy sources before beginning work.

 Avoid performing maintenance or repairs while the equipment is in operation.
 Wear proper protective equipment during equipment installation, maintenance, or repair.
Replacing Components
 Verify that all components (such as cables, hoses, etc.) are tagged and labeled during
assembly and disassembly of equipment to ensure correct installation.
 Replace failed or damaged components with NOV 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 Chapter 5, Maintenance, Inspection and
Lubrication for maintenance recommendations.
!
Failure to conduct routine maintenance could result in equipment damage
or injury to personnel.
Proper Use of Equipment

National Oilwell Varco equipment is designed for specific functions and applications, and should
be used only for its intended purpose.
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Chapter 2: Overview
Tool Description
The ST-80C Iron Roughneck is an oil-rig tool used for make-up and break-out of drilling tubular
connections. Designed for use on smaller rigs where floor space is limited, the durable ST-80C
Iron Roughneck features an extend/retract scissor-arm system and is available in standard and tall
models. With the tall pedestal Iron Roughneck model, the operator has the capability of raising the
Iron Roughneck above the deck crew’s head in the parked position. Thus, the ST-80C allows
clearance around well center and mousehole both during use and when placed in the parked
position.
i
For safety considerations, the ST-80C Iron Roughneck cannot be operated
when placed in the parked position.
The control console, which mounts on the front left or right side of the Iron Roughneck carriage,
operates the hydraulic components safely and quickly providing up to 80,000 ft.-lbs. of torque to
make-up and break-out drilling tubular connections.
The ST-80C is installed on the drill floor and uses either a single, floor-mounted socket or a floor-
mounted bearing and upper mast attachment for elevated storage. No hanging cable is needed.
The ST-80C works at well center and the mousehole. This automated Iron Roughneck can be
rotated by hand about the pedestal for storage when not in use.
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Tool Description
Iron Roughneck Components
ST-80C Standard
Carriage
The carriage is connected to the pedestal and is a compact, heavy-duty enclosure for the Iron
Roughneck components. The control console support is located on the front of the carriage.
Control Console
The ST-80C Iron Roughneck operator-controlled control console is installed on the front of the Iron
Roughneck carriage. The control console can be mounted on the front left or front right side,
depending on space requirements of the rig floor.
Pedestal
The pedestal, which is mounted on the drill floor, provides vertical and rotational travel for the Iron
Roughneck for required alignment with either the mousehole or well center.
Scissor-Arm
Capable of extending and retracting, the scissor arm assembly supports and provides horizontal
travel of the Iron Roughneck for positioning at the mousehole, well center, and parked/standby
positions.
Torque Wrench with Spin Rollers
The ST-80C uses a combination spinner and torque wrench. The dies of the upper jaws are
located between the spin rollers. The spin rollers grip the connection and spin with a torque of
1,750 ft.-lb.
The torque wrench can make up the connection with a maximum torque of 60,000 ft.-lb. The
wrench can break out connections with a maximum torque of 80,000 ft.-lb.
The ST-80C Iron Roughneck can make or break all tool connections from 4-1/4" to 8-1/2" outside
diameter, and can handle nominal drill pipe from 3-1/2" up to 6-5/8".
ST-80C Tall
Remote Hoist/Lower Kit
The remote hoisting and lowering kit operates as an extension to raise the Iron Roughneck to the
parked/stored position above the deck floor. This feature is only available for the ST-80 tall model.
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Overview
2
Tool Description
ST-80C Range of Operation
The ST-80C is compact and flexible for positioning as required according to rig floor specifications
and dimensions. Models are available in standard and tall pedestal heights. The tall pedestal
model can be raised to a high parked position using a hoist/lower kit. Refer to 4,Hoist/Lower Kit
i
Information and illustrations in this document feature the Tall pedestal
model. However, information can be used for the ST-80C standard pedestal
model or tall pedestal model.
8.5" Pipe
Connection
53.0" 4.25" Pipe
R46.5 Connection
R102.6
R19.1
11.5
89.7 (Fully Extended)
64° 29.7 (Fully Retracted)
158.8" Hydraulic
144.2" Shut-Off
Scissor Valve
Arm
86.8"
70.8" QD
CONNECTIONS
1 1/4" Return
(NOV Supply)
Socket Flange TO HPU

Swivel Assembly 4.4" Drill Floor
1" PRESSURE
(PN 30172616)
(NOV Supply)
Figure 2-1. ST-80C Range of Operation
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Tool Description
Pinch Point Hazards
Keep all body parts clear of pinch point hazards.
Figure 2-2. ST-80C Pinch Point Hazards
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Overview
2
General Specifications
Hydraulic Requirements
Hydraulic supply pressure (Max.) 2,500 psi (172 bar)
Hydraulic supply pressure (Min.) 2,100 psi (145 bar)
Hydraulic flow rate required (Min.) 28 gpm @ 1000 psi
Hydraulic flow rate required (Max.) 40 gpm (151 L/pm)
Supply connections (Min.) 1 - inch Hose (1-1/4 - inch if hose length > 20 ft.)
Return connections (Min.) 1-1/4 - inch Hose (1-1/2 - inch if hose length > 20 ft.)
Wrench Assembly
Motor spinning roller ratio 2:1
Spin speed (rollers) 135 rpm
Spin speed (8 1/2” OD) 90 rpm
Make up torque (Max.) 60,000 ft.-lb Max.
Break out torque (Max.) 80,000 ft.-lb Max.
Shipping Data
(appr ox., allowing f or crate/palet te)
Height (in shipping skid) 97.6" Tall: 125" Short: 87"
Width 60"
Depth 66"
Weight 7,400 lbs.
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General Specifications
Allowable Tool Joint Differentials
Neither pin nor box may be smaller than 4-1/4"

nor larger than 8-1/2".
D + 5/8" max. D - 3/8" min.
D D
Max. difference in diameter Max. difference in diameter

pin larger than box. pin smaller than box.
Figure 2-3. Drill Pipe Allowable Tool Joint Differentials
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Overview
2
Tool Orientation
The ST-80C front is positioned over the well center or mousehole for pipe handling procedures. For
positioning information, refer to 4,Positioning ST-80C for Operation
Rear Right
Left Front
Figure 2-4. Tool Orientation
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General Description
The ST-80C Iron Roughneck can make-up or break-out tubular connections from 4-1/4" to 8-1/2"
outside diameter, and can handle drill pipe from 3-1/2" up to 6-5/8".
Pedestal
Transport
Frame
Handle
Carriage
Wrench
Controls
Socket Flange
and Base
Floor Socket
Figure 2-5. ST-80C General Description
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Overview
2
General Description
Socket Flange
The ST-80C is installed on the drill floor using a single, floor-mounted socket. The socket flange
enables the Iron Roughneck to be rotated for proper placement over the well center or mousehole.
Socket Flange
and
Base Assembly
Socket
Cover
Rig
Floor
Floor
Socket
Figure 2-6. Socket Flange
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General Description
Carriage
The Iron Roughneck carriage attaches to the scissor-arm which provides horizontal travel to align
the Iron Roughneck with the well center or mousehole. The scissor-arm is retractable and can
place the Iron Roughneck in operating, standby, or parked positions.
i
The controls can be installed on either the left or right side of the ST-80C
carriage. Refer to 3,Installing the Control Console
Valve Bank
Hydraulic
Manifold
Carriage
Guide
Handle
LH Torque
Adjustment
and Horizontal
Travel Wrench
Adjustment
Control Assembly
Figure 2-7. ST-80-C Carriage Assembly
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Overview
2
General Description
Pedestal
The pedestal support is mounted on the drill floor using a single, floor-mounted socket or a floor-
mounted bearing and upper mast attachment. The pedestal provides vertical and rotational travel
to align the Iron Roughneck with the well center or mousehole.
Shut Off Valve

With Lockout Feature
Hydraulic
Filter
Pressure
Reducing
Valve
Behind Cover
Extend/Retract
Duplex Cylinder
Lift Cylinder
Inside Support
Column
Transport Pin
Install in
! Stored Position
for Operation
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 center, the air will compress

causing the support arm to extend rapidly. Support
unit with tugger and stand to the side until air is
purged.
Figure 2-8. Pedestal Assembly
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General Description
Wrench
The ST-80C uses a combination spinner and torque wrench. The dies of the upper jaws are
located between the spin rollers. The spin rollers grip the connection and spin with a torque of
1,750 ft.-lb.
The torque wrench can make up the connection with a maximum torque of 60,000 ft.-lb. The
wrench can break out connections with a maximum torque of 80,000 ft.-lb.
Follow general safety precautions when working around wrench spin rollers. 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 wrench/spin rollers 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.
Ensure tools, clothing, or personal equipment do not come in contact

with the spin rollers during operation. Objects can become tangled in
the spin rollers and lead to serious injury to personnel, and/or
damage to equipment.
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Overview
2
General Description
Wrench
Centralizer
Plate
Upper Jaw Dies

1 each side
Clamp Cylinder
2 places
Spin Rollers
2 each side
Lower Die
and Die Holder
1 each side
Torque Cylinder Spinner
1 each side 1 each side
Figure 2-9. Wrench Assembly
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General Description
Controls Positioning Range
The ST-80C control console can be located on the right or left side and can be adjusted out 64°.
Position
Range
64°
Control
Console
Figure 2-10. Controls Positioning Range
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Overview
2
General Description
Control Console
BACK UP TW UNCLAMP BREAK OUT

FWD DOWN SW CLAMP MAKE IN
30171793-1 Rev B
Detail of Control Panel
Torque
Gauge
TW
SW BREAK
Engages torque wrench MAKE
or spinning wrench Makes or breaks
a connection
BACK
FWD BACK UP TW UNCLAMP BREAK OUT
Extend and retracts
to or from well center 30171793-1 revB
or mousehole
UP OUT
DOWN IN
Adjusts the vertical height Spins in or out
UNCLAMP
CLAMP
Clamps and unclamps
the wrench on a tubular
Push/Pull
Cable
Figure 2-11. Control Console
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General Description
Hoist/Lower Kit (ST-80C Tall)
The ST-80C Tall model includes a hoist/lower kit. The hoist/lower valve enables the operator to
move the Iron Roughneck between the parked/stored and operating positions. Refer to 4,Hoist/
Lower Kit
Whenever hoisting or lowering the iron roughneck, ensure

all personel and equipment are clear of the operating area.
Failure to follow this warning may result in injury to
personnel or damage to equipment.
Valve
Guard
ST-80C Iron Roughneck

Tall Model
Directional
Valve
Directional
Valve
Handle
Figure 2-12. Hoist/Lower Kit (ST-80C Tall)
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Chapter 3: Installation
Pre-Installation and Setup

The information in this chapter assumes that all pre-installation planning and rig-up has been
accomplished prior to installation of the Iron Roughneck.
Requirements
Although many installation layout arrangements are possible, critical preparation and installation
consideration must be performed before attempting to install the Iron Roughneck.
Before installing the Iron Roughneck system, consider the ideal location of the Iron Roughneck,
HPU, and service loop to ensure accessibility and safety. Installation considerations help to
prevent possible restrictions.
Prior to field installation, ensure all Iron Roughneck components are included and are in
serviceable condition. Fill all lubricants systems to correct levels with specified lubricants.
Initial Inspection
After unpacking all Iron Roughneck components and parts, inspect as follows:
 Inventory all components and parts. Notify National Oilwell Varco if parts are missing or
incorrect. Refer to Chapter 7, Contact Information.
 Inspect all components and parts for shipment damage and corrosion. Notify the carrier if
components or parts were damaged during shipment.
Customer Verification of Hydraulic Fluid Cleanliness
Prior to attaching any National Oilwell Varco equipment to the customer's hydraulic plumbing, the
customer must ensure that the hydraulic fluid/system cleanliness is at a level of ISO 440615/12
or better.
Equipment Differences
The National Oilwell Varco Iron Roughneck is available in standard pedestal and extended
pedestal models. Each Iron Roughneck model is hydraulically similar. The illustrations and
information in this document include the common systems and components installation.
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Pre-Installation Requirements and Procedures

Hydraulic System and Components
Hydraulic systems and components are designed for the intended use in the drilling industry. The
hydraulic operating pressure for this equipment is 2,100 psi.
 Before beginning work on any portion of the hydraulic system, familiarize yourself with the
hydraulic schematics. Refer to the Technical Drawing Package.
 Isolate, lock out, and tag the hydraulic power controls.
 Take precautions when bleeding down residual system pressure, when using bleed valves
or equivalent techniques.
 Properly discharge all system-stored fluid pressure.
 Collect all residual hydraulic fluid in a container to prevent rig or environmental
contamination.
 Take precautions to prevent hydraulic oil from leaking into other open mechanical
components such as junction boxes.
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Installation
3
Pre-Installation Requirements and Procedures

Special Tools
The following table lists special tools and support equipment required to install and commission an
Iron Roughneck.
Description Supplier and Accuracy Range

Model No.
Hydraulic Pressure Test Gauge Various 3-5%-FS 0-3000 psi (0-206 Bar)
Equipment Motion Hazards

The Iron Roughneck equipment travels either horizontally or vertically.
Avoid placing objects in or near the path of motion for this equipment.
Such interference could cause serious injury and/or death to
personnel and/or damage to the equipment.
Keep the working envelope/zone of the equipment free from

personnel.
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Installation
Floor Socket Location
Before installing the floor socket support for the Iron Roughneck, determine the proper floor socket
location. The placement and installation of the floor socket is specific to the rig.
Well Center
Allowable Socket
Center Position
R71.0 Stay toward center to
R89.0 allow for tolerances.
Rig
Specific
R89.0
R71.0
Mouse Hole
Figure 3-1. Floor socket Location Layout
Rotary table
(reference only) Floor Socket
Allowable Pedestal
Well Center
Center Zone
(See Technical
Drawing Package for
details.)
Rig Structure
Mousehole Floor Socket

(Alternate Placement) Floor Beams
Figure 3-2. Floor Socket Placement
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Installation
3
Installation
Floor Socket Location
Install the Iron Roughneck clear of the well center and mousehole position for tong applications.
The following illustration shows the Iron Roughneck in the closest installation position to the well
center and mousehole.
Tong Sweep
R48.0
R60.0
Tong
360°
R60.1
71.0
71.0
Figure 3-3. Tong Sweep for ST-80C
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Installation
Floor Socket Installation
Install the floor socket into the rig floor as shown in the Figure 3-4. Ensure the floor socket is
positioned to receive the Iron Roughneck pedestal facing forward.
Socket
Drill Flange
Floor
.5 - 1.5"
Top of Drill Floor
to Bottom of
Socket Flange
Optional: Add boxing plates

to structure to increase
welding area for the floor socket.
4X 45° X .50
Chamfer to
2X Jackscrews
weld socket
2X Column Pins to rig structure
1.1
Column Base
10.0
Socket Flange
14.8
1.0
20.6 Ø8.0
11.0
15.5 15.1 14.4
Ø23.0 Ø10.0
Socket Flange and Assembly (480 lbs.) Floor Socket (190 lbs.)
Figure 3-4. Floor Socket Components
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Installation
3
Installation
Reach Extender Plate (Optional)
25.0
'X' DIM
ST-80C COLUMN
COLUMN BASE ASSY

TURNTABLE BEARINGS
REACH EXTENDER
'Y' DIM 2nd BEARING
SOCKET FLANGE
ST-80C Reach Extender Plate
Choose Optional Reach Extender

PART NO. 'X' DIM 'Y' DIM 2nd BEARING The use of extenders is optional if the position
30172058 15.00 2.50 NO diamond covers area that contains an obstruction.
30172505 21.00 4.56 YES
30174040 25.00 5.06 YES
Figure 3-5. Reach Extender Plate Installation
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Installation
Use of Optional Reach Extender
Floor Socket
Reach Extender
(optional)
Well
Center
Position
Diamond
Mousehole
Figure 3-6. Reach Extender (Optional)
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Installation
3
Installation
Lifting the Iron Roughneck
Before lifting the Iron Roughneck, ensure that the pedestal is in the full down position and that the
transport pin is installed in the transport position. When the Iron Roughneck is in use, store the
transport pin in the brackets located on the back of the pedestal. Use a lifting device attached to
the two lifting shackles attached to lugs on top of the support arm when lifting the Iron Roughneck.
National Oilwell Varco recommends using a double chain sling with master link when lifting the Iron
Roughneck.
!
When lifting the Iron Roughneck, always use the lifting lugs and shackles
provided. No other part of the Iron Roughneck is rated for, nor intended to
support the full weight of the Iron Roughneck (7,420 lbs.)
The ST-80C has a transportation skid that can be used to hoist the Iron Roughneck through the V-
door onto the drill floor, where the ST-80C will be installed in the floor socket.
Always ensure hoisting operations are conducted safely to avoid

equipment damage and/or injury to personnel.
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Installation
Lifting the Iron Roughneck
Pedestal
In full down
position
Lifting Transport
Shackles Pin
Transport Unit Weight 7,420 lbs. Install in stored
Frame position
for operation.
Rear View of Support Column
Transport
Pin
Installed in
transport position
Jackscrew
Both sides
Lock Pin
2 places
Socket Flange
and Base
Assembly
Hairpin Floor
2 places Socket
Figure 3-7. Lifting the Iron Roughneck
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Installation
3
Installation
Removing Transport Frame and Skid
Remove Transport Frame and Skid

Lifting 1. Pull out hairpins from the lock pins.
Shakles Pins are located on the left side of the carriage
when viewing the roughneck from the front.
2. Pull out lock pins (3 places).
3. Hoist the transport frame up and out of the hole in the
top of the pedestal assembly.
4. Use lifting equipment and hoisting shackles to
safely move the roughneck to the required location.
Transport
Frame
Hairpin
Lock
Pins
Transport
Skid
Figure 3-8. Transport Frame and Skid Removal
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Installation
Iron Roughneck Installation
For detailed information on installing the Iron Roughneck, refer to the Technical Drawing Package
for ST-80C Iron Roughneck assembly.
1. With the Iron Roughneck positioned over the rig floor, remove the transport frame and shipping pin.
Refer to Chapter 3, Lifting the Iron Roughneck.
2. Align the bottom of the pedestal with the floor socket collar and insert the collar pins (2 places.) Refer
to Figure 3-9.
3. Disengage lifting device.
4. Remove the shipping/parking lock pins and place them in the pin storage position.
!
Ensure the pedestal is level and perpendicular to the floor socket collar.
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Installation
3
Installation
Iron Roughneck Installation
Ensure the pedestal is level and

perpendicular to the floor socket collar.
Hydraulic
Connection
Shipping Pin
Collar Pins
Drill Floor
60,000 ft.-lb. Max.
(72,000 ft.-lb. Max. Typical as required

with extender)
Figure 3-9. Floor Socket Installation and Loading
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Installation
Installing the Control Console
The control console attaches to either the front left or right of the Iron Roughneck carriage. Refer
to the ST-80CTechnical Drawing Package for detailed drawings.
The ST-80C controls can be mounted on either side of the carriage. The orientation of the controls
can be adjusted to accommodate the best operating angle. The controls can be changed from one
side of the ST-80C to the other side using the following procedures.
Positioning the Control Console

Moving the control console
1. Remove the hairpins from the top and bottom of the control console.
2. Remove the screws and lock washers from the top and underside of the carriage assembly.
3. Lift the control console (100 lbs.) from the pin, and give some slack to the cable-tree.
4. Unhook the cable-tree and hook it on the other side of the ST-80C carriage.
5. Lift the control console onto the support pin on the other side of the ST-80C carriage.
6. Orient the control console to achieve the proper working angle and replace the screw, lock washer, and
hairpin.
For console operating instructions, refer to Chapter 4, Operating the ST-80C.
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Installation
3
Installation
Installing the Control Console
Position
Range
64°
Control Console
(Left Side Installation)
Control Console
(Right Side Installation)
Figure 3-10. Installing the Control Console
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Installation
Installing the Service Loops
Refer to the following ST-80C hydraulic system configurations:
 Customer System Configuration
 NOV System Configuration
1. Check that all circuit breakers at the Hydraulic Power Unit (HPU) are OFF.
!
All equipment should be shut down, isolated and tagged "OUT OF
SERVICE" before any maintenance procedure is performed. Any
unexpected start-up of equipment during operation can cause serious injury
or death to personnel and / or damage to the equipment.
2. Locate the hydraulic service loops. Connect the hydraulic supply and return hose from the HPU to the
Iron Roughneck.
!
Exercise extreme caution when performing maintenance on the hydraulic
system. Fluid escaping under pressure can cause serious injury or death
to personnel and / or damage to equipment.
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Installation
3
Installation
Installing the Hydraulic Power Unit (HPU)
Refer to the Hydraulic Schematic included in the ST-80C Technical Drawing Package for details.
1. Locate the HPU and isolate incoming power OFF.
All equipment should be shut down, isolated and tagged "Out of

Service" before any maintenance procedure is performed. Any
unexpected start-up of equipment during operation can cause
serious injury or death to personnel and/or damage to the
equipment.
i
Before connecting and/or disconnecting hydraulic connection fittings, the
installation in the vicinity is to be cleaned, and all openings closed by caps
to ensure that dirt cannot enter the system.
Exercise extreme caution when performing maintenance on the

hydraulic system. Fluid escaping under pressure can cause serious
injury or death to personnel and/or damage to the equipment.
2. Fill all hydraulic systems to the correct levels with specified hydraulic fluids. For hydraulic fluid
specifications, refer to Chapter 5, Lubricant Specifications.
3. Locate the HPU service loops. Connect the hydraulic supply and return from the HPU to the
Iron Roughneck.
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Checkout Procedure
Iron Roughneck Installation Checkout Procedure
 Ensure that the Iron Roughneck is fully inserted in the socket and column is vertically
aligned.
 Grease all Iron Roughneck grease points.
 Check that all service loop hydraulic lines are connected.
 Make sure all hose quick disconnects (QD) are properly engaged.
HPU Installation Checkout Procedure
 Check the HPU hydraulic service loop. Ensure the hydraulic hoses are properly secured
and free from snag hazards, leaks, and crimping.
 Check the hose quick-disconnect coupling connection between the HPU and the Iron
Roughneck to ensure that coupling connections are tightened.
 Check the fluid level in HPU.
 Ensure the hydraulic filter, which is located in the rear of the pedestal, is in proper
condition.
Controls Installation Checkout Procedure
 Check the HPU hydraulic service loop. Connect the hydraulic supply (1 hose) and return
(1 hose) from the HPU to the Iron Roughneck.
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Installation
3
Storing the Iron Roughneck

 Palletize the Iron Roughneck for indoor storage. A cargo container is appropriate for
indoor or outdoor storage.
 Avoid wide temperature and humidity variations. The ideal environment for storing the Iron
Roughneck is clean and dry with an ambient temperature of 60° F (16° C). If high humidity
cannot be avoided, National Oilwell Varco recommends storing the Iron Roughneck at 70°
F (21° C).
 All exposed, unpainted metal surfaces are coated with rust preventative at the factory prior
to shipment. Coat all unpainted metal surfaces with rust preventative prior to storage or
transport.
 Cover all openings to prevent water or dust from entering. National Oilwell Varco does not
recommend using silica or dehydrating agents.
 When the Iron Roughneck is not being used for more than 3 months, perform the following
maintenance:
1. Clean the Iron Roughneck.
2. Grease the Iron Roughneck as described in Chapter 5: Maintenance.
3. When transporting the Iron Roughneck, ensure the unit remains vertical and is stable.
Always transport the Iron Roughneck with the transportation skid installed to increase stability.
!
Never position the Iron Roughneck on its side. This will damage the
equipment.
Attach tie-down straps to the two lifting shackles attached on the side of the Iron Roughneck
frame. Additional straps can be attached to major structural components of the Iron Roughneck as
required.
Never attach straps to, or drape straps across the control assembly
or side guards of the Iron Roughneck. These components are not
designed or intended to handle transport loads. Using straps in this
manner will damage the equipment and create pinch points. Pinch
points can cause serious injury to personnel.
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Using an Iron Roughneck on Floating Vessels

Floating vessels are subject to wave action and wind, resulting in unpredictable floor motion.
Unpredictable floor motion can cause an ST-80C to make sudden and unexpected movements.
When this begins to occur, operations should cease and the ST-80C should be secured at well
center, mousehole, or standby position. Refer to Chapter 4, Securing the ST-80C on a Floating
Vessel.
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Chapter 4: Operation
Operating the ST-80C

Checking System Pressure
Procedure
1. Attach a pressure gauge to test port LC on the main manifold.
2. Clamp the ST-80C using the clamp lever. It is not necessary to
have a pipe in the jaws. Read the pressure on the gauge, while
holding the lever in the clamp position. The pressure should
be 2,100 psi.
3. Remove the gauge.
Perform the following procedure when the system pressure is

not 2,100 psi.
1. Remove the tamper resistant cover from the PRV cartridge.
2. Follow steps 1 through 3 as described above.
3. One person needs to hold the clamp lever in the clamp position.
4. Another person adjusts hex socket on the PRV cartridge.
(Clockwise to increase pressure, counterclockwise to decrease
pressure.)
5. Remove gauge and replace tamper resistant cover.
Cartridge
Adjustment
Hex Socket
Cover
PRV Manifold
Test Port
LC
Main Manifold
Unclamp/Clamp
Lever
Figure 4-1. Checking System Pressure
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Control Console
The operation procedures in this chapter require the use of the control console.

30171793-1 Rev B
Detail of Control Panel
Torque
Gauge
TW
SW BREAK
Engages torque wrench MAKE
or spinning wrench Makes or breaks
a connection
BACK
FWD BACK UP TW UNCLAMP BREAK OUT
Extend and retracts
to or from well center 30171793-1 revB
or mousehole
UP OUT
DOWN IN
Adjusts the vertical height Spins in or out
UNCLAMP
CLAMP
Clamps and unclamps
the wrench on a tubular
Push/Pull
Cable
Figure 4-2. Control Console
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Operation
4

Hoist/Lower Kit
The ST-80C Tall model includes a hoist/lower valve that enables the operator to move the Iron
Roughneck between the parked/stored and operating positions.
Procedure
1. Retract the ST-80C to the parked position: On

the control panel, move the BACK FWD lever to Whenever hoisting or lowering the iron roughneck,
the BACK position, ensure all personnel and equipment are clear of
the operating area. Failure to follow this warning
2. On the left side of the ST-80C, locate the hydraulic
may result in injury to personnel and/or damage
hoist /lower valve. to equipment.
Ensure that there is proper clearance for the

ST-80C to be elevated to the stored position.
3. Raise the ST-80C to the parked (fully raised)

position: Turn the hoist/lower directional valve
handle counterclockwise.
4. When the ST-80C is fully raised, install the
storage pin in the back of the pedestal.
5. To lower the ST-80C to the standby position:
remove the storage pin and turn the directional
valve handle clockwise.
Valve
Guard Left
Directional ST-80C Iron Roughneck

Valve (Tall Pedestal)
Directional
Valve
Handle
Figure 4-3. Hoist/Lower Kit (ST-80C Tall)
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Positioning ST-80C for Operation
!
Before operating the ST-80C for the first
time, be sure to remove the transport pin Use the control console levers to
and place it in its storage position. perform steps 2, 3, and 5 on this page.
The ST-80C requires adjustment

whenever the connection or pipe diameter
changes and requires periodic verification
per step 5 of adjustment procedure.
Procedure
1. Push the extend/retract lever Connection

(on top of the carriage) to the fully Pin
retracted position. Extend/Retract
2. On the control console, pull forward on Lever
the BACK/FWD handle to fully extend Bubble
the ST-80C. Level
3. Move the UP/DOWN handle to 2 places
raise the ST-80C to position the top of
the box above the lower dies and below
the spin rollers.
Spin Rollers
4 places
Special attention is necessary if
hard banding is present. Do not grip
on hard banding.
4. Pull the Extend/Retract handle Box

(on top of the carriage) to adjust the Shoulder
ST-80C until the base plate touches Range
the connection diameter. Verify that
the base plate is on the connection
diameter and not on the taper or pipe.
Adjust elevation as necessary, staying
within the guidelines of step 3.
!
Over extension will show contact with
the base plate, but will tilt the wrench out
of alignment. Control
Console Lower Dies
2 places
5. Verify correct adjustment:
Use the BACK/FWD handle to retract Base Plate Socket Flange
and extend ST-80C, a full stroke. Lightly Swivel Assembly
swing the ST-80C by placing your left
hand on top of controls guard, and your
right hand on the front of lower left jaw
body. Listen and feel for bumping Connection
contact against the connection and Box
verify the bubble is within window.
Figure 4-4. Positioning ST-80C
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Operation
4

Making and Breaking Connections
Making Connections Left Right Right
Hand Hand Hand
1 Use the control panel UNCLAMP/CLAMP lever, to clamp 4 6 7
the jaws on the connection, then release the lever.
2 Hold the TW/SW lever in the SW position. Wait
1 second before torquing.
3 Spin the connection IN.
4 Hold the TW/SW lever in the TW position. Wait
1 second before torquing.
5 Hold the BREAK/MAKE lever in the MAKE
position until the desired torque is achieved.
If the wrench does not reach the desired

value in one stroke, repeat.
6 UNCLAMP the jaws.

7 Recycle the torque wrench to BREAK to prepare for the
next connection. 2 1 5 3
Left Right Right Right
Hand Hand Hand Hand
If the wrench does not reach the desired
value in one stroke, repeat. Left Right Right Right
Hand Hand Hand Hand
2 6 3 5
Breaking
Making Connections
Connections
1 Use the control panel UNCLAMP/CLAMP lever, to clamp
the jaws on the connection, then release the lever.
2 Hold the TW/SW lever in the TW position. Wait 1 second
before torquing.
3 Hold the BREAK/MAKE lever in the BREAK position until
the connection is broken.
4 Hold the TW/SW lever in the SW position. Wait 1 second
before spinning.
5 Spin the connection OUT.
6 UNCLAMP the jaws.
7 Recycle the torque wrench to MAKE to prepare for the next
connection.

4 1 7
Left Right Right
30171793-1 revB Hand Hand Hand
Detail of Control Plaque Control Panel Levers
Figure 4-5. Making and Breaking Connections
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Adjusting the Makeup Torque
PRV Adjustment
Knob
Zero Adjust
located backside
of torque gauge
Reference
Indicator
(Red)
Torque
Gauge
Procedure
1. Back the adjustment knob of the pressure
reducing valve (PRV) all the way out.
2. Verify the gauge is adjusted to read zero.
Pressure
Turning the PRV adjustment knob counter Indicator
clockwise decreases torque. Turning the PRV (Black)
adjustment knob clockwise increases the torque.
3. Cycle jaws to break and clamp onto a tubular.

4. Spin the connection in.
5. Torque the connection. National Oilwell Varco offers an additional gauge kit
6. While holding the torque handle, turn the PRV that can be installed in the driller’s cabin (Remote
adjustment knob clockwise while watching the Torque Gage kit, PN 30173445).
torque gauge until the desired torque is achieved.
!
If torque cylinders reach end of stroke, the
gauge reads zero. Recycle jaws and retorque.
7. Position the reference indicator (red needle) on

the torque gauge at the desired torque value.
Figure 4-6. Adjusting Makeup Torque
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Operation
4

Adjusting Torque Gauge
!
National Oilwell Varco offers an additional gauge DO NOT operate the TORQUE lever
kit that can be installed in the driller’s cabin while zeroing the torque gauge dial.
(Remote Torque Gauge kit, (P/N 30173445).
Procedure
! 1. Rotate the knob on the backside of the gauge to

zero out the torque gauge dial.
Zero out the torque gauge every time you 2. Open the hydraulic shut-off valve handle to allow
start up the ST-80C, or when the torque setting pressure to the system.
has changed. 3. Rotate the small knob on the back of the gauge so
that it shows zero.
Return line pressure affects the gauge reading.
See the Chapter 6, Troubleshooting for gauge

responsiveness setting.
Torque Gauge
Adjustment
Knob
Turn Handle
to CLOSED position
Hydraulic Shut-off
Valve Handle
Shown in OPEN position
Control
Console
Figure 4-7. Adjusting Torque Gauge
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Securing the ST-80C on a Floating Vessel
When operating an ST-80C on a floating vessel, high waves and wind cause the
ST-80C to make sudden and unexpected movements.
!
Floating vessels are subject to wave action and wind, resulting in
unpredictable floor motion. Unpredictable floor motion can cause an ST-80C
to make sudden and unexpected movements. When this begins to occur,
operations should cease and the ST-80C should be secured at well center,
mousehole, or standby position. Refer to procedures in Figure 4-8.
Procedure
1. Stop operation.
2. On the control panel, move the BACK/FWD lever to
the BACK position: move the ST-80C to parked position.
3. Turn the base assembly jackscrews (2 places)
clockwise until they tighten against the base plate to
prevent pedestal rotation.
When ST-80C operation can proceed safely, turn the

base assembly jackscrews (2 places) counterclockwise
to allow pedestal rotation.
Jackscrew
(2 places)
ST-80C Left Side, Parked Position

(Cover Removed)
Figure 4-8. High Wind and Wave Precautions
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Chapter 5: Maintenance
Lubricant Specifications
Refer to the Recommended Lubricaants and Hydraulic Fluids documet in the equipment User
Manual.
i
The Lubrication intervals described in this manual are based on lubricant
supplier recommendations. Severe conditions such as extereme loads or
temperature, corrosive atmosphere, and so on, may require more frequent
lubrication.
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Inspection and Lubrication

Inspecting Hardware and Fittings
Visually inspect the ST-80C for loose or missing hardware and fittings daily. Make sure all lock
safety wire is undamaged and that the safety cable between the 3 guiding pins of the lower jaws is
present.
Check the inline pressure filter weekly. Replace as necessary if the indicator is red during
operation.
Inspect all hoses for wear or damage. Replace as necessary.
i
All hoses are clearly labeled. Consult hose kit drawings for proper routing
and hose specification and always label when replacing hoses on the ST-
80C.
Lubricating the ST-80C

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.
Apply grease daily to all grease fittings as shown on the following page.
i
When greasing the spinner assembly, watch for clean grease extruding from
under the spinning wrench rollers. If it becomes difficult to inject grease and
no grease extrudes from under the spinner rollers, the grease vent may be
missing or clogged. This can jam the spinner rollers. Repair or replace as
necessary.
!
Clean any grease which falls to the floor to prevent personal injury due to
slipping.
5-2
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D811000124-MAN-001
Revision 03
Page 5-3 of 12
Maintenance
5

Daily
Each grease fitting is to be greased until clean grease

is seen extruding from the related component.
During operation, surfaces may become hot enough to

Arm Pins
cause bodily injury. To reduce the risk of injury from
(12 places)
a hot component, allow the surface to cool before touching.
Guide Pins
Grease
Brush mating
Fitting
surfaces with grease
(2 places)
Grease Grease
Grease
Fitting Fitting
Fitting
(1 each side) (1 each side)
(2 places)
Grease Grease
Fitting Fitting
(2 places) (2 places)
Grease
Grease Fittings
Grease Fitting
Fitting (2 places)
ST-80C Left Side
ST-80C Front (Cover Removed)
Figure 5-1. Daily Lubrication
5-3
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D811000124-MAN-001
Page 5-4 of 12

Weekly
Grease
Fitting
Grease
Fitting
Grease
Fitting Grease
SOCKET FLANGE Fitting
Grease SWIVEL ASSEMBLY
Fitting (PN 30172616) Grease
Grease
Fitting
Fitting
ST-80C Front ST-80C Rear
Figure 5-2. Weekly Lubrication
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D811000124-MAN-001
Revision 03
Page 5-5 of 12
Maintenance
5

Monthly
Spinner
Gearbox
Check oil level
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.
Procedure
1. Remove the fitting and view the oil level.

2. Oil level should be approximately 2-1/2 inches
below the top surface of the top plate.
Figure 5-3. Monthly Lubrication
5-5
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D811000124-MAN-001
Page 5-6 of 12

6 Months
Changing Oil
RH Spinner
Assembly Manifold
Spinner
LH Spinner Gearbox
Assembly Manifold
Fill Plug
Spinner Spinner
Gearbox Assembly
Pivot Pin
Spinner
Assembly
Level Plug Pivot Pin
Fill Plug
Typical each
gearbox Drain Plug
(On bottom of gearbox)
Procedure
Change the oil in the ST-80C spinner gearbox every 6 months.
1. Disconnect the hydraulic hoses from the spinner
assembly manifolds and cap fittings.
2. Remove the spinner assembly pivot pin. During operation, surfaces may become
3. Lift out the spinner assembly. hot enough to cause bodily injury. To reduce
the risk of injury from a hot component, allow
4. Remove the fill and level plug.
the surface to cool before touching.
5. Drain the oil by removing the plug on the bottom of
the gearboxes. (Gearboxes must be swung out.) Look
for signs of debris or contamination. Report any
unusual findings to your local National Oilwell Varco
Service Center.
6. Replace the drain plug.
7. Fill the gearboxes with fresh oil through the fill port (
approx. 0.5 gallons). For Lubricant information refer to
Chapter 5 Maintenance, Lubricant Specifications.
8. Replace the fill and level plug.
Figure 5-4. Changing Oil
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D811000124-MAN-001
Revision 03
Page 5-7 of 12
Maintenance
5

MPI Inspections
MPI inspect bore every two years

for linear indications and
repair as necessary.
Disassembly is required.
MPI inspect radius including
overlap of one inch on top
and bottom surfaces yearly
Disassembly is not required.
MPI inspect bore every two years

Disassembly is required.
Upper Right Hand Jaw Shown

Inspection is Typical for
Upper Right Hand Jaw,
Lower Right Jaw,
Upper Left Hand Jaw
and Lower Left Jaw.
Figure 5-5. Inspect MPI
5-7
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D811000124-MAN-001
Page 5-8 of 12
Disassembly and Assembly

Precautions
!
Transport hydraulic components to a clean, dust-free service area before
disassembling for service.
Disassembly procedures are performed when replacing damaged components that are causing a
tool function to fail. Whenever performing a disassembly, practice preventive maintenance by:
 Cleaning and inspecting all disassembled parts.
 Replacing all worn and damaged parts before they can cause another failure.
 Installing thread protectors on exposed threads.
!
Torque all fasteners to the limits given in DS 00008 (Design Specification
Design Torque Standard) unless an alternative torque value is given in the
procedure.
5-8
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D811000124-MAN-001
Revision 03
Page 5-9 of 12
Maintenance
5

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 ST-80C.
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 center, the air will compress causing the support arm to
extend rapidly. Support unit with tugger and stand to the side until air
is purged.
before touching.
5-9
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D811000124-MAN-001
Page 5-10 of 12

Changing Dies
Procedure
Replacing Upper Dies
1. Clean the area around the dies and remove the two screws holding
each die and discard screws.
Carriage 2. Remove worn die.
3. Clean the backing surfaces with wire brush, inspect and grease
lightly.
4. Install new dies and screws, torque to 138-152 ft.-lb.
Replacing Lower Dies

1. Remove all main socket head screws (2 per die carrier) and all set
screws (4 per die carrier) from both die carriers.
2. Screw handtight 1 socket head screw in each of the 4 corners.
3. Advance each of the 4 socket head screws 1/2 turn at a time in an
X pattern until die carrier comes free.
!
Caution the die can slip out of the die holder
once its free of the housing.
4. Remove die and socket head screws from die carrier.

5. Discard the existing screws, set screws, and dies after disassembly.
6. Clean receiving pocket and die holder thoroughly, and liberally
apply anti-seize to all mating surfaces before reinstalling them.
7. Install new dies in die carrier and slide die carrier back in pocket.
8. Install new screws and torque to 70-80 ft.-lb.
9. Install and tighten the jacking screws to prevent them from falling out
(15-20 ft.-lb).
Upper During operation, surfaces may

Die become hot enough to cause
(1 each side) bodily injury. To reduce the risk
of injury from a hot component,
Screw allow the surface to cool before
(2 each side) touching.
Die Holder
(1 each side)
Jacking Screw
(4 each side)
Screw Lower Die
(2 each side) (1 each side)
Figure 5-6. Changing Dies
5-10
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D811000124-MAN-001
Revision 03
Page 5-11 of 12
Maintenance
5

Replacing Spin Rollers and Slide Rings
Spinner
Assembly
Pivot Pin
RH Spinner
Assembly
Manifold
Lift Thread
1/2-UNC
During operation, surfaces may become hot enough to

Spinner
cause bodily injury. To reduce the risk of injury from a Gearbox
hot component, allow the surface to cool before touching.
Disassembly
1. Disconnect the hydraulic hoses from the spinner assembly manifolds Upper
and cap fittings. Slide Ring
2. Remove the spinner assembly pivot pin.
3. Lift out the spinner assembly and place it on a table.
Key
4. Remove the socket head screw from the bottom of the lower
assembly.
5. Remove the lower assembly.
6. Slide off rollers, remove keys and upper and lower slide rings.
Roller
Assembly
1. Install upper slide rings with grooves.
2. Ensure the shaft keys are in place and slide on new rollers.
3. Install lower slide rings and replace the lower assembly. Lower
4. Replace socket head screw in bottom of lower assembly. Apply Slide Ring
anti-seize to entire length and torque to 450-500 ft.-lb.
5. Reassemble the spinner assembly to upper jaws and install spinner
assembly pivot pin. Apply anti-seize to the threads of the pin and Lower
torque to 350-400 ft.-lb. Assembly
6. Attach hydraulic hoses to spinner assembly manifold. Socket
7. Operate the tool and verify SPIN-IN causes all rollers to turn CCW as Head
viewed from above. Screw
Figure 5-7. Replace Spin Roller and Slide Rings
5-11
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D811000124-MAN-001
Page 5-12 of 12
Adjusting Torque Gauge Responsiveness
Jam Nut
Screw
Torque
Gauge
Procedure
If the torque gauge is not responding or is too sensitive, 1. Untighten the jam nut.
adjust the needle valve on the torque gauge until the 2. Clamp the jaws on the pipe and operate the lever
gauge reacts with the desired response. for making up pipe. (The needle will show activity
when pressure is building up.)
3. Rotate the screw with a screwdriver to change
responsiveness (CW decreases speed).
4. If necessary repeat step 2 and 3 until the desired
speed is acquired.
During operation, surfaces may become hot enough to 5. Tighten the jam nut.
cause bodily injury. To reduce the risk of injury from
a hot component, allow the surface to cool before touching.
Do not screw out set screw all the way. It will
loose engagement with counterpart.
Figure 5-8. Adjust Torque Gage
5-12
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D811000124-MAN-001
Revision 03
Page 6-1 of 6
Chapter 6: Troubleshooting
Troubleshooting the ST-80C

This section describes general troubleshooting methods and provides tables for troubleshooting
specific problems or components.
!
Make sure all hydraulic lines are isolated and the ball valve is closed before
any work is performed on the ST-80C.
!
Whenever hoisting or lowering or operating the Iron Roughneck, ensure all
personnel and equipment are clear of the operating area. Failure to follow
this warning may result in injury to personnel or damage to equipment.
before touching.
When troubleshooting the ST-80C, make sure the hydraulic pressure is between 2,000 and
2,100 psi at the inlet of the manifold. Check the back pressure of the tank line (ensure the pressure
does not exceed 30 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, Maintenance.
The most important things to check after each rig move and before operating the ST-80C are:
1. Ensure that the ST-80C is fully inserted in the socket.
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.
6. Lubricate entire ST-80C and check the condition of the filter per Chapter 5, Maintenance.
6-1
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D811000124-MAN-001
6 Troubleshooting Revision 03
Page 6-2 of 6

Troubleshooting Tables
Symptom Probable cause Remedy
Hydraulic quick disconnect

Tool runs slowly. on supply or return lines Tighten until fully shouldered.
not fully shouldered.
Power unit not delivering Check power supply flow while spin out valve
full flow. is actuated. Flow should be 40 GPM.
Power unit return line filter

Replace filter element of HPU.
dirty.
Pressure filter dirty. Replace filter element of ST-80C.
Torque pressure set too

Increase pressure setting.
low.
Symptom Probably cause Remedy
Vertical positioning
assembly moves in one Power supply not operating,
Re-establish hydraulic power.
direction only or does not or pressure too low.
move at all.
Lift cylinder damaged or

Clean or repair cylinder.
dirty.
Binding of carriage in
Lubricate or replace side rollers.
pedestal.
Push/Pull cable broken. Replace cable.
Does not maintain vertical Counterbalance valve out Replace, or adjust counterbalance valve to
position of adjustment. maintain vertical position.
Lift cylinder leak. Replace seals.
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D811000124-MAN-001
Revision 03
Page 6-3 of 6
Troubleshooting
6

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 next bite.
of stroke.
Torque setting damaged. Check, clean, or replace.
Torque setting pressure reducing

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

Torque cylinders drift in Sticking or worn main operating
contamination or wear, and repair or
makeup direction. valve.
replace.
Check for restriction in return line.

Torque cylinders drift in Excessive back pressure on Check hydraulic power supply. Check
breakout direction. return line. for other equipment using same tank
line.
Disassemble valve, inspect for

Sticking or worn main operating
contamination or wear, and repair or
valve.
replace.
Torque cylinder don’t move

or move slowly.
Dirty return filter in power supply. Replace filter element.
Torque gauge does not

indicate pressure during Dirty inlet port or gauge. Clean inlet port or replace gauge.
makeup
Dump valve stuck open Adjust full CW test if still no pressure

(depressed, pressure does not reading, replace, readjust 1/4 turn from
build up) or set incorrectly. full CCW position.
Torque cylinders reached end of

Reset for additional stroke.
stroke and actuated dump valve.
Open damper located on top front of

Gauge damper closed.
gauge (rotate counterclockwise).
Torque gauge goes not Rotate zero adjust knob on back of

Gauge not adjusted to zero.
return to zero. gauge case. Recheck torque setting.
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D811000124-MAN-001
Page 6-4 of 6
Tank line pressure. Check and correct.
Defective gauge. Replace.
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Revision 03
Page 6-5 of 6
Troubleshooting
6

Jaws slip on tool joint. Worn or broken dies. Replace dies.
Make sure the pressure at the manifold

Hydraulic pressure too low.
is set to 2,000 - 2,100 psi.
Upper torque wrench body

Interference between upper and
lifts while cycling in Check and remove interference.
lower body sets.
makeup or breakout 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.
Spinner assemblies do not

clamp or unclamp and/or Flow restricted. Locate cause or restriction and correct.
motors do not run.
Power supply defective. Check power supply.
Return valve to center position

Spinner assemblies or motor
manually. If problem persists, inspect
creep with valve in neutral Leaking or sticky valve.
valve spool for wear or contamination.
position.
Repair or replace.
Motor runs irregularly. Contaminated motor. Repair motor or replace.
Bent shaft. Repair motor or replace.
Spinner assemblies do not Check hinge pins and bores and repair
Defective pivot.
move in unison. or replace as required.
Lack of lubrication. Lube all grease fittings.
Defective piston/gland. Repair or replace.
Check for pinched, clogged, or

Restriction in hydraulic line. otherwise obstructed hydraulic lines.
Clear obstruction.
6-5
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D811000124-MAN-001
Page 6-6 of 6
Troubleshooting the ST80C

Spin rollers do not turn with

motor running, or have Sheared drive roller key. Replace key.
insufficient power.
Nut that keeps bevel gear in

Remove motor, retighten nut and
place on motor shaft is
secure nut with lock tab.
backed off.
Replace motor seals. Check that motor

Motor seal blown.
drain lines are open to tank.
Flow restricted to motor. Locate cause of restriction and correct.
Defective roller bearings. Replace bearings.
Defective motor. Repair motor.
Motor Drive shaft broken. Replace Shaft.
Check power supply pressure gauge

for indication. Ensure that supply
Loss of power, torque. Power supply not operating.
pressure 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 spinner housing Replace spin rollers.
excessively.
during spinning.
Check pressure at manifold set to

2,000-2,100 psi. Check for leaks in
Insufficient clamping
Spin rollers slip. clamping lines and replace as required.
pressure.
Replace and check relieving valves in
manifold (CB8, CB9 and RV1).
Defective seal on spin clamp

Replace seal.
cylinder piston.
Slippery connection. Clean connection.
Spin rollers worn. Replace spin rollers.
Spinner motor does not run. Push/Pull cable broken. Replace cable.
6-6
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Recommended
Lubricants Guide
This guide is not all-inclusive. It is only intended to cover
the recommended lubricants for the product lines and
models specified within the guide.
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
and remains the property of NOV. Reproduction, in whole or in
National Oilwell Varco
part, or use of this design or distribution of this information to RIG SOLUTIONS
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
upon completion of the use for which it was loaned. This Houston, TX 77041
document and the information contained and represented
herein is the copyrighted property of NOV.
© National Oilwell Varco
Document Number Rev.
D811000719-PRO-001 06
www.nov.com
Form D811001123-GEN-001/07
Revision History
06 23.04.2014 Engineering Update A. Donovan S. Blanco S. Williams
05 15.08.2012 Engineering Update B. Dominguez S. Sobreira R. Luher
04 21.02.2012 Engineering Update B. Dominguez B. Levay B. Levay
03 30.11.2009 Engineering Update B. Dominguez P. Williams P. Williams
02 09.14.2009 Publication update B. Dominguez P. Williams P. Williams
01 10.01.2008 First Issue TCD BMD BDW
D811000719-PRO-001
Revision 06
www.nov.com
Form D811001123-GEN-001/07
Change Description
1. Changed equipment reference to cover page.

2. Added temperature range reference to hydraulic fluids and gear lubricant pour point advisories to
page 1.
3. Changed and added frequency of fluid changes for hydraulic fluids and gear lubricants to pages 4
and 8.
4. Changed Non-Arctic Service heading to Non-Arctic Service Fluids to page 6.
5. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Non-Arctic Service Fluid table
to page 6.
6. Changed Arctic Service heading to Arctic Service Fluids to page 7.
7. Changed “Viscosity” reference to “Kinematic Viscosity” reference in Arctic Service Fluid table to
page 7.
8. Added “SUS” viscosities to best choice supreme grade arctic service hydraulic fluids to
page 7.
9. Added “SUS” viscosities to alternative supreme grade arctic service hydraulic fluids to page
02
7.
10. Changed gearbox reference and added cross-reference information to operating temperature table
for draining of gear oil to page 8.
11. Added “Conventional” reference to washpipe lubricant recommendation section to page 10.
12. Removed "AC" reference to page 10.
13. Removed grease brand example to page 11.
14. Added External Pinion and Gear Sets section with recommended grease information tables to page
9 and 10.
15. Changed “Viscosity” cell title to “Kinematic Viscosity” cell title in Lubricants and Fluids Reference
Chart to pages 14 and 15.
16. Added "External Pinion and Gear Sets" component lubricant reference to page 15.
17. Removed "AC" reference from drilling motor bearings to page 15.
18. Changed all primary temperature degrees to Celsius and changed all reference temperature
degrees to Fahrenheit.
1. Added caution note and contact information note to page 2.

03
2. Removed oil additive recommendation note to page 15.
1. Moved Motor Bearings Lubricating Greases section from page 11 to page 12.
2. Moved External Pinion & Gear Set Lubricating Greases section from page 12 to page 13.
3. Moved Air Lubricator Misting Oil section from page 13 to page 17.
04
4. Add Wire Rope Lubricant section with recommended wire rope lubricant information (Titled:
Inspection, Lubricating, and Rope Lubricants) to page 14 through page 16.
5. Added Wire Rope reference information to Lubricants and Fluids Reference Chart to page 20.
D811000719-PRO-001
Revision 06
www.nov.com
Form D811001123-GEN-001/07
Change Description (continued)
1. Corrected cross-reference page information on page 9 to refer to the table on page 10.
2. Placed ambient temperature minus symbol in front of 9 Celsius on column one, row two of
Recommended Gear Oil for the Transmission Gearbox Table (page 10).
3. Placed ambient temperature minus symbol in front of 4 Celsius on column one, row three of
05 Recommended Gear Oil for the Transmission Gearbox Table (page 10).
4. Changed ambient temperature -10 Celsius to -9 Celsius on column two, row three of Recommended
Gear Oil for the Transmission Gearbox Table (page 10).
5. Corrected inverted primary (Celsius) and reference (Fahrenheit) temperature degree call-outs to
column two, row four of Recommended Gear Oil for the Transmission Gearbox Table (page 10).
1. Updated the document to the latest Technical Publications template

2. Updated the title to “Recommend Lubricants Guide”
3. Removed the NOV product lines from the cover
4. Updated the overall text and tables to reflect the current information for the various products (whole
guide)
5. Updated the Introduction section (page 1)
6. Created the Hydraulic Fluid Quick Reference table (page 4)
7. Added a note explaining the top drive lubrication in the Gear Oil section (page 5)
8. Updated the gear oil grade tables to differentiate between the PS Series, TDS-150, and TDH-150 top
drive and the TDS, TDX, and IDS top drive product lines (pages 4 and 5)
06 9. Updated the lubricants and fluids reference tables by combining the relevant information for each
component and placed them at the end of their corresponding sections (pages 2 through 14)
10. Added the Below -6°C (21°F) procedure to the gear oil grade tables and lubricants and fluids
reference tables (pages 7 through 9)
11. Added the recommended procedures column to Table 1-5 and 1-6 (page 7 and 8)
12. Added Recommended Gear Oil for Top Drive, and Iron Roughneck and Pipe Racking sections (page
8 and 9)
13. Created the Gear Oil Quick Reference table (page 10)
14. Added the Landing Collar subsection to the External Pinion and Gear Set (page 12)
15. Added the Grease Quick Reference table (page 14)
16. Deleted the Wire Rope Lubricant section (page 15)
D811000719-PRO-001
Revision 06
www.nov.com
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hydraulic Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic Fluid Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recommended Top Drive Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Recommended Iron Roughneck and Pipe Racking Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gear Oil Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Washpipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IBOP/Kelly Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
External Pinion and Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Handling-Ring/Repositioner/RLA Pinion and Gear Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Crowned Tooth Gear Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Landing Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Grease Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Grease Quick Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air Lubricator Misting Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
D811000719-PRO-001
Revision 06
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Table of Contents
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ii D811000719-PRO-001
Revision 06
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List of Tables
Table 1-1. Approved product lines and models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Table 1-2. Recommended hydraulic fluids for non-arctic conditions:
-12 to 52°C (10 to 125°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Table 1-3. Recommended hydraulic fluids for arctic conditions:
-40 to 17°C (-40 to 63°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Table 1-4. Recommended hydraulic fluids (quick reference table) . . . . . . . . . . . . . . . . . . . . . . . .5
Table 1-5. Recommended gear oil grades
(PS and PS2 Series, TD-500PAC, TDS-150, and TDH-150 Top Drives) . . . . . . . . . . .7
Table 1-6. Recommended gear oil grades and procedures
[TDS (except for TDS-150), TDX, and IDS top drive series] . . . . . . . . . . . . . . . . . . . . .8
Table 1-7. Recommended gear oil grades
(ST-80 Series Iron Roughnecks, ST-120 Iron Roughneck,
ST-160 Iron Roughneck, and STV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Table 1-8. Gear oil specifications (quick reference table) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Table 1-9. Recommended grease for washpipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Table 1-10. Recommended grease for crowned tooth gear coupling . . . . . . . . . . . . . . . . . . . . . .12
Table 1-11. General recommended grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Table 1-12. Recommended grease for various components (quick reference table) . . . . . . . . . . .14
Table 1-13. Recommended misting oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
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List of Tables
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Recommended Lubricants Guide
If the operating equipment service manual contains a Recommended Lubricants

section, please disregard this guide and adhere to the section.
Reason: This is a general guide; a Recommended Lubricants section within the
service manual is specific to that particular equipment.
Introduction
This guide contains the recommended lubricants to be used on the approved product lines and
models listed in table 1-1.
Reference: If the operating equipment is not listed in this table, see the equipment vendor
documentation or contact an NOV representative.
Table 1-1. Approved product lines and models
Product line Models
Fingerboard All
Hydraulic Cathead HC-26EV
Hydraulic Power Unit (HPU) HP-45Q
Iron Roughneck AR Series, ST-80 Series, ST-100, ST-120, and ST-160
Pipe Racking Systems (PRS) Standard Transfer Vehicle (STV)
Power Rotating Bail Adapter (PRBA) All
Power Rotating Hook Adapter (PRHA) All
Rotary Table and Swivel All
IDS-1, IDS-3, IDS-4A, IDS-350P, IDS-350PE, IDS-

350P+, PS and PS2 Series, TD-500PAC, TDS-150,
Top Drive System (TDS)/ TDH-150, TDS-3, TDS-3H, TDS-4, TDS-4S, TDS-4H,
Integrated Drilling System (IDS) TDS-5, TDS-6S, TDS-8SA, TDS-9SA, TDS-10SA, 
TDS-10SH, TDS-10SRR, TDS-11SA, TDS-11SH,
TDS-1000, TDX-1000, and TDX-1250
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Recommended Lubricants Guide Introduction
Before equipment operation, it is essential to determine the grade and quality of lubricant
appropriate for the minimum ambient temperature of operation. To determine if this guide is
applicable, refer to the General Recommendations section in this guide.
This guide provides recommendations for selecting the appropriate grade and quality of the
following lubricants:
• Hydraulic Fluid
• Gear Oil
• Grease
• Air Lubricator Misting Oil
Consult engineering for lubrication requirements in extreme conditions, such as:

• Extreme service temperature
• Extreme pressure
• Emergency lubrication
General Recommendations
Adhere to the lubrication product information and instructions listed in/on:
• The design notes on the assembly drawing in the technical drawing package
• The nameplate on the equipment
• The documentation of the original equipment manufacturer (OEM)
If there is no information for selecting the appropriate lubricant for the NOV equipment provided,
refer to the NOV recommendations provided in this guide.
This guide lists the specifications or required qualities, not particular brand names, of the
recommended lubricants for the equipment. If none of the recommended lubricants have the
correct properties for the ambient and operating temperature ranges at your location, contact an
NOV service center for instructions.
Reference: For application and maintenance information, see the OEM documentation or NOV
service manual.
If the application and maintenance information is not available, contact your NOV representative.
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Hydraulic Fluid
An anti-wear (AW) hydraulic fluid of the proper viscosity grade is recommended for the hydraulic
system.
The AW hydraulic fluid is typically mineral-based and contains AW additives

along with rust and oxidation inhibitors.
Selecting the appropriate fluid viscosity grade to operate a typical hydraulic system involves the
consideration of the following interdependent variables:
• The starting viscosity at the minimum ambient temperature
• Verification that:
– The pour point temperature of hydraulic fluid will be at least 17°C (30°F) lower than the
expected minimum ambient temperature.
– The hydraulic fluid pours freely at the minimum operating temperature.
Operating the equipment in cold temperatures requires hydraulic fluid with a

viscosity that allows the oil to flow freely and transmit power. If the ambient
temperature approaches the hydraulic fluid pour point, a heater may be used
to get the fluid flowing for proper lubrication of the component.
• Maximum expected operating temperature limits

• Permissible and optimum viscosity range for the component
– Minimum viscosity at maximum ambient temperature and in severe duty-cycle operation
– Maximum viscosity at cold start
Use table 1-2 and table 1-3 as a general guide for selecting the hydraulic fluids for equipment
operation in non-arctic or arctic conditions, respectively.
Table 1-2. Recommended hydraulic fluids for non-arctic conditions: 

-12 to 52°C (10 to 125°F)
Choice Parameter Unit
Kinematic viscosity 6.9 cSt @ 100°C (49 SUS @ 210°F)
Minimum viscosity index 105

Best
Pour point -30°C (-22°F)
ISO viscosity grade 46

Alternative
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Recommended Lubricants Guide Hydraulic Fluid
Table 1-3. Recommended hydraulic fluids for arctic conditions: 

-40 to 17°C (-40 to 63°F)
Choice Parameter Unit

Best
ISO/ASTM viscosity grade 15

Alternative 1
Kinematic viscosity 6.4 cSt @ 100°C (47.5 SUS @ 210°F)

Alternative 2
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Hydraulic Fluid Quick Reference Table
Use table 1-4 as a quick reference table for selecting the recommended hydraulic fluids information presented in this section.
Table 1-4. Recommended hydraulic fluids (quick reference table)
ASTM/
Revision 06
Kinematic Viscosity
Component Environment Lube Type ISO-VG/ NLGI AGMA Pour Point
Viscosity Index
SAE
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Hydraulic Fluid
D811000719-PRO-001
6.9 cSt @ 100°C
Hydraulic Oil1 Grade 46 --- --- 105 -30°C (-22°F)
-12°C to 52°C (49 SUS @ 210°F)
(-10°F to 125°F)
Hydraulic 6.9 cSt @ 100°C
Grade 46 --- --- 100 (min.) -37°C (-35°F)
Transmission Oil (49 SUS @ 210°F)
-30°C to 17°C 6.4 cSt @ 100°C

Typical (-22°F to 63°F) Hydraulic Oil2 Grade 32 --- --- 155 -50°C (-58°F)
(47.5 SUS @ 210°F)
hydraulic
systems -30°C to 17°C) Grade 7.5 cSt @ 100°C
(-22°F to 63°F) AT Fluid --- --- 172 -48°C (-54°F)
10W (51 SUS @ 210°F)
3.72 cSt @ 100°C

Hydraulic Oil3 Grade 15 --- --- 140 -42°C (-44°F)
-40°C to 0°C (39 SUS @ 210°F)
(-40°F to 32°F)
5.5 cSt @ 100°C
Hydraulic Oil Grade 15 --- --- 377 -60°C (-76°F)
(44 SUS @ 210°F)
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 Must be supreme grade high shear stability, anti-wear hydraulic oil with anti-rust and anti-wear additives
5
Gear Oil
This section is a general guide for selecting the gear oil used on the top drive, iron roughneck, and
pipe racking systems only.
Reference: If the gearbox is not part of a top drive, iron roughneck, or pipe racking system, see the
equipment vendor documentation or contact an NOV representative.
Always use an extreme pressure (EP) gear oil when working with gearboxes.
The EP gear oils are typically mineral oils that contain sulfur-phosphorous
additives. Most EP gear oils meet the American Gear Manufacturers
Association (AGMA) extreme pressure-performance requirements.
The proper grade and type of gear oil is selected by viscosity.

Reference: For the brand or trade name of the lubricant for the applicable viscosity range, consult
the lubricant suppliers.
Using oil with a greater viscosity than required can damage:

! • The gearbox, as a result of reduced oil flow.
• The oil pump, as a result of excessive load.
The pour point temperature of the oil should be at least 6°C (10°F) lower than the expected
minimum ambient temperature. The gear oil must pour freely at its minimum operating
temperature.
Operating the equipment in low temperatures requires gear oil with a

viscosity:
• High enough to carry the load.
• Low enough to allow the oil to circulate.
At start-up, the oil should flow freely and not cause high torque. If the ambient temperature
approaches the gear oil pour point, a heater may be used to get the fluid flowing and to ensure
proper lubrication of components.
This section will cover the following:
• Recommended Top Drive Gear Oil
• Recommended Iron Roughneck and Pipe Racking Gear Oil
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Gear Oil Recommended Lubricants Guide
Recommended Top Drive Gear Oil

Use table 1-5 as a general guide for selecting the recommended gear oil grades used for the
following top drive models:
• PS and PS2 Series
• TD-500PAC
• TDS-150
• TDH-150
Table 1-5. Recommended gear oil grades 

(PS and PS2 Series, TD-500PAC, TDS-150, and TDH-150 Top Drives)
Ambient temperature Minimum gear oil

Recommended gear oil grade
range operating temperature
10 to 52°C
16°C (60°F) AGMA no. 7 EP, ISO VG 460
(50 to 125°F)
-9 to 16°C
4°C (40°F) AGMA no. 6 EP, ISO VG 320
(15 to 60°F)
-29 to -4°C
-23°C (-9°F) AGMA no. 4 EP, ISO VG 150
(-20 to 25°F)
-46 to -18°C
-40°C (-40°F) Synthetic AGMA no. 3 EP, ISO VG 100
(-50 to 0°F)
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Recommended Lubricants Guide Gear Oil
Recommended Top Drive Gear Oil
Use table 1-6 as a general guide for selecting the recommended gear oil grades and procedures
used for the following top drive models:
• TDS series (excluding TDS-150; see table 1-5)
• TDX series
• IDS series
Table 1-6. Recommended gear oil grades and procedures 

[TDS (except for TDS-150), TDX, and IDS top drive series]
Ambient temperature range Recommended gear oil grade Recommended procedures
Above 21°C --
AGMA no. 6 EP, ISO VG 320
(Above 70°F)
7 to 30°C --
(45 to 86°F)
-6 to 16°C Synthetic AGMA no. 3 EP,  If using AGMA no. 2 EP

(21 to 61°F) ISO VG 100 (mineral base oil), ISO VG 68,
the oil must be changed every
If synthetic AGMA no. 3 EP, 1,000 operating hours or every
ISO VG 100 is unavailable, use four months.
AGMA no. 2 EP (mineral base
oil), ISO VG 68.
Below -6°C See recommended procedures The oil temperature will need to
(Below 21°F) be raised above -6°C (21°F)
by completing the following
steps:
1. Warm the top drive up by
rotating at a very light load
and very slow speeds until the
oil temperature is raised to 
-6°C (21°F).
2. If specific instructions are
needed for warming up the
top drive, contact your local
NOV service center.
Once the oil temperature has
been raised above -6°C (21°F),
refer to the -6 to 16°C ambient
temperature range row in this
table.
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Gear Oil Recommended Lubricants Guide
Recommended Iron Roughneck and Pipe Racking

Gear Oil
Use table 1-7 as a general guide for selecting the recommended gear oil grades used for the
following iron roughneck and pipe racking models:
• ST-80 Series
• ST-120
• ST-160
• STV
Table 1-7. Recommended gear oil grades
(ST-80 Series Iron Roughnecks, ST-120 Iron Roughneck, 
ST-160 Iron Roughneck, and STV)
Ambient temperature range Recommended gear oil grade
Above 21°C
(Above 70°F)
7 to 30°C
(45 to 86°F)
-6 to 16°C
(21 to 61°F)
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Gear Oil Quick Reference Table
Use table 1-8 as a quick reference table for selecting the gear oil specifications used for the top drive, iron roughneck, and pipe racking systems
listed in this section.
10
Table 1-8. Gear oil specifications (quick reference table)
ASTM/ Kinematic Viscosity

Lube Type NLGI AGMA Pour Point1
ISO-VG/SAE Viscosity1 Index1
30.3 cSt @ 100°C

EP Gear Oil Grade 460 --- #7 EP 95 -7°C (20°F)
(150 SUS @ 210°F)
24.0 cSt @ 100°C

EP Gear Oil Grade 320 --- #6 EP 95 -18°C (0°F)
(120 SUS @ 210°F)
EP Gear Oil 14.5 cSt @ 100°C

Grade 150 --- #4 EP 95 -23°C (-10°F)
(78.1 SUS @ 210°F)
8.8 cSt @ 100°C

EP Gear Oil Grade 68 --- #2 EP 102 -20°C (-4°F)
(55.5 SUS @ 210°F)
#3 EP &  14.4 cSt @ 100°C

Synthetic Gear Oil
Grade 100 --- 149 -46°C (-50°F)

#3 S (77.1 SUS @ 210°F)
1 Values are for reference only, and may vary slightly depending on manufacturer
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Grease
This section will cover the recommended grease for the general preventive maintenance for the
following components.
• Washpipe Assembly
• Motor Bearings
• IBOP/Kelly Valve Actuator
• External Pinion and Gear Set
For all other components requiring grease lubrication, see the General Grease Lubrication
subsection.
Washpipe Assembly
For general preventative maintenance of the washpipe assembly, use table 1-9 as a general guide
for selecting the washpipe grease for moderate operating conditions or extreme operating
conditions, such as high speed, pressure, or fluid temperature.
Table 1-9. Recommended grease for washpipe assembly
Moderate operating conditions Extreme operating conditions
NLGI grade 2 NLGI grade 3
Non-soap based moly grease Non-soap based moly grease
NOV part number 7806084 NOV part number 7806663
Motor Bearings
Some motors are equipped with greased bearings, which must be lubricated at manufacturer-
recommended intervals.
Always use the recommended lubrication product specified by the original

! equipment manufacturer.
Generally, the drilling motors and blower motors are vendor-supplied equipment; therefore, the
motor housing may have a nameplate attached to it that provides the recommended lubrication
product, amount to use, and lubrication intervals.
Reference: If there is no nameplate, see the vendor documentation in the owner’s manual. If no
vendor documentation is supplied, contact an NOV representative.
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Recommended Lubricants Guide Grease
IBOP/Kelly Valve Actuator
IBOP and Kelly valve actuators may be vendor-supplied equipment.
Always use the recommended lubrication product specified by the original

! equipment manufacturer. Using the incorrect lubrication product can cause
damage to the equipment.
Reference: If the actuator assembly does not have a nameplate that lists the recommended
grease, see the vendor documentation in the owner’s manual.
If the vendor documentation does not list the recommended grease, use grease with properties
that meet the NLGI grade 1.5 specifications.
External Pinion and Gear Set

This subsection covers the recommended greasing procedures for the following components:
• Handling-Ring/Repositioner/RLA Pinion and Gear Set
• Crowned Tooth Gear Coupling
• Landing Collar
Handling-Ring/Repositioner/RLA Pinion and Gear Set

For all environmental conditions, coat the gear teeth with an extreme pressure lubricant, such as
NOV Copper Top (Jet-Lube Kopr-Kote®) or equivalent.
Crowned Tooth Gear Coupling

Use table 1-10 as a general guide for selecting the grease for moderate or extreme operating
conditions, such as normal or high speed and torque:
Table 1-10. Recommended grease for 

crowned tooth gear coupling
Operating conditions NLGI grade
Moderate 1
Extreme 2
Landing Collar
For all environmental conditions, coat the landing collar halves, main shaft grooves, and inside
diameter of the retainer ring with a generous amount of NLGI Grade 2 Jet-Lube Arctic™ Extreme
Service Grease, a Calcium 12- Hydroxystearate grease with exceptional resistance to salt water
spray and wash-down.
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Grease Recommended Lubricants Guide
General Grease Lubrication

For all other components not specified in the Grease section, use EP, lithium-based, general-
purpose grease. Use table 1-11 as a general guide for selecting the appropriate NLGI grade.
Table 1-11. General recommended grease
Ambient temperature range NLGI grade
0°C (32°F) and below 1
Above -20°C (-4°F) 2
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Grease Quick Reference Table
Use table 1-12 as a quick reference table for selecting the recommended grease information presented in this section.
Table 1-12. Recommended grease for various components (quick reference table)
14
ASTM/
Kinematic Viscosity
Component Environment Lube Type ISO-VG/ NLGI AGMA Pour Point
Viscosity Index
SAE
Moderate Operating
Primrose Plus # 327 --- #2 --- --- --- ---
Conventional Conditions
Washpipe Packing
Grease Extreme Operating
Primrose Plus # 327 C --- #3 --- --- --- ---
Conditions
Drilling Motor
All EP Grease1 #2 --- --- --- ---
Bearings
Blower Motor
All EP Grease1 #2 --- --- --- ---
Bearings
Above -20°C (-4°F) EP Grease2 --- #2 --- --- --- ---

General Grease
Bearings 0°C (32°F) 
EP Grease2 --- #1 --- --- --- ---

and below
IBOP/Kelly Valve Metalon 

All --- #1.5 --- --- --- ---
Actuator Hi-Tech 1.5 Grease3
External Pinion and

Gear Sets, and
Elevator and Main All EP Grease4 --- -- --- --- --- ---
Links Contact
Surfaces
Calcium 12-
Landing Collar All --- -- --- --- --- ---
Hydroxystearate5
1
Polyurea-based grease or as specified by the motor manufacturer
2
Lithium base, general-purpose, extreme pressure grease
3
Use the product specified by the original equipment manufacturer
4
For example: Jet-Lube Kopr-Kote or NOV Copper Top
5 Use Jet-Lube Arctic™ Extreme Service Grease or equivalent
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Grease
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Air Lubricator Misting Oil

Along with table 1-13, it is recommended that the misting oils for the air lubricator have the
following properties:
• Turbine-quality lubricant
• Long life
• Rust and oxidation-inhibited
Table 1-13. Recommended misting oil
Parameter Unit
Kinematic viscosity1 29-35 cSt @ 40°C (136-165 SUS @ 100°F)
Viscosity Index1 100-104
1
Values are for reference only, and may vary slightly depending on manufacturer
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DS00008
Design Specification
Design Torque Standard
THIS DOCUMENT CONTAINS PROPRIETARY AND CONFIDENTIAL INFORMATION WHICH BELONGS

TO NATIONAL-OILWELL, L.P. IT IS LOANED FOR LIMITED PURPOSES ONLY AND REMAINS THE
PROPERTY OF NATIONAL-OILWELL, L.P. REPRODUCTION, IN WHOLE OR IN PART OR USE OF
THIS DESIGN OR DISTRIBUTION OF THIS INFORMATION TO OTHERS IS NOT PERMITTED WITHOUT
THE EXPRESS WRITTEN CONSENT OF NATIONAL-OILWELL, L.P. THIS DOCUMENT IS TO BE
RETURNED TO NATIONAL-OILWELL, L.P. UPON REQUEST AND IN ANY EVENT UPON COMPLETION
OF THE USE FOR WHICH IT WAS LOANED. THIS DOCUMENT AND THE INFORMATION CONTAINED
AND REPRESENTED IS THE COPYRIGHTED PROPERTY OF NATIONAL-OILWELL, L.P.
TITLE
CURRENT INITIAL Design Torque Standard
DRAWN
D.TRUONG A. Vargas
CHECKED
B.RICE B. Levay
SIZE DWG NO REV
APPVD
B.RICE JB A DS00008 F
DATE
7/25/11 11.13.1992 SCALE NONE WT LBS SHEET 1 OF 16
DCF0045 (REV B)
NOTES
1. Unless noted, all values are based on light machine oil or anti seize lubricated bolts (not high
pressure lubes)
2. NOV does not recommend assembling bolts dry
3. Proof Strength is 92% of minimum yield strength
4. Torque values given represent 70% to 80% of proof strength
5. Clamp force is based on 75% of proof strength
6. These torque values are to be followed unless otherwise specified
7. If torqueing into aluminum, contact engineering for appropriate torque value.
8. After proper torque has been established in accordance with specification, fasteners shall be
immediately identified as being torqued by either:
a) Being safety wired in accordance with ASP00019 and/or
b) Marked with an “X” using either a red or yellow paint marker.
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR LIGHT MACHINE OIL LUBRICATED BOLTS
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
PROOF STRENGTH = 55,000 PSI PROOF STRENGTH = 85,00 PSI
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
COARSE THREAD SERIES - UNC
Max. Clamp Min. Max. Clamp
Dia-Threads Min. Torque
Torque Force Torque Torque Force
Per Inch (ft-lbf)
(ft-lbf) (lb) (ft-lbf) (ft-lbf) (lb)
1/4 – 20 5.7 6.3 1,320 7.6 8.4 2,020
5/16 – 18 10.5 11.6 2,160 16 18 3,340
3/8 – 16 19 21 3,200 29 32 4,940
7/16 – 14 29 32 4,380 48 53 6,800
1/2 – 13 48 53 5,840 71 79 9,050
9/16 – 12 67 74 7,500 105 116 11,600
5/8 – 11 95 105 9,300 143 158 14,400
3/4 – 10 166 184 13,800 247 273 21,300
7/8 – 9 157 173 11,400 409 452 29,400
1–8 238 263 15,000 608 672 38,600
1 1/8 – 7 333 368 18,900 760 840 42,300
1 1/4 – 7 475 525 24,000 1,064 1,176 53,800 7
1 3/8 – 6 627 639 28,600 1,387 1,533 64,100 7
1 1/2 – 6 827 914 34,800 1,843 2,037 78,000 7
FINE THREAD SERIES – UNF

1/4 – 28 5.7 6.3 1,500 9.5 10.5 2,320
5/16 – 24 11.4 12.6 2,400 18 20 3,700
3/8 – 24 22 24 3,620 33 37 5,600
7/16 – 20 33 37 4,900 52 58 7,550
1/2 – 20 52 58 6,600 86 95 10,700
9/16 – 18 76 84 8,400 114 126 12,950
5/8 – 18 105 116 10,600 162 179 16,300
3/4 – 16 185 205 15,400 285 315 23,800
7/8 – 14 176 194 12,600 447 494 32,400
1–4 257 284 16,400 665 735 42,200
1 1/8 – 12 380 420 21,200 836 924 47,500 7
1 1/4 – 12 523 578 26,600 1,178 1,302 59,600 7
1 3/8 – 12 703 777 32,500 1,596 1,764 73,000 7
1 1/2 – 12 931 1,029 39,100 2,090 2,310 87,700 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
GRADE 8 HOLO-KROME
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI

Per Inch (ft-lbf)
1/4 – 20 11.4 12.6 2,860 12 14 3,240
5/16 – 18 24 26 3,720 26 28 5,340
3/8 – 16 43 47 7,000 47 51 7,920
7/16 – 14 67 74 9,550 75 83 10,850
1/2 – 13 105 116 12,750 114 126 14,450
9/16 – 12 143 158 16,100 163 181 18,500
5/8 – 11 209 231 20,350 226 250 23,000
3/4 – 10 361 399 30,100 404 446 34,000
7/8 – 9 570 630 41,600 651 719 47,000
1–8 855 945 54,500 7 969 1,071 61,700 7
1 1/8 – 7 1,216 1,344 68,700 7 1,349 1,491 77,800 7
1 1/4 – 7 1,729 1,911 87,200 7 1,967 2,174 98,700 7
1 3/8 – 6 2,261 2,499 104,000 7 2,565 2,835 117,800 7
1 1/2 – 6 3,002 3,318 126,500 7 3,411 3,770 143,200 7

1/4 – 28 13.3 17.7 3,280 14 16 3,750
5/16 – 24 24 26 5,220 29 32 5,920
3/8 – 24 48 53 7,900 52 58 8,050
7/16 – 20 75 84 10,700 84 92 12,150
1/2 – 20 114 126 14,400 124 137 16,250
9/16 – 18 162 179 18,250 183 203 20,700
5/8 – 18 228 252 23,000 258 286 26,200
3/4 – 16 399 441 33,600 451 499 38,000
7/8 – 14 627 693 45,800 7 718 794 51,900 7
1–4 950 1,050 59,700 7 1,064 1,176 67,600 7
1 1/8 – 12 1,368 1,512 77,000 7 1,511 1,670 87,000 7
1 1/4 – 12 1,900 2,100 96,600 7 2,180 2,410 109,400 7
1 3/8 – 12 2,584 2,856 118,400 7 2,926 3,234 134,000 7
1 1/2 – 12 3,382 3,738 142,200 7 4,769 5,271 201,000 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
STAINLESS ASTM F593G & F593H STAINLESS ASTM F593U
T.S. = 100,000 PSI to 5/8” DIA TENSILE STRENGTH = 135,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
Per Inch (ft-lbf)
1/4 – 20 5.7 6.3 1,407 8.6 9.5 2,266
5/16 – 18 11.4 12.6 2,319 18.1 20.0 3,734
3/8 – 16 20.0 22.1 3,429 33.3 36.8 5,522
7/16 – 14 32 36 4,704 52 58 7,574
1/2 – 13 49 55 6,279 80 88 10,110
9/16 – 12 72 80 8,054 116 128 12,968
5/8 – 11 99 109 10,001 160 176 16,103
3/4 – 10 122 134 10,271 282 312 23,798
7/8 – 9 197 217 14,207 456 504 32,918
1–8 295 327 18,635 684 756 43,179
1 1/8 – 7 418 462 23,462 968 1,070 54,364 7
1 1/4 – 7 590 652 29,797 1,366 1,510 69,041 7
1 3/8 – 6 773 855 35,516 1,792 1,980 82,294 7
1 1/2 – 6 1,026 1,134 43,204 2,378 2,628 100,106 7

1/4 – 28 6.7 7.4 1,611 10.5 11.6 2,594
5/16 – 24 12.4 13.7 2,567 20.9 23.1 4,133
3/8 – 24 22.8 25.2 3,885 37 41 6,256
7/16 – 20 36 40 5,252 59 65 8,457
1/2 – 20 56 62 7,076 90 100 11,393
9/16 – 18 80 88 8,983 129 143 14,464
5/8 – 18 112 124 11,328 181 200 18,240
3/4 – 16 136 150 11,470 315 349 26,576
7/8 – 14 217 239 15,652 503 555 36,266
1–4 323 357 20,387 748 826 47,239 7
1 1/8 – 12 469 519 26,322 1,087 1,201 60,900 7
1 1/4 – 12 653 721 32,995 1,513 1,973 76,451 7
1 3/8 – 12 881 973 10,436 2,040 2,254 93,694 7
1 1/2 – 12 1,154 1,276 49,616 7 2,675 2,957 122,646 7
F593 F593
G or H U
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS LUBRICATED WITH AN ANTI-SEIZE COMPOUND
GRADE 2 GRADE 5
T.S. = 74,000 PSI to ¾” DIA T.S. = 120,000 PSI to 1” DIA
T.S. = 60,000 PSI 7/8” to 1-1/2” DIA T.S. = 105,000 PSI 1-1/8” to 1-1/2” DIA
Per Inch (ft-lbf)
1/4 – 20 4.3 4.7 1,320 5.7 6.3 2,020
5/16 – 18 7.8 8.7 2,160 12.1 13.4 3,340
3/8 – 16 14.3 15.8 3,200 21.4 23.6 4,940
7/16 – 14 21.4 23.6 4,380 36 39 6,800
1/2 – 13 36 39 5,840 53 59 9,050
9/16 – 12 50 55 7,500 78 87 11,600
5/8 – 11 71 79 9,300 107 118 14,400
3/4 – 10 125 138 13,800 185 205 21,300
7/8 – 9 118 130 11,400 306 339 29,400
1–8 178 197 15,000 456 504 38,600
1 1/8 – 7 249 276 18,900 570 630 42,300
1 1/4 – 7 356 394 24,000 798 882 53,800 7
1 3/8 – 6 470 520 28,600 1,040 1,150 64,100 7
1 1/2 – 6 620 685 34,800 1,382 1,528 78,000 7

1/4 – 28 4.3 4.7 1,500 7.1 7.9 2,320
5/16 – 24 8.6 9.5 2,400 13.5 15 3,700
3/8 – 24 16.4 18.1 3,620 25 28 5,600
7/16 – 20 25 28 4,900 39 43 7,550
1/2 – 20 39 43 6,600 64 71 10,700
9/16 – 18 57 63 8,400 86 95 12,950
5/8 – 18 78 87 10,600 121 134 16,300
3/4 – 16 139 154 15,400 214 236 23,800
7/8 – 14 132 146 12,600 335 370 32,400
1–4 192 213 16,400 499 551 42,200
1 1/8 – 12 285 315 21,200 627 693 47,500 7
1 1/4 – 12 392 433 26,600 884 977 59,600 7
1 3/8 – 12 527 583 32,500 1,197 1,323 73,000 7
1 1/2 – 12 698 772 39,100 1,568 1,733 87,700 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
GRADE 8 HOLO-KROME
TENSILE STRENGTH = 150,000 PSI TENSILE STRENGTH = 170,000 PSI

Per Inch (ft-lbf)
1/4 – 20 8.6 9.5 2,860 9.3 10.2 3,240
5/16 – 18 17.8 19.7 3,720 19 21 5,340
3/8 – 16 32 35 7,000 35 39 7,920
7/16 – 14 50 55 9,550 56 62 10,850
1/2 – 13 78 87 12,750 86 95 14,450
9/16 – 12 107 118 16,100 123 135 18,500
5/8 – 11 157 173 20,350 170 187 23,000
3/4 – 10 271 299 30,100 303 335 34,000
7/8 – 9 428 473 41,600 488 539 47,000 7
1–8 641 709 54,500 7 727 803 61,700 7
1 1/8 – 7 912 1,008 68,700 7 1,012 1,118 77,800 7
1 1/4 – 7 1,297 1,433 87,200 7 1,475 1,630 98,700 7
1 3/8 – 6 1,696 1,874 104,000 7 1,924 2,126 117,800 7
1 1/2 – 6 2,252 2,489 126,500 7 2,558 2,827 143,200 7

1/4 – 28 10 11 3,280 10.7 11.8 3,750
5/16 – 24 17.8 19.7 5,220 21 24 5,920
3/8 – 24 36 39 7,900 39 43 8,050
7/16 – 20 57 63 10,700 63 69 12,150
1/2 – 20 86 95 14,400 93 102 16,250
9/16 – 18 121 134 18,250 138 152 20,700
5/8 – 18 171 189 23,000 194 214 26,200
3/4 – 16 299 331 33,600 338 374 38,000
7/8 – 14 470 520 45,800 7 539 595 51,900 7
1–4 713 788 59,700 7 798 882 67,600 7
1 1/8 – 12 1,026 1,134 77,000 7 1,133 1,252 87,000 7
1 1/4 – 12 1,425 1,575 96,600 7 1,635 1,807 109,400 7
1 3/8 – 12 1,938 2,142 11,840 7 2,195 2,426 134,000 7
1 1/2 – 12 2,537 2,804 142,200 7 3,577 3,953 201,000 7
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
STAINLESS ASTM F593G & F593H STAINLESS ASTM F593U
T.S. = 100,000 PSI to 5/8” DIA TENSILE STRENGTH = 135,000 PSI
T.S. = 85,000 PSI 3/4” to 1-1/2” DIA
PROOF STRENGTH = 41,000 PSI
Per Inch (ft-lbf)
1/4 – 20 4.3 4.7 1,407 6.4 7.1 2,266
5/16 – 18 8.6 9.5 2,319 13.5 15 3,734
3/8 – 16 15 16.5 3,429 24.9 27.6 5,522
7/16 – 14 24 27 4,704 39 43 7,574
1/2 – 13 37 41 6,279 60 66 10,110
9/16 – 12 54 60 8,054 87 96 12,968
5/8 – 11 74 82 10,001 120 132 16,103
3/4 – 10 91 101 10,271 212 234 23,798
7/8 – 9 147 163 14,207 342 378 32,918
1–8 222 245 18,635 513 567 43,179
1 1/8 – 7 314 347 23,462 726 802 54,364 7
1 1/4 – 7 442 489 29,797 1,025 1,132 69,041 7
1 3/8 – 6 580 641 35,516 1,344 1,485 82,294 7
1 1/2 – 6 770 851 43,204 1,783 1,971 100,106 7

1/4 – 28 5.0 5.5 1,611 7.8 8.7 2,594
5/16 – 24 9.3 10.2 2,567 15.7 17.3 4,133
3/8 – 24 17.1 18.9 3,885 28 31 6,256
7/16 – 20 27 30 5,252 44 49 8,457
1/2 – 20 42 46 7,076 68 75 11,393
9/16 – 18 60 66 8,983 97 107 14,464
5/8 – 18 84 93 11,328 135 150 18,240
3/4 – 16 102 113 11,470 237 261 26,576
7/8 – 14 162 180 15,652 377 417 36,266
1–4 242 268 20,387 561 620 47,239 7
1 1/8 – 12 352 389 26,322 815 901 60,990 7
1 1/4 – 12 489 541 32,995 1,135 1,254 76,451 7
1 3/8 – 12 660 730 40,436 1,530 1,691 93,694 7
1 1/2 – 12 866 957 48,616 7 2,006 2,218 112,646 7
F593 F593
G or H U
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
PROOF STRENGTH = 225 MPa PROOF STRENGTH = 600 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Min. Torque
Diameter - pitch Torque Force Torque Torque Force
(ft-Ibf)
(ft-Ibf) (Ib) (ft-Ibf) (ft-Ibf) (lb)
M3 - .5 .4 .5 183 .9 1.2 489
M3.5 - .6 .6 .73 247 1.5 1.9 659
M4 - .7 .9 1.1 320 2.1 2.9 854
M5 - .8 1.7 2.1 516 4.3 5.8 1,378
M6 - 1 2.9 3.7 732 7.2 9.9 1,954
M8 - 1.25 6.9 8.9 1,331 17 23 3,550
M10 - 1.5 14 17 2,106 33 47 5,617
M12 - 1.75 24 31 3,055 57 81 8,148
M14 - 2 38 48 4,177 91 129 11,141
M16 - 2 57 74 5,664 141 199 15,106
M18 – 2.5 81 104 6,975 195 278 18,600
M20 – 2.5 112 145 8,851 274 388 23,604
M22 – 2.5 151 196 10,940 372 524 29,174
M24 - 3 193 251 12,746 472 671 33,989
M27 – 3 280 365 16,570 690 974 44,186
M30 - 3.5 381 496 20,216 934 1,325 53,911 7
M33 – 3.5 514 670 24,961 1,267 1,787 66,563 7
M36 – 3.5 656 857 29,422 1,627 2,285 78,460 7
M39 - 4 852 1112 35,122 2,102 2,966 93,661 7
M42 - 4.5 1,059 1380 40,363 2,599 3,681 107,634 7
M48 - 5 1,586 2069 53,038 7 3,899 5,518 141,435 7
M56 - 5.5 2,535 3310 73,007 7 6,253 8,828 194,686 7
4.6 8.8
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Min. Torque
(ft-Ibf)
M3 - .5 1.3 1.7 676 1.5 2.0 790
M3.5 - .6 2.1 2.7 911 2.5 3.1 1,065
M4 - .7 3.1 4.0 1,182 3.7 4.7 1,381
M5 - .8 6.2 8.0 1,906 7.3 9.4 2,228
M6 - 1 10.6 13.7 2,703 12 16 3,159
M8 - 1.25 25 33 4,910 29 38 5,739
M10 - 1.5 50 65 7,771 58 76 9,082
M12 - 1.75 87 112 11,271 101 131 13,172
M14 - 2 138 179 15,411 162 210 18,011
M16 - 2 212 275 20,897 247 321 24,422
M18 – 2.5 297 384 25,730 347 449 30,070
M20 – 2.5 414 537 53,911 483 628 38,159
M22 – 2.5 557 726 40,358 651 848 47,165 7
M24 – 3 715 929 47,019 7 836 1,086 54,950 7
M27 – 3 1,034 1,347 61,125 7 1,209 1,574 71,435 7
M30 - 3.5 1,408 1,833 74,577 7 1,646 2,142 87,157 7
M33 – 3.5 1,896 2,473 92,079 7 2,216 2,890 107,611 7
M36 – 4 2,421 3,161 108,536 7 2,829 3,695 126,843 7
M39 – 4 3,145 4,103 129,564 7 3,675 4,795 151,418 7
M42 - 4.5 3,907 5,093 148,894 7 4,566 5,952 174,009 7
M48 - 5 5,853 7,633 195,652 7 6,840 8,921 228,654 7
M56 – 5.5 9,352 12,212 269,316 7 10,930 14,272 314,743 7
10.9
12.9
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 4.6 CLASS 8.8
T.S. = 400 MPa T.S. = 830 MPa
T.S. is for all dia. T.S. is for all dia
*Metric socket head screws*
METRIC SERIES
Min. Torque
(ft-Ibf)
M3 - .5 0.3 0.4 183 0.7 0.9 489
M3.5 - .6 0.5 0.6 247 1.1 1.5 659
M4 - .7 0.7 0.9 320 1.6 2.0 854
M5 - .8 1.3 1.7 516 3.2 4.2 1,378
M6 - 1 2.2 2.8 732 5.4 7.0 1,954
M8 - 1.25 5 7 1,331 13 17 3,550
M10 - 1.5 11 14 2,106 25 32 5,617
M12 - 1.75 18 23 3,055 43 56 8,148
M14 - 2 29 37 4,177 68 89 11,141
M16 - 2 43 56 5,664 106 137 15,106
M18 – 2.5 61 79 6,975 146 190 18,600
M20 – 2.5 84 109 8,851 206 267 23,604
M22 – 2.5 113 147 10,940 279 363 29,174
M24 - 3 145 188 12,746 354 460 33,989
M27 – 3 210 273 16,570 518 673 44,186
M30 - 3.5 286 371 20,216 701 911 53,911 7
M33 – 3.5 386 501 24,961 950 1235 66,563 7
M36 – 3.5 492 640 29,422 1220 1586 78,460 7
M39 - 4 639 831 35,122 1577 2049 93,661 7
M42 - 4.5 794 1033 40,363 1949 2534 107,634 7
M48 - 5 1190 1546 53,038 7 2924 3802 141,435 7
M56 - 5.5 1901 2472 73,007 7 4690 6097 194,686 7
4.6 8.8
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
TORQUE VALUES FOR BOLTS WITH AN ANTI-SEIZE COMPOUND
CLASS 10.9 CLASS 12.9
T.S. = 1040 MPa T.S. = 1220 MPa
T.S. is for all dia T.S. is for all dia.
* Metric socket head screws*
Min. Torque
(ft-Ibf)
M3 - .5 1.0 1.3 676 1.1 1.5 790
M3.5 - .6 1.6 2.0 911 1.9 2.4 1,065
M4 - .7 2.3 3.0 1,182 2.8 3.6 1,381
M5 - .8 4.7 6.0 1,906 5.5 7.1 2,228
M6 - 1 8.0 10.3 2,703 9.0 11.7 3,159
M8 - 1.25 19 24 4,910 22 28 5,739
M10 - 1.5 38 49 7,771 44 57 9,082
M12 - 1.75 65 85 11,271 76 98 13,172
M14 - 2 104 135 15,411 122 158 18,011
M16 - 2 159 207 20,897 185 241 24,422
M18 – 2.5 223 290 25,730 260 338 30,070
M20 – 2.5 311 404 32,652 362 471 38,159
M22 – 2.5 418 543 40,358 488 635 47,165 7
M24 – 3 536 697 47,019 7 627 815 54,950 7
M27 – 3 776 1008 61,125 7 907 1179 71,435 7
M30 - 3.5 1056 1373 74,577 7 1235 1605 87,157 7
M33 – 3.5 1422 1849 92,079 7 1662 2161 107,611 7
M36 – 4 1816 2360 108,536 7 2122 2758 126,843 7
M39 – 4 2359 3066 129,564 7 2756 3583 151,418 7
M42 - 4.5 2930 3809 148,894 7 3425 4452 174,009 7
M48 - 5 4390 5707 195,652 7 5130 6669 228,654 7
M56 – 5.5 7014 9118 269,316 7 8198 10657 314,743 7
10.9
12.9
The following tables specify torque values for fasteners used

with Nord-Lock washers.
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt 8.8
Oil Graphite
Pitch Torque Clamp Torque Clamp
Washer Size Bolt Size
(mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.2 540 1.2 540
NL4 M4 .7 3.0 944 2.7 944
NL5 M5 .8 5.8 1,529 5.2 1,529
NL6 M6 1.0 10 2,181 9.1 2,181
NL8 M8 1.25 24 4,047 22 4,047
NL10 M10 1.5 47 6,295 43 6,295
NL12 M12 1.75 82 8,992 74 8,992
NL14 M14 2.0 129 12,364 117 12,364
NL16 M16 2.0 197 16,861 177 16,861
NL18 M18 2.5 276 20,682 249 20,682
NL20 M20 2.5 385 26,527 348 26,527
NL22 M22 2.5 525 32,822 474 32,822
NL24 M24 3.0 664 37,993 599 37,993
NL27 M27 3.0 968 49,683 873 49,683
NL30 M30 3.5 1,322 60,474 1,192 60,474
NL33 M33 3.5 1,779 74,861 1,600 74,861
NL36 M36 4.0 2,295 88,125 2,067 88,125
NL39 M39 4.0 2,960 105,211 2,663 105,211
NL42 M42 4.5 3,663 120,947 3,297 120,947

Oil Graphite
Washer Pitch Torque Clamp Torque Clamp
Bolt Size
Size (mm) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 M3 .5 1.7 719 1.5 764
NL4 M4 .7 3.9 1,259 3.5 1,326
NL5 M5 .8 7.8 2,046 6.7 2,158
NL6 M6 1.0 14 2,900 12 3,057
NL8 M8 1.25 33 5,171 29 5,620
NL10 M10 1.5 64 8,318 56 8,768
NL12 M12 1.75 110 12,140 95 12,814
NL14 M14 2.0 175 16,636 151 17,535
NL16 M16 2.0 268 22,481 230 23,830
NL18 M18 2.5 375 27,651 323 29,225
NL20 M20 2.5 524 35,070 451 37,093
NL22 M22 2.5 714 43,613 613 46,086
NL24 M24 3.0 903 50,582 776 53,505
NL27 M27 3.0 1,318 66,094 1,128 69,691
NL30 M30 3.5 1,798 80,482 1,542 84,978
NL33 M33 3.5 2,422 99,590 2,068 105,211
NL36 M36 4.0 3,125 117,350 2,673 123,870
NL39 M39 4.0 4,030 140,281 3,440 148,149
NL42 M42 4.5 4,988 160,963 4,262 170,180
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
Oil Graphite
Bolt Size
NL3 M3 .5 1.9 877 1.6 922
NL4 M4 .7 4.4 1,506 3.8 1,596
NL5 M5 .8 8.7 2,450 7.4 2,585
NL6 M6 1.0 15 3,462 13 3,664
NL8 M8 1.25 36 6,295 31 6,744
NL10 M10 1.5 72 9,892 61 10,566
NL12 M12 1.75 123 14,613 105 15,287
NL14 M14 2.0 196 20,008 167 21,132
NL16 M16 2.0 298 26,977 252 28,551
NL18 M18 2.5 419 33,272 355 35,070
NL20 M20 2.5 585 42,264 494 44,512
NL22 M22 2.5 797 52,380 670 55,303
NL24 M24 3.0 1,009 60,698 850 64,295
NL27 M27 3.0 1,470 79,133 1,235 83,629
NL30 M30 3.5 2,005 96,668 1,688 102,063
NL33 M33 3.5 2,699 119,598 2,265 126,343
NL36 M36 4.0 3,483 140,730 2,927 148,823
NL39 M39 4.0 4,490 168,157 3,763 177,599
NL42 M42 4.5 5,560 193,336 4,666 204,126
NORD-LOCK Stainless Steel with Stainless Steel Bolt A4

A4-70 w/ Graphite Lube A4-80 w/ Graphite Lube
Bolt Size
NL3 M3 .5 0.9 337 1.2 450
NL4 M4 .7 1.9 585 2.6 764
NL5 M5 .8 3.7 922 5.1 1,236
NL6 M6 1.0 7 1,326 9 1,754
NL8 M8 1.25 16 2,473 21 3,147
NL10 M10 1.5 32 3,822 41 5,171
NL12 M12 1.75 54 5,620 72 7,419
NL14 M14 2.0 85 7,644 114 10,116
NL16 M16 2.0 130 10,341 174 13,713
NL18 M18 2.5 183 12,589 244 16,861
NL20 M20 2.5 256 16,186 341 21,357
NL22 M22 2.5 349 20,008 465 26,527
NL24 M24 3.0 441 23,155 588 30,799
NL27 M27 3.0 643 30,124 858 40,241
NL30 M30 3.5 877 36,869 1,170 49,233
NL33 M33 3.5 1,182 45,636 1,576 60,698
NL36 M36 4.0 1,525 53,729 2,034 71,714
NL39 M39 4.0 1,968 64,071 2,624 85,652
NL42 M42 4.5 2,435 73,737 3,247 98,241
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 5
Oil Graphite
Washer Bolt Pitch Torque Clamp Torque Clamp
Size Size (TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.1 550 1.0 550
NL3.5 #6 32 1.4 630 1.3 630
NL4 #8 32 2.7 970 2.4 970
NL5 #10 24 3.9 1,200 3.5 1,200
NL1/4” ¼ 20 9.1 2,200 8.3 2,200
NL8 5/16 18 18 3,600 16 3,600
NL3/8” 3/8 16 30 5,400 28 5,400
NL11 7/16 14 47 7,300 42 7,300
NL1/2” ½ 13 73 9,800 66 9,800
NL14 9/16 12 104 12,600 94 12,600
NL16 5/8 11 145 15,600 131 15,600
NL3/4” ¾ 10 254 23,100 230 23,100
NL22 7/8 9 408 31,900 369 31,900
NL 1” 1 8 617 41,800 557 41,800
NL30 1 1/8 7 771 46,400 697 46,400
NL33 1¼ 7 1075 58,900 969 58,900
NL36 1 3/8 6 1410 70,200 1,270 70,200
NL39 1½ 6 1860 85,500 1,670 85,500
NORD-LOCK “Delta Protekt” Washers with Zinc Plated Bolt Grade 8

Oil Graphite
(TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.5 740 1.3 780
NL3.5 #6 32 1.9 840 1.7 890
NL4 #8 32 3.5 1,300 3.1 1,400
NL5 #10 24 5.1 1,600 4.6 1,700
NL1/4” ¼ 20 12 2,900 11 3,100
NL8 5/16 18 24 4,900 21 5,100
NL3/8” 3/8 16 41 7,200 36 7,600
NL11 7/16 14 64 9,800 56 10,400
NL1/2” ½ 13 99 13,100 86 13,900
NL14 9/16 12 138 16,800 122 17,800
NL16 5/8 11 197 20,900 171 22,100
NL3/4” ¾ 10 346 30,900 299 32,700
NL22 7/8 9 556 42,700 479 45,100
NL 1” 1 8 840 56,000 724 59,200
NL30 1 1/8 7 1,190 70,600 1,030 74,500
NL33 1¼ 7 1,660 89,600 1,430 94,600
NL36 1 3/8 6 2,180 107,000 1,880 113,000
NL39 1½ 6 2,870 130,000 2,470 137,000
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
NORD-LOCK Stainless Steel with ASTM A574 Bolt
Oil Graphite
(TPI) (ft-lbf) (lb) (ft-lbf) (lb)
NL3 #5 40 1.7 870 1.6 910
NL3.5 #6 32 2.2 990 2.0 1,050
NL4 #8 32 3.8 1,500 3.7 1,600
NL5 #10 24 5.8 1,900 5.5 2,000
NL1/4” ¼ 20 13 3,400 12 3,700
NL8 5/16 18 26 5,700 23 6,000
NL3/8” 3/8 16 45 8,400 39 8,900
NL11 7/16 14 70 11,500 60 12,200
NL1/2” ½ 13 109 15,400 93 16,300
NL14 9/16 12 148 19,800 141 20,900
NL16 5/8 11 216 24,600 184 26,000
NL3/4” ¾ 10 378 36,400 321 38,400
NL22 7/8 9 607 50,200 514 53,000
NL 1” 1 8 916 65,900 776 69,600
NL30 1 1/8 7 1,300 83,000 1100 87,700
NL33 1¼ 7 1,810 105,000 1530 111,000
NL36 1 3/8 6 2,380 126,000 2020 133,000
NL39 1½ 6 3,140 153,000 2640 161,000
NORD-LOCK Stainless Steel with ASTM F593 Bolt

Oil Graphite
(TPI) (ftlb) (lb) (ftlb) (lb)
NL3 #5 40 - - - -
NL3.5 #6 32 - - - -
NL4 #8 32 - - - -
NL5 #10 24 - - - -
NL1/4” ¼ 20 5.2 1,300 5.2 1,300
NL8 5/16 18 10.3 2,200 10.3 2,200
NL3/8” 3/8 16 18 3,300 18 3,300
NL11 7/16 14 28 4,500 28 4,500
NL1/2” ½ 13 43 6,000 43 6,000
NL14 9/16 12 61 7,700 61 7,700
NL16 5/8 11 85 9,500 85 9,500
NL3/4” ¾ 10 104 9,800 104 9,800
NL22 7/8 9 166 13,500 166 13,500
NL 1” 1 8 251 17,700 251 17,700
NL30 1 1/8 7 356 22,300 356 22,300
NL33 1¼ 7 497 28,300 497 28,300
NL36 1 3/8 6 653 33,800 653 33,800
NL39 1½ 6 859 41,100 859 41,100
SIZE DWG NO REV
A DS00008 F
DCF0045 (REV B)
Hydraulic
Fluid
Cleanliness
Supplement
SM00081 Rev. C
October 26, 2000
Copyright 2000, Varco International, Inc.
All rights reserved. This publication is the property of

and contains information proprietary to Varco
International, Inc. No part of this publication may be
reproduced or copied in any form or by any means,
including electronic, mechanical, photocopying,
recording, or otherwise, without the prior written
permission of Varco International, Inc.
Product names mentioned in this publication may be

trademarks or registered trademarks of their respective
holders and are hereby acknowledged.
ii Hydraulic Fluid Cleanliness SM00081-C

Contents
Supplement
Hydraulic Fluid Cleanliness

Scope .................................................................................................................... 5
Hydraulic Fluid Cleanliness ................................................................................. 6
Hydraulic fluid ............................................................................................... 6
Hydraulic Fluid Contamination ............................................................................ 7
Solid contamination ....................................................................................... 7
Classes of contamination ......................................................................... 7
Measuring the contamination of a system ............................................... 9
Taking samples .................................................................................. 9
Analyzing the samples .......................................................................... 10
Cleanliness during installation ........................................................................... 11
Service loops ................................................................................................ 11
Hydraulic pipe cleaning ............................................................................... 11
Reference documents: ........................................................................... 11
Pipe cleaning (carbon steel): ................................................................. 11
Pipe cleaning (stainless steel) ................................................................ 13
SM00081-C Contents iii

October 26, 2000
iv Hydraulic Fluid Cleanliness SM00081-C

Supplement
Hydraulic Fluid
Cleanliness
Scope
The purpose of this document is to provide guidance to the installers and users of
Varco’s hydraulically powered equipment and to ensure that each piece of equipment
performs as intended. Prior to connecting Varco equipment to a hydraulic system, the
piping/plumbing/hoses/service loops must be cleaned and the hydraulic fluid filtered to
minimize hydraulic fluid contamination. The following paragraph defines the
hydraulic fluid cleanliness levels required for operating Varco equipment. Failure to
maintain these cleanliness levels could result in premature equipment damage and
nullification of the equipment warranty.
This document outlines fluid cleanliness measurement and analysis criteria and also
describes procedures for filtering and cleaning a hydraulic system.
Each final assembly item from Varco will be function tested with clean hydraulic fluid
maintained at ISO 4406 18/15 (was 9) or better (See Table 1). The hydraulic fluid
cleanliness levels will be recorded on Test Specification document (TS00419) for each
piece of equipment prior to shipment.
SM00081-C Hydraulic Fluid Cleanliness 5

October 26, 2000
Hydraulic Fluid Cleanliness
Hydraulic fluid
Varco recommends hydraulic fluid levels be maintained at a cleanliness level of ISO
4406 18/15 (was 9) or better prior to the initial connection, startup, and commissioning
of Varco equipment. After initial system operation, Varco recommends that the
hydraulic supply system be capable of continuously maintaining this level of
cleanliness or better to assure that fluid contamination is not a factor in any component
failure during the desired useful life of the hydraulic powered equipment. The final
level of acceptable cleanliness prior to equipment hook up must be determined by a
hydraulic fluid sample and should be analyzed by a qualified laboratory.
6 Hydraulic Fluid Cleanliness SM00081-C

Hydraulic Fluid Contamination
Hydraulic Fluid Contamination
Solid contamination
When determining contamination of hydraulic fluids, you must consider the size and
quantity of the solid particle contamination within a representative fluid sample. The
contamination of hydraulic fluids by solid particles is covered by a number of different
classification systems:
❏ ISO DIS 4406

❏ MIL STD 1246 A
❏ NAS 1638
❏ SAE 749 D
❏ CETOP RP 70 H
CLASSES OF CONTAMINATION
The various classes of contamination define the quantity of particles of a certain size in
a 100 ml sample of fluid.
A classification is determined by counting and sizing the contaminating solid particles.

The classification is performed either under a microscope, or by using an electronic
particle counter. The electronic counter method is more objective than using the
microscope.
Above a dirt concentration of about 20 mg per liter, or if the fluid is very turbid, the
contamination can only be ascertained by weight, i.e., by gravimetric analysis.
However, with this method, the individual dirt particles cannot be classified.

October 26, 2000
ISO DIS Particles ACFTD Mil STD NAS 1638 SAE 749 D
4406 per ml solids 1246 A (1967) (1963)
or >10 µm content (1967)
Cetop RP mg/L
70 H
26/23 140000 1000
25/23 85000 1000
23/20 14000 100 700
21/18 4500 12
20/18 2400 500
20/17 2300 11
20/16 1400 10
19/16 1200 10
18/15 580 9 6
17/14 280 300 8 5
16/13 140 1 7 4
15/12 70 6 3
Acceptable range for Varco equipment
Acceptable range for Varco equipment

14/12 40 200
14/11 35 5 2
13/10 14 0.1 4 1
12/9 9 3 0
18/8 5 2
10/8 3 100
10/7 2.3 1
10/6 1.4 0.01
9/6 1.2 0
8/5 0.6 00
7/5 0.3 50
6/3 0.14 0.001
5/2 0.04
Figure 1. Comparison of contamination classifications

Comparison of contamination classifications
MEASURING THE CONTAMINATION OF A SYSTEM

Solid particle contamination is measured by taking a sample of fluid from the output of
the hydraulic supply system at a location just prior to the Varco equipment and
analyzing it.
The analysis can reveal the following:
❏ Solid particle contamination of fluid delivered by suppliers

❏ Effectiveness of the system filters
❏ Flushing time when commissioning a system
❏ State of the system and any possible damage to components when making regular
checks
Taking samples
Take a sample from a moving fluid (known as dynamic sampling)
Sampling point: Take the sample within a system that is operating and which contains
turbulent flow. (See ISO 4021.)
Since obtaining a fluid sample can be an input for contamination the following general
measures should be utilized when taking a fluid sample.
❏ Utilize continuous flow monitoring equipment that records a cleanliness level over
a period of time whenever possible.
❏ Take a sample of the circulating fluid of a system that is at operating conditions and
temperature. All fluid samples shall be taken from a system test-port fitting using
a on/off flow sampling device. Never loosen or break a hydraulic fitting to establish
a leak point as a fluid source for fluid contamination sampling.
❏ Before attaching the sampling device, carefully flush out the device and clean the
system test-port fitting.
❏ Open sampling device and allow approximately 2 liters of fluid to flow through the
test port prior to sampling the fluid.
❏ Without shutting the test port, open and fill the sterile sampling bottle by holding
it in the continuous fluid stream. Cap and seal the test bottle.
❏ Label and date the sample bottle to identify the tool and sample hydraulic circuit
location.
e Only properly trained personnel should be allowed to take the fluid samples. Errors in
sampling procedures can greatly affect contamination classes below ISO 18/IS.

October 26, 2000
ANALYZING THE SAMPLES

Analyzing the fluid samples involves using a microscope to make a quick estimate of
the amount of solid particle contamination. From this assessment, you can roughly
assess the state of the system.
To avoid errors in sampling, conduct particle counting off site. Do not allow rig
personnel to attempt to check the samples at the time of sampling. Send the samples to
an appropriate institute for testing.
Usually, samples are analyzed by means of an electronic particle counter. These

particle counters are employed by major users of hydraulics, manufacturers of
hydraulic filters, and by various institutions. Since testing by an outside source may not
be easily accessible from a rig, you can make a quick assessment of the fluid samples
on the spot by using the assessment test charts in this document.
z Mobile laboratory services can also perform the measurements for customers.

Cleanliness during installation
Service loops
Varco service loops are blown clean in the factory and capped prior to shipment. They
are not flushed. All service loops and hoses should be flushed as part of the overall
hydraulic system prior to connecting Varco equipment.
Hydraulic pipe cleaning

z Clean hydraulic piping is critical to the cleanliness of the overall hydraulic system. The
following processes are examples of pickling, cleaning, and flushing procedures for
cleaning carbon steel and stainless steel pipes prior to hydraulic system installation and
are provided for information and reference only. Varco is typically not responsible for
any part of the pickling, cleaning, or flushing process of derrick and rig floor piping.
The process for cleaning and preparing hydraulic pipes is dependent on the type of pipe
(carbon or stainless), the condition of the pipe (pickled or not pickled), the types and
levels of contamination, the types and temperatures of the pickling and flushing
solutions in use, and the type of flushing equipment.
REFERENCE DOCUMENTS:
❏ ASTM Standard 5.02 D-4174, standard practice for cleaning, flushing, and
purification of petroleum fluid hydraulic system.
PIPE CLEANING (CARBON STEEL):

Obtain the following chemicals:
Hydrochloric acid - 35% commercial grade
Alkaline cleaner, KD-500
Potable water - Unless otherwise specified
Passivator - iron phosphate, KO-30
Inhibitor - Rodine 214 for HCL

October 26, 2000
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present. Pipes and fittings with heavy rust, varnish
or other tough soils should be sandblasted prior to pickling.
Rinse
Rinse carbon steel pipe with potable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 10-15% inhibited hydrochloric acid solution at
ambient temperature (for at least one hour) until all scale, slag, rust, etc. Is removed.
Rinse with potable water until all alkaline cleaner is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH (7.0).
Flush
Begin flushing the piping with the hydraulic power unit until the desired state of
cleanliness is met.

PIPE CLEANING (STAINLESS STEEL)

Use the following recommended procedure for cleaning stainless steel pipe:
Obtain the following chemicals:
Nitric acid - 42% technical grade
Hydrofluoric acid - 35% technical grade
Alkaline cleaner, KD-500
Potable water - unless otherwise specified
Degrease
Spray, immerse, or circulate with alkaline cleaner. Degreasing time for pipe depends
on the nature of any contaminants present.
Rinse
Rinse pipe with portable water until all alkaline cleaner is removed.
Acid pickle
Immerse or spray the pipe with a 15-17% nitric acid/3-5% hydrofluoric acid mixture at
ambient temperature (for at least two hours) until all scale, slag, rust, etc. is removed.
Rinse
Rinse the pipe with potable water until the water reaches a neutral PH.
Passivate
Use a 10 - 15% nitric acid/75-80% potable water mixture at ambient temperature for
approximately one-half the time used in acid pickling.
Rinse
Rinse with potable water until the PH of the effluent equals the pH of the influent.
Dry
Dry with oil-free air until all visible traces of moisture are removed.
Final inspection
Use a white light to inspect all pipe and/or fittings for visible contamination. Prior to
hooking up equipment pump clean hydraulic fluid through the plumbing and measure
the contamination of the system per this specification. Additional flushing and cleaning
may be required if contamination levels do not meet the requirements of this
specification.

TABLE OF CONTENTS
Revision: 02
Page: 1

Section
Spares Kit, ST-80C General Spares 30181152 E
www.nov.com
TABLE OF CONTENTS
Revision: 02
Page: 1
Vol. Chapter/ Title

Section
1 3 Technical Documents & Drawings
1 3.2 System/Process Diagrams
1 3.3 Electrical/Instrument
Remarks: Section Not Applicable
1 3.4 Performance Data

www.nov.com
TABLE OF CONTENTS
Revision: 02
Page: 1

Section
Assembly, Manifold - ST80 30154910 L
Assembly, Die Holder 30160384 D
Assembly, LH Spin Wrench 30160387 L
Lower Assembly, LH 30160388 D
Assembly, LH Transmission 30160389 P
Assembly, RH Spin Wrench 30160390 M
Lower Assembly, RH 30160391 E
Assembly, RH Transmission 30160392 R
Assembly, Piston, SW Clamp 30160658 D
Assembly, Manifold, Load Hold 30170647 C
Control Valve Assembly 30171621 G
Column Base Assembly 30171626 -
Package, Lower Die Set 30172029 C
Hose Assembly 30172128 A
ST-80 Manifold Assembly 30172354 H
Socket Flange and Base Assembly 30172616 A
Kit, ST-80 Floater 30173525 -
Assembly, Upper Jaw 30174072 G
Jaw Lower Assembly 30174073 C
Package, Upper Die Set 30174222 C
Assembly, ST-80 Wrench 30174930 H
Assembly, Ironroughneck, ST-80C 30176031 C
Assembly, Iron Roughneck, ST-80C (Tall) 30179800 F
Assembly, Carriage, ST-80C 30179883 J
Hose Kit, Carriage ST-80C 30180253 E
Assembly, Platform, ST-80C (Tall) 30180452 G
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TABLE OF CONTENTS
Revision: 02
Page: 2

Section
Assembly, Extension Arm, ST-80C 30180453 D
Assembly, Valve Control, ST-80C 30180459 B
Assembly, Cover, ST-80C 30180461 A
Assembly, Manifold, Load Hold, ST-80C 30180838 -
Assembly, Manifold, Load Holding 30181124 -
Package, Shipping, ST-80C 30181800 C
Assembly, Hydr Damper, ST-80C/R/CL M364000848-ASM-001 01
www.natoil.com
DCN Varco
PARTS DRAWING NO. REVISION
USE REWORK SCRAP NOTED
DISPOSTION SHEET 1
Systems
30174222 C
RAW MATERIALS X OF 1
IN PROCESS X DOCUMENT TITLE
A Varco Company
COMPLETED X DCR NO.
REASON FOR CHANGE (FROM DCR) :
ASSEMBLED X PACKAGE, UPPER DIE SET
DISPOSITION NOTED
1 X COST REDUCTION/EASE OF MANUFACTURING
76242
2 X BOM CORRECTION 3 DRAWING CORRECTION
4 IMPROVED SERVICEABILITY 5 IMPROVED PERFORMANCE PREPARED CHECKED APPROVED
6 IMPROVED INSTALLATION 7 CUSTOMER REQUIREMENT
8 OTHER: __ _______________________________________________________
H. SETH B. DE JONG N. WEST
EFFECTIVE DATE 05/02/05
ADDITIONAL DISTRIBUTION TO: TECH PUBS X SPARES OTHER: _________________________________
1. CHANGED NOTE 6 TO REMOVE ½” SCREWS
2. REMOVED: 5X 50108-8-C, 1/2UNC SCREW, SOCKET HEAD
3. REMOVED: 1X 30174647-6 1/2 SQ BIT SOCKET, 3/8 HEX
REASON FOR REMOVING THE 5 SCREWS. DURING THE JAW UPGRADE WE CHANGED THE THREAD SIZE TO A STRONGER BOLT. IN THE TRANSITION
PHASE WE COULD SEE BOTH THREADS, AND THEREFORE 2 TYPES OF BOLTS WERE INCLUDED IN THESE PACKAGES. THE UPGRADE PROGRAM IS
ALMOST FINALIZED, SO OLD STYLE BOLTS CAN BE REMOVED FROM THE PACKAGE.
DCF00010 (REV E)
TABLE OF CONTENTS
Revision: 02
Page: 1

Section
1 3.2 System/Process Diagrams
Hydraulic Schematic ST-80C 30179953 C
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TABLE OF CONTENTS
Revision: 02
Page: 1

Section
1 3.3 Electrical/Instrument
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TABLE OF CONTENTS
Revision: 02
Page: 1

Section
1 3.4 Performance Data

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TABLE OF CONTENTS
Revision: 02
Page: 1

Section
1 4 Vendor Documentation
Remarks: Chapter Not Applicable
www.nov.com
National Oilwell Varco Brands
Advanced Wirecloth Mission Downhole Solutions

Aktro Molde
Alberta Instrument Mono
Albin’s Enterprises Monoflo
AmClyde National
Baylor National Oilwell
Best Flow Products
BLM
Norson
Oil Tools Solutions Drilling Solutions
Bowen Oilwell
Brandt Omega Pumps
Cabot Pacific Inspection
Cardwell PCE
Chimo Equipment Peck-O-Matic
Continental Emsco PEP Engineering and Project Management
Cooper Procon As
Crestex Quality Tubing Solutions
Custom Die & Insert Rebound Rig
DELCO Retsco
Corporate Dreco RMI (Rig Manufacturing International)
Headquarters DSS (Drilling Support Services) Roberds Johnson
Eastern Oil Tools ROSS HILL
7909 Parkwood Circle Elmar Rucker Lifting and Handling Solutions
Drive EMD (Electro Motive Division) Russell Subservice
Houston, Texas 77036 Fibercast Sauerman
United States Fidmash Shaffer
Phone: +1 713 375 3700 Flanagan Ironworks Shearer
Phone: +1 1 888 262 8645 Franks Skytop Brewster
Gardner Denver (Hoisting) Smith Fiberglass Production Solutions
Gator Hawk Specialty
Gregory SSR
Griffith Stålprodukter
HALCO Star Fiberglass
Harrisburg Tech Power
Hepburn TEM (Tulsa Equipment Manufacturing)
HITEC Texas Oil Tools Supply Chain Solutions
Houston Scientific TS&M
Hydra Rig Tuboscope
Ideco Turner Oilfield Service
IPS (Integrated Power Systems) UNIFLEX
IRI International Unit (Cranes)
Koomey Universal Tubular and Corrosion Control
Kremco USF (Utility Steel Fabricators)
LOIS ALLIS Varco Solutions
Lucker Vector
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M/D Totco Western Oilfield Engineering
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MATTCO Wildcat Services
McElroy Marine Machinery Wilson Well Service and Completion Solutions
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Iron Roughneck ST-80C

Generation 1 Tall Column without Reach Extender

02 19.03.2015 For Information I. Vargas L. Krajenbrink J. Walker

Revision Change Description

Vol. Chapter/ Title Remarks

1 2 Installation, Operation, & Maintenance

1 2.2 Spare Parts List

1 3 Technical Documents & Drawings

1 3.1 General/Mechanical Drawings

1 3.2 System /Process Diagrams

1 3.3 Electrical/Instrument Section Not Applicable

1 3.4 Performance Data Section Not Applicable

1 4 Vendor Documentation Chapter Not Applicable

Vol. Chapter/ Title Document Number Rev.

Functional Design Specification, ST-80C D364000206-FDS-001 01

Compact Iron Roughneck for highly portable installations. Pedestal

SIZE DWG NO REV

Vol. Chapter/ Title

1 2 Installation, Operation & Maintenance

1 2.2 Spare Parts List

Vol. Chapter/ Title Document Number Rev.

Commissioning Procedure ST-80 Gen 3 & ST-80C 3TS00688 B

The Use of and Application of Safety Wire for Secondary ASP00019 A

Service Manual ST-80C Iron Roughneck D811000124-MAN-001 03

Recommended Lubricants Guide D811000719-PRO-001 06

Design Torque Standard DS00008 F

Hydraulic Fluid Cleanliness SM00081 C

ST-80 GEN 3 & ST-80C

Serial Number: ____________________________

Part Number: ____________________________

2. ST-80 physical condition checklist:

2.2. Inspect Socket Flange and Base Assembly for damage.

SIZE DWG NO REV

SIZE DWG NO REV

3.14. Make the connection in the following sequence:

SIZE DWG NO REV

3.16. Verify if ST-80 meets the timing table presented below.

SIZE DWG NO REV

SIZE DWG NO REV

THE USE OF AND APPLICATION OF

National Oilwell Varco

Client Document Number

A 15/04/2011 SEE ECN C. SILVA T. GORMSEN T. GORMSEN

Revision Change Description

This procedure is intended to help eliminate the risk of dropped objects in

Use of safety wire to prevent rotation of fasteners is a safe and primarily

Secondary Retention – The means of effectively retaining a fastener/joining component

DS00008-DES DESIGN TORQUE STANDARDS

3.1 MATERIAL AND SIZE

3.1.2 Lock-wire sizes

a. 0.5080 mm (0.020 inch) diameter

3.2 GENERAL REQUIREMENTS

3.2.1 Safety wire shall be new upon each application.

a) No more than three (3) bolts may be tied together.

Figure 1: Safety Wire / Lock Wire

3.3 LOCK-WIRING METHODS

3.3.2 The double-twist method:

3.3.4 Single wire method:

Figure 2: Safety Wire / Lock Wire Single

3.4 OTHER APPLICATIONS

3.4.4 Internal snap rings shall never be lockwired.

Figure 3: Safety Cable Installation Procedure

3.5 ILLUSTRATION OF TYPICAL LOCK-WIRE APPLICATION

Reference Reference Description