Iron Roughneck ST-100 Service Manual

Service Manual
ST-100 Iron Roughneck
Reference
Reference Description
This document contains proprietary and confidential

information which is the property of National Oilwell Varco,
L.P., its affiliates or subsidiaries (all collectively referred to
hereinafter as "NOV"). It is loaned for limited purposes only
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 or
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
www.nov.com
National Oilwell Varco

RIG SOLUTIONS
11000 Corporate Centre Drive
Houston, TX 77041
Document Number
Rev.
D811003994-MAN-001
05
Form D811001123-GEN-001/07
Revision History
05
01.10.2013
Engineering Update
A. Donovan
J. Adkins
J. Adkins
04
20.06.2013
Engineering Update
A. Donovan
J. Adkins
J. Adkins
03
18.06.2012
Engineering Update
J. Roman
J. Adkins
J. Walker
02
13.02.2012
Engineering Update
T. Drake
J. Adkins
J. Walker
01
06.06.2011
First Issue
T. Drake
J. Adkins
J. Walker
Rev
Date (dd.mm.yyyy)
Reason for issue
Prepared
Checked
Approved
Change Description
Revision
Change Description
01
First Issue: Original Instructions
02
Corrected conversion error to weight specification (page 2-13).

Added and/or updated the following:
Orientation illustrations showing new control panel (page 2-11 and page 2-12).
Arm assembly illustration to show Hydraulic E-Stop Lanyard and new gauge (page 2-27).
Hydraulic assemblies illustration to show Hydraulic E-Stop Pressure Gauge (page 2-30).
Manual Control Console to show modified panel components (page 2-34).
Electrical Controls illustration for clarity (page 2-32).
E-Stop precaution (page 4-43).
Manual Control Console reference art (page 4-47).
E-Stop information to Manual Control Console section (page 4-53).
Diffuse sensor equipment shutdown information (page 4-65).
E-Stop information to Pedestal-Mounted Control Console section (page 4-66).
Maintenance Pins information and illustration (page 5-82 and page 5-84).
Made the following additional compliance checklist changes:
Added emission of noise information for checklist item 2.8 (page 1-8 and page 4-44).
Added location of instructions information for checklist item 3.7 (page 1-9 and page 3-40).
Added safe disposal information for items 2.11 and 4.6 (page 1-9, page 3-41, and page 5-81).
Added reminder cards, stickers, or labels information for checklist item 4.5 (page 2-17).
D811003994-MAN-001
Revision 05
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Form D811001123-GEN-001/07
Change Description (continued)

Revision
03
04
05
D811003994-MAN-001
Revision 05
www.nov.com
Change Description
Added E-Stop Symbol to (page 1-2), (page 4-44) and to illustration (page 2-26).
Added Lightning Precaution table to Safe Equipment Operation (page 1-7).
Added Modifications section and warning to (page 1-9).
Added descriptive paragraphs to (page 2-31), (page 3-38), (page 4-68) and restructured (page 4-68)
Added Footnote to Torque Wrench Specifications (page 2-14).
Changed descriptive paragraph (page 2-20) and (page 4-56).
Corrected N-m to Torque Assembly and changed die size to paragraph (page 2-24).
Changed illustration to show separate die configurations (page 2-25).
Added (section titled "ST-100 Quick Reference" on page 4-45).
Changed Making and Breaking Connections procedures (page 4-60) through (page 4-61).
Add and changed top views to (page 4-49) and change illustration text (page 4-72).
Added OEM Precaution caution table (page 5-82).
Changed illustrations on (page 5-84), (page 5-87), (page 5-95) and (page 5-103).
Added table to Monthly Inspection (page 5-85), Added illustrations (page 5-101) and (page 5-105).
Rearrange and changed Probable Cause and Remedy tables from (page 6-114) through (page 6117).
Updated template, advisory symbols, and page numbering (Entire Book)

Added Counter Balance Valve section (Page 7)
Added Hydraulic Requirements note (Page 13)
Updated Tong Die and Die Retainer (2) Lower Jaws callout to Front View on Figure 2-9 (Page 25)
Updated Lifting Info breakout on Figure 3-1 (Page 39)
Added Leveling the Head Assembly section (Page 42)
Updated the Test display on the Control Console for Figure 4-9 and 4-10 (Page 55 and 56)
Added Humidity and Altitude rows to Operating and Survival Environment tables (Page 80)
Added NOV policy information to Spare Parts You May Need section (Page 81)
Added monthly roughneck maintenance note (Page 88)
Added Malfunction Log section (Page 111)
Added Torque wrench unclamps... row on Troubleshooting Table (Page 116)
Added Operational Environment section to Chapter 1, General Information (Page 5)

Added red zone reference to Warning (Page 6)
Updated the Adjusting Arm Assembly Target Positions section (Page 64)
Updated Figure 4-15. Adjusting Arm Assembly Target Positions (Page 64)
Updated Diffuse Sensor Interlock section to clarify that Once a diffuse sensor has activated, only the
arm functions are disabled. (Page 69)
Table of Contents
Chapter 1: General Information
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safe Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General System Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counter Balance Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Equipment Documentation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 2: Description
Introduction to the ST-100 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Equipment Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Requirements (Remote Control Option Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Equipment Operating Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Nameplate and Warning Plaques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Equipment Pinching Hazard Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hydraulic Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Electrical Assemblies (Remote Control Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Socket Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Operator Control Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Manual Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Pedestal-Mounted Remote Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Chapter 3: Installation
Transporting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drill Floor Position Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removing and Installing the Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation and Commissioning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Storing the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Returning Equipment to Service After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Leveling the Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 4: Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operating Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ST-100 Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Pre-Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Normal Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Normal Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Control Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Operation Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Control Console Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Manual Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Positioning and Adjusting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Setting and Adjusting Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Emergency Stop (E-Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Stopping the Equipment in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Restarting the Equipment After a Hydraulic E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Remote Control Console Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pedestal-Mounted Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Sequential Tripping Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Setting and Adjusting Makeup Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Adjusting Arm Assembly Target Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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Object Detection Equipment Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Emergency Stop (E-Stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Stopping the Equipment in an Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Restarting the Equipment After an Electrical E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Interlock Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Interlock Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Electrical Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Hydraulic Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rotating the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Releasing the Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Releasing the Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Moving the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electrical Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Securing Equipment on a Floating Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Chapter 5: Maintenance
Pre-Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Spare Parts You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Spare Parts and Fluids Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Securing the Equipment for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Inspection Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inspection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Equipment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Spin Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Spin Wrench Support Structure Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Torque Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Arm Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Column Assembly Carriage Guide Roller Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Socket Base Slew Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
iii
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General Maintenance Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Nord-Lock Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Replacing Torque Wrench Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Replacing Spin Wrench Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Spin Wrench Rollers Assembly - Retention Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Changing the Hydraulic Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Removing the Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Removing the Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Carriage Lift Counterbalance Valve Adjustment Procedure . . . . . . . . . . . . . . . . . . . 109
Chapter 6: Troubleshooting
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Malfunction Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Determining the Nature of the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Pre-Troubleshooting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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General Information
Overview
This service manual is part of the National Oilwell Varco (NOV) documentation package for your
NOV equipment. Along with a description of the equipment, the service manual contains
information for the installation, operation, maintenance, and troubleshooting of the equipment.
Intended Audience
This manual is intended for use by field engineering as well as installation, operation, and
maintenance personnel. The procedures within this manual should never be performed by
untrained individuals.
Reference: For more information about training, see the Safety Requirements section (in this
chapter).
Disclaimer
While every reasonable effort has been made to ensure the accuracy of the information contained
herein, NOV makes no representations or warranties as to the accuracy or completeness of the
information. NOV reserves the right to revise this manual at any time without the obligation to notify
any person or organization.
NOV shall not be liable for any damages arising from the use of this manual. It is the responsibility
of the owner/operator to ensure safe usage and operation of the equipment. All operators must be
properly trained before they handle or operate the equipment.
The illustrations in this manual may not be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.
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General Information
Conventions
This section of the chapter describes the service manual conventions.
Advisories
The graphical symbols within this manual indicate advisories that provide the user (intended
audience) with additional information about a topic or inform the user of the potential or definite
risks to personnel or equipment and the necessary action the user should or should not take to
avoid the risks. The following lists the symbols and an explanation of each:
Note
The note symbol indicates details or additional information that may be useful
for better understanding the related topic.
Caution
This symbol indicates a potential risk of injury to personnel or damage to

equipment. Failure to follow instructions explicitly and use extreme care when
performing operations and procedures could result in injury to personnel,
damage to equipment, or rig downtime.
Warning
WARNING
The warning symbol indicates a definite risk of equipment
damage or danger to personnel. Failure to follow safe work
procedures could result in serious or fatal injury to
personnel, significant equipment damage, or extended rig
down time.
Hot Surface
This symbol indicates the presence of a potentially hot surface or component.
Failure to allow the hot surface or component to cool before touching it could
result in bodily injury.
Pinch Point
The pinch point symbol indicates the potential for part of the body becoming
caught or pinched between two objects. Failure to avoid pinch point areas
while the equipment is operating or use extreme care around the pinch points
could result in serious or fatal bodily injury.
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General Information
Conventions
Advisories
Electrostatic Discharge
This symbol indicates the potential for electrostatic discharge (ESD). Always
remove static electricity prior to working on ESD sensitive components or in
flammable environments. Failure to do so could result in ESD:
Damaging or destroying sensitive electronic components
Setting off explosions or fires in flammable environments
E-Stop
E-Stop symbol indicates that an emergency stop device is present.
Emergency stop (or E-stop) devices are located on the NOV control panel and
may be present at several other areas on NOV equipment. These provide a
method for rapidly disconnecting the energy source from the equipment,
immediately stopping any movement, to protect rig floor personnel.
Illustrations
The illustrations (figures) provide a graphical representation of equipment components or
screenshots for use in identifying parts or establishing nomenclature. These illustrations may not
be drawn to scale.
Reference: For your rig-specific configurations, see the technical drawings included with your NOV
documentation.
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General Information
Safety Requirements
NOV equipment is installed and operated in a controlled drilling-rig environment involving
hazardous situations. Proper maintenance is important for safe and reliable operation. Procedures
in the manuals are the recommended methods for performing installation, operations,
maintenance, and troubleshooting.
To avoid injury to personnel or damage to equipment, carefully observe the

requirements outlined in this section.
Proper Use
NOV equipment is designed for specific functions and applications and, therefore, should be used
only for its intended purposes.
Safe Lifting
Operators and maintenance personnel should be properly trained in safe lifting procedures and in
the inspection of material handling equipment and lifting components. When lifting and handling
NOV equipment or components, always:
Follow all federal, state, and local rules, industry and company standards, and rig-specific safety
guidelines.
Use approved safe lifting procedures and safe methods.
NOV recommends using the supplied 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 or shipping skid is
rated for, nor intended to support the full weight of the iron roughneck.
Before beginning, make sure the shackles are secure and that slings are rated
for the appropriate weight.
WARNING
Lifting equipment improperly creates a hazardous working
environment. To avoid lifting hazards, lift equipment only
with material handling equipment rated for the expected
load and from the designated lift points. Failure to follow
safe lifting guidelines may result in serious or fatal injury to
personnel, significant damage to equipment, and extended
rig downtime.
Safe lifting recommendations provided in this manual do not take precedence
over local safety rules and regulations, OSHA regulations, or instructions issued
by the manufacturers of rig hoisting equipment and other tools on the rig.
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Safety Requirements
General Information
Personnel Training
To ensure their safety, all personnel performing installation, operations, maintenance, or repair
procedures on or in the vicinity of the equipment should be trained in rig safety and equipment
operation and maintenance. This tool should not be used by untrained personnel.
This manual is and should be treated as part of the equipment. As such, the
manual should be passed on to subsequent users.
Reference: For more information about personnel training, contact the NOV training department.
Recommended Tools
When an operation requires a specific tool recommended by the manufacturer, the use of that tool
should be enforced, and the tool should be used in a manner that:
Follows the procedures for the operation
Safeguards personnel and equipment
Operational Environment
The operator of the ST-100 should never enter the red zone of the other equipment. If the operator
inadvertently enters the red zone of other equipment, work should cease and the operator should
evacuate to a safe location until the conflict of red zones has been cleared.
Additionally, it is the responsibility of the owner to create procedures, rig layouts or any other
required documentation to ensure the operator of the ST-100 does not enter the red zone of other
equipment.
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Safety Requirements
General Information
Safe Equipment Operation

WARNING
Make sure that all personnel are clear of the equipment
operating path before operating or restarting the
equipment. If the tool moves unexpectedly, shut down
the equipment and lock out hydraulics immediately.
Inspect equipment for damage. Failure to adhere to
this precaution may result in severe injury.
WARNING
Under no circumstances should anyone place their
hands or limbs in any part of the iron roughneck red zone
while the equipment is enabled or operating. Failure to
adhere to this precaution may result in severe injury.
WARNING
Replace damaged or worn guards. Do not operate the
tool with guards that are damaged.
General System Safety Practices

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

maintenance, read and follow these guidelines to avoid endangering exposed
persons or damaging the equipment:
Isolate energy sources before beginning work.
Avoid performing maintenance or repairs while the equipment is in
operation.
Wear proper protective equipment during equipment installation,
operations, maintenance, and repair.
Replacing Components
When replacing components:
Verify that components such as cables and hoses are tagged and labeled during assembly and
disassembly of equipment to ensure correct installment.
Replace failed or damaged components with original manufacturer-certified components.
Failure to replace failed or damaged components could result in injury to

personnel or damage to equipment.
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General Information
Counter Balance Valve

The Counter Balance (CB) valves are load-holding devices.
WARNING
If adjusted, the load can possibly fall. Prior to adjusting the
CB valves, ensure the load is in safe condition and all
personnel are aware of the potential outcome.
If the CB is removed while a load is suspended, the valve
could be projected at high speeds. Failure to ensure the
load is safe could result in injury to personnel or damage
to equipment.
Routine Maintenance
Equipment must be routinely maintained.
Failure to conduct routine maintenance could result in injury to personnel or

damage to equipment.
Equipment Documentation Location

The User Manual provided with the equipment order contains this service manual, the engineering
installation and commissioning procedures, the Technical Drawing Package (TDP), along with
specifications, parts lists, and other instructions. These documents must be used by the
installation and commissioning crew, equipment operators, and maintenance personnel. Make
sure an equipment User Manual is available in the location where the equipment is being installed,
commissioned, operated, and maintained.
Equipment Disposal
The equipment owner is responsible for disassembling and removing the equipment at the end of
the equipments useful operating life. It is also the equipment owners responsibility to conform to
applicable regulatory policies and standards, as well as recycling guidelines, when removing the
equipment and when disassembling equipment components and disposing of fluids and
consumable spare parts after scheduled and unscheduled equipment maintenance.
Service Centers
For a directory of NOV service centers, see Service Center Directory, document number
D811001337-DAS-001 in the NOV documentation package.
This link provides after-hours and 24-hour contact information for emergencies or equipment
issues requiring an immediate response from NOV service personnel:
www.nov.com/contact_us/24hr_EmergencyList.asp.
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General Information
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Description
Introduction to the ST-100 Iron Roughneck

The ST-100 Iron Roughneck is a drill floor tool used to make up and break out drill string
connections. This durable iron roughneck is designed for use on both offshore rigs and land-based
rigs. It allows clearance around well center and the mousehole when in standby and parked
positions. It can also be controlled manually or remotely, depending on the equipment option
ordered. Other equipment options include an extend and retract scissor-arm system that can
deploy to 5 feet (ft) (1.5 meters [m]) or 8 ft (2.5 m).
This manual provides basic operation and maintenance information for the ST100 Iron Roughneck. Rig personnel must be thoroughly trained and familiar
with this iron roughneck before operating and maintaining this or any
associated equipment.
Overview
The ST-100 Iron Roughneck can make up or break out drill collar connections from 4 inches to
9-3/4 inches outside tool joint diameter (OD) and handle drill pipe from 3-1/2 inches up to 7 inches
OD. The torque wrench provides up to 100,000 foot-pounds (ft-lb) (135,581 Newton-meters [N-m])
of makeup torque and 120,000 ft-lb (162,698 N-m) of breakout torque. The spin wrench can spin in
and spin out connections at speeds up to 60 rpm while providing up to 3,000 ft-lb (4,067 N-m) of
torque. (Spin speed will vary based on pipe size and flow rate.)
The ST-100 Iron Roughneck is installed with a single, floor-mounted socket base assembly (with
no hanging cable). When not in use, the iron roughneck can be rotated into a parked position.
Always park the iron roughneck when it is not being used.

The ST-100 Iron Roughneck consists of the following components:
Head Assembly Connected to the arm assembly, the head assembly consists of the spin
wrench and torque wrench assemblies. A control console is installed on the front of the head
assembly, if the iron roughneck is equipped with the manual control console option. (See the
section titled "Head Assembly" on page 21.)
Spin Wrench Assembly Consists of rollers that grip the pipe and spin in or spin out
tubular connections. (See the section titled "Spin Wrench Assembly" on page 23.)
Torque Wrench Assembly Supports clamping jaws that make up and break out tubular
connections. (See the section titled "Torque Wrench Assembly" on page 24.)
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Description

Overview
Arm Assembly Supports and provides horizontal travel for the head assembly. The arm
assembly extends and retracts as necessary for accurate positioning of the head assembly at
well center, the mousehole, or in the parked position. (See the section titled "Arm Assembly" on
page 26.)
Column Assembly Provides vertical travel for the iron roughneck. The column assembly is
connected to the floor-mounted socket base assembly. (See the section titled "Column
Assembly" on page 28.)
Hydraulic Assemblies Support all iron roughneck hydraulic functions, such as clamping and
unclamping the torque wrench, moving the carriage assembly up and down the column,
spinning the rollers, and extending and retracting the arms. (See the section titled "Hydraulic
Assemblies" on page 29.)
Electrical Assemblies If equipped with the remote operator control option, the iron
roughneck has an additional I/O J-box, sensors, along with other electrical and hydraulic
components. (See the section titled "Electrical Assemblies (Remote Control Option)" on page
31.)
Socket Base Assembly Provides platform support and rotational travel for the iron
roughneck. The floor-mounted socket base assembly allows the iron roughneck to rotate and
align with the mousehole or well center. (See the section titled "Socket Base Assembly" on page
33.)
Operator Control Assemblies There are multiple operator control options for the ST-100
Iron Roughneck. Manually controlled models have a console installed on the front of the unit, on
either the left or right side. Remotely controlled units include a pedestal-mounted control
console. If the iron roughneck is remotely controlled, the manual control console assembly is not
present. (See the section titled "Operator Control Options" on page 20.)
Figure 2-1 shows the orientation of the ST-100 Iron Roughneck. Figure 2-2 on page 12 shows the
location for major equipment components.
The illustrations in this manual are general in nature and may not show the
exact equipment configuration. Always refer to the Technical Drawing
Package (TDP) for rig-specific information and engineering drawings specific
to the equipment order.
10
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Description
Equipment Orientation
Left
Rear
Head Assembly
Front
The manual control console

model is shown in this illustration.
Front View
Right
Right
Front
Arm Assembly
Column Assembly
Socket Base Assembly
Rear
Rear View
Left
ST1000001
Figure 2-1. Equipment Orientation
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Description
Component Locations
Spin Wrench Manifold
Spin Wrench
Assembly
Torqe Wrench
Main Functions
Manifold
Control Console
Assembly (Option)
Torque Gauge
Head Assembly
Controls
Arm Assembly
Controls
Torque Wrench
Assembly
Front View
Transfer Barrier
Assembly (Option)
Column Assembly
Arm Assembly
Hydraulic Enable
Manifold Assembly
Carriage Lift
Cylinder Assembly
Torque Wrench
Rubber Guard
Rear Guard
(removable)
Rear View
ST1000002
Figure 2-2. Component Locations
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Description
Specifications
Weight
Manually Controlled ST-100
(tool only)
11,500 lb (5,216 kg)
Remotely Controlled ST-100

(tool only)
12,000 lb (5,443 kg)
1,190 lb (540 kg)
Hydraulic Requirements
Operating Pressure
2,500 psi (172 bar)
Minimum Input Pressure
2,500 psi (172 bar)
Maximum Input Pressure
3,000 psi (206 bar)
Minimum Flow Rate
35 gpm (132 lpm)
Maximum Flow Rate
45 gpm (170 lpm)
Inlet Connections
1 inch; supply pressure

11/4 inch; return to tank
1/2 inch; drain
The ST-100 Iron Roughneck has hydraulic fluid in all the lines and the amount
of hydraulic fluid required is up to the customer. It is based on the available
HPU and the amount of equipment it is running.
The quantity of hydraulic fluid required to operate the ST-100 is dependent on
the HPU supply hydraulic power to the tool. The required volume should be
sufficient to fill the reservoir and the supply lines up until they reach the tool.
The hydraulic lines on board the ST-100 are full when the tool ships.
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Specifications
Description
Spin Wrench
Speed (5-inch OD tubular)
60 rpm at 35 gpm (132 lpm)

80 rpm at 45 gpm (170 lpm)
Torque (5-inch OD tubular)
3,000 ft-lb (4,067 N-m)
Pipe Range
3 1/2" to 9 3/4" (tubular diameter)
Torque Wrench
Makeup Torque
100,000 ft-lb (135,582 N-m)
Breakout Torque
120,000 ft-lb (162,698 N-m)
Connection Range
4" to 9 3/4" (tool joint diameter) *
* See page (page 24) for further information.
Electrical Requirements (Remote Control Option

Only)
Power (stand-alone
equipment)
230 VAC, 20 Amps
Cables (integrated equipment)
Fiber cable for communication

7-conductor E-Stop cable
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Description
Specifications
Equipment Operating Dimensions

Rear Guard
removable
Top View
Fully Retracted
Center of
Rotation
Optional Manual
Control Console
alternate mounting
location
Front Slew Radius
42.6 in (1082 mm)
55 in
(1397 mm)
Optional Manual
Control Console
standard mounting
location
18.1 in
(460 mm)
Rear Slew Radius
31.6 in (803 mm) w/guard
29.1 in (739 mm) no guard
30.3 in
(770 mm)
For Reference Only. Refer to the General

Arrangement drawing in the TDP for rig-specific
equipment operating dimensions and space
considerations.
57.1 in
(1450 mm)
134.6 in
(3419 mm)
Raised (max)
Front View
98.6 in
(2504 mm)
Lowered (min)
Connection
Height
66.4 in
(1687 mm)
Raised (max)
48.6 in
(1234 mm)
Raised (max)
Rig Floor
Side View
Raised/Lowered
12.6 in
(320 mm)
Lowered (min)
Rig Floor
30.4 in
(772 mm)
Lowered (min)
Socket Base
Assembly
ST1000003
Figure 2-3. Equipment Operating Dimensions (1 of 2)
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Specifications
Description
Equipment Operating Dimensions
Console Swivel Radius

17.18 in (436 mm)
126.2 in
(3205 mm)
Fully Extended
30.2 in
(767 mm)
Fully Retracted
18.4 in
(467 mm)
3.50 in
Pipe Connection
9.75 in
Pipe Connection
Top View
Fully Extended
Slew Radius
(extended)
135.5 in (3442 mm)
Center of
Rotation
For Reference Only. Refer to the General

Arrangement drawing in the TDP for rig-specific
equipment operating dimensions and space
considerations.
133.5 in
(3391 mm)
Raised (max)
92.8 in
(2357 mm)
Raised (max)
95.5 in
(2426 mm)
Lowered (min)
56.8 in
(1443 mm)
Lowered (min)
Rig Floor
50.2 in
(1275 mm)
Raised (max)
Side View
14.2 in
(361 mm)
Lowered (min)
Socket Base
Assembly
ST1000004
Figure 2-4. Equipment Operating Dimensions (2 of 2)
16
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Description
Nameplate and Warning Plaques

Figure 2-5 shows the equipment nameplate and examples of warning plaques fastened to the
equipment. These plaques identify hazards and must be cleaned or replaced if they become worn,
dirty, or otherwise illegible.
Equipment Nameplate
(P/N M364001411)
Hot Surface Hazard
Warning Plaque
(P/N M364000292)
Pinching Hazard
Warning Plaque
(P/N 30170758)
WARNING
If an equipment plaque is worn,

dirty, or otherwise illegible, clean it
or order a new plaque. Failure to
adhere to this warning could result
in severe injury to rig personnel.
ST1000054
Figure 2-5. Equipment Nameplate and Warning Plaques

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Description
Equipment Pinching Hazard Locations

Pinch points exist in certain locations on the iron roughneck. In these
locations, part of the body can be caught between moving parts of the
equipment, between the moving and stationary parts of the equipment, or
between material being handled and part of the equipment. Take extreme
care around pinch points. Avoid these areas while the equipment is operating.
WARNING
In addition to pinch points, the potential exists to be caught
between the iron roughneck and the rig structure or other
equipment. Other than the operator, make sure to keep all
personnel away from the equipment when it is operating,
moving to standby, or rotating to a parked position. Refer
to the General Arrangement drawing in the TDP to identify
all areas of motion for the iron roughneck. Failure to
adhere to this warning could result in serious injury or
death.
Figure 2-6 shows the locations for pinch points on the ST-100 Iron Roughneck.
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Equipment Pinching Hazard Locations
Take extreme care around equipment

pinch points. Avoid these areas while
the equipment is operating.
Description

ST1000014
Figure 2-6. Equipment Pinch Points
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Description
Operator Control Options

The ST-100 Iron Roughneck is available with either manual or remote control.
Manual Control
The manual control console is mounted on the front of the iron roughneck (on either the left or right
side). Figure 2-2 on page 12 shows the console location on the iron roughneck.
The console can pivot out to 90 for better control panel access. The console provides separate
joystick controls for the arm and head assemblies. Each joystick control provides pilot pressure to
the hydraulic valves on the unit. When actuated, these valves support all iron roughneck functions.
Figure 2-15 on page 34 shows manual control console.
Refer to Chapter 4, titled "Operation" for additional operator control information.
Remote Control
A remote control console is mounted on a pedestal away from the iron roughneck (Figure 2-16). A
derrick J-box umbilical cable connects the iron roughneck to the control console. Buttons and
joysticks on the remote console send electrical signals to actuate hydraulic valves on the unit. This
stand-alone system is not integrated into the Amphion multi-tool controller system, if used.
In the event of a control system or electrical failure, emergency controls on the
iron roughneck can be used to release the torque wrench, retract the arms,
and rotate the unit into the parked position. For additional information, refer to
the section titled "Electrical Failure Operation" on page 79.
Figure 2-16 on page 35 shows the pedestal-mounted remote control console.
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Description
Major Components
The following assemblies and components make up the ST-100 Iron Roughneck:
Head Assembly
Spin Wrench Assembly
Torque Wrench Assembly
Arm Assembly
Column Assembly
Primary Hydraulic Manifold Assemblies
Torque Wrench Main Functions Manifold Assembly
Spin Wrench Manifold Assembly
Arm Functions Manifold Assembly
Hydraulic Enable Manifold Assembly
Transfer Barrier Assembly (manual option)
Electrical Assemblies (remote option)
Operator Control Assemblies
The following sections show each of these ST-100 Iron Roughneck assemblies and components.
Many of the illustrations shown in this manual are general in nature. Refer to
the engineering drawings included in the TDP for rig-specific information
about the equipment order.
The NOV components are constantly being improved and their design may
change over time. Make sure to refer to the TDP for current engineering
drawings and component details.
Head Assembly
The ST-100 Iron Roughneck head assembly consists of the spin wrench and torque wrench
assemblies. The head assembly provides backup and torque capability for making up and
breaking out pipe connections, along with spinning in and spinning out connections.
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Major Components
Description
The head assembly attaches to a scissor-arm assembly that provides horizontal travel, allowing
the head to be aligned with well center or the mousehole. A control console is installed on the front
of the head assembly, if the iron roughneck is equipped with the manual control console option.
Spin Wrench
Manifold

pinch points. Avoid these areas while the
equipment is operating.
Spin Wrench
Assembly
Torque Wrench
Main Functions
Manifold
Torque Wrench
Assembly
ST1000005
Figure 2-7. Head Assembly
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Description
Major Components
Head Assembly
Spin Wrench Assembly

The spin wrench assembly has four drive rollers. Each roller is powered by a direct-drive hydraulic
motor. The spin wrench supports 3-1/2 inch OD drill pipe up to 9-3/4 inch OD drill collars, with no
adjustments. Its floating-mount design compensates for minor pipe misalignment.
The spin speed can be reduced when working with drill collars (remote control option). When
operating manually, the proportional spin wrench control can be feathered to spin at a lower spin
speed.
Hydraulic Motor (4)
WARNING
Objects can get caught in the rollers.

Make sure that tools, clothing, or personal
equipment do not contact the rollers during
operation. These objects can get tangled in
the rollers and cause serious injury and/or
equipment damage.
Drive Roller (4)
Hydraulic Manifold
Front View
Clamp Cylinder
Pinching Hazard. Make sure hydraulic power

is OFF to the ST-100 before touching or getting
near the spin wrench for maintenance and
repairs.
Rear View
Rollers become hot when operating. Make

sure to allow rollers to cool off before touching
them or getting near the equipment for
maintenance and repairs.
ST1000006
Figure 2-8. Spin Wrench Assembly
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Description
Major Components
Head Assembly

The ST-100 Iron Roughneck torque wrench assembly is an open-throat design, eliminating all
gates and latches. It consists of upper and lower clamping jaws that provide a maximum of
100,000 ft-lb (135,582 N-m) of makeup torque and 120,000 ft-lb (162,698 N-m) of breakout torque.
There are four hydraulic cylinders used in the torque wrench assembly:
A torque cylinder is mounted on each side of the assembly. These two torque cylinders are
attached at the front and back of the upper and lower clamping jaws. The cylinders turn the
upper jaws to make up or break out the connection.
Upper and lower clamp cylinders are mounted at the rear of the assembly. These two clamp
cylinders provide the clamping force for the upper and lower jaws.
When the two clamp cylinders actuate, the upper and lower jaws close and grip the connection.
With the lower jaws gripping the pipe, the torque cylinders actuate. Torque cylinder actuation
causes rotary motion of the upper jaw, turning the tool joint in one direction or the other, making up
or breaking out the connection.
Die assemblies are bolted to each clamping jaw. These consist of easily removable tong dies and
die retainers. The die retainers must be swapped out if the pipe is changed and the tool joint
diameter falls outside of the range for the dies installed. All four (4) die assemblies must be a
matched set on the torque wrench.
The following ranges apply to the tool joint diameter that the torque wrench clamps on:
5-1/2 to 9-3/4 (140 mm to 248 mm) tool joint diameter Die set for large diameter tool joint (P/
N 86711-1 supplied)
4 to 6 (102 mm to 152 mm) tool joint diameter Die set for small diameter tool joint (P/N
86711-2 supplied)
Adjust tool joint spacer as shown in Figure 5-11 on page 101
The two die sets supplied with the equipment support the full range of pipe
sizes that can be used with this iron roughneck. Do not use dies
interchangeably.
Figure 2-9 shows the torque wrench assembly.
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Description
Major Components
Head Assembly

Tong Die and Die Retainer (2)
Upper Jaws
Top View
Front View
Torque Cylinder (2)
86711-1
Roughly Flush
Tong Die and Die Retainer (2)

Lower Jaws
Pinching Hazard. Make sure hydraulic power
is OFF to the ST-100 before touching or getting
near the torque wrench for maintenance and
repairs.
Clamp Cylinder (2)
86711-2
Roughly 1 Proud
ST1000007
Figure 2-9. Torque Wrench Assembly
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Description
Major Components
Arm Assembly
The arm assembly supports and provides horizontal travel for the head assembly. The scissorarms extend and retract the head assembly to well center, to mousehole, and can then fully retract
to bring the head back to the home (parked) position. The arms extend and retract at about one
foot per second.
The well center and mousehole positions are set by the operator. Refer to the following sections for
further information about positioning the equipment.
Manually Controlled See the section titled "Positioning and Adjusting the Iron Roughneck" on
page 48 for instructions.
Remotely Controlled See the section titled "Adjusting Arm Assembly Target Positions" on
page 64 for instructions.
Figure 2-10 shows the arm assembly along with its primary components.
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Description
Major Components
Arm Assembly
Arm Functions
Manifold Assembly
Transfer Barrier
Assembly (option)
Hydraulic Enable
Manifold Assembly
Front
Arm Extend/Retract
Cylinder Assembly (2)
Hydraulic E-Stop
Lanyard (2)
ST1000008
Figure 2-10. Arm Assembly
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Major Components
Description
Column Assembly
The column assembly provides vertical travel for the iron roughneck. Vertical movement allows the
iron roughneck to be positioned at different heights for makeup or breakout operations. The
column assembly is connected to the floor-mounted socket base assembly.
Column Assembly
Carriage Lift
Cylinder Assembly
Carriage Assembly
Hydraulic Supply
Shutoff Lever
Rear
ST1000009
Figure 2-11. Column Assembly
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Major Components
Description
Hydraulic Assemblies
The ST-100 Iron Roughneck hydraulic assemblies support all iron roughneck hydraulic functions,
such as clamping and unclamping the torque wrench, moving the carriage assembly up and down
the column, spinning the rollers, and extending and retracting the arms.
One of these hydraulic assemblies, the Transfer Barrier Cylinder, is used in manually controlled
iron roughnecks to preset a deploy travel limit for the arm assembly. This allows the iron roughneck
to be deployed completely, without the operator having to make further travel adjustments once the
head gets close to well center. Once iron roughneck operations are complete, this component also
allows the unit to be fully retracted to the standby position, instead of being held at a partially
deployed position. (Remotely controlled iron roughnecks use proximity sensors to achieve these
results.)
Refer to the section titled "Specifications" on page 13 for hydraulic requirements.
The following assemblies are shown in Figure 2-12:
Main Functions Manifold
Torque Wrench Manifold
Torque Wrench Cylinders
Spin Wrench Manifold
Arm Functions Manifold
Arm Extend/Retract Cylinders
Hydraulic Enable Manifold
Transfer Barrier Cylinder (manual option)
Torque Cylinders
The pilot manifold used on remotely controlled iron roughneck models is shown in Figure 2-13 on
page 32. The slew manifold is on the socket base assembly and is shown in Figure 2-14 on page
33.
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Major Components
Description
Hydraulic Assemblies
Transfer Barrier
Cylinder (option)
Torque Wrench
Manifold
Main Functions
Manifold
Arm Functions
Manifold
Spin Wrench
Manifold
Drain
Shutoff Valve Handle
Pressure
Front
Hydraulic Filter
Tank
System
Pressure Gauge
Hydraulic Enable
Manifold Assembly
ST1000010
Figure 2-12. Hydraulic Assemblies
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Major Components
Description
Electrical Assemblies (Remote Control Option)

The following electrical devices are installed only on remotely controlled ST-100 Iron Roughnecks.
Refer to Chapter 4, titled "Electrical Interlocks" for interlocks associated with these devices.
Extend/Retract Proximity Sensors (3)
Home Proximity Sensor Provides feedback to the control system that the
ST-100 arm is in the home position when this sensor detects its target.
Position 1/Position 2 Proximity Sensor Provides feedback to the control system that
the ST-100 arm has reached the kickdown position when this sensor detects its target. This
feature slows down arm deployment as the unit nears the pipe. The ST-100 is equipped
with a kickdown sensor for the well center and mousehole position (see page 64 for setup
procedure).
Position feedback from these sensors can also be sent to the Zone Management System
(ZMS), if the iron roughneck is part of an integrated ZMS-enabled NOV control system.
Carriage Up/Down Proximity Sensor Provides position feedback for vertical arm position
once the arm has reached a pre-defined height. (May also be used with a ZMS-enabled control
system.) The light on the back of sensor will turn on when a target is detected.
Non-driven Motion Pressure Transducer Provides feedback for non-driven motion, by
monitoring the pressure inside the carriage lift cylinder.
Slew Proximity Sensors (2) Provide position feedback once slewing has reached the well
center or mousehole positions. The ST-100 must be slewed to one of these positions and sensor
must detect its target, before the unit can be operated. Slew position is adjustable. The proximity
device senses the slew stops mounted on the drill floor and determines the position based on
which sensor is activated. The light on the back of the sensor will turn on when a target is
detected.
Torque Pressure Transducer Provides pressure feedback for applied torque
(0 to 3,000 psi [207 bar]).
System Pressure Transducer Provides pressure feedback for system pressure (0 to 3,000
psi [207 bar]).
Torque Wrench Proximity Sensor (1) Provides makeup and breakout
end-of-stroke feedback for the upper torque wrench.
Pipe Detection Sensor Provides feedback when a pipe is detected.
Object Detection Diffuse Sensors (2) Provides feedback if an object is in the collapse zone
of the arm. Triggering this sensor shuts down all functions.
Figure 2-13 shows several of the sensors used on the remotely controlled iron roughneck
Refer to the engineering drawings in the TDP for the locations of all electrical
components used on the remotely controlled ST-100 Iron Roughneck.
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Major Components
Description
Electrical Assemblies (Remote Control Option)
Extend/Retract
Proximity Sensors
I/O J-Box
Hazardous Area
Beacon/Strobe Light
Object Detection
Diffuse Sensor
Assembly (2)
Equipment
E-Stop Buttons
Carriage Up/Down
Proximity Sensor
Carriage Up/Down
Proximity Sensor
Target
Pilot Manifold
Assembly
Torque Wrench
Proximity Sensor
Front
Pipe Detection Sensor
Slew Proximity
Sensor (2)
ST1000011
Figure 2-13. Electrical Assemblies (Remote Control Option)
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Description
Major Components

The ST-100 Iron Roughneck is installed on the drill floor using a single, floor-mounted socket. The
socket base assembly enables the iron roughneck to be rotated and aligned with well center or the
mousehole.
Hydraulic Motor
with Brake (2)
Motor Guard
Column
Connecting Pin (2)
Drain
Tank
Pressure
Floor Socket
included with the
shipping package
Slew Manifold
Assembly
Rear
Socket Flange
ST1000012
Figure 2-14. Socket Base Assembly
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Major Components
Description

Manual Control Console
System Pressure
Gauge
Torque Adjustment
Knob
Valve Body
Hydraulic Enable
Hydraulic E-Stop
Head Assembly
Controls
Arm Assembly
Controls
Hydraulic
Connections
Access Panel
Rear
Front
UNCLAMP
TW
CLAMP
BREAK
TW
MAKE
OUT
SW
IN
SW MODE
UNCLAMP
SW
CLAMP
Head Assembly Functions
UP
CARRIAGE
DOWN
RETRACT
DEPLOY
EXTEND
CW
SLEW
CCW
RETRACT
ADJUST
EXTEND
Arm Assembly Functions

ST1000013
Figure 2-15. Manual Control Console
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Description
Major Components
Pedestal-Mounted Remote Control Console
ST1000027
Figure 2-16. Pedestal-Mounted Remote Control Console
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Description
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Installation
Transporting the Iron Roughneck

When transporting the iron roughneck, make sure the equipment remains vertical and stable.
Always transport the iron roughneck secured to the shipping skid to increase equipment stability.
See section titled "Removing and Installing the Shipping Skid" on page 37 for additional
information about the shipping skid.
Always keep the iron roughneck in an upright position. Never place the iron
roughneck on its side or back. Placing the iron roughneck on its side or back
will damage the equipment.
Drill Floor Position Recommendations

For optimum equipment performance, the ST-100 Iron Roughneck should be positioned as follows:
8-foot arm model Position the equipment at a minimum of 89 inches (226 cm) and a
maximum of 122 inches (310 cm) away from well center and the mousehole.
5-foot arm model Position the equipment at a minimum of 71 inches (183 cm) and a
maximum of 89 inches (226 cm) away from well center and the mousehole.
The iron roughneck must be secured to the rig floor and the supporting structure should be able to
support the weight and overturning moment of the equipment. Refer to the section titled
"Specifications" on page 13 and the General Arrangement engineering drawing in the Technical
Drawing Package (TDP) for dimensions, weights, rig-floor loading, and rig-floor layout drawings.
Removing and Installing the Shipping Skid

NOV recommends using the supplied 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 or shipping
skid is rated for, nor intended to support the full weight of the iron
roughneck. Before beginning, make sure the shackles are secure and that
slings are rated for the appropriate weight.
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Installation
Removal
1. Using the two lifting shackles and the supplied sling, hoist the iron roughneck slightly so the
weight is off the shipping skid.
2. Remove the front and rear shipping pins.
3. Hoist the iron roughneck away from the shipping skid and move it to its operating location.
4. Remove the storage pin when the iron roughneck is ready for operation.
5. Place the shipping skid and all pins in storage.
Make sure to remove the storage pin before operating the iron roughneck.
Installation
1. Fully retract the iron roughneck and disconnect all hydraulic lines connecting the column to the
socket base assembly.
2. Install the storage pin.
3. Place the shipping skid on a hard and level surface.
4. Attach the supplied sling to the two lifting shackles.
5. Remove the two column connecting pins connecting the column to the socket base assembly
(see Figure 2-14 on page 33).
6. Hoist and center the iron roughneck over the shipping skid.
a. Align the iron roughneck rear column base support with the rear supports on the
shipping skid.
b. Align the bottom of the torque wrench base plate with the front supports on the shipping
skid.
7. Insert the front and rear shipping pins (and cotter pins) securing the iron roughneck.
8. Using the supplied sling, hoist and move the iron roughneck to the proper location.
9. Place wood blocks between spin wrench and torque wrench.
10.Using ratchet strap supplied in shipping kit to secure spin wrench so it does not shift while
transporting.
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Installation
Lifting Shackle
Lifting Shackle
Storage Pin
Rear Shipping Pin
Shipping Skid
Front Shipping Pin
ST1000025
Figure 3-1. Shipping Skid
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Installation
Installation and Commissioning

Procedures
Engineering installation and commissioning procedures are developed for each ST-100 Iron
Roughneck configuration. These installation and commissioning procedures are included in the
equipment User Manual. Refer to the Installation Procedure, ST-100 or the Installation Procedure,
ST-100 Remote for rig-specific installation information.
40
The User Manual provided with the equipment order contains this service
manual, the engineering installation and commissioning procedures, the
Technical Drawing Package (TDP), along with specifications, parts lists, and
other instructions. These documents must be used by the installation and
commissioning crew, equipment operators, and maintenance personnel.
Make sure an equipment User Manual is available in the location where the
equipment is being installed, commissioned, operated, and maintained.
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Installation
Storing the Iron Roughneck

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

Before placing the iron roughneck back into service, the following tasks should be completed and
verified:
Remove all rust preventative and any corrosion, taking special care with all load-carrying
components.
Blow out all dust and dirt from equipment as required with clean, dry air.
A complete system test and adjustment should be performed as detailed in the ST-100 Iron
Roughneck Commissioning Procedure.
Equipment Disposal
The equipment owner is responsible for removing and dismantling the equipment at the end of the
equipments useful operating life. It is also the equipment owners responsibility to conform to all
applicable regulatory policies, standards, and recycling guidelines when removing the equipment,
dismantling equipment components, disposing of fluids, and disposing of consumable spare parts
after periodic maintenance.
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Installation
Leveling the Head Assembly

The ST-100 head level can be adjusted. Ensure the head assembly for the iron roughneck is level
to the drill floor. If the head needs to be adjusted forward or backward, remove the leveling cam
retention bolt (see Figure 3-2). With the bolt removed, tilt the head assembly forward or backward
until it is level. Once the head assembly is level, rotate the leveling cam until it is tangent with head
frame. Reinsert the retaining bolt, and ensure the leveling cam on the other side of the unit is
rotated the same amount.
Head
Assembly
Leveling Cam
Retention Bolt
Use an adjustable wrench to remove the

leveling bolt. Bolt cannot be removed by
hand.
Leveling Cam
ST1000057
Figure 3-2. Leveling The Head Assembly
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Operation
Introduction
There are two operator interface methods typically used to control the ST-100 Iron Roughneck.
Refer to the section titled "Manual Control Console Operation" on page 47 for operating instructions.
Pedestal-Mounted Remote Control Console
Refer to the section titled "Pedestal-Mounted Control Console" on page 55 for operating instructions.
This chapter provides basic operating information for the ST-100 Iron
Roughneck. Rig personnel must understand the information provided in this
chapter and be thoroughly trained before operating this equipment.
Operating Considerations
Please make note of the following before operating the iron roughneck.
Precautions
WARNING
Identify all emergency stops (E-Stops) on the various iron
roughneck models (see page 53 or page 66) and
understand how to operate them. Failure to adhere to this
precaution may result in severe injury or death.
WARNING
Make sure that all personnel are clear of the equipment
operating path before operating or restarting the
equipment. If the tool moves unexpectedly, shut down the
equipment and lock out hydraulics immediately. Inspect
equipment for damage. Failure to adhere to this precaution
may result in severe injury.
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Operation
Precautions
WARNING
Under no circumstances should anyone place their hands
or limbs in any part of the iron roughneck while the
equipment is enabled or operating. Failure to adhere to this
precaution may result in severe injury.
E-Stop tool in the event if any unsafe condition occurs or if the ST-100 Iron
Roughneck does something unexpected.
44
An iron roughneck, top drive, and pipe racking system may reach unsafe
noise levels when operating together on the rig floor. Always use hearing
protection when operating the iron roughneck during normal drilling
operations.
Shut down the equipment when it is not being used.
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Operation
ST-100 Quick Reference

Information on this page is supplied to be a quick reference and does not replace the need for the
operator to read and understand this manual in its entirety. The subsequent sections of this
manual discuss these topics in much greater detail and must be read and understood before the
equipment is operated.
Dos
Donts
Actuate E-Stop (hydraulic or electronic) if the

equipment exhibits any abnormal behavior, and
investigate the cause. Take care when restarting
equipment after E-Stop.
Read and understand this manual before
operating the ST-100.
Shut down equipment when not in use.
Ensure storage pin is removed before operation.
Ensure tool joint diameter is tangent to the
throat of the torque wrench before clamping.
Ensure the torque wrench and spin wrench are
fully open before extending/retracting to/from
pipe.
Ensure arm adjustment procedures are
followed.
Ensure replacement parts are OEM parts.
Perform scheduled maintenance and inspection
per guidelines in this manual.
Ensure ST-100 torque is set properly for desired
connection make up torque.
Check warning plaques and ensure they are
legible. Replace if necessary.
Do not operate equipment when personnel are

in the path of the equipment.
Do not place hand or limbs in the iron roughneck
while the equipment is enabled or operating.
Do not clamp toque wrench dies on hard
banding.
Do not use ST-100 as a backup device for the
Top Drive, Rotary Table, or any external torque
device.
Do not reuse Nord-Lock washers.
Do not perform maintenance unless hydraulic
power is completely removed and locked from
the ST-100.
Do not perform maintenance unless the arm has
been locked by installing the maintenance pins.
Do not use die assemblies that are not sized for
the tubular being used.
Do not interchange die assemblies. All die
assemblies on the torque wrench should match.
Do not operate spin wrench on spiral collars or
any non circular tubular.
Do not clamp spin wrench on stabilizers or
bottom hole assembly tools.
Do not modify the tool in any way.
Pre-Operation Checks
Make sure the iron roughneck is secure in the floor socket.
Make sure the storage pin is removed.
Make sure all quick-disconnect couplings (QDs) are fully engaged.
Make sure operating pressures are correct.
Check all fittings for leaks.
Lubricate the entire iron roughneck and check the condition of the filter. Refer to Chapter 5 for
lubrication and filter replacement procedures. Refer to Recommended Lubricants and Fluids
(D811000719) in the equipment User Manual for recommended lubricants and hydraulic fluids.
For remotely controlled iron roughnecks, verify that all control cables are properly connected to
the I/O J-box and remote control console.
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Operation
Normal Sounds
The following may occur during normal operation:
Humming When the iron roughneck slews there may be a humming sound coming from the
slewing system.
Whooshing When the arm is extending or retracting, the transfer barrier may make a
whooshing noise.Operating Considerations
Normal Occurrences
The following may occur during normal operation:
When going to the full makeup position, the torque gauge will drop to zero.
When other functions are operating, the spin rollers may rotate very slowly.
When operating on angled mouseholes, the head assembly will pivot once the torque wrench
jaws clamp on the pipe.
Component motion that may occur when operating other functions is due to
high return pressure.
Manual Control Lever Operation

Manually controlled iron roughnecks are controlled via proportionally controlled hydraulic valves.
Based on the manner in which the joysticks are operated, iron roughneck functions can occur
gradually or abruptly.
Arm assembly control levers must be worked carefully when extending and retracting the arms for
this feature to work properly. Immediately pushing or pulling a lever all the way to the stop will
result in the arms immediately extending or retracting at full speed. Pushing or pulling the lever
gradually will result in smooth and controlled equipment operation.
To take advantage of the ramped-up start velocity feature for manually
controlled iron roughnecks, move the arm assembly control levers gradually to
the full deploy position when extending/retracting the arms near the extension/
retraction limits.
Manual Operation Verification

Make sure the following are verified before beginning the manual breakout or makeup operations
described in the following sections:
The iron roughneck is fully retracted and the carriage is in its lowest position.
The required makeup torque has been set (see the section titled "Setting and Adjusting Makeup
Torque" on page 50).
The arm extension has been set (see the section titled "Positioning and Adjusting the Iron
Roughneck" on page 48).
The torque wrench jaws and the spin wrench are fully opened.
The tool is properly aligned with the drill pipe connection at well center using the slew function.
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Operation
Manual Control Console Operation

This section provides manual operating instructions for the ST-100 Iron Roughneck.
UNCLAMP
TW
CLAMP
BREAK
TW
MAKE
OUT
SW
IN
SW MODE
UNCLAMP
SW
CLAMP
Head Assembly Controls
UP
CARRIAGE
DOWN
RETRACT
DEPLOY
EXTEND
CW
SLEW
CCW
RETRACT
ADJUST
EXTEND
Arm Assembly Controls

ST1000015
Figure 4-1. Manual Control Console
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Operation
Positioning and Adjusting the Iron Roughneck
!
Before operating the ST-100 Iron
Roughneck for the first time, make
sure to remove the storage pin
and place it in a secure location.
Do not operate the iron roughneck
with the storage pin installed.
This procedure only needs to be

completed when changing to a new
destination or changing pipe sizes.
After adjustment is complete, the
arm will extend and stop at the
destination.
Procedure

Arm Assembly Controls
Hold the SLEW lever until the

tool aligns with well center or
the mousehole, as required.
Hold the DEPLOY lever in the
RETRACT position until the arm
deploy cylinder is fully retracted.
Then, hold the ADJUST lever in
the RETRACT position for an
additional 30 seconds. (This
ensures the transfer barrier
piston is fully stroked.)
Left
Hand
Left
Hand
Right
Hand
Right
Hand
UP
CARRIAGE
DOWN
RETRACT
DEPLOY
EXTEND
CW
SLEW
CCW
RETRACT
ADJUST
EXTEND
While holding the ADJUST lever

in the EXTEND position, push
the DEPLOY lever to the
EXTEND position. The arm
deploy cylinder should extend
slowly.
Release the ADJUST lever
when the head reaches well
center. Release the DEPLOY
lever.
!
The drill pipe must be
tangent to the throat of the
torque wrench as shown.
Proper distance from home
to the deployed location will
vary with pipe diameter.
Special attention is necessary if hard

banding is present. Do not grip on
hard banding.

Left
Hand
Right
Hand
Hold the CARRIAGE lever in the

UP or DOWN position to align
the torque wrench vertically with
the drill pipe.
During operation, use the DEPLOY

lever for consistent alignment with
the drill pipe.
ST1000016
Figure 4-2. Positioning and Adjusting the Iron Roughneck
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Operation
Positioning and Adjusting the Iron Roughneck
!
The drill pipe must be
tangent to the throat of the
torque wrench as shown.
Proper distance from home
to the deployed location
will vary with pipe diameter.
Use the controls to center the torque

wrench assembly on the drill pipe.
Die set for small tool joint

4 to 6 diameter
(102 mm to 152 mm)
Pin-End
Connection
Die set for large tool joint

5-1/2 to 9-3/4 diameter
(140 mm to 248 mm)
Upper Die
Assembly (2)
4.0 in
(102 mm)
Box Shoulder
Range
Box-End
Connection
Lower Die
Assembly (2)
ST1000017
Figure 4-3. Positioning the Iron Roughneck
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Operation
Setting and Adjusting Makeup Torque

Torque Adjustment Knob
Torque Gauge
Procedure

If not already completed, position

a tubular (drill pipe or drill collar)
in the throat of the torque wrench
and spin in the connection.
SYSTEM PRESSURE
TORQUE
ADJUSTMENT
TORQUE DISPLAY
HYDRAULIC
ENABLE
Turn the torque adjustment knob

counterclockwise (decreasing
torque) until it stops.
ST-100
HYDRAULIC
E-STOP
Verify that the torque gauge

reads zero.
PUSH TO STOP
Position the reference indicator

(red needle) at the desired
torque value.
UNCLAMP
TW
CLAMP
BREAK
TW
MAKE
OUT
SW
IN
SW MODE
UNCLAMP
SW
CLAMP
Actuate the TW lever in the

BREAK position until it stops.
While holding the TW CLAMP
and TW MAKE levers, turn the
torque adjustment knobs
clockwise until the desired torque
value is set.
UP
CARRIAGE
DOWN
RETRACT
DEPLOY
EXTEND
CW
SLEW
CCW
RETRACT
ADJUST
EXTEND
If the torque cylinders reach end of

stroke during a makeup cycle and the
gauge reads zero, recycle the jaws
and re-torque.
Torque Wrench (TW)

BREAK/MAKE Lever
Breakout torque is applied at system

pressure and is not set or adjusted.

ST1000020
Figure 4-4. Setting and Adjusting Makeup Torque (Manual Models)
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Operation
Making Connections
The arm must be deployed to the pipe

and centered on the connection before
beginning the following procedure.
Refer to the section titled Adjusting

Makeup Torque for information about
setting the correct makeup torque.
Procedure

Hold the SW MODE lever to the

down position and activate TW
lever in CLAMP position until the
lower jaws make contact on the
drill pipe. Release.
Hold the SW lever in the
CLAMP position.
While holding the SW-CLAMP
lever, hold SW lever in the IN
position until the drill pipe
shoulders. Release.
Left
Hand
Right
Hand
Right
Hand
UNCLAMP
TW
CLAMP
BREAK
TW
MAKE
SW MODE
OUT
SW
IN
UNCLAMP
SW
CLAMP

Left
Hand
Right
Hand
Hold the SW lever in the

UNCLAMP position to fully
retract the roller carriers.
Hold the TW lever in the BREAK
position until the upper wrench
is aligned in the READY-MAKE
position. Release.
Hold the TW lever in the CLAMP
position until the upper jaws
make contact with the drill pipe.
While holding TW-CLAMP, move
TW lever to the MAKE position
until the required torque is
reached.

Left
Hand
Right
Hand
Right
Hand
If the wrench does not reach the

required torque value in one stroke,
unclamp and repeat steps 5, 6, and 7.
Hold the TW lever in the

UNCLAMP position to retract
jaws. Release.
ST1000018
Figure 4-5. Making Connections
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Operation
Breaking Connections
The arm must be deployed to the pipe

and centered on the connection before
beginning the following procedure.
Breakout torque requires no adjustment.

Breakout occurs at full system pressure.
Procedure

To place the upper torque

wrench in position for breaking
out a connection, hold the TW
lever in the MAKE position until
the wrench stops rotating. (This
is READY-BREAK.) Release.
Hold the TW lever in CLAMP
position.
Left
Hand
Right
Hand
Left
Hand
Right
Hand
UNCLAMP
TW
CLAMP
BREAK
TW
MAKE
OUT
SW
IN
UNCLAMP
SW
CLAMP
SW MODE
While holding TW-CLAMP, move

the TW lever to BREAK position
until the connection is broken.
Hold the SW MODE lever in the
down position until the upper
jaws retract from the pipe.
Release.
Hold the SW lever in CLAMP
position.
While holding at SW-CLAMP,
move the SW lever to the OUT
position until the connection
spins free. Release.
If the spin wrench will not spin out the

connection, repeat steps 1, 2, and 3.

Right
Hand
Left
Hand
Left
Hand

Right
Hand
Move the SW lever to UNCLAMP

to retract the spin rollers.
Release.
Move the TW lever to the
UNCLAMP position to retract the
clamping jaws. Release.
ST1000019
Figure 4-6. Breaking Connections
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Operation
Emergency Stop (E-Stop)

Stopping the Equipment in an Emergency
System Pressure
Gauge (Console)
Hydraulic Enable
Knob
E-Stop Button
System Pressure
Gauge
(Inlet Manifold)
E-Stop Procedure

Press the E-Stop Button or pull one

of the E-Stop lanyards.
Verify that the System Pressure
Gauge on the console (if equipped)
or on the inlet manifold shows that
hydraulic pressure has been
released from the system.
Hydraulic E-Stop
Lanyard (2)
Clear the emergency stop situation.

ST1000050
Figure 4-7. E-Stop Component Locations (Manual Models)
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Operation
Restarting the Equipment After a Hydraulic E-Stop

Hydraulic Enable
Knob
System Pressure
Gauge
SYSTEM PRESSURE

TORQUE
ADJUSTMENT
TORQUE DISPLAY
Restart Procedure
HYDRAULIC
ENABLE
Verify that the emergency stop

situation has been cleared.
Reset the E-Stop button that was
activated.
ST-100
HYDRAULIC
E-STOP
Turn the Hydraulic Enable Knob

clockwise (increasing system
pressure) until it stops.
Gauge registers system pressure.
PUSH TO STOP
UNCLAMP
TW
CLAMP
BREAK
TW
MAKE
OUT
SW
IN
SW MODE
UNCLAMP
SW
CLAMP
Begin normal operation.
E-Stop Button
UP
CARRIAGE
DOWN
RETRACT
DEPLOY
EXTEND
CW
SLEW
CCW
RETRACT
ADJUST
EXTEND

ST1000049
Figure 4-8. Restarting After a Hydraulic E-Stop (Manual Models)
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Operation
Remote Control Console Operation

This section provides operating instructions for an ST-100 Iron Roughneck operated remotely from
a pedestal-mounted control console.
Pedestal-Mounted Control Console

All switches on the remote control
console return to center.
page 56
page 57
page 58
page 59
Figure 4-9. Pedestal-Mounted Control Console (1 of 5)
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Operation

Mode
Slow Press to initiate Slow Mode for spinning in drill collars and HT and XT type drill
pipe. Slow mode reduces the speed of the spin wrench rollers by half (80 rpm to 40 rpm).
The green indicator lights when in this mode.
SW Backup Press to put the torque wrench in backup mode. In this mode, the lower
torque wrench soft clamps, providing additional stability for spin wrench operations without
deforming the box. The green indicator lights in this mode.
Interlock
When the Interlock status indicator is red, press and hold the Override button to momentarily
override the interlock condition. See the section titled "Interlock Conditions" on page 68 for
precautions and additional information about this function.
Test
Lamp Test Turn and hold the switch to test all lights on the panel.
Spare (Three Total) These modes have currently been left as SPARE (no function). The
modes may be assigned a function in future iterations.
Gauge
Tool Joint Length (Optional) Used to adjust the tool joint length for models equipped with
the tool joint finder.
Torque Shows the torque being applied during iron roughneck operations. To adjust
torque, refer to "Setting and Adjusting Makeup Torque" on page 63.
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Operation
Trip
Out indicator Green indicates the current operating mode is tripping out.
Out / In Turn and release the switch to select Trip In or Trip Out mode. Once the mode is
selected, you can start a sequential tripping operation (see the section titled "Sequential
Tripping Operation" on page 62). When used for a non-sequential operation, select the
mode and use the associated console controls to manually control the tripping operation.
In indicator Green indicates the current operating mode is tripping in.
Arm
Retract / Extend Turn and hold the switch to extend to the target destination or retract to
home position.
Down / Up Turn the switch to move the carriage up or down, raising or lowering the arm
assembly.
Spin Wrench
Unclamp / Clamp Turn switch to unclamp the jaws or clamp on drill pipe.
Out / In Turn switch to spin out or spin in a drill pipe connection.
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Operation

Slew
CCW / CW Turn the switch to slew the iron roughneck counterclockwise or clockwise to
Position 1 (this is typically well center) or Position 2.
Well Center / Position 1 Green indicates the iron roughneck has reached the Position 1
target destination. This is typically Well Center.
Position 2 Green indicates the iron roughneck has reached the preset Position 2 target
destination.
Torque Wrench
Unclamp / Clamp Turn the switch to unclamp or clamp the torque wrench jaws.
Break / Make Turn the switch when clamped on a connection, to make up or break out the
connection.
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Operation

Tool On
Press to take ownership of the iron roughneck. Hydraulic power will be enabled. Green indicates the
iron roughneck is hydraulically enabled and ready for operation.
Sequence
Refer to the section titled "Sequential Tripping Operation" on page 62 for additional information about
using this feature.
Start / Continue Press to start a new sequence or continue to the next step in a running
sequential operation.
Ready / Continue status light Steady green indicates a sequential operation has started
and is in progress. Flashing green indicates a system request for operator input. When
flashing green, the operator should press the Start /Continue button to initiate the next step
in a sequential operation.
Pressing the E-Stop button stops hydraulic power to the iron roughneck. Once the emergency
condition is cleared, pull the button to release the E-Stop and press the Tool On button to enable
hydraulic power.
WARNING
Identify all emergency stop (E-Stop) components on the
unit (refer to page 66) and understand how they operate.
Failure to adhere to this precaution may result in severe
injury or death.
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59
Operation
Making Connections
Verify the following before beginning this procedure:
The iron roughneck is fully retracted.
The required torque has been set.
The arm designation target positions have been set.
The tool is properly aligned with the drill pipe connection at well center (using the slew function).
Complete the following steps to make up a connection using the iron roughneck:
1. Extend the arms using the Arm Extend switch. The head assembly will be deployed to the
preset target destination.
2. Raise the torque wrench using the Arm Up switch and center the upper and lower jaws on
the tool joint (adjust as necessary see Figure 4-3 on page 49). If the torque wrench is already
raised, verify that the upper and lower jaws are centered on the tool joint.
3. Press the SW Backup button to activate spin wrench backup mode.
4. Turn the Torque Wrench Unclamp/Clamp switch to Clamp. The lower torque wrench jaw will
soft clamp to provide stability for spin wrench operations.
5. Turn the Spin Wrench Unclamp/Clamp switch to Clamp.
6. Turn the Spin Wrench Out/In switch to In until the connection is shouldered. Once the
connection is shouldered, release switch.
7. Turn the Spin Wrench Unclamp/Clamp switch to Unclamp to release the spin wrench clamp
from the pipe.
8. Turn the Torque Wrench Break/Make switch to Break until the upper wrench is aligned in the
READY-MAKE position.
9. Press the SW Backup button to turn off spin wrench backup mode.
10.Turn the Torque Wrench Unclamp/Clamp switch to Clamp. The upper and lower jaws clamp
on the connection.
11.Turn the Torque Wrench Break/Make switch to Make. The upper jaws rotate the pipe
clockwise (as viewed from above).
12.Once the torque gauge shows the correct makeup torque, release both Torque Wrench
switches. (If correct makeup torque setting is not reached and/or the torque gauge drops to
zero, repeat step 8 through step 12.)
13.Turn the Torque Wrench Unclamp/Clamp switch to Unclamp. The upper and lower jaws
retract.
14.Retract the arms to the home position using the Arm Retract switch.
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Operation
Verify the following before beginning this procedure:
The iron roughneck is fully retracted.
The arm designation target positions have been set.
The tool is properly aligned with the drill pipe connection at well center (using the slew function).
Complete the following steps to break out a connection using the iron roughneck:
1. Extend the arms using the Arm Extend switch. The head assembly will be deployed to the
preset target position.
2. Raise the torque wrench using the Arm Up switch and center the upper and lower jaws on
the tool joint (adjust as necessary see Figure 4-3 on page 49). If the torque wrench is already
raised, verify that the upper and lower jaws are centered on the tool joint.
3. Turn the Torque Wrench Break/Make switch to Make until the upper wrench is aligned in the
READY-BREAK position.
4. Turn the Torque Wrench Unclamp/Clamp switch to Clamp. The upper and lower jaws clamp
on the connection.
5. Turn the Torque Wrench Make/Break switch to Break. The upper jaws rotate the pipe
counterclockwise (as viewed from above). Stay clamped on the connection during the breakout
operation. This will keep the wrench from slipping on the pipe.
If the connection does not break, repeat steps 3 through 5.

6. Once the connection is broken, release the Break switch.
7. Press the SW Backup button to activate spin wrench backup mode. The upper torque wrench
jaw retracts.
8. Turn the Spin Wrench Unclamp/Clamp switch to Clamp.
9. Turn the Spin Wrench Out/In switch to Out until the connection is unthreaded. Once the
connection unthreads, release switch.
Repeat Steps 3 through 9 if connection does not spin out.

10.Turn the Spin Wrench Unclamp/Clamp switch to Unclamp. The spin wrench opens.
11.Turn the Torque Wrench Unclamp/Clamp switch to Unclamp. The lower torque wrench jaws
retract.
12.Retract the arms to the home position using the Arm Retract switch.Remote Control Console
Operation
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Operation

Sequential Tripping Operation

The Sequence control function allows the iron roughneck to cycle through a pre-programmed
makeup or breakout sequence by simply pressing the Start/Continue button instead of using
individual function switches.
Sequential operations use feedback from electronic components, operator input, and logic
programmed into the system. Refer to Figure 4-13 on page 59 for the location of this function on
the console.
During the sequential tripping operation, the arms extend, the torque wrench clamps on the
connection, it makes or breaks the connection, and then the spin wrench clamps on and spins the
connection in or out. The Ready/Continue status light will flash at each sequence in the operation.
To complete a sequential tripping operation:
1. Turn the Trip switch to select the desired tripping mode (In or Out).
2. Press the Sequence Start/Continue button. The tripping operation will begin.
3. When the green Ready/Continue status light flashes, press the button to initiate the next step.
The Ready/Continue status light will flash several times during the operation
for operator input. Depending on the iron roughneck model and the amount of
sensors installed, there may be up to six operator input requests.
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Operation
Adjustment Procedures
Setting and Adjusting Makeup Torque
To set or adjust makeup torque for the iron roughneck, complete the following steps:
1. If not already completed, position a tubular (drill pipe or drill collar) in the throat of the torque
wrench and spin in the connection.
2. Turn the adjustment knob counterclockwise (decreasing torque) until it stops (see Figure 4-14).
Verify that the torque gauge reads zero.
3. Position the reference indicator (red needle) at the desired torque value.
4. Turn the Torque Wrench Break/Make switch to the Break position and hold it.
5. While holding Torque Wrench Clamp and Torque Wrench Make, turn the adjustment knob
clockwise to the desired torque setting.
6. When set, release the Break position switch and unclamp the torque wrench jaws and the spin
wrench.
Torque Adjustment
Knob
Breakout torque is applied at system

pressure and is not set or adjusted.
ST1000033
Figure 4-14. Setting and Adjusting Makeup Torque (Remotely Controlled Models)
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Operation
Adjustment Procedures
Adjusting Arm Assembly Target Positions

Once the deploy target sensors identify the arm assembly targets, the arm speed will decrease.
The arm assembly targets are arm-speed kickdown sensors.
To set or adjust the arm assembly targets, complete the following steps:
1. Extend the arm assembly to Position 1.
2. Adjust the Position 1 target as shown in Figure 4-15.
3. Retract the arm assembly to the fully retracted (home) position.
4. With no pipe at Position 1, extend the arm to the location set for Position 1. Confirm that the
arm speed is reduced prior to the ST-100 reaching Position 1, and that the tool stops when the
Position 1 sensor no longer detects the Position 1 target.
Repeat all steps to set the location for Position 2. (Two positions can be set.)
The magnified view shows the

sensors and targets as they would
appear when the iron roughneck is
extending to Target Position 1.
(Position 1 is typically well center.)
Sensor
Fully Retracted
Sensor
Position 1
Sensor
Position 2
Target
Fully Retracted
Target
Position 2
Target
Position 1
ST1000048
Figure 4-15. Adjusting Arm Assembly Target Positions
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Operation
Object Detection Equipment Shutdown

There are diffuse sensors on the iron roughneck that stop the equipment if a sensor light beam is
broken, indicating that an object is in the arm assembly collapse zone. Figure 2-13 on page 32
shows the location of these diffuse sensors on the equipment.
Complete the following steps to restart the equipment after sensor shutdown:
1. Clear the object from the arm assembly collapse zone and verify that there are no objects in the
path of equipment travel.
2. Reset the emergency stop circuit by pushing one of the E-Stop buttons and then pulling the
button back out.
3. Initialize the tool:
a. Unclamp the Torque Wrench.
b. Unclamp the Spin Wrench.
c. Actuate the Torque Wrench to make or break.
4. Begin normal operation.
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Operation

Stopping the Equipment in an Emergency
Equipment
E-Stop Buttons
System Pressure
Gauge
E-Stop Procedure

Press the console E-Stop button,

press one of the equipment E-Stop
Buttons, or pull one of the E-Stop
lanyards.
Gauge shows hydraulic pressure is
released from the system.
Clear the emergency.
Hydraulic E-Stop
Lanyard (2)
ST1000051
Figure 4-16. E-Stop Component Locations (Pedestal-Mounted Console Models)
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Operation
Restarting the Equipment After an Electrical E-Stop
Restart Procedure

Pull out the console E-Stop button or

the E-Stop button on the equipment
(see previous figure).
Press the Tool On button.
Gauge registers system pressure.
Initialize the tool:
Unclamp the Torque Wrench.
Unclamp the Spin Wrench.
Actuate the Torque Wrench to
make or break.
Begin normal operation.
ST1000052
Figure 4-17. Restarting After an Electrical E-Stop (Pedestal-Mounted Console Models)
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Operation
Interlock Conditions
This section describes the rules within the ST-100 control system that govern the interlock
functions.
Integrated sensors and interlocks enable the ST-100 to perform several functions without operator
intervention. Interlocks also prevent an operator from inadvertently initiating inappropriate
operating sequences.
Interlock Considerations
For the safety of rig personnel and the protection of equipment, several components on the iron
roughneck will not operate under certain conditions. These interlock conditions are provided
below.
Hydraulic Interlocks
These interlocks are present on both ST-100s remote and manual control.
Torque Wrench Clamp Interlock If the torque wrench is clamped the Arm extend/retract,
Slew left/right and Carriage up/down functions are disabled. When the torque wrench is
unclamped, the functions are enabled. See the hydraulic schematic head functions manifold
section for diagnostics.
Electrical Interlocks
WARNING
Electronic interlock conditions can be overridden using the
override function on the remote control console. Always
check the area of operation for rig personnel and
equipment before overriding an interlock condition. Failure
to do so may result in severe injury, death, and/or
equipment damage.
Slew Interlock The slew function is disabled when the arm is extended. Slewing can only be
done when the Home Extend/Retract Proximity Sensor detects its target. This interlock
condition protects the slewing system. See Figure 2-13 on page 32 for the locations of the Slew
Proximity Sensors and refer to section titled "Electrical Assemblies (Remote Control Option)" on
page 31 for description.
Lift Cylinder Pressure Interlock The carriage lift cylinder pressure is monitored by a
pressure transducer. If the pressure deviates from the pre-set working range, the torque wrench
and spin wrench open. This protects the tool from non-driven motion (i.e. lowering the pipe while
the ST-100 is still clamped). See the interconnect diagram and assembly drawing for locations of
each sensor on the I/O J-box.
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Interlock Conditions
Operation
Electrical Interlocks
Carriage Interlock The carriage must be raised two inches before head functions can be
activated. Head functions are activated once the Carriage Up/Down Proximity Sensor does NOT
detect its target. This interlock ensures the ST-100 is operated at a height that provides enough
room for the torque wrench to unclamp before it reaches the fully lowered position in the event of
non-driven motion (i.e. lowering pipe while the ST-100 is still clamped). See Figure 2-13 on page
32 for the location of the Carriage Proximity Sensor and refer to section titled "Electrical
Assemblies (Remote Control Option)" on page 31 for description.
System Pressure Interlock Hydraulic system pressure is monitored by a pressure
transducer. If pressure drops below 2,000 psi, the system pressure interlock is activated and the
current function is aborted. This protects the tubular by ensuring the torque wrench and spin
wrench do not slip, as well as ensuring accurate make up torque. See the interconnect diagram
and assembly drawing for locations of each sensor on the I/O J-Box, and refer to section titled
"Electrical Assemblies (Remote Control Option)" on page 31 for description.
Torque Wrench Clamp Interlock The arm functions are disabled while the torque wrench is
clamped. This interlock protects the tool from damage and is based on last software command
sent to the torque wrench. An UNCLAMP command must be given to deactivate this interlock.
Spin Wrench Interlock The arm functions are disabled while the spin wrench is clamped.
This interlock protects the tool from damage and is based on last software command sent to the
spin wrench. An UNCLAMP command must be given to deactivate this interlock.
Diffuse Sensor Interlock The Object Detection Diffuse Sensors detect objects that have
entered into the crush zone of the arm. Once a diffuse sensor has activated, only the arm
functions are disabled. See page 31 for description and locations of the Object Detection Diffuse
Sensors. Refer to section titled "Object Detection Equipment Shutdown" on page 65 for the
reset procedure that must be performed after this interlock is triggered.
In addition to the interlocks, the remotely controlled ST-100 Iron Roughneck
automatically stops moving when it has reached its preset target destination
or if an emergency stop (E-Stop) is initiated.
For iron roughnecks that are integrated into a complete rig-equipment Zone
Management System (ZMS), there may be additional interlocks based on
where iron roughneck is located on the rig, relative to other drilling equipment.
These interlocks may impact the operation of the iron roughneck.
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Operation
Hydraulic Failure Operation

Safety Precautions
Review and adhere to the following safety precautions before operating the iron roughneck under
hydraulic failure conditions.
Review all precautions in the section titled "Safety Requirements" on page 4."
Identify all equipment pinch points as described in the section titled "Equipment Pinching
Hazard Locations" on page 18.
WARNING
Hydraulic failure operating procedures must only be
performed in emergency conditions. Manual operation
includes procedures that will slow production and may
cause injury to personnel and damage to equipment.
Perform manual operating procedures with extreme
caution.
WARNING
Bleed all hydraulic pressure from the iron roughneck
before disconnecting hydraulic lines. Hydraulic oil under
pressure can penetrate skin and cause serious injury.
Shut off hydraulic supply and disconnect lines from the iron roughneck before
performing any of the procedures in this section. Refer to the section titled
"Hydraulic Assemblies" on page 29 for the location of the hydraulic shutoff
valve. Once the hydraulic supply is shut off, actuate all iron roughneck
functions to bleed hydraulic pressure from the unit.
During operation, surfaces may become hot enough to injure personnel. Allow
surfaces to cool before touching or working around the equipment.
70
This advisory 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.
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Operation
Safety Precautions
Rotating the Iron Roughneck

In the event of hydraulic failure, the iron roughneck may need to be rotated away from its last
location. Complete the following steps to manually rotate (slew) the socket base assembly:
1. If necessary, extend the arm assembly to allow access to the base.
2. Turn the switch on the hand pump manifold assembly from Normal Mode to Hand Pump
Mode. (see Figure 4-18).
3. Connect the hand pump to the quick-disconnect (QD) fitting HP on the front face of the hand
pump manifold assembly.
4. Actuate the hand pump to release the brake. Once the brake is released, you should be able to
rotate the iron roughneck.
5. Rotate the iron roughneck into the desired position.
6. Release hydraulic pressure on the brake by depressurizing the pump.
7. Disconnect the hand pump from the manifold and turn the switch to Normal Mode. (see Figure
4-18)
The hand pump switch must remain in Normal Mode during normal iron
roughneck operation. Failure to do so could result in unreliable slew motor
and brake operation.
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Operation
Rotating the Iron Roughneck
Hand Pump
Quick-Disconnect Fitting
HP
HAND
PUMP
MODE
NORMAL
MODE
Front
Hand Pump
Manifold Switch
Hand Pump
included with recommended
operating spares
ST1000021
Figure 4-18. Hand Pump Manifold Assembly
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Operation
Releasing the Torque Wrench

In the event of hydraulic failure, the clamping action of the torque wrench may need to be released
by manually retracting the clamp cylinders. To manually retract the clamp cylinders, plugs are
removed from the clamp cylinder manifolds.
Complete the following steps to remove plugs and manually retract the clamp cylinders:
1. Locate the EU port on the upper clamp cylinder manifold.
2. Locate the EL port on the lower clamp cylinder manifold.
3. Slowly remove the plugs or fittings from EU and EL ports on the upper and lower clamp cylinder
manifolds.
WARNING
Remove clamp cylinder plugs slowly so hydraulic pressure
is released gradually. If a plug is removed too quickly, it
could be projected at high velocity. Always wear protective
eye wear when working on hydraulic components.
WARNING
Pressurized hydraulic oil can penetrate skin and cause
serious injury to personnel. Always wear protective
clothing when working on hydraulic components.
4. After releasing hydraulic pressure from the cylinders, use a pry bar to retract the clamp
cylinders from the drill pipe.
5. Once the torque wrench is unclamped replace all plugs/fittings.
Figure 4-19 shows the location of the EU and EL ports on the clamp cylinder manifolds.
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Operation
Releasing the Torque Wrench
EU Port
EU Plug
Torque Wrench Top
Upper Clamp
Cylinder Manifold
EL Port
EL Plug
end of manifold
not shown
Torque Wrench Bottom
Lower Clamp
Cylinder Manifold
ST1000022
Figure 4-19. Torque Wrench Clamp Cylinder Manifold Ports
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Operation
Releasing the Spin Wrench

In the event of hydraulic failure, the spin wrench may need to be released by manually retracting
the spin wrench clamp cylinders. To manually retract the clamp cylinders, fittings are loosened on
the clamp cylinder to release hydraulic pressure.
Complete the following steps to remove plugs and manually retract the clamp cylinders:
1. Slowly and carefully loosen the fittings on the spin wrench clamp cylinder.
WARNING
Loosen the fittings slowly so hydraulic pressure is
released gradually. If a fitting is loosened and removed too
quickly, it could be projected at high velocity. Always wear
protective eye wear when working on hydraulic
components.
WARNING
Pressurized hydraulic oil can penetrate skin and cause
serious injury to personnel. Always wear protective
clothing when working on hydraulic components.
2. After releasing hydraulic pressure from the cylinders, disconnect the hydraulic connections
from the spin wrench clamp cylinder.
3. Use a pry bar to move the drive rollers away from the drill pipe.
4. Once the cylinder is retracted, replace all fittings and/or hoses.
Figure 4-20 shows the location of the relief fittings on the spin wrench clamp cylinder.
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Operation
Releasing the Spin Wrench
Fittings
Clamp Cylinder
Rear View
ST1000023
Figure 4-20. Spin Wrench Clamp Cylinder Relief Fittings
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Operation
Moving the Arm Assembly

In the event of hydraulic failure, the arm assembly may need to be manually extended or retracted.
To move the arm assembly, hydraulic pressure must be released from the extend/retract cylinders.
This procedure may result in hydraulic fluid being expelled from cylinder
manifold ports when the arms are moved. Take precautionary measures to
catch or contain the hydraulic fluid. Spilled hydraulic fluid can cause slip-andfall injuries and environmental contamination. Collect and clean up any spilled
or escaping oil. Dispose of excess hydraulic fluids, lubricants, and cleaning
material appropriately.
Complete the following steps to release pressure from the extend/retract cylinders and move the
arm assembly:
1. Identify the test fittings on each extend/retract cylinder. There are two test fittings on each
cylinder (Figure 4-21).
2. Slowly screw Stauff test couplings on all four cylinder test fittings to slowly release pressure
from the cylinders.
3. After releasing hydraulic pressure from the cylinders, remove the Stauff test couplings from
the cylinders (or see option below).
As an option, consider attaching open-ended hoses to the test couplings.
Place the open end of each hose in a container to catch hydraulic fluid that
may be expelled when the arm assembly is manually extended or retracted.
4. Push or pull the head assembly in the required direction to manually extend or retract the arm
assembly. (Alternatively, lifting up on the shackles will cause the arm to retract.)
Figure 4-21 shows the location of the test fittings on the arm assembly extend/retract cylinder.
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Operation

Moving the Arm Assembly
Shackle (2)
Arm Assembly
Arm Extend/Retract
Cylinder Assembly
2 cylinders; one on each arm
Test Fitting 1
Test Fitting 2
ST1000024
Figure 4-21. Test Fittings on the Extend/Retract Cylinders
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Operation
Electrical Failure Operation

In the event of electrical failure or controller failure, a remotely controlled iron roughneck can be
operated using an emergency control panel located on the equipment. This control panel is for use
only when there is an electrical failure and there is still hydraulic power available for the equipment.
WARNING
This control panel must only be used

when there is an electrical or remote
control failure. Failure to adhere to this
warning could result in severe injury to
rig personnel.
Rig hydraulic power must be available to

operate the equipment using these controls.
Procedure
Install the supplied lever into the

ENABLE panel function and
move it to ON. It must be held in
the ON position to use the other
controls.
Install a lever into the first panel

function required to move the iron
roughneck out of the way.
Continue to use each panel

function as needed until the iron
roughneck is in a safe area.
!
Enabling hydraulics using
this method will cause
the torque wrench and
spin wrench to unclamp
without warning.
ST1000026
Figure 4-22. Emergency Control Panel (Remote Control Option)

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Operation
Securing Equipment on a Floating Vessel

Floating vessels are subject to wave action and wind, resulting in unpredictable rig floor motion.
Unpredictable rig floor motion can cause the iron roughneck to make sudden and unexpected
movements. When this begins to occur, stop operating the iron roughneck and secure it in standby
position.
The following table provides the environmental limits for normal operation. When conditions
exceed these values, immediately stop operation, secure the iron roughneck in standby position,
and install the storage (parking) pin (see Figure 3-1 on page 39).
Operating Environment
Condition
Parameter
Roll/Pitch
Roll:
Pitch:
Heave
2% acceleration force
Temperature
-20 C to +55 C
Ice Thickness
None
Humidity
None
Altitude
None
4 pitch, single amplitude with a 10 second period

50 foot roll center, below rig floor
The following table provides the environmental limits for the iron roughneck secured in position
with the storage pin installed (Figure 3-1 on page 39).
Survival Environment
Condition
Parameter
Roll/Pitch
Roll:
Pitch:
Heave
30 ft. with a 10 second period
Temperature
-20 C to +55 C
Ice Thickness
None
Humidity
None
Altitude
None
20 pitch, single amplitude with a 10 second period

50 foot roll center, below rig floor
Contact your NOV representative if the iron roughneck is installed and may be
operated where the environmental conditions exceed any values provided.
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Maintenance
Pre-Maintenance Checklist
Documentation You Will Need
Make sure you have the following reference documentation available prior to beginning
maintenance procedures:
Hydraulic Schematics
Electrical Interconnects (remote option)
ST-100 Technical Drawing Package
ST-100 User Manual
Recommended Lubricants and Hydraulic Fluids (D811000719)
Design Specification, Design Torque Standard (DS00008)
Safety Wiring Procedure (ASP00019)
Spare Parts You May Need

Refer to the recommended spare parts list in your User Manual and contact your NOV
representative or an NOV Service Center. It is NOV policy to support spares for as long as the
equipment is active.
Spare Parts and Fluids Disposal

The equipment owner is responsible for conforming to applicable regulatory policies and standards
when removing the equipment, dismantling equipment components, disposing of fluids, and
disposing of consumable spare parts during and after maintenance.
The equipment owner is responsible for the recycling guidelines when

removing the equipment.
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Maintenance
Safety Precautions
Avoid equipment damage or injury to personnel by paying close attention to the important safety
notes highlighted as Notes, Cautions, and Warnings used throughout this manual.
To avoid serious injury or death, read and understand the following warning advisories before
performing maintenance or troubleshooting procedures.
WARNING
Secure the equipment with the maintenance pins prior to
starting maintenance (see section titled "Securing the
Equipment for Maintenance" on page 84).
Surfaces may become hot enough during operation to cause injury. Allow
surfaces to cool before touching them.
WARNING
Under no circumstances should work be performed on the
ST-100 while the hydraulic lines are connected. Even with
the hydraulic power unit shut off, residual pressure may
remain in the ST-100 hydraulic circuit that could cause
unsafe motion resulting in serious injury. Always shut off
hydraulic power, cycle all operator valves, and remove
hydraulic lines prior to working on the ST-100 Iron
Roughneck.
WARNING
Complete all appropriate job safety analysis (JSA)
worksheets, permits, and crew safety briefings
immediately prior to each maintenance activity or session.
If, at any point during maintenance tasks, the planned
tasks change for any reason, review the job safety
requirements again to ensure the crew involved is aware of
the changes. Make sure all appropriate personal safety
equipment is in good condition and used when necessary.
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Safety Precautions
WARNING
Replacement parts shall be OEM parts. Failure to use OEM
parts can result in damage to the equipment or injury to
personnel.
WARNING
Unless specifically noted in this manual, properly lock out
the main power source before performing lubrication,
inspection, or replacement procedures.
Wear protective glasses to prevent eye injuries from fluids

under pressure, as well as other hazards.
Read and understand all safety precautions and warnings

before performing maintenance procedures.
Do not attempt repairs you do not understand.
Use caution when draining lubricant. It can be hot.
Never check for hydraulic leaks with your hands. Oil under
pressure escaping from a hole can be nearly invisible and
can penetrate skin causing serious injury. Always check
for leaks with a piece of wood or cardboard and always
wear protective eye wear when working on hydraulic
components.
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Maintenance
Securing the Equipment for Maintenance

Two pins are provided for use when equipment maintenance procedures are required. These pins
lock down the arm assembly when installed in the unit as shown in Figure 5-1. The maintenance
pins are attached and stored on the equipment when not in use.
Maintenance Pins
WARNING
Lock out hydraulic power to the tool

before beginning any maintenance or
removing any guards.
Ball Valve
WARNING
Make sure to install both maintenance

pins prior to beginning equipment
maintenance. Failure to adhere to this
warning could result in severe injury to
rig personnel.
The maintenance pins pass through two

components to lock down the arm
assembly. The arms may need to be
extended or retracted until the component
holes line up correctly for pin installation.
ST1000053
Figure 5-1. Maintenance Pins
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Maintenance
Equipment Inspection
Inspection Schedules
The following provide the recommended intervals and components to inspect on the iron
roughneck. Refer to the section titled "Equipment Lubrication" on page 88 for recommended
lubricants, lubrication intervals, and lubrication points.
The following inspection intervals are based on average operating conditions.
More frequent service intervals may be required for severe environmental
conditions.
Daily
Inspection
Make sure the equipment and work area are clean. Remove corrosives and
contaminants (salt, sand, mud, oil, and grease). Dispose of components properly.
Check the die assemblies in the torque wrench jaws for wear or damage. See the
section titled "Replacing Torque Wrench Dies" on page 99.
Function each E-Stop to ensure proper operation. Do not operate tool if E-Stop is
not functioning. See the section titled "Inspection Points" on page 87.
If equipped, check diffuse sensors for proper operation. Do not operate tool if
diffuse sensor is not functioning.
Weekly
Inspection
Check all fasteners for looseness and tighten to proper torque. Replace all missing
fasteners.
Check all quick-disconnect (QD) fittings. Tighten all hose connections.
Replace damaged, leaking, or kinked hoses.
Check for loose electrical connectors (remote option).
Check for worn or damaged rollers in the spin wrench assembly. See the section
titled "Replacing Spin Wrench Rollers" on page 102.
Check for worn or damaged rollers in the carriage assembly. If rollers show
excessive wear or damage, contact the NOV representative or Service Center.
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Maintenance
Inspection Schedules
Monthly
Inspection
86
Inspect the hydraulic inlet manifold filter. Replace the filter if the differential
pressure (DP) indicator has popped up. See the section titled "Changing the
Hydraulic Filter Element" on page 106.
Check main spin wrench support screw torque on all four (4) rollers. Torque should
be 430 ft-lb. See page 102 for assembly details.
Check equipment plaques for weariness, dirty or legible, otherwise clean it or order
a new plaque. See Chapter 2, titled "Nameplate and Warning Plaques."
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Maintenance
Inspection Points
Overall Inspection
Make sure the equipment and the area
around the equipment are clean (daily).
pinch points. If possible, avoid these areas
Remove corrosives and contanimants.
while the equipment is operating.
Check all fasteners for looseness (weekly).
Tighten to correct torque. Replace missing
fasteners.
Check all hoses and QD fittings (weekly).
Tighten connections. Replace damaged,
The remotely controlled ST-100 model is
leaking, or kinked hoses.
shown in this illustration.
(Remote option) Check all electrical cables
and connections (weekly).
Carriage Rollers (4 places)
Tighten connections. Replace damaged
cables.
Inspect rollers for damage or wear.
Spin Wrench Rollers (4 places)
Repair or replace as necessary.
Check main spin wrench support
Weekly
screw torque. See Page 109.
Should be 430 ft-lb.
Monthly
E-Stop
Check or test valve.
Repair or replace
as necessary.
Daily
Monthly
Hydraulic Inlet Manifold Filter
Check the differential pressure (DP)
pop-up indicator.
Replace filter element as necessary.
Daily
Weekly
E-Stop (2 places)
Spin Wrench Rollers (4 places) Check or test E-Stop assuring
Die Assemblies (4 places)
Inspect rollers for damage or wear. cable is secured.
Secure or replace if necessary.
Inspect dies for damage or wear. Repair or replace as necessary.
Repair or replace as necessary.
Daily
ST1000034
Figure 5-2. Equipment Inspection Points
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Maintenance
Equipment Lubrication
WARNING
Properly lock out the hydraulic power source before
performing lubrication, inspection, or replacement
procedures.
WARNING
Wear protective glasses to prevent eye injuries from fluids
under pressure, as well as other hazards.
WARNING
Use caution when draining lubricant. It can be hot.
Recommended Lubricants
Refer to Recommended Lubricants and Fluids (D811000719) in the equipment User Manual for
recommended lubricants and hydraulic fluids for all derrick-mounted equipment.
The lubrication intervals described in this manual are based on lubricant supplier
recommendations. Severe conditions such as extreme loads or temperature, corrosive
atmosphere, and so on, may require more frequent lubrication.
Worn bushings, binding parts, rust accumulations, and other abnormal conditions indicate more
frequent lubrication is necessary.
Lubrication Schedules
The following lubrication intervals are based on average operating conditions.
More frequent lubrication intervals may be required for severe environmental
conditions.
Pump grease into the fitting until clean grease is seen extruding from the
component. This makes sure that old grease is purged and that the
component is completely lubricated.
The ST-100 Iron Roughneck needs approximately 1.66 liters of grease per
month.
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Maintenance
Lubrication Schedules
Weekly
Lubrication
Spin
Wrench
Assembly
Grease the external fittings on the motor and roller guards, that
lubricate the upper and lower bearings.
Grease the fittings on the spin wrench bogey arms.
Grease the fitting on the compression spring strut.
Refer to the section titled "Spin Wrench Assembly Lubrication" on page

90 for component and grease fitting locations.
Spin
Wrench
Support
Structure
Grease the fittings on the spin wrench mount.
Grease the fittings on the link hanger pins.
Grease the track roller fittings.
Refer to the section titled "Spin Wrench Support Structure Lubrication"

on page 91 for component and grease fitting locations.
Torque
Wrench
Assembly
Arm
Assembly
Column
Assembly
Grease the fittings on the clamping jaws.
Grease the fittings on the torque cylinder.
Refer to the section titled "Torque Wrench Assembly Lubrication" on

page 92 for component and grease fitting locations.
Grease all fittings on the arm assembly.
Refer to the section titled "Arm Assembly Lubrication" on page 93 for

component and grease fitting locations.
Grease the carriage guide rollers.
Refer to the section titled "Column Assembly Carriage Guide Roller

Lubrication" on page 94 for component and grease fitting locations.
Monthly
Lubrication
Socket
Base
Assembly
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Grease the slew bearing in the socket base assembly.
Refer to the section titled "Socket Base Slew Bearing Lubrication" on

page 95 for component and grease fitting locations.
89
Maintenance
Lubrication Procedures
Spin Wrench Assembly Lubrication
Spin Wrench
Assembly
Rear
Weekly
Spin Wrench Bogey Arm
3 places each side (6 places total)
Weekly
Compression Spring Strut (1 place)
Weekly
Spin Roller Assembly
Upper Bearings
Weekly
Front
Spin Roller Assembly

Lower Bearings
ST1000035
Figure 5-3. Lubricating the Spin Wrench Assembly
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Maintenance
Spin Wrench Support Structure Lubrication
Spin Wrench
Support Structure
Weekly
Spin Wrench Mount
2 places each side
(4 places total)
Weekly
Hanger Link Pins
2 places each side
(4 places total)
Weekly
Rear Track Rollers
1 place each side
(2 places total)
Weekly
Front Track Rollers
1 place each side
(2 places total)
ST1000037
Figure 5-4. Lubricating the Spin Wrench Support Structure
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Maintenance
Torque Wrench Assembly Lubrication
Torque Wrench
Assembly
Upper Clamping Jaws

3 places on one side
1 place on the other side
(4 places total)
Weekly
Torque Wrench
Rubber Guard
Lift the rubber guards

to access the torque
cylinder grease fittings.
Front
Weekly
Weekly
Lower Clamping Jaws
3 places on one side
1 place on the other side
(4 places total)
Torque Cylinder
2 places each side
(4 places total)
ST1000036
Figure 5-5. Lubricating the Torque Wrench Assembly
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Maintenance
Arm Assembly Lubrication

pinch points.
Timing Link Pins

2 place each side
(4 places total)
Weekly
All Timing Link Pin grease fittings

are accessible only when the arm
assembly is retracted.
Weekly
Weekly
Upper Arm Pins

2 place each side
(4 places total)
Upper Arm Pins

2 place each side
(4 places total)
Weekly
Head Pivot Pin
1 place each side
(2 places total)
Weekly
Head Tilt Cam Pin
1 place each side
(2 places total)
Weekly
Lower Arm Pins
2 place each side
(4 places total)
Weekly
Extend Cylinder Pin
1 place each side
(2 places total)
ST1000038
Figure 5-6. Lubricating the Arm Assembly
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Maintenance
Column Assembly Carriage Guide Roller Lubrication

Carriage Guide
Assembly

pinch points.
Weekly
Carriage Rollers
2 places each side
(4 places total)
ST1000039
Figure 5-7. Lubricating the Carriage Guide Rollers
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Maintenance
Socket Base Slew Bearing Lubrication

pinch points.
Monthly
Slew Bearing
2 places each side
(4 places total), then
slew ST-100 and
grease again.
Repeat through full
range of slew rotation.
ST1000040
Figure 5-8. Lubricating the Socket Base Slew Bearing
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Maintenance
General Maintenance Procedures

Precautions
Before beginning to disassemble hydraulic components, move the

components to a safe, clean, and dust-free service area.
Disassembly procedures are performed when replacing damaged components that are causing a
tool function to fail. Whenever completing a disassembly procedure, practice preventive
maintenance as follows:
Clean and inspect all disassembled parts.
Replace all worn and damaged parts before they can cause another failure.
Install thread protectors on exposed threads.
Install bolts with anti-seize compound and tighten based on the Design
Torque Standard (DS00008), unless an alternative torque value is given in the
procedure. The Design Torque Standard is included in the equipment User
Manual.
WARNING
Release all hydraulic pressure before disconnecting
hydraulic lines. Oil under pressure can penetrate skin
causing serious injury. Always wear protective clothing
and eye wear when working on hydraulic components.
WARNING
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.
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Maintenance

Precautions
WARNING
Make sure all hydraulic lines are isolated and the hydraulic
inlet shutoff valve is closed before any work is performed
on the iron roughneck.
WARNING
If air is introduced to the extend cylinders, use extreme
caution when extending the unit for the first time. As the
load moves over well center, the air will compress, causing
the arm assembly to extend rapidly. Support the unit with a
tugger and stand to the side until air is purged from the
cylinders.
During operation, surfaces may become hot enough to cause injury. To
reduce the risk of injury from a hot component, allow the surface to cool
before touching.
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Maintenance
Nord-Lock Washers
Equipment components may use a Nord-Lock bolt securing system to safely lock bolted joints.
This system consists of a pair of washers with wedge-locking action.
The rise of the cams between these washers is greater than the pitch of the bolt. When the bolt is
tightened, the teeth grip and seat the mating surfaces. The bolt cannot rotate loose because of the
wedge effect of the cams.
When the bolt is loosened with a wrench, the pair of washers expand more than the corresponding
pitch of the bolt thread, allowing the bolt to rise.
Do not reuse Nord-Lock washers. Always replace used Nord-Lock washers

with new washers after completing any disassembly procedures.
Secured Bolt
Top Washer
Bottom Washer
Figure 5-9. Nord-Lock Washer
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Maintenance
Replacing Torque Wrench Dies
Once the screws are removed the die may slip out of the die carrier. Secure
the die to avoid injury or damage.
Replace all dies and die carriers. Check all fasteners and associated
components for wear and replace if needed.
Complete the following steps to replace dies in the torque wrench. Figure 5-10 shows the location
of components disassembled in this procedure.
1. Using the Unclamp function on the operator controls, completely open the jaws.
Lock out hydraulics to disable equipment operation and to avoid injury or

equipment damage.
2. Remove hydraulic power from the equipment.

3. Reduce hydraulic pressure to zero.
4. Clean the area around the dies and die carriers.
5. Remove the two mounting bolts from the die carrier and remove the carrier.
If the carrier is difficult to pull out, remove the two outer plugs and use an Allen wrench to tighten the
pry-out set screws. This will force the die carrier out of the socket. Make sure the set screws are flush
with the rear surface of the die carrier before it is reinstalled in the socket.
6. Remove the mounting bolts from the two die keepers.
7. Remove the die.
8. Using a wire brush, clean the die groove on the carrier and the carrier socket in the torque
wrench body.
9. Inspect and lightly grease the die carrier.
10.Install the new die in the carrier.
11.Install the die keepers against the new die and tight the bolts.
12.Install the die carrier in its socket and secure the mounting bolts as specified in the Design
Torque Standard (DS00008).
13.Complete this procedure for the other dies and die carriers.
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Maintenance
Torque Wrench
Assembly

pinch points.
Die Keeper Bolt (2)
Die Carrier
Die Keeper (2)
Outer Plug (2)

Die
Die Carrier
Mounting Bolt (2)
ST1000041
Figure 5-10. Replacing Torque Wrench Dies
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Maintenance


pinch points.
Torque Wrench
Assembly
Jaw Assembly (4)
Pipe Guard
Assembly
Tool Joint Guide

Mounting Bolt (2)
Tool Joint Guide

Tool Joint Guide
Mounting Bolt (2)
ST1000055
Figure 5-11. Adjusting Tool Joint Guide for Use with Small Diameter Tool Joints
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Maintenance
Replacing Spin Wrench Rollers
!
!
Lock out hydraulic supply pressure to disable the equipment before working
on the Spin Wrench. Failure to lock out hydraulics may result in injury or
equipment damage.
Parts may slip from the Spin Wrench once they are loosened. For instance,
when loosening the screws for the Lower Bearing Housing, make sure to
support the bearings, the lower drive hub, and other parts that make up the
Lower Bearing Assembly. Secure and place all parts removed in a clean, safe
location.
Complete the following steps to replace a spin wrench roller. Figure 5-12 shows the components
referenced in the following procedure.
1. Remove the plug from the lower cover plate.
2. Use the roller torque tool to keep the roller from turning.
3. Remove the large support screw inside the cover plate.
4. Remove the screws to release and remove the lower cover plate, lower drive hub, and lower
bearing assembly.
5. Remove the spin roller.
6. Clean the spin wrench assembly.
7. Install the new roller. When a roller is correctly installed, the roller grooves are interlaced with
the opposing roller.
8. Use the roller torque tool to keep the roller from turning.
9. Install the cover plate, lower drive hub, and lower bearing assembly.
10.Slightly oil the washer, and install the washer and the large support screw in the bottom of the
lower bearing assembly. Torque the large support screw to 430 ft-lb.
While the spin rollers are disassembled, worn or damaged bearing
assemblies and other parts should be replaced. Refer to the Figure 5-13 on
page 104 for an exploded view of the spin wrench roller assembly.
102
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Maintenance

Spin Wrench
Assembly
Roller Torque Tool
Roller Inspection Notes

Minimum allowable spin roller
diameter is 6.9 inches (17.5 cm). This
equates to 1/8-inch of radial wear
(3.175 cm).
Replace all spin rollers with new rollers.
Replace worn screws with new screws.
Clean and inspect parts and hardware
for damage and wear. Replace damaged
parts and hardware.
Torque large support screw 430 ft-lb.
(585 N-m).
Re-check large support screw and torque
after 5 hours of spin wrench operation.
Spin Wrench Roller
Lower Bearing
Assembly
Lower Bearing
Housing
Lower Drive
Hub
Lower Cover Plate

Nord-Lock Washers (4)
Seal
Hex Head
Mounting Screws (4)
Bearing
Nord-Lock Washers (4)

Socket Head
Mounting Screws (4)
Bearing
Nord-Lock Washer
Large Support Screw
Retaining Ring
Plug
Lower Bearing Assembly
ST1000042
Figure 5-12. Replacing the Spin Wrench Rollers
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Maintenance
Upper Bearing Assembly

Retaining Ring
Hydraulic Motor
Bearing
Bearing
Bearing
Seal
Upper Bearing
Housing
Upper Drive Hub
Upper Bearing
Assembly
Lower Bearing Assembly

Grooved Roller
Lower Drive Hub
Seal
Bearing
Lower Bearing
Assembly
Bearing
Retaining Ring
Lower Bearing
Housing
Seal
Cover Plate
Large Support
Screw
Bearings
When replacing bearings,
note the orientation of the
bearings and seal.
Plug
ST1000043
Figure 5-13. Spin Wrench Roller Assembly - Exploded View
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Maintenance
Spin Wrench Rollers Assembly - Retention Bolt
Grooved Roller
Roller Torque Tool

3 Months
Large Support Screw
Torque to 430 ft-lb (585 N-m)
and always use a calibrate torque
wrench. 2 places each side
(4 places total)
Plug
Remove to access
Large Support Screw
ST1000056
Figure 5-14. Spin Wrench Roller Assembly - Bolt Maintenance
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Maintenance
Changing the Hydraulic Filter Element

WARNING
Lock out hydraulic supply pressure

before replacing the filter. Failure to
lock out hydraulics may result in injury
or equipment damage.
Filter Cap
Differential Pressure (DP)

Pop-Up Indicator
Hydraulic Manifold
Shutoff Handle
Procedure

Shut off hydraulic pressure to the

equipment using the manifold
shutoff handle.
Bleed any residual pressure from
the system.
Remove the filter cap.
Replace the filter element.
Install the filter cap.
ST1000044
Figure 5-15. Replacing the Hydraulic Filter Element
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Maintenance
Disassembly Procedures
Removing the Spin Wrench Assembly
WARNING
Spin Wrench
Hanger Links
Lock out hydraulic supply pressure before

removing the spin wrench assembly.
Failure to lock out hydraulics may result in
injury or equipment damage.
Hanger
Link Pin (2)
Spin Wrench
Manifold
Spin Wrench
Assembly
Procedure

Disconnect the hydraulic hoses at

the spin wrench manifold.
Using a crane, support the weight
of the spin wrench.
Disconnect the spin wrench
hanger links from the hanger.
Lift and remove the spin wrench.
ST1000045
Figure 5-16. Removing the Spin Wrench Assembly
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Disassembly Procedures
Maintenance
Removing the Torque Wrench Assembly
!
Lock out hydraulic supply pressure before
removing the torque wrench assembly.
Failure to lock out hydraulics may result in
injury or equipment damage.
Procedure

Disconnect all hydraulic lines going to

the two torque cylinders and the two
clamp cylinders.
Remove the torque wrench shims
and the torque wrench cover.
Remove the torque wrench guide
ring.
Cover Bolt (4)
Attach lifting lugs to the lift points on

the top of the torque wrench. While
lifting, support the weight of the
torque wrench through the lifting lugs.
Unbolt the torque wrench mount base
from the torque wrench frame.
Pull the torque wrench from the head
assembly and set on a level surface
to perform cylinder maintenance.
Shims
Cover
Guide Ring
Lifting Points
Mount Base
Mount Base
Bolt (8)
ST1000046
Figure 5-17. Removing the Torque Wrench Assembly
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Maintenance
Carriage Lift Counterbalance Valve

Adjustment Procedure
The procedure for adjusting the counterbalance valve on the carriage lift
cylinder should only be done by a qualified NOV technician.
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Maintenance
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Troubleshooting
Introduction
This chapter provides guidelines to inspect and troubleshoot the mechanical, hydraulic, and
electrical components and circuits for the ST-100 Iron Roughneck.
All procedures and methods provided in this manual are superseded by the
procedures and methods approved for use at the location where the
equipment is installed and commissioned.
Refer to the Maintenance chapter in this service manual for specific
maintenance procedures and other information that may help you identify the
cause of the issue.
For remotely controlled iron roughnecks, verify that all control cables are
properly connected to the I/O J-box and remote control console. Many issues
can be resolved simply by securing these connections.
Service Centers
When problems cannot be solved, contact an authorized NOV Service Center. For a directory of
NOV Service Centers, see NOV document number D811001337-DAS-001, titled Service Center
Directory. This document is located in the equipment User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
http://www.nov.com/ContactUs/24HrEmergencyContacts.aspx
Malfunction Log
It is the users responsibility to keep and maintain a Malfunction Log, to include information such as
date, description, solution, parts replaced, etc.
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Introduction
Troubleshooting
Personnel Qualifications
Personnel conducting the troubleshooting procedures should be experienced and thoroughly
familiar with this iron roughneck. The personnel conducting troubleshooting procedures must read
and understand the information in all equipment documentation as well as understand all the
functions of the iron roughneck.
Follow the general system safety practices included in this manual before
troubleshooting or performing maintenance on the iron roughneck.
Personnel troubleshooting the iron roughneck must be experienced and

thoroughly familiar with its function, operation and maintenance requirements.
WARNING
Failure to follow safe work procedures could result in
serious or fatal injury to personnel, significant equipment
damage, and/or extended rig down time.
Determining the Nature of the Problem

When troubleshooting the iron roughneck, determine the nature of the problem using the
troubleshooting tables, detailed theory of operation information for components, and diagnostic
procedures. Potential component failure for most iron roughnecks falls into the following
categories:
Mechanical System components
Hydraulic System components
Electrical System components
Lubrication components
Make sure to have all engineering schematic drawings available before
beginning troubleshooting procedures.
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Troubleshooting
Pre-Troubleshooting Inspection
Make sure to review the following information before starting troubleshooting procedures.
WARNING
Whenever hoisting, lowering and operating the iron
roughneck, ensure all personnel and equipment are clear
of the operating area. Failure to follow this warning may
result in personal injury or equipment damage.
Make sure all hydraulic lines are isolated and the hydraulic shutoff valve is
closed before any work is performed on the iron roughneck. Refer to Figure 212 on page 30 for the location of the inlet valve assembly.
Make sure the iron roughneck is fully inserted in the floor socket.
Make sure the storage pin is removed.
Make sure all hoses and quick-disconnect couplings (QDs) are properly connected.
Check manifold, fittings, QDs, and hoses for leaks or damage.
Make sure operating pressures are correct.
Check all fittings for leaks.
Lubricate the entire iron roughneck and check the condition of the filter.
Refer to Chapter 5 for lubrication and filter replacement procedures. Refer to Recommended
Lubricants and Fluids (D811000719) in the equipment User Manual for recommended lubricants and
hydraulic fluids.
For remotely controlled iron roughnecks, verify that all control cables are properly connected to
the I/O J-box and remote control console. Many issues can be resolved simply by securing
these connections.
When troubleshooting the iron roughneck, make sure there is 2,500 psi of
hydraulic pressure at the hydraulic enable inlet. Check the back pressure of
the tank return line and make sure it does not exceed 100 psi.
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Troubleshooting
Troubleshooting Tables
The tables in this section provide the symptoms, possible causes, and troubleshooting information
for issues that may be encountered when operating the iron roughneck.
Symptom
Probable Cause
Remedy
Tool runs slowly
Hydraulic quick disconnect

on supply or return lines
not fully shouldered
Tighten until fully shouldered.
Power unit not delivering

full flow
Check power supply flow while spin out valve

is actuated. Flow should be 35 gpm (132 lpm)
minimum.
Hydraulic power unit

(HPU) return line filter dirty
Replace HPU filter element.
Pressure filter dirty
Replace ST-100 hydraulic filter element.
Power supply not

operating, or pressure too
low
Re-establish hydraulic power.
Lift cylinder damaged or

dirty
Clean or repair cylinder.
Carriage guide binds in

column
Check for obstruction.

Lubricate or replace side rollers.
Pilot pressure is set too

low
Check pressure and adjust.
Counterbalance valve out

of adjustment
Replace, or adjust counterbalance valve to

maintain vertical position*.
Lift cylinder leak
Replace seals.
Tool does not brake (slew)
Brake manifold set to

Manual mode
Set to manifold to Normal mode.
Tool does not raise
Torque wrench hydraulic

interlock activated
Unclamp torque wrench.
E-Stop activated
(remote control model)
Reset E-Stop (see page 67).
Hydraulic E-Stop activated

(remote and control
models)
Reset Hydraulic E-Stop (see page 54)
Vertical positioning
assembly moves in one
direction only or does not
move at all
Does not maintain vertical

position
* See Warning on page 7.
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Troubleshooting
Symptom
Probable Cause
Remedy
Tool does not rotate (slew)
Base assembly quick disconnect

couplings are not connected
Fully connect all base assembly quick

disconnect couplings.

interlock activated
Brake manifold set to Manual

mode
Set manifold to Normal mode.
E-Stop activated
(Remote Control Model)
Reset E-Stop (see page 67).

(Remote and Control models)
Reset Hydraulic E-Stop (see page 54).
Obstruction
Make sure storage pin is removed.
Low system pressure
Verify system pressure is set to 2,500

psi.
Transfer barrier not set up

correctly.
Set up transfer barrier (see page 48).

interlock activated
E-Stop activated
(Remote Control Model)
Reset E-Stop (see page 67)

(Remote and Control models)
Reset Hydraulic E-Stop (see page 54)
Low system pressure

psi.
Torque valve or pressure

reducing valve stuck closed,
dirty, or damaged
Check valves, clean, or replace.
Torque cylinders already at end

of stroke
Recycle the upper jaw for another bite.
Torque valve damaged
Check, clean, or replace.
Torque cylinders do not

break out connections
Low system pressure

psi.
Torque cylinders drift in

makeup direction
Sticking or worn main operating

valve
Disassemble valve, inspect for

contamination or wear, and repair or
replace.
Torque cylinder does not

move or moves slowly
Dirty return filter in hydraulic

power supply
Replace filter element.
Tool does not extend
Torque cylinders do not

make up connections
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Troubleshooting
Symptom
Probable Cause
Remedy
Torque gauge does not

indicate pressure during
makeup operation
Dirty inlet port or gauge
Clean inlet port or replace gauge.
Torque cylinders reached end of

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

gauge (rotate counterclockwise).
Gauge not adjusted to zero
Rotate zero adjust knob on back of

gauge case. Recheck torque setting.
High tank line pressure
Check and correct.
Worn or broken dies
Replace dies.
Hydraulic pressure too low

psi.
Clamping on hard banding
Reposition torque wrench so dies do

not contact hard banding.
Not holding torque wrench

clamp while torquing
Hold torque wrench clamp during

torquing operation.
Incorrect die holder installed
Install correct die holder (see page 24).
Check valves on manifold

contaminated or defective
Clean, repair, or adjust valves.
Lack of lubrication
Lubricate all grease fittings.
Torque wrench unclamps

after clamping with interlock
lamp
Non-driven motion Pressure

Transducer (PT)
Verify that real non-driven motion

condition does not exist.
Compare PT reading to gauge
reading.
Check wiring.
Replace PT.
Spin wrench assemblies do

not clamp or unclamp and/
or motors do not run
Flow restricted
Locate cause or restriction and correct.
Power supply defective
Check power supply.
Spin wench assemblies or

motor creep with valve in
neutral position
Leaking or sticky valve
Return valve to center position

manually. If problem persists, inspect
valve spool for wear or contamination.
Repair or replace.
High tank line pressure
Check and correct.
Contaminated motor
Repair motor or replace.
Bent shaft
Repair motor or replace.
Torque gauge does not

return to zero
Jaws slip on tool joint
Torque wrench clamp

cylinders too slow or
uneven
Motor runs irregularly
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Troubleshooting
Symptom
Probable Cause
Remedy
Rollers do not turn with

motor running or have
insufficient power.
Damaged motor spline
Check motor spline.
Motor seal blown
Replace motor seals.
Flow restricted to motor
Locate cause of restriction and correct.
Defective roller bearings
Replace bearings.
Defective motor
Repair motor.
Motor drive shaft broken
Replace motor.
Power supply not operating
Read power supply pressure gauge.

Make sure that pressure remains high
with operating valve energized.
Restricted hydraulic lines
Check for pinched, clogged, or

otherwise obstructed hydraulic lines.
Clear obstruction.
Worn cylinder seals
Replace seals.
Drill pipe or collars rub

against spin wrench motor
during spinning
Rollers worn excessively
Replace rollers.
Rollers slip
Insufficient clamping pressure
Check pressure at manifold set to 2,500

psi. Check for leaks in clamping lines
and replace as required.
Defective seal on spin clamp

cylinder piston
Replace seal.
Slippery connection
Clean connection.
Rollers worn
Replace rollers.
Grease on rollers.
Remove grease.
Not holding spin wrench clamp

while spinning.
Hold spin wrench clamp during

spinning operation.
Loss of power and torque
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Iron Roughneck ST-100 Service Manual

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Service Manual

ST-100 Iron Roughneck

This document contains proprietary and confidential

National Oilwell Varco

Reason for issue

First Issue: Original Instructions

Corrected conversion error to weight specification (page 2-13).

Change Description (continued)

Updated template, advisory symbols, and page numbering (Entire Book)

Added Operational Environment section to Chapter 1, General Information (Page 5)

This page is intentionally blank.

This symbol indicates a potential risk of injury to personnel or damage to

To avoid injury to personnel or damage to equipment, carefully observe the

Safe Equipment Operation

General System Safety Practices

Before installing, operating, or troubleshooting equipment or performing

Failure to replace failed or damaged components could result in injury to

Counter Balance Valve

Failure to conduct routine maintenance could result in injury to personnel or

Equipment Documentation Location

This page is intentionally blank.

Introduction to the ST-100 Iron Roughneck

Always park the iron roughneck when it is not being used.

Introduction to the ST-100 Iron Roughneck

Introduction to the ST-100 Iron Roughneck

The manual control console

Socket Base Assembly

Figure 2-1. Equipment Orientation

Introduction to the ST-100 Iron Roughneck

Socket Base Assembly

Figure 2-2. Component Locations

11,500 lb (5,216 kg)

Remotely Controlled ST-100

12,000 lb (5,443 kg)

Socket Base Assembly

1,190 lb (540 kg)

2,500 psi (172 bar)

Minimum Input Pressure

2,500 psi (172 bar)

Maximum Input Pressure

3,000 psi (206 bar)

Minimum Flow Rate

35 gpm (132 lpm)

Maximum Flow Rate

45 gpm (170 lpm)

1 inch; supply pressure

60 rpm at 35 gpm (132 lpm)

Torque (5-inch OD tubular)

3,000 ft-lb (4,067 N-m)

3 1/2" to 9 3/4" (tubular diameter)

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

120,000 ft-lb (162,698 N-m)

4" to 9 3/4" (tool joint diameter) *

* See page (page 24) for further information.

Electrical Requirements (Remote Control Option

230 VAC, 20 Amps

Cables (integrated equipment)

Fiber cable for communication

Equipment Operating Dimensions

For Reference Only. Refer to the General

Figure 2-3. Equipment Operating Dimensions (1 of 2)

Equipment Operating Dimensions

Console Swivel Radius

For Reference Only. Refer to the General