M2910-R2

6311 Breen Road Houston, Texas 77086 Phone: 281-820-5332 Fax: 281-820-3861 [email protected]

www.americanblock.comMODEL NUMBER

PART NUMBER

DOCUMENT NUMBER

ISSUE DATE

REVISION:

DESCRIPTION

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Form # 49 Rev. 1 Jan 2012

M2910

37 1/2" ROTARY TABLE

MAY 2013

29100000

RK-37.5

2

DOC.: M2910 REVISION: 2

TABLE OF CONTENTS

1.0 GENERAL INFORMATION 1.1 Equipment Specifications 1.2 Certificate of Compliance 1.3 Warranty Information 2.0 OPERATION AND ROUTINE MAINTENANCE

2.1 Warning 2.2 Installation 2.3 Lubrication

2.4 Maintenance 3.0 DISASSEMBLY / ASSEMBLY 3.1 Disassembly 3.2 Assembly 4.0 ASSEMBLY DRAWINGS 5.0 SPARE PARTS

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1.0 GENERAL INFORMATION 1.1 Equipment Specifications 1.2 Certificate of Compliance 1.3 Warranty Information

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1.1 Equipment Specifications

Product Description: 37 Rotary Table

Model Number: RK37

Maximum Load Rating: 650 Short Tons (590 Metric Tons)

Weight: 14,800 Lbs (6.720 kg) Gear Ratio: 3.6 Center of Table to Center of Sprocket Teeth: 53.25 inches (1352 mm) Pinion Shaft Extension: 4.938 inches (125 mm) (API #5 standard) Lubrication Oil Capacity: 13 gallons (49.6 liters) Design and Dimensions meet requirements of API 7K

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1.2 Certificate of Compliance

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Remove this page and replace with Certificate of Compliance

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1.3 Warranty Information Product information and support is provided during normal business hours by contacting: Manufacturer: American Block Manufacturing Company Address: 6311 Breen Road Houston, Texas 77086 U.S.A Telephone Number: (281) 820-5332 Facsimile Number: (281) 820-3861 Internet Address: [email protected] www.americanblock.com

1 2.0 OPERATION AND ROUTINE MAINTENANCE 2.1 Warning 2.2 Installation 2.3 Lubrication

2.4 Maintenance

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2.1 WARNING

Carefully read and understand the operating and maintenance instructions. Failure to follow these instructions may cause serious equipment damage, severe personal injury, or death. It is the buyers responsibility to obtain all accessories and safety devices necessary to complete the application of the product for safe operation. This product is supplied in accordance with the buyers specification and does not necessarily include all accessories or safety devices required to put this product into operation. Safety devices, such as, but not limited to rotating equipment guards, chains, cables and wrenches are available from other suppliers. This product and many of its parts are heavy and difficult to handle. Plan lifts carefully and use proper lifting gear to avoid equipment damage and personal injury. Provide safe supports for all equipment and parts. Do not lift the rotary table by its cover. Use the lifting holes provided in the corners of the rotary table housing near the bottom. Lubricate the rotary table before starting operation. Prior to shipment all lubricant is drained from the rotary table. Before operation the rotary table must be filled with lubricant as instructed in the lubrication section of this manual. Shut down equipment and disconnect power during maintenance. The equipment should be shut down and the power disconnected during maintenance and inspection to prevent personal injury. Always employ safe mechanical practices when providing service, making adjustments or making repairs.

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2.2 Installation

The rotary table should be set level. Angular or tilted operation may be detrimental to the lubrication system and result in serious damage to the rotary table. Lubricant leakage indicates a serious problem. The cause of the problem should be determined and corrections made as soon as practical. Safety guards should be installed to cover all moving parts. Flooring around the rotary table should be firm and should provide safe and secure footing. The rotary table must be properly supported. The foundation and attachment devices for the rotary table must be sufficient size and design to maintain the equipment without undue strain. Secure the rotary table to the foundation. Locating devices and high strength bolts should be used. Check the alignment of all driving devices. Improper alignment may damage the equipment. Provide adequate clearance around the rotary table housing and support frame to prevent mud build-up. Provide ample clearance between the bottom of the rotary table and the top of the bell nipple to prevent overflow of drilling mud from impinging on the bottom of the rotary table.

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2.3 Lubrication

CAUTION: Lubricate the rotary before starting operation.

2.3.1 Table Proper lubrication is essential for trouble free performance or the rotary table. All rotating components of the rotary table are lubricated by a single oil bath reservoir. The table lock is lubricated with grease.

When the rotary table reservoir is properly filled with oil the lower part of the pinion gear is submerged in the oil. When the pinion turns it carries oil up to the ring gear. A portion of this oil is deposited on the main bearing and drains down through the up-thrust bearing before returning to the reservoir. A collector cover on the pinion shaft housing gathers another portion of the oil carried up by the pinion gear. This oil passes into the pinion shaft housing and lubricates the pinion shaft bearings before returning to the reservoir. Oil is retained in the pinion shaft housing to provide short-term lubrication for the pinion shaft bearings during start-up.

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The oil in the reservoir should be changed each 6 months or when contaminated. To drain the oil, remove the plug on the bottom of the reservoir under the pinion gear and the plug on the bottom of the pinion shaft housing. Opening both these drains is necessary to drain all the oil from the rotary. Carefully inspect the oil for contamination by mud, water or metal particles. If the oil is contaminated the rotary should be opened and cleaned internally. If this is not practical, the rotary should be flushed in accordance with instructions given in section 2.3.3.

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After the reservoir is properly drained and cleaned, replace the plugs and fill the reservoir through the filling opening on the top of the pinion shaft housing. This filler opening is accessible through an opening in the table cover. DO NOT fill the reservoir through the dipstick opening. Use heavy duty high temperature extreme pressure gear oil as specified in the lubricant chart below. When the specified volume is used the oil level should be within the knurled area on the dipstick. Operate the rotary at a medium speed for 5 minutes. Stop and gage the oil level again. Adjust the oil level again to remain within the knurled area on the dipstick.

Reservoir Lubricant Temperature Lubricant +20F. (-7C) &

Above AGMA No. 6 EP or ASTM/ISO-VG Grade 320 (Viscosity 1533-1881

SSU at 100F.) Non-corrosive, Anti-Foaming Gear Lube -20F. (-28C)

to +60F. (16C)

AGMA No. 2 EP or ASTM/ISO-VG Grade 68 (Viscosity 318-389 SSU at 100F.) Non-corrosive, Anti-Foaming Gear Lube

Reservoir Capacity: 13 Gallons (49 liters)

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2.3.2 Rotary Table Locking Mechanism The rotary table lock is accessible from the top of the rotary. Oil or a small amount of grease may be applied to the lock to ease movement.

2.3.3 Contaminated Gear Oil When contaminated gear oil is observed, the rotary should be removed from service immediately. If the rotary cannot be removed from service long enough to properly clean the reservoir, the following procedure is suggested. Drain the contaminated gear oil from the rotary. Fill the reservoir to the normal operating level with 30W mineral oil. Operate the rotary UNDER NO LOAD at slow speed (20-30 RPM) for 2 to 3 minutes. Drain the reservoir. Refill with the normal lubricant and proceed. As soon as practical, remove the rotary from service, disassemble sufficiently to clean the sump and the inside of the pinion capsule.

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2.4 Maintenance

A careful preventive maintenance program will contribute to reduced down time and lower the cost of repairs. The following represents a minimum program for maintenance of the rotary. Careful attention by the owner/operator will indicate adjustment and/or additions to this program. 2.4.1 Daily 2.4.1.1 Check the oil level and adjust as necessary. If there is evidence of

contamination, clean the reservoir as soon as possible to prevent further damage to the gears and bearings of the rotary. See section 2.3.3.

2.4.1.2 Check the locking mechanism and clean or lubricate as necessary. 2.4.1.3 Check for oil leaks at the pinion shaft seals or at the labyrinth seals at the

top and bottom of the rotary. Schedule maintenance as necessary. 2.4.1.4 Lubricate the master bushing. 2.4.1.5 Check for cleanliness. Wash the table after a trip or after each wet joint is

handled. Wash the bottom of the rotary table. DO NOT direct a jet of water directly at the lower labyrinth seal. This may force water into the rotary table.

2.4.2 Monthly 2.4.2.1 Drain a small amount of oil from the reservoir and check for

contamination. If contamination is suspected follow the instructions in the lubrication section of this manual. Serious damage can occur if the rotary is operated with contaminated lubricant.

2.4.3 Semi-Annually 2.4.3.1 Drain the reservoir and refill with clean lubricant. 2.4.3.2 Check all fasteners for proper tightness. 2.4.3.3 Check the rotary drive for alignment and chain tension as necessary. 2.4.4 Annually 2.4.4.1 Remove the rotary table from the base housing; inspect the interior of the

reservoir for contamination. Clean as necessary. 2.4.4.2 Inspect the gears for proper operation and wear pattern. 2.4.4.3 Check the clearance in the rotary table main bearing assembly and adjust

as necessary. 2.4.4.4 Check the pinion shaft bearings for excessive clearance and replace as

necessary. 2.4.4.5 Check the backlash of the gear set and adjust as necessary.

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3.0 DISASSEMBLY / ASSEMBLY 3.1 Disassembly 3.2 Assembly

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3.1 Disassembly 3.1.1 Setup 3.1.1.1 Remove the master bushing. 3.1.2.1 Place the rotary on firm supports that allow access to the under side of the

rotary. 3.1.2.2 Follow support instructions given in the warning section. 3.1.2.3 Preserve and protect any parts removed from the rotary for future use.

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3.1.2 Remove the Rotary Table from the Base Housing 3.1.2.1 From the top of the rotary, remove the four (4) 3/4 flat head screws

holding the top cover to the base housing. 3.1.2.2 Remove the cover. 3.1.2.3 From the bottom of the rotary, remove the nuts and sealing washers from

the four (4) 3/4 studs holding the main bearing into the base housing. 3.1.2.4 Lift the rotary table straight up from the base housing. 3.1.2.5 Set the rotary table aside for further disassembly. 3.1.2.6 Carefully remove and retain the shim pack from the shelf that supported

the main bearing. The shims will be used when the rotary is assembled.

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3.1.3 Main Bearing Disassembly 3.1.3.1 Place the rotary table, topside down on a firm support. 3.1.3.2 Remove the twelve (12) capscrews holding the lower labyrinth to the

rotary table. 3.1.3.3 Carefully remove the lower labyrinth 3.1.3.4 Remove and retain the shim pack. The shims will be used when the

rotary is assembled.

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3.1.3.5 Remove the two sets of balls and ball spacers along with the middle

bearing race. 3.1.3.6 Place at least three (3) lifting lugs under the lower main bearing race that

is now at the top of the bearing. 3.1.3.7 While assuring that the race remains flat and square with the rotary table,

gently pull the bearing race from the rotary table. This race is slightly tight. There will be a small resistance.

3.1.3.8 Do not remove the upper race of the main bearing from the rotary table

unless the bearing is being replaced. Removal risks serious damage to the bearing race.

3.1.3.9 If the bearing race must be removed, drive several thin wedges between the race and the rotary table. This process may be eased by gently heating the race if the race is to be discarded.

WARNING: NEVER heat a bearing race with a torch unless the race will be

discarded.

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3.1.4 Remove the Pinion Cartridge 3.1.4.1 Remove the six (6) capscrews holding the pinion cartridge in the base

housing. 3.1.4.2 Remove the pinion cartridge from the base housing. 3.1.4.3 Remove and retain the shims between the cartridge flange and the base

housing. These shims will be used when the pinion cartridge is reinstalled.

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3.1.5 Remove the Table Lock 3.1.5.1 Lift the rotary table lock from its guide. 3.1.6 Disassemble the Pinion Cartridge 3.1.6.1 Do not disassemble the pinion capsule unless the bearings shall be

replaced. 3.1.6.2 Place the pinion capsule on a firm support such that it will not roll or slide. 3.1.6.3 Remove the six (6) capscrews holding the oil seal retainer on the shaft

end of the pinion cartridge. 3.1.6.4 Remove the oil seal retainer. 3.1.6.5 Remove the two (2) seals from the retainer and discard the seals. 3.1.6.6 Heat the pinion gear to 400. If using a torch, do not allow the flame to

impinge upon the pinion teeth as this can cause micro-cracks in the teeth. 3.1.6.7 Use a hydraulic puller to remove the pinion from the shaft. 3.1.6.8 Remove the pinion key. 3.1.6.9 Remove the two (2) capscrews holding the tapered roller bearing

retainers. 3.1.6.10 Hold the pinion capsule horizontal and behind the flange; press on the

shaft extension end of the pinion shaft to push the shaft from the pinion capsule. There will be significant resistance as the tapered roller bearing is tight in the housing. Be careful not to damage any of the parts during this operation. The pinion shaft will fall free as the tapered roller bearing exits its fit.

3.1.6.11 Use a collar around the shaft to pull the tapered roller bearing inner race from the shaft.

3.1.6.12 In the same way, pull the seal race and straight roller bearing inner race from the other end of the shaft.

3.1.6.13 Remove the straight roller bearing roller assembly from the pinion capsule. 3.1.6.14 Pull the straight roller bearing outer race from the pinion capsule.

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3.2 Assembly

3.2.1 General 3.2.1.1 All parts must be clean and free of burrs, raised metal, and paint on the

contacting surfaces. 3.2.1.2 Follow part and assembly support instructions given in the section 2.1. 3.2.1.3 Lubricate bolts before assembly with mineral oil. 3.2.1.4 Tighten screws to 50 ft-lb (6.9 m-kg), screws to 175 ft-lb (24.2 m-kg)

and 1 screws to 380 ft-lb (52.5 m-kg). 3.2.2 Assemble the Pinion Cartridge 3.2.2.1 Place the pinion shaft on a firm support that will prevent lateral and

longitudinal motion of the shaft. 3.2.2.2 Heat the tapered roller bearing to 250F. (120C.) And press it on the

pinion end of the shaft. Hold the bearing against the shoulder until it cools. Do not cool with water.

DO NOT HEAT BEARINGS WITH A TORCH. Bearing races are made from high carbon steel and may develop micro-cracks if heated with a torch. ALWAYS use an oven or an oil bath to heat a bearing.

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3.2.2.3 Heat the inner race of the straight roller bearing to 250F. (120C.) and

press it on the extension end of the shaft. Hold the race against the shoulder until it cools.

3.2.2.4 Heat the oil seal race to 250F. (120C.) and press it on the shaft against the inner race of the straight roller bearing. Hold the seal race against the shoulder until it cools.

3.2.2.5 Tap the outer race and rollers of the straight roller bearing into the pinion capsule.

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3.2.2.6 Heat the pinion end of the pinion cartridge to 250F. (120C.). Be careful

to protect the bearing in the other end of the capsule. 3.2.2.7 Insert the pinion shaft into the cartridge. Carefully work the oil seal race

and bearing race through the straight roller bearing. 3.2.2.8 Press the tapered roller bearing into its cartridge fit until seated against the

shoulder. Hold the shaft until the cartridge has cooled. 3.2.2.9 Install the two (2) tapered roller retainers with cap screws and torque

the screws to the value stated in 3.2.1.4. 3.2.2.10 Insert the pinion key into the shaft. 3.2.2.11 Heat the pinion to 450F. (231C.). Push the pinion on the shaft until it

rests against the tapered roller bearing. Hold the pinion in place until it cools. Do not cool with water.

3.2.2.12 Install the oil seals in the straight roller bearing retainer. The first seal is the outer seal and its lip should face the retainer as it is being installed. The second seal is the inner seal and its lip should face away from the retainer as it is being installed.

3.2.2.13 Place the bearing retainer gasket on the retainer.

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3.2.2.14 Install the bearing retainer assembly on the extension end of the pinion

capsule with eight (8) screws. Torque the screws to the value stated in section 3.2.1.4.

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3.2.3 Install the Pinion Capsule in the Base Housing 3.2.3.1 The face of the pinion gear is stamped with the part number, the mounting

distance and the backlash. Note and record the mounting distance and the backlash for later use.

3.2.3.2 If old gears are used, place the shims removed in section 3.1.4.3 on the

inside of pinion capsule flange. Otherwise do not use any shims. 3.2.3.3 Install the pinion capsule into the rotary base housing. 3.2.3.4 Install at least four (4) bolts, equally spaced, and tighten firmly. NOTE:

The holes in cartridge flange are staggered and the cartridge is stamped TOP.

3.2.3.5 Measure the distance from the 50 pilot diameter for the main bearing to the face of the pinion with a depth micrometer, and write it down.

3.2.3.6 Add 25.003 to the value measured in 3.2.3.5. 3.2.3.7 Subtract the sum found in 3.2.3.6 from the mounting distance recorded in

3.2.3.1. 3.2.3.8 A negative value in 3.2.3.7 means remove shims, and a positive value

means add shims.

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3.2.3.9 Remove the pinion capsule and add or remove shims of the thickness

indicated in 3.2.3.8. 3.2.3.10 Repeat sections 3.2.3.3 through 3.2.3.9 until the value found in 3.2.3.7 is

greater than 0.003 and less than 0.003. 3.2.3.11 Install the pinion capsule with all twelve (12) screws and torque the

screws to the value stated in section 3.2.1.4. 3.2.4 Install the Main Bearing Upper Race 3.2.4.1 Place the rotary table upside down on a solid support. 3.2.4.2 Heat the bearing race evenly to 250F. (122C.). Use an oil bath or an

oven. Do not overheat. 3.2.4.3 Set the race squarely on the rotary table and tap it into place quickly. Be

sure that the back of the race is solidly against the table flange.

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3.2.5 Assemble the Main Bearing 3.2.5.1 Place the rotary table upside down on a solid support. 3.2.5.2 Set the main bearing hold down ring on the rotary table with the studs

pointing upward. 3.2.5.3 Set the upper bearing ball cage on the upper race. 3.2.5.4 Place the balls in the pockets of the cage. 3.2.5.5 Set and center the middle race on the balls. 3.2.5.6 Set the lower bearing ball cage on the middle race. 3.2.5.7 Place the balls in the pockets of the cage. 3.2.5.8 Set the lower race on the rotary table. The lower race is fairly tight on the

rotary table. Keep the race square with the rotary table and tap it down until it is near but not tight against the balls.

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3.2.5.9 Install the lower labyrinth plate and pull the lower bearing race down on

the rotary table with the twelve (12) 3/4 capscrews. Use no more than 10-20 ft-lb (6-12 m-kg) bolt torque. Be sure the lower labyrinth plate is square on the rotary table. Be Careful do not warp the lower labyrinth plate.

3.2.5.10 As the labyrinth plate is pulled down maintain an equal space between the plate and the table around the circumference to assure that the plate is square on the table.

3.2.5.11 Measure the gap between the lower labyrinth plate and the rotary table at several places around the circumference when the bearing is snugly assembled. There should be no resistance to rotational movement of the middle race. These measurements should not vary by more than 0.005 inch (0.13 mm).

3.2.5.12 The thickness of the shim pack between the lower labyrinth and the rotary table is the average final measurement less 0.004 0.001 inch (0.10 0.025 mm). This sets the internal clearance of the bearing at -0.003/-0.005 or 0.003 to 0.005 tight.

3.2.5.13 Install the proper shims, lower labyrinth plate and the twelve (12) capscrews. Torque the screws to the value stated in section 3.2.1.4.

3.2.5.14 There should be some resistance to rotational movement of the middle race; but the race should move without significant force

3.2.6 Set the Gear and Pinion Backlash

3.1.2.1 Place the rotary base housing with the previously installed pinion capsule

on firm supports that allow access to the under side of the rotary. 3.1.2.2 Turn the rotary table right side up and set it in the base housing. Take

care that the main bearing hold down ring is rotated to the proper position and that the studs enter the holes in the base.

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3.1.2.3 The outer ends of two adjacent gear teeth are marked and the end of one

pinion tooth is also marked. Place the marked pinion tooth between the marked gear teeth. The pinion may be rotated to mate the gear teeth.

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3.2.6.3 The main bearing middle race should enter the pilot diameter in the rotary

base housing as the table seats in the base. 3.2.6.4 After the table is seated in the base, gently rock the pinion shaft back and

forth. Do not move the rotary table. The pinion shaft movement is determined by the backlash in the gear set.

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3.2.6.5 Measure the rotation of the pinion shaft at a distance of 8.438 inch (214

mm) from the center of the pinion shaft. 3.2.6.6 Subtract the measurement taken in section 3.2.6.5 from the backlash

value recorded in 3.2.3.1. 3.2.6.7 Remove the table from the base housing. 3.2.6.8 Place shims of thickness equal to the value determined in section 3.2.6.6

on the main bearing seat. 3.2.6.9 Reinstall the table into the base housing. 3.2.6.10 Repeat sections 3.2.6.5 through 3.2.6.7. 3.2.6.11 A negative number means to remove shims, and a positive number means

to add shims. Add or remove shims as indicated by the value determined in section 3.2.6.6.

3.2.6.12 Reinstall the table into the base housing. 3.2.6.13 Repeat sections 3.2.6.10 through 3.2.6.12 until the value determined in

3.2.6.6 is greater than 0.003 and less than 0.003. 3.2.6.14 Install the four (4) sealing washers and nuts on the four (4) hold-down

studs that are accessible from the bottom of the base housing. 3.2.6.15 Torque the nuts to the value stated in section 3.2.1.4.

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3.2.7 Install the Table Lock and the Top Cover 3.2.7.1 Set the table lock in the middle of its track. 3.2.7.2 Rotate the handle to allow the lock body to sit down fully in the track. 3.2.7.3 Slide the lock body to engaged with a slot in the table 3.2.7.4 Rotate the handle to point away from the center of the table. 3.2.7.5 Place the top cover on the rotary and install the four (4) 3/4 flat head

screws holding the cover to the base. 3.2.7.6 Assure that the table remains firmly locked when the lock is moved

against the cover opening. 3.2.7.7 Lift the table lock handle and slide the lock away from the center of the

table to disengage the lock. 3.2.7.8 The rotary table should turn freely by hand; but should feel firmly retained.

There should be no sound or erratic operation during the rotation.

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3.2.8 Final Inspection 3.2.8.1 Install the two (2) plugs in the bottom of the lubricant reservoir and the

pinion housing. 3.2.8.2 Install the oil adding cover on the top of the pinion housing. 3.2.8.3 Insert the dipstick into the reservoir. 3.2.8.4 Check the accessibility of the oil filler and dipstick. 3.2.8.5 Tag or mark the rotary to assure that lubricant will be added before the

rotary is placed in service.

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4.0 ASSEMBLY DRAWINGS 29100000 Main Assembly 29101000 Pinion Capsule Assembly

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5.0 SPARE PARTS

Recommended Spares for : American Block RK-37.5 Rotary Table

Assembly Part Number: 29100000

ITEM PART NUMBER DESCRIPTION CLASS 1 YEAR CONSUMPTION 2 YEAR

CONSUMPTION 1 107-0037 Pinion Bearing B 0 1 2 109-0013 Shaft Bearing B 0 1 3 122-0052 Shaft Oil Seal A 1 2 4 29081500 Bearing Retainer Gasket A 1 2 5 29080500 Table Shim Pack B 0 1 6 29080600 Main Bearing Shim Pack B 0 1 7 29080400 Pinion Capsule Shim Pack B 0 1

Class A : Maintenance Items - Expendable items requiring periodic service or replacement. Class B : Repair Items - Wearing Parts which normally have an extended, but not indefinite life. Class C : Major Repair Items - Parts ordinarily replaced only during major overhaul.

Product Description: 37 Rotary TableMaximum Load Rating: 650 Short Tons(590 Metric Tons)Reservoir Lubricant2.3.3 Contaminated Gear Oil

2.4.1 Daily2.4.2 Monthly2.4.3 Semi-Annually2.4.4 Annually3.1.2 Remove the Rotary Table from the Base Housing5.0 SPARE PARTS

M2910-R2

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