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RK-495 Rotary Table - Operations & Maintenance Manual (29170000, Rev.1)
RK-495 Rotary Table - Operations & Maintenance Manual (29170000, Rev.1)
RK-495 Rotary Table - Operations & Maintenance Manual (29170000, Rev.1)
5
29170000
49 1/2" ROTARY TABLE
M2917
1
JULY 2015
6311BreenRd.
Houston,TX77086
Phone:281.820.5330 FMͲ8.49REV.0MAR2014
TABLE OF CONTENTS
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2.0 OPERATION AND ROUTINE MAINTENANCE
2.1 Warning
2.2 Installation
2.3 Lubrication
2.4 Maintenance
DOC.: M29170000
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2.1 WARNING
This product and many of its parts are heavy and difficult to handle. Plan
lifts carefully and use proper lifting gear to avoid equipment damage and
personal injury. Provide safe supports for all equipment and parts.
Do not lift the rotary table by its cover. Use the lifting holes provided in the
corners of the rotary table housing near the bottom.
Lubricate the rotary table before starting operation. Prior to shipment all
lubricant is drained from the rotary table. Before operation the rotary table must
be filled with lubricant as instructed in the lubrication section of this manual.
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2.2 Installation
The rotary table should be set level. Angular or tilted operation may be
detrimental to the lubrication system and result in serious damage to the rotary
table.
Lubricant leakage indicates a serious problem. The cause of the problem should
be determined and corrections made as soon as practical.
Safety guards should be installed to cover all moving parts. Flooring around the
rotary table should be firm and should provide safe and secure footing.
The rotary table must be properly supported. The foundation and attachment
devices for the rotary table must be sufficient size and design to maintain the
equipment without undue strain. Secure the rotary table to the foundation.
Locating devices and high strength bolts should be used.
Check the alignment of all driving devices. Improper alignment may damage the
equipment.
Provide adequate clearance around the rotary table housing and support frame
to prevent mud build-up. Provide ample clearance between the bottom of the
rotary table and the top of the bell nipple to prevent overflow of drilling mud from
impinging on the bottom of the rotary table.
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2.3 Lubrication
2.3.1 Table
Proper lubrication is essential for trouble free performance or the rotary table. All
rotating components of the rotary table are lubricated by a single oil bath
reservoir. The table lock is lubricated with grease.
When the rotary table reservoir is properly filled with oil the lower part of the
pinion gear is submerged in the oil. When the pinion turns it carries oil up to the
ring gear. A portion of this oil is deposited on the main bearing and drains down
through the up-thrust bearing before returning to the reservoir. A collector cover
on the pinion shaft housing gathers another portion of the oil carried up by the
pinion gear. This oil passes into the pinion shaft housing and lubricates the
pinion shaft bearings before returning to the reservoir. Oil is retained in the
pinion shaft housing to provide short-term lubrication for the pinion shaft bearings
during start-up.
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PAGE 2 - 4
The oil in the reservoir should be changed each 6 months or when contaminated.
To drain the oil, remove the plug on the bottom of the reservoir under the pinion
gear and the plug on the bottom of the pinion shaft housing. Opening both these
drains is necessary to drain all the oil from the rotary. Carefully inspect the oil for
contamination by mud, water or metal particles. If the oil is contaminated the
rotary should be opened and cleaned internally. If this is not practical, the rotary
should be flushed in accordance with instructions given in section 2.3.3.
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After the reservoir is properly drained and cleaned, replace the plugs and fill the
reservoir through the filling opening on the top of the pinion shaft housing. This
filler opening is accessible through an opening in the table cover. DO NOT fill
the reservoir through the dipstick opening. Use heavy duty high temperature
extreme pressure gear oil as specified in the lubricant chart below. When the
specified volume is used the oil level should be within the knurled area on the
dipstick. Operate the rotary at a medium speed for 5 minutes. Stop and gage
the oil level again. Adjust the oil level again to remain within the knurled area on
the dipstick.
Reservoir Lubricant
Temperature Lubricant
+20F. (-7C) & AGMA No. 6 EP or ASTM/ISO-VG Grade 320 (Viscosity 1533-1881
Above SSU at 100F.) Non-corrosive, Anti-Foaming Gear Lube
-20F. (-28C) AGMA No. 2 EP or ASTM/ISO-VG Grade 68 (Viscosity 318-389
to +60F. SSU at 100F.) Non-corrosive, Anti-Foaming Gear Lube
(16C)
Reservoir Capacity: 19 Gallons (71.8 liters)
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Drain the contaminated gear oil from the rotary. Fill the reservoir to the normal
operating level with 30W mineral oil. Operate the rotary UNDER NO LOAD at
slow speed (20-30 RPM) for 2 to 3 minutes. Drain the reservoir. Refill with the
normal lubricant and proceed. As soon as practical, remove the rotary from
service, disassemble sufficiently to clean the sump and the inside of the pinion
capsule.
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2.4 Maintenance
2.4.1 Daily
2.4.1.1 Check the oil level and adjust as necessary. If there is evidence of
contamination, clean the reservoir as soon as possible to prevent
further damage to the gears and bearings of the rotary. See section
2.3.3.
2.4.1.2 Check the locking mechanism and clean or lubricate as necessary.
2.4.1.3 Check for oil leaks at the pinion shaft seals or at the labyrinth seals at
the top and bottom of the rotary. Schedule maintenance as necessary.
2.4.1.4 Lubricate the master bushing.
2.4.1.5 Check for cleanliness. Wash the table after a trip or after each wet
joint is handled. Wash the bottom of the rotary table. DO NOT direct a
jet of water directly at the lower labyrinth seal. This may force water
into the rotary table.
2.4.2 Monthly
2.4.2.1 Drain a small amount of oil from the reservoir and check for
contamination. If contamination is suspected follow the instructions in
the lubrication section of this manual. Serious damage can occur if the
rotary is operated with contaminated lubricant.
2.4.3 Semi-Annually
2.4.3.1 Drain the reservoir and refill with clean lubricant.
2.4.3.2 Check all fasteners for proper tightness.
2.4.3.3 Check the rotary drive for alignment and chain tension as necessary.
2.4.4 Annually
2.4.4.1 Remove the rotary table from the base housing; inspect the interior of
the reservoir for contamination. Clean as necessary.
2.4.4.2 Inspect the gears for proper operation and wear pattern.
2.4.4.3 Check the clearance in the rotary table main bearing assembly and
adjust as necessary.
2.4.4.4 Check the pinion shaft bearings for excessive clearance and replace
as necessary.
2.4.4.5 Check the backlash of the gear set and adjust as necessary.
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3.0 DISASSEMBLY / ASSEMBLY
3.1 Disassembly
3.2 Assembly
DOC.: M29170000
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3.1 Disassembly
3.1.1 Setup
3.1.1.1 Remove the master bushing.
3.1.2.1 Place the rotary on firm supports that allow access to the under side of the
rotary.
3.1.2.2 Follow support instructions given in the warning section.
3.1.2.3 Preserve and protect any parts removed from the rotary for future use.
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3.1.3.5 Remove the two sets of balls and ball spacers along with the middle
bearing race.
3.1.3.6 Place at least three (3) lifting lugs under the lower main bearing race that
is now at the top of the bearing.
3.1.3.7 While assuring that the race remains flat and square with the rotary table,
gently pull the bearing race from the rotary table. This race is slightly tight.
There will be a small resistance.
3.1.3.8 Do not remove the upper race of the main bearing from the rotary table
unless the bearing is being replaced. Removal risks serious damage to
the bearing race.
3.1.3.9 If the bearing race must be removed, drive several thin wedges between
the race and the rotary table. This process may be eased by gently
heating the race if the race is to be discarded.
WARNING: NEVER heat a bearing race with a torch unless the race will be
discarded.
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3.1.6.1 Do not disassemble the pinion capsule unless the bearings shall be
replaced.
3.1.6.2 Place the pinion capsule on a firm support such that it will not roll or slide.
3.1.6.3 Remove the six (6) ½”capscrews holding the oil seal retainer on the shaft
end of the pinion cartridge.
3.1.6.4 Remove the oil seal retainer.
3.1.6.5 Remove the two (2) seals from the retainer and discard the seals.
3.1.6.6 Heat the pinion gear to 400°. If using a t orch, do not allow the flame to
impinge upon the pinion teeth as this can cause micro-cracks in the teeth.
3.1.6.7 Use a hydraulic puller to remove the pinion from the shaft.
3.1.6.8 Remove the pinion key.
3.1.6.9 Remove the two (2) ½”capscrews holding the tapered roller bearing
retainers.
3.1.6.10 Hold the pinion capsule horizontal and behind the flange; press on the
shaft extension end of the pinion shaft to push the shaft from the pinion
capsule. There will be significant resistance as the tapered roller bearing
is tight in the housing. Be careful not to damage any of the parts during
this operation. The pinion shaft will fall free as the tapered roller bearing
exits its fit.
3.1.6.11 Use a collar around the shaft to pull the tapered roller bearing inner race
from the shaft.
3.1.6.12 In the same way, pull the seal race and straight roller bearing inner race
from the other end of the shaft.
3.1.6.13 Remove the straight roller bearing roller assembly from the pinion capsule.
3.1.6.14 Pull the straight roller bearing outer race from the pinion capsule.
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3.2 Assembly
3.2.1 General
3.2.1.1 All parts must be clean and free of burrs, raised metal, and paint on the
contacting surfaces.
3.2.1.2 Follow part and assembly support instructions given in the section 2.1.
3.2.1.3 Lubricate bolts before assembly with mineral oil.
3.2.1.4 Tighten ½” screws to 50 ft-lb (6.9 m-kg), ¾” screws to 175 ft-lb (24.2 m-kg)
and 1” screws to 380 ft-lb (52.5 m-kg).
DO NOT HEAT BEARINGS WITH A TORCH. Bearing races are made from
high carbon steel and may develop micro-cracks if heated with a torch.
ALWAYS use an oven or an oil bath to heat a bearing.
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3.2.2.3 Heat the inner race of the straight roller bearing to 250F. (120C.) and
press it on the extension end of the shaft. Hold the race against the
shoulder until it cools.
3.2.2.4 Heat the oil seal race to 250F. (120C.) and press it on the shaft against
the inner race of the straight roller bearing. Hold the seal race against the
shoulder until it cools.
3.2.2.5 Tap the outer race and rollers of the straight roller bearing into the pinion
capsule.
3.2.2.6 Heat the pinion end of the pinion cartridge to 250F. (120C.). Be careful
to protect the bearing in the other end of the capsule.
3.2.2.7 Insert the pinion shaft into the cartridge. Carefully work the oil seal race
and bearing race through the straight roller bearing.
3.2.2.8 Press the tapered roller bearing into its cartridge fit until seated against the
shoulder. Hold the shaft until the cartridge has cooled.
3.2.2.9 Install the two (2) tapered roller retainers with ½” cap screws and torque
the screws to the value stated in 3.2.1.4.
3.2.2.10 Insert the pinion key into the shaft.
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3.2.2.11 Heat the pinion to 450F. (231C.). Push the pinion on the shaft until it
rests against the tapered roller bearing. Hold the pinion in place until it
cools. Do not cool with water.
3.2.2.12 Install the oil seals in the straight roller bearing retainer. The first seal is
the outer seal and its lip should face the retainer as it is being installed.
The second seal is the inner seal and its lip should face away from the
retainer as it is being installed.
3.2.2.13 Place the bearing retainer gasket on the retainer.
3.2.2.14 Install the bearing retainer assembly on the extension end of the pinion
capsule with eight (8) ½” screws. Torque the screws to the value stated in
section 3.2.1.4.
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3.2.3.2 If old gears are used, place the shims removed in section 3.1.4.3 on the
inside of pinion capsule flange. Otherwise do not use any shims.
3.2.3.3 Install the pinion capsule into the rotary base housing.
3.2.3.4 Install at least four (4) ¾” bolts, equally spaced, and tighten firmly. NOTE:
The holes in cartridge flange are staggered and the cartridge is stamped
“TOP”.
3.2.3.5 Measure the distance from the 50” pilot diameter for the main bearing to
the face of the pinion with a depth micrometer, and write it down.
3.2.3.6 Add 25.003” to the value measured in 3.2.3.5.
3.2.3.7 Subtract the sum found in 3.2.3.6 from the mounting distance recorded in
3.2.3.1.
3.2.3.8 A negative value in 3.2.3.7 means remove shims, and a positive value
means add shims.
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3.2.3.9 Remove the pinion capsule and add or remove shims of the thickness
indicated in 3.2.3.8.
3.2.3.10 Repeat sections 3.2.3.3 through 3.2.3.9 until the value found in 3.2.3.7 is
greater than –0.003 and less than 0.003.
3.2.3.11 Install the pinion capsule with all twelve (12) ¾” screws and torque the
screws to the value stated in section 3.2.1.4.
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3.2.5.9 Install the lower labyrinth plate and pull the lower bearing race down on
the rotary table with the twelve (12) 3/4” capscrews. Use no more than
10-20 ft-lb (6-12 m-kg) bolt torque. Be sure the lower labyrinth plate is
square on the rotary table. Be Careful!! Do not warp the lower labyrinth
plate.
3.2.5.10 As the labyrinth plate is pulled down maintain an equal space between the
plate and the table around the circumference to assure that the plate is
square on the table.
3.2.5.11 Measure the gap between the lower labyrinth plate and the rotary table at
several places around the circumference when the bearing is snugly
assembled. There should be no resistance to rotational movement of the
middle race. These measurements should not vary by more than 0.005
inch (0.13 mm).
3.2.5.12 The thickness of the shim pack between the lower labyrinth and the rotary
table is the average final measurement less 0.004 ±0.001 inch (0.10
±0.025 mm). This sets the internal clearance of the bearing at -0.003/-
0.005 or 0.003 to 0.005 tight.
3.2.5.13 Install the proper shims, lower labyrinth plate and the twelve (12) ¾”
capscrews. Torque the screws to the value stated in section 3.2.1.4.
3.2.5.14 There should be some resistance to rotational movement of the middle
race; but the race should move without significant force
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3.1.2.3 The outer ends of two adjacent gear teeth are marked and the end of one
pinion tooth is also marked. Place the marked pinion tooth between the
marked gear teeth. The pinion may be rotated to mate the gear teeth.
REVISION: 1
PAGE 3 - 15
3.2.6.3 The main bearing middle race should enter the pilot diameter in the rotary
base housing as the table seats in the base.
3.2.6.4 After the table is seated in the base, gently rock the pinion shaft back and
forth. Do not move the rotary table. The pinion shaft movement is
determined by the backlash in the gear set.
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3.2.6.5 Measure the rotation of the pinion shaft at a distance of 8.438 inch (214
mm) from the center of the pinion shaft.
3.2.6.6 Subtract the measurement taken in section 3.2.6.5 from the backlash
value recorded in 3.2.3.1.
3.2.6.7 Remove the table from the base housing.
3.2.6.8 Place shims of thickness equal to the value determined in section 3.2.6.6
on the main bearing seat.
3.2.6.9 Reinstall the table into the base housing.
3.2.6.10 Repeat sections 3.2.6.5 through 3.2.6.7.
3.2.6.11 A negative number means to remove shims, and a positive number means
to add shims. Add or remove shims as indicated by the value determined
in section 3.2.6.6.
3.2.6.12 Reinstall the table into the base housing.
3.2.6.13 Repeat sections 3.2.6.10 through 3.2.6.12 until the value determined in
3.2.6.6 is greater than –0.003 and less than 0.003.
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3.2.6.14 Install the four (4) sealing washers and ¾” nuts on the four (4) hold-down
studs that are accessible from the bottom of the base housing.
3.2.6.15 Torque the nuts to the value stated in section 3.2.1.4.
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REVISION: 1
4.0 ASSEMBLY DRAWINGS
29170000 Main Assembly (2 PAGES)
29171000 Pinion Capsule Assembly
DOC.: M29170000
REVISION: 1
5.0 SPARE PARTS
1 YEAR 2 YEAR
ITEM PART NUMBER DESCRIPTION CLASS
CONSUMPTION CONSUMPTION
1 107-0037 Pinion Bearing C 0 1
2 109-0013 Shaft Bearing C 0 1
3 122-0063 Shaft Oil Seal A 2 4
4 29081500 Bearing Retainer Gasket A 1 2
5 29170500 Table Shim Pack C 0 1
6 29170600 Main Bearing Shim Pack C 0 1
7 29170400 Pinion Capsule Shim Pack C 0 1
8 123-0028 Sealing Washer A 4 8
9 29171200 Pinion Shaft C 0 1
10 29081400 Oil Seal Race B 0 1
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DOC.: M29170000
REVISION: 1
4.0 GENERAL ARRANGEMENT DRAWINGS
Please see the next pages for General Arrangement Drawings.
REVISION: 1
MODEL NO.
SERIAL NO.
OPENING SIZE
MAX TORQUE
MAX RPM
DATE OF MFG.
TYPE SERIAL NUMBER MADE IN U.S.A.
WEIGHT LESS MASTER BUSHING
REMOVE COVER PERIODICALLY AND
WARNING SCRAPE OUT ACCUMULATED MUD
DO NOT OPERATE WITHOUT GUARDS OR COVER. TURN OFF
POWER TO INSTALL OR SERVICE.
5
15
D D
3
C 13
4 C
8 9
10
11
A ASSEMBLY A
.XX CHECKED DATE
THIS DOCUMENT EMBODIES A CONFIDENTIAL PROPRIETARY DESIGN OF WHICH .015 PS 12/13
AMERICAN BLOCK COMPANY RETAINS ALL PATENT AND OTHER RIGHTS,
- 0 INITIAL RELEASE 12/13 AMR MSK
.XXX 125 ON APPROVED DATE
49 1/2" ROTARY TABLE (W/STANDARD LOCK)
INCLUDING EXCLUSIVE RIGHT OF MANUFACTURE AND SALE. THIS DOCUMENT .005 MACHINED
SURFACES
MSK 12/13
IS SUBMITTED ONLY UNDER A CONFIDENTIAL RELATIONSHIP; AND MAY NOT
29171000
SCALE REV
CHANGE APPROV FRACTIONS ANGLES SHEET
N.T.S.
ALL DIMENSIONS ARE IN INCHES UNLESS NOTED
BE COPIED, DISCLOSED, OR MADE PUBLIC KNOWLEDGE. ECN NO. REV. DESCRIPTION DATE
BY BY 1/16 1/2 DEBURR ALL SHARP CORNERS WITH 0.03R MAX. 1 OF 1 0
8 7 6 5 4 3 2 1
REVISION
1 UPDATED SPARE PARTS & DRAWINGS SG 07/15 MJS 07/15 MJS 07/15
3855
- 0 INITIAL RELEASE AMR 12/13 SRS 12/13 SRS 12/13
REVISION: 1