Actuator Manual 4 Inch

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    LWCV ACTUATOR 4 BORE ASSEMBLY

    AND

    MAINTENANCE INSTRUCTIONS

    CANDOC LWCV ACTUATOR - 4 INCH BORE MANUAL COPYRIGHT 2006 CANRIG DRILLING TECHNOLOGY LTD.ALL RIGHTS RESERVED

    This Top Drive System is protected by one or more of the following US patents and foreign counterparts:

    US 4,478,291 * US 4,951,709 * US 5,251,709 * US 6,024,181 and other patents pending.

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    Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any formor by any means, electronic or mechanical, for any purpose, without the express written permission of Canrig Drilling Technology Ltd.

    Printed in the United States of America.

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    LWCVACTUATOR ASSEMBLY AND INSTALLATION INSTRUCTIONS

    Actuator Assembly & Interface Instructions:AY12221 Actuator Assy, LWCV, CDTL, 8.45 x 3.82AY12221-1 Actuator Assy, LWCV, CDTL, 8.45 x 3.06AY12221-2 Actuator Assy, LWCV, CDTL, 8.45 x 3.82AY12222 Guard Assy, Actuator, LWCV, 8.45 INAY12341-1 Kit, Interface, LWCV, 8.45 INAY14043 Anti-Rotation Kit, Interface, LWCV, 8.45 IN OD VLVSC10046 Maintenance Schedule LWCV Actuator

    Assembly and Installation Instructions:Canrig LWCV Actuator Assembly...................................................................................... 1LWCV Valve Stack Adjustment Instructions.................................................................... 15LWCV Check Valve Installation Instructions.................................................................... 16

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    CANRIG LWCV ACTUATOR ASSEMBLY - 4 BORE

    Assembly Description Drawing Rev

    AY12221 ACTUATOR ASSY, LWCV, CDTL, 8.45 X 3.82 AY12221 D

    AY12221-1 ACTUATOR ASSY, LWCV, CDTL, 8.45 X 3.06 AY12221-1 A

    AY12221-2 ACTUATOR ASSY, LWCV, CDTL 8.45 X 3.82 AY12221-2 0

    AY12222 GUARD ASSY, ACTUATOR, LWCV, 8.45 IN AY12222 A

    AY12341-1 KIT, INTERFACE, LWCV, 8.45 IN AY12341-1 B

    AY14043 ANTI-ROTATION KIT, LWCV, 8.45 IN OD VLV AY14043 B

    SC10046 MAINTENANCE SCHEDULE, LWCV ACTUATOR SC10046 A

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    Part: AY12221ACTUATOR ASSY, LWCV, CDTL, 8.45, HYD

    Drawing ID: AY12221 Rev No: D

    Item Qty Part ID DescriptionUnits

    EngineeringBill of Material

    Description:

    Eng ID: 3

    Eng ID

    57 2.00 PLATE, STOP, LWCV ACTUATOR, 8.45 INEA DT14262

    58 4.00 CAPSCR, HEX HD, 3/8-16UNC x 1.25, GR8, WEA HH-0375NC-0125-GR8-W

    59A 2.00 SHIM, STOP PLATE, ACTUATOR, 0.015 THKEA DT14159-015

    59B 2.00 SHIM, STOP PLATE, ACTUATOR, 0.030 THKEA DT14159-030

    59C 2.00 SHIM, STOP PLATE, ACTUATOR, 0.060 THKEA DT14159-060

    59D 2.00 SHIM, STOP PLATE, ACTUATOR, 0.120 THKEA DT14159-120

    60 2.00 ADAPTER, MALE 1/2 ORFS, MALE 3/8 ORBEA H15-520120-08-06

    61 2.00 CAP, 1/2 ORFSEA H15-520112-08

    R01 1.00 PLATE, SERIAL NO., LWCV, 8.45 INEA DT13773

    R02 4.00 SCREW, DRIVE, U-TYPE, #0 x 0.188 LGEA DS-U-0-188

    Printed: 7/25/2007 Page 2 of 2

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    Part: AY12221ACTUATOR ASSY, LWCV, CDTL, 8.45, HYD

    Drawing ID: AY12221 Rev No: D

    Item Qty Part ID DescriptionUnits

    EngineeringBill of Material

    Description:

    Eng ID: 3

    Eng ID

    03 1.00 SLEEVE, MTG, ACTUATOR, LWCV, 8.45 INEA DT13632

    04 2.00 SLEEVE, INNER,ACTUATOR, 8.45, FINAL MACHEA DT13633

    05 2.00 RETAINER, BRG, ACTUATOR, LWCV, 8.45 INEA DT13634

    06 2.00 HOUSING, BRG, ACTUATOR, LWCV, 8.45 INEA DT14355

    07 2.00 SLEEVE, GUIDE, ACTUATOR, LWCV, 8.45 INEA DT13636

    08 4.00 RETAINER PLATEEA DT12930

    09 2.00 HYDRAULIC CYLINDEREA DT10715

    09A 0.00 SEAL KIT, CYL, 2 BORE, 1 3/8 RODEA S08-1038-010

    10 2.00 CYLINDER MOUNTING BRACKETEA DT10716

    11 4.00 RETAINING WASHEREA DT10717

    12 2.00 GROMMETEA DT10718

    13 2.00 RING, LABYRINTH, ACTUATOR, LWCV,8.45 INEA DT13642

    14 2.00 O-RINGEA S01-1267-01N

    15 2.00 RETNG RING, EXT, 8.50 SHAFT, 0.187 THKEA M10168

    16 2.00 WIPER, 8.997 ID x 9.501 OD x 0.151 SHEA S02-1018-010

    17 2.00 BRG, BALL, DEEP GROOVEEA M10249

    18 2.00 RETNG RING, INT, 13.75 BORE, 0.187 THKEA M10247

    19 2.00 BRG, PLAIN, 9.00 x 9.187 x 0.75EA M02-1041-010

    20 8.00 GREASE NIPPLE, 1/8 NPT, STRAIGHTEA M12-1000-010

    21 12.00 CAPSCR, HEX SOC HD, 3/8-16UNC x 1.00EA SH-0375NC-0100-W

    22 12.00 LOCKWASHER, 3/8 INT TOOTHEA LW-0375-IT

    23A 4.00 CAPSCR, HEX SOC HD, 3/4-10UNC x 1.00, WIEA SH-0750NC-0100-W

    23B 4.00 CAPSCR, HEX SOC HD, 3/4-10UNC x 1.25, WEA SH-0750NC-0125-W

    25 8.00 LOCKWASHER, 3/4 NORD-LOCKPAIR LW-0750-NL

    29 2.00 LOCKNUT, 1-8UNC, GR8, STOVEREA LN-1000NC-GR8

    30 1.00 RING, STOP, ACTUATOR, LWCV, 8.45 INEA DT13643

    31 2.00 WASHER, F, 1, PLAIN, TYPE AEA FW-1000-A

    34 8.00 CAPSCR, BUTTON HD SOC, 3/8-16UNC x 0.75EA BH-0375NC-0075

    36 84.00 WIRE ROPE, 1/16" DIAIN M21-2000-010

    37 20.00 OVAL SLEEVE 1/16" DIA ALUMINUMEA M19-3006-010

    47 1.00 GUARD ASSY, ACTUATOR, LWCV, 8.45 INEA AY12222 0

    48 2.00 TUBE ASSY, LWCV, 8.45 INEA DT13686

    49 2.00 PLUG, SOC HEX, 3/8 ORBEA H15-090109B-06

    50 4.00 ELL 90, MALE 1/2 JIC, MALE 3/8 ORBEA H15-070220-08-06

    52 1.00 KIT, ANTI-ROTATION, LWCV, 8.45IN OD VLVEA AY14043 0

    53 16.00 LOCKWASHER, 3/8 NORD-LOCKPAIR LW-0375-NL

    54 2.00 PLUG, SOC HEX, 1/8 NPTEA H15-140109P-02

    55 1.00 DEFLECTOR, MUD, LWCV, 8.45 INEA DT13685

    56 4.00 CAPSCR, HEX HD, 3/8-16UNC x 1.00, GR8EA HH-0375NC-0100-GR8-W

    Printed: 7/25/2007 Page 1 of 2

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    Part: AY12221-1ACTUATOR ASSY, LWCV, CDTL, 8.45 x 3.06

    Drawing ID: AY12221-1 Rev No: A

    Item Qty Part ID DescriptionUnits

    EngineeringBill of Material

    Description:

    Eng ID: 2

    Eng ID

    01 1.00 ACTUATOR ASSY, LWCV, CDTL, 8.45, HYDEA AY12221 3

    02 2.00 PINION, LWCV ACTUATOREA DT15105

    Printed: 8/8/2007 Page 1 of 1

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    Part: AY12221-2ACTUATOR ASSY, LWCV, CDTL 8.45 x 3.82

    Drawing ID: AY12221-2 Rev No: 0

    Item Qty Part ID DescriptionUnits

    EngineeringBill of Material

    Description:

    Eng ID: 0

    Eng ID

    01 1.00 ACTUATOR ASSY, LWCV, CDTL, 8.45, HYDEA AY12221 3

    02 2.00 PINION, 18T, ACTUATOR, LWCV , 8620EA DT14521

    Printed: 8/1/2007 Page 1 of 1

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    Part: AY12222GUARD ASSY, ACTUATOR, LWCV, 8.45 IN

    Drawing ID: AY12222 Rev No: A

    Item Qty Part ID DescriptionUnits

    EngineeringBill of Material

    Description:

    Eng ID: 0

    Eng ID

    01 2.00 GUARD, CYLINDER, ACTUATOR, LWCV, 8.45 INEA DT13644

    02 2.00 GUARD, HINGE PLATE, LWCV, 8.45 INEA DT13645

    03 8.00 PIN, 0.38 DIA, 1.50 LG, HEAD/REA 1006-038-150

    04 4.00 SAFETY PINEA M24-2000-010

    05 16.00 OVAL SLEEVE 1/16" DIA ALUMINUMEA M19-3006-010

    06 6.00 WIRE ROPE, 1/16" DIAFT M21-2000-010

    07 2.00 BUMPER, GUARD, LWCVEA DT13399

    08 4.00 LOCKNUT, 1/4-20UNC, GR8, STOVEREA LN-0250NC-GR8

    09 4.00 WASHER, F, 1/4, PLAIN, TYPE AEA FW-0250-A

    10 4.00 CAPSCR, BUTTON SOC HD, 1/4-20UNC x 0.50EA BH-0250NC-0050

    11 4.00 COTTER PIN, 1/8 x 1.00EA M24-3001-010

    Printed: 7/25/2007 Page 1 of 1

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    BYNo. Y/M/D

    .010 IN 5 INCHES .005 IN 5 INCHES

    TOLERANCEREMOVE SHARP CORNERS AND BURRS

    .010 IN 5 INCHESWITHOUT PERMISSION AND RETURNED

    CANRIG DRILLING TECHNOLOGY LTD..

    AND INVENTION ARE RESERVED BY

    UPON DEMAND. ALL RIGHTS OF DESIGN

    REVISION

    MACHINED SURFACES

    PARALLELISMTRUE POSITION

    125

    .005

    THAT IT IS NOT TO BE REPRODUCED

    FURNISHED WITH THE UNDERSTANDING

    TECHNOLOGY LTD.. THIS PRINT IS

    AND INVENTION OF CANRIG DRILLING

    SHOWN THEREON ARE THE PROPERTY

    THIS PRINT AND DESIGN AND DETAIL

    CASTING

    STRAIGHTNESSSQUARENESS

    CONCENTRICITY .005 TIR

    1/16

    .005".xxx

    1ANGULAR

    0 TO 24"

    > 24"

    ANGULAR 2

    1/16"

    1/8"

    .015"

    .030"

    MACHINING IMPERIAL

    FABRICATING IMPERIAL

    - UNLESS OTHERWISE SPECIFIED

    FABRICATING [METRIC]

    > 600 mm

    0 TO 600 mm

    DECIMAL 3 mm 1 mm

    .xx

    .x

    A

    WELDING PROCEDURE UNLESS NOTED OTHERWISE AS PER CANRIG SPECIFICATION - ENG 704

    IF IN DOUBT.......PLEASE ASK!

    IF IN DOUBT.......PLEASE ASK!

    MIN. RADIUS UNLESS SHOWN = 0.03 MAX.CHK'D APVD

    A 05/02/09 JAS ECN 1105; VISUAL UPDATE ONLY TO REFLECT GUARD CHANGES. SEA FJY

    1

    3

    1

    2

    2

    1

    4

    1

    2

    3

    5 6

    5 6

    56

    15.5

    0

    REF

    22.14 REF

    10

    7

    7

    7

    16.1

    0

    REF

    11

    810 9

    15.65 REF

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    Part: AY12341-1KIT, INTERFACE, LWCV, 24V, 8.45 IN

    Drawing ID: AY12341-1 Rev No: B

    Item Qty Part ID DescriptionUnits

    EngineeringBill of Material

    Description:

    Eng ID: 2

    Eng ID

    04 1.00 HOSE ASSY, 1/2, SWV STR, 45 ELL, 36.00EA F451JSJ7080808-36.00-X-32.9 0

    05 1.00 HOSE ASSY, 1/2, SWV STR, SWV STR, 37.3EA F451JSJS080808-37.3-X-34.5 0

    10 5.00 ELL 90, MALE 1/2 ORFS, MALE 1/2 ORBEA H15-520220-08-08

    16 0.00 ACTUATOR ASSY, LWCV, CDTL, 8.45, HYDEA AY12221 3

    17 3.00 WIRE ROPE, 1/16" DIAFT M21-2000-010

    18 4.00 OVAL SLEEVE 1/16" DIA ALUMINUMEA M19-3006-010

    19 1.00 VLV, HYD, CBAL, 3:1 RATIO, SAE-8, D05EA H10255

    20 1.00 HOSE ASSY, 1/2, SWV STR, 90 SHT, 43.25EA F451JSJ9080808-43.25-X-40.5 0

    21 1.00 HOSE ASSY, 1/2, SWV STR, 90 SHT, 41EA F451JSJ9080808-41-X-38.25 0

    28 2.00 CAPSCR, HEX HD, 5/16-18UNC x 1.75, GR8,WEA HH-0312NC-0175-GR8-W

    29 1.00 CLAMP, DOUBLE, 3/4 IN DIAEA H25-1005-010

    32 2.00 HOSE ASSY, 1/2, SWV STR, 45 ELL, 92.57EA F451JSJ7080808-92.57-X-89.5 0

    33 3.00 ADAPTER, MALE 1/2 ORFS, MALE 1/2 ORBEA H15-520120-08-08

    34 1.00 ELL 90, MALE 1/2 ORFS, FEM SWV 1/2 ORFSEA H15-520221-08

    36 1.00 VLV, HYD, PRESSURE REDUCING, SAND, D03EA H10252

    38 15.00 CABLE, 4 C #16 AWG, EXANE, 600VFT E03-1023-010

    39 2.00 STRAIN RELIEF, 1/2 NPT, 0.375 - 0.500EA E04-2002-010

    40B 1.00 VLV, HYD, DIR, 3 POS, 4 WAY, 24V, D03EA H10059

    41B 4.00 THREADED ROD, 10-24 x 5.88 IN LGEA H13-1036-588 0

    42 4.00 STUDNUT, 10 - 24EA H13-1035-01A

    46 8.00 CABLE TIE, 13.4 IN LG, 120 LBEA E03-2000-010

    49 1.00 CHECK VALVEEA H07-1010-030

    R01 1.00 CHART, TOOL JOINT CLAMPEA 1028-XXX

    R02 1.00 MANIFOLD, TAP-IN, D03 SAEEA H12-1002-010

    R03 2.00 TEST STATION, #4 SAEEA H22-1000-010

    REF 1.00 SCHEMATIC, 8.45in LWCV, NON-INT, 120 VACEA SC10048-1

    REF 1.00 SCHEDULE, MAINTENANCE, LWCVEA SC10046

    Printed: 7/25/2007 Page 1 of 1

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    Part: AY14043KIT, ANTI-ROTATION, LWCV, 8.45IN OD VLV

    Drawing ID: AY14043 Rev No: B

    Item Qty Part ID DescriptionUnits

    EngineeringBill of Material

    Description:

    Eng ID: 0

    Eng ID

    01 1.00 BRACKET, ANTI-ROTATION, LWCV, 4IN ACTEA DT16104 1

    02 4.00 CAPSCR, HEX SOC HD, 3/8-16UNC x 1.00EA SH-0375NC-0100-W

    03 4.00 LOCKWASHER, 3/8 INT TOOTHEA LW-0375-IT

    04 1.00 WIRE ROPE, 1/16" DIAFT M21-2000-010

    05 2.00 OVAL SLEEVE 1/16" DIA ALUMINUMEA M19-3006-010

    06 4.00 WASHER, F, 3/8, PLAIN, TYPE AEA FW-0375-A

    Printed: 8/1/2007 Page 1 of 1

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    BYNo. Y/M/D

    .010 IN 5 INCHES .005 IN 5 INCHES

    TOLERANCE

    REMOVE SHARP CORNERS AND BURRS

    .010 IN 5 INCHESWITHOUT PERMISSION AND RETURNED

    CANRIG DRILLING TECHNOLOGY LTD..

    AND INVENTION ARE RESERVED BY

    UPON DEMAND. ALL RIGHTS OF DESIGN

    REVISION MACHINED SURFACES

    PARALLELISMTRUE POSITION

    125

    .005

    THAT IT IS NOT TO BE REPRODUCED

    FURNISHED WITH THE UNDERSTANDING

    TECHNOLOGY LTD.. THIS PRINT IS

    AND INVENTION OF CANRIG DRILLING

    SHOWN THEREON ARE THE PROPERTY

    THIS PRINT AND DESIGN AND DETAIL

    CASTING

    STRAIGHTNESSSQUARENESS

    CONCENTRICITY .005 TIR

    1/16

    .005".xxx

    1ANGULAR

    0 TO 24"> 24"

    ANGULAR 2

    .06"

    .12" ES

    .015"

    .030"

    MACHINING IMPERIAL

    FABRICATING IMPERIAL

    - UNLESS OTHERWISE SPECIFIED

    FABRICATING [METRIC]

    > 600 mm

    0 TO 600 mmDECIMAL 3 mm

    1 mm

    .xx

    .x

    CH

    MA

    AP

    DRWELDING PROCEDURE UNLESS NOTED OTHERWISE AS PER CANRIG SPECIFICATION - ENG 704

    IF IN DOUBT......PLEASE ASK!

    IF IN DOUBT......PLEASE ASK!

    A 04/10/20 JAS REMOVE "REPLACE GREASE FITTINGS WITH PLUGS..." NOTE

    6 MONTWEEKLY MAINTENANCE

    REMOVE THE TWO PINS ANDOPEN THE DOOR. GREASE

    THE INNER SLEEVE RACKS,

    TWO SHOTS ONCE A WEEK.

    ROTATE THE ACTUATOR 90DEGREES AND REPEAT THIS

    PROCEDURE.CONTINUE UNTIL ALL SIX

    LOCATIONS ARE GREASED.

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    ASSEMBLY INSTRUCTIONS

    CANDOC LWCV ACTUATOR MANUAL COPYRIGHT 2004 CANRIG DRILLING TECHNOLOGY LTD.ALL RIGHTS RESERVED

    This Top Drive System is protected by one or more of the following US patents and foreign counterparts:

    US 4,478,291 * US 4,951,709 * US 5,251,709 * US 6,024,181 and other patents pending.

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    Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any formor by any means, electronic or mechanical, for any purpose, without the express written permission of Canrig Drilling Technology Ltd.

    Printed in the United States of America.

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    Revision July 2007 1 of 16

    CANRIG LWCV ACTUATOR ASSEMBLY

    Clean all machined surfaces with Varsal, Bright Clean or equivalent.

    1) Install the ball bearing (17) into the bearing housing (6) using a rubbermallet until firmly seated.

    2) Install the bearing retaining ring (18) into the groove in the bearing housing(6).

    Figure 1

    3) Repeat above two steps (1 & 2) for the second bearing housing.

    4) Install one labyrinth ring (13) onto each of the two inner sleeves (4) ensuringthat the tapered surface is facing the side where the racks are present.

    Figure 2

    5) Place the bearing/ housing assembly onto the inner sleeve (4) and use arubber mallet to tap on the top of the bearing inner race until the bearinginner race is seated on the inner sleeve.

    6) Install one plug (54) and one grease fitting (20) in the bearing housingassembly.

    17

    6

    18

    13

    4

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    Canrig LWCV Assembly Instructions

    Revision July 2007 2 of 16

    Figure 3

    7) Grease the bearing through the grease fitting while rotating the bearing.Visually ensure that the grease fills the bearing consistently and that no dryareas exist in the bearing.

    8) Repeat the same for the other bearing housing assembly and inner sleeve.

    9) Install the Guide Sleeve (7) into the ID of the inner sleeve (4) until it isseated on the lower shoulder and that the tab on the end of the guide sleevefit properly into the notch in the inner sleeve.

    10) Install the plain bearing strip (19) into the ID of the inner sleeve (4) until it isseated on top of the guide sleeve (7).

    Figure 4

    11) Repeat step 9 & 10 for the other inner sleeve.

    12) Place bearing retainer (5) on top of the bearing housing (6), ensuring that allsix holes are properly aligned with holes in the bearing housing.

    19

    Bearing/Housing

    Assembly

    544

    20

    4

    Notch

    Lowershoulder

    Tab

    7

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    Canrig LWCV Assembly Instructions

    Revision July 2007 3 of 16

    13) Install the six 3/8 socket head cap screws (21) and lock washers (22)ensuring that all threads are coated with Loctite 242. Torque to 40 ft. lbs.Install safety wire (36) and ferrules (37) through all bolts.

    14) Install the wiper (16) into the ID groove of the bearing retainer (5).

    Figure 5

    15) Repeat steps 12, 13 & 14 for the other bearing housing/ inner sleeveassembly.

    16) Install the inner sleeve/bearing housing assembly onto the mounting sleeve(3) - slide the assembly down until the top of the bearing retainer (5) isapproximately flush with the end of the tapered portion of the mountingsleeve.

    Figure 6

    17) Turn the assembly over and repeat step 16. Use the pinion (2) to space theracks in the approximate location- the hole in the mounting sleeve (3)should be located between the racks at this time.

    3

    21, 22

    5

    6

    16

    5

    16

    Note orientation

    BearingHousing/ InnerSleeve

    Assembly

    Note orientation ofrack to hole in

    mounting sleeve

    6

    18

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    Canrig LWCV Assembly Instructions

    Revision July 2007 4 of 16

    Figure 7

    18) Ensure that the valve (1) is in the closed position (see Figure 9).

    19) Standard valve only (see Figure 8a): Place the valve (1) vertically on thebox end. Install a retaining ring (15) into the upper groove on the OD of thevalve body. Turn the valve body over to sit on the pin end. Install the stopring (30) until it rests on the pin end retaining ring (15).

    20) Install two o-rings (14) into the two middle o-ring grooves on the OD of thevalve body.

    Figure 8a

    Standard 7.70 OD Valve

    21) Grease the o-rings prior to installing the mounting sleeve (3).

    22) Note: it is important at this time to verify the timing of the valve with theactuator. This can be done by looking at the crank socket- identify thesocket that opens the valve when it is turned counterclockwise. The upper

    3

    2

    BearingHousing/ Inner

    SleeveAssemblies

    1

    14

    Figure 8b

    Stepped 8.45 x 7.70 OD Valve3.06 ID ONLY

    1

    1530

    14

    8.45 OD

    7.70 OD

    7.70 OD

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    Canrig LWCV Assembly Instructions

    Revision July 2007 5 of 16

    rack should be located on the left of the socket when it is installed on thevalve.

    Figure 9

    23) Standard valve only (see Figure 8a): With the valve in the closedposition, install the inner sleeve/ bearing housing assembly on the OD of thevalve body and slide it down until it is seated against the top of the stop ring(30). Ensure that the holes in the mounting sleeve are aligned with the twocrank sockets in the valve and verify the rack location per step 22.

    24) Not Applicable

    Notch as shownindicates valve isclosed assembactuator with valin this position

    Identify side of vathat opens the vawhen rotated incounterclockwisedirection as show

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    Canrig LWCV Assembly Instructions

    Revision July 2007 6 of 16

    Figure 10

    25) Align the outer scribed grooves on the upper and lower racks with thecenterline of the crank socket.

    26) Install one pinion (2) into the crank socket ensuring that the scribe lines onthe face of the pinion are aligned with the outer scribed grooves on theracks. Move the racks towards the pinion until teeth are engaged.

    Figure 11

    27) Install the opposing pinion (2) into the opposite crank socket. It may benecessary to tap on the back side of the rack to allow the insertion of thepinion.

    Caution must be exerted when installing the pinion not to damage therack teeth. If the pinion will not install easily into the socket, thenadjust rack positions to ease insertion. Do not hammer pinion intoplace, light tapping is acceptable.

    Inner Sleeve /Bearing Housing

    Assembly

    Components tbe aligned asshown

    Install pinionwith rackaligned asshown

    2

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    Canrig LWCV Assembly Instructions

    Revision July 2007 7 of 16

    28) Verify the function of the actuator by opening and closing the valve using a7/8 hex wrench. If the actuator does not open and close, remove pinions,rotate actuator 180 degrees on valve and repeat steps 22-27.

    29) Standard valve only (see Figure 8a): Install the upper retaining ring (15)into the groove above the mounting sleeve.

    Figure 12

    30) Install the four pinion retainers (8), two per pinion using button socket headcap screws (34) and Nord-lock washers (53). Torque the button socket capscrew to 31 ft-lb.

    31) Install the six grease fittings (20) in the racks. Grease two shots in eachfitting.

    Figure 13

    32) On each of the two cylinders (9), install washer (11), grommet (12), bracket(10), washer (11), washer (31) with locknut (29) - torque to 350 ft/lbs.

    15

    8

    34, 53

    20

    20

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    Figure 14

    33) Install the cylinder assembly by mounting the bracket on the rod end (10) tothe lower bearing housings (6) using x 1 long socket head cap screw(23A) and lock washer (25) - apply anti-seize to bolts prior to installation.Hand tighten only at this time.

    34) Align the holes in the upper bracket of the cylinder assembly to the holes inthe side of the upper bearing housing.

    35) Mount the upper cylinder bracket using two 1-1/4 long socket head capscrews (23B) and lock washers (25) - apply anti-seize to bolts prior toinstallation. Turn the actuator to the opposite side and mount the othercylinder using one 1-1/4 long socket head cap screws (23B) on the left sideand one 1-1/2 long socket head cap screws (23C) on the right side andlock washers (25). Hand tighten only at this time.

    36) Torque lower bracket (10) socket head cap screws to 350 ft/lbs. Do nottorque upper cylinder bolts at this time. Safety wire bolts after tightening tospecified torque.

    12

    11

    11

    29

    10

    31

    9

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    Figure 15 Figure 16

    37) Install the four elbow fittings (50) into the cylinders facing inward. Install twohydraulic tubes (48) onto the fittings (50). Ensure adequate clearancebetween tube and moving parts on actuator. Temporarily install guard (47)on actuator and ensure that the tube seats between the tabs inside theguard- adjust tube as necessary. Tighten all fittings.

    Figure 17

    Grease fittingthis side

    Plugthis si

    23B, 25

    23A, 25

    CylinderAssy

    23A, 25

    23B, 25

    52

    48

    50

    Hydraulic tubes to bemounted on bracket

    side of actuator

    10 10

    CylinderAssy

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    38) Install 0.060 thick shim (59C) and stop plate (57) onto lower bearinghousing (6) using lock washers (53) and 3/8 hex head cap screws (58). Donot tighten at this time. Repeat for other side.

    Figure 18

    39) Open the valve completely. Ensure that valve is fully open by visuallyinspecting bore- also inspect stops to ensure that no clearance existsbetween stops and upper bearing housing. Adjust stop height as necessaryif the valve is not opening completely or the stops are not contacting theupper bearing housing by replacing 0.060 thick shim (59C) with 0.015 thickshim (59A) or 0.030 thick shim (59B). Tighten the 3/8 bolts to 40 ft/lbs.

    Figure 19Figure 20

    40) Remove socket head cap screws (23A, 23B and 23C) and lock washers(25) from the upper cylinder bracket.

    57

    6

    59

    53, 58

    Inspect toensure valveis restingagainst stops

    Inspect valve toensure valve is

    fully open

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    41) Remove the four safety pins and the 3/8 diameter hinge pins on the guard(47) to separate the guard into two assemblies.

    42) Install one of the side guard assemblies on the cylinder bracket using x1-1/4 long socket head cap screws (23B) and lock washers (25). Installtwo 3/8 x 1 long hex head cap screws (56) and lock washers (53). Rotatethe actuator to the opposite side and install the other side guard assembly

    using one 1-1/4 long socket head cap screws (23B) and lock washer (25).Mount the anti-rotation bracket (locate from anti-rotation kit (52)- AY14043using the 3/8 x 1 long socket head cap screws, flat washers and lockwashers. Torque socket head cap screws to 350 ft/lbs and torque 3/8socket head cap screws to 40 ft/lbs. Safety wire bolts after tightening tospecified torque.

    Figure 21Figure 22

    43) Close the side guards and ensure that the hydraulic tubes (48) are centeredin the tabs located inside the guards. Adjust the hydraulic tubes asnecessary. Replace the 3/8 diameter hinge pins and the four safety pins.Check to ensure that all safety and hinge pins are properly wired.

    23B, 25

    52

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    Figure 23

    44) Position the actuator on the side opposite of the hydraulic tubes. Install thetwo plugs (49) on the right hand cylinder (upper and lower ports). Install thetwo adapters (60) and the caps (61) on the left hand cylinder (upper andlower ports).

    45) Slide the mud deflector (55) over the box end of the valve until it seatsagainst the upper retaining ring (15).

    Figure 24

    Check for properfit of hydraulic

    tubes within guidetabs

    60, 6149

    55

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    46) Locate serial number plate (R01) in position. Using the serial number plateas a template, drill four #40 (0.098 diameter) holes in cylinder guard. Mountserial number plate (R01) to guard using four drive screws (R02).

    Figure 25

    R02

    R01

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    LWCV VALVE STACK ADJUSTMENT INSTRUCTIONS

    For integrated style manifoldsRefer to Canrig drawing number AY12341-1

    1) Locate test port labeled GA-5 on hydraulic manifold assembly- it islocated directly under the LWCV valve stack on the hydraulic manifold.

    This will be the test port for the high pressure side of the LWCV hydraulicsystem- note that the high pressure side must be set before the lowpressure side is set.

    2) Remove protective cap from test port and install gauge fitting to test port.

    3) Remove protective cap from high pressure reducing valve (located in thehydraulic manifold body- labeled 20E). Loosen the locknut securing theadjusting screw.

    4) Function actuator open and closed. Note pressure reading on gauge-regulate the adjusting screw in order to obtain the proper pressurereading. The pressure should be set to 2200 psi. Continue to operate the

    actuator as required to maintain pressure in the system.

    5) Once the correct pressure is obtained, hold the adjusting screw in positionwith the hex wrench and tighten the locking nut.

    6) Operate the actuator to verify that the pressure is correct.

    7) Remove pressure gauge from the test port and replace the protective cap.

    8) Replace the protective cap on the pressure reducing valve.

    9) Locate test port labeled GB-5 on hydraulic manifold assembly. This willbe the test port for the low pressure side of the LWCV hydraulic system.

    10) Remove protective cap from test port and install gauge fitting to test port.11) Locate the low pressure reducing valve in the LWCV valve stack- it will be

    the valve directly under the directional valve. Remove protective cap andloosen the locknut securing the adjusting screw.

    12) Function actuator open and closed. Note pressure reading on gauge-regulate the adjusting screw in order to obtain the proper pressurereading. The pressure should be set to 1100 psi. Continue to operate theactuator as required to maintain pressure in the system.

    13) Repeat steps 18 - 21 as shown above to complete setting the lowpressure side of the LWCV system.

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    LWCV CHECK VALVE INSTALLATION INSTRUCTIONS

    Procedure for installing check valve in LWCV hydraulic valve stack.

    1) Relieve pressure on system by turning HPU off- lock out HPU asnecessary to prevent start-up during the check valve installation.

    2) Relieve pressure on system by operating link tilt or other hydraulic

    function.

    3) Thoroughly clean valve stack and manifold around valve stack to eliminatecontamination of hydraulic system.

    4) Remove solenoid from top of valve stack.

    5) Remove four nuts from retaining studs on valve stack.

    6) Remove all valves (proportional valve and pressure reducing valve(s) fromvalve manifold. Note location of each valve as it is critical that they arereinstalled in their original orientation.

    7) Unscrew four studs from hydraulic manifold and discard.

    8) Screw new longer studs into manifold block.

    9) Install check valve on manifold. Ensure that the alignment pin hole isaligned with pin hole in manifold for correct orientation- see Figure 1.

    Figure 26

    Mounting Side View10) Install previously removed valves in reverse order as noted in step 6.

    11) Install hex nuts on studs and tighten.

    12) Replace solenoid on valve stack.

    13) Unlock HPU, turn on and check system for leaks. Cycle LWCV actuator toverify function.

    Alignment PinHole