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15

Service Manual
ST-160
Iron Roughneck

Reference Reference Description

ST-160 Iron Roughneck
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 National Oilwell Varco
and remains the property of NOV. Reproduction, in whole or in RIG SOLUTIONS
part, or use of this design or distribution of this information to
others is not permitted without the express written consent of
11000 Corporate Centre Drive
NOV. This document is to be returned to NOV upon request or Houston, TX 77041
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
Document Number Rev.

D811001444-MAN-001 01

www.nov.com
Form D811001123-GEN-001/06

TC Number: D811001444-MAN-001 Printed REV: 01 Latest REV: 01

Printed By: imacdonald Printed On: 2013.06.19.10.05.15

D811001444-MAN-001
Revision 01

Revision History

01 15.01.2012 First Issue B. Dominguez S. Sobeira J. Walker

Rev Date Reason for issue Prepared Checked Approved

(dd.mm.yyyy)

Change Description

Revision Change Description

01 First Issue

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TC Number: D811001444-MAN-001 Printed REV: 01 Latest REV: 01

Printed By: imacdonald Printed On: 2013.06.19.10.05.15
D811001444-MAN-001
Revision 01
Page i of iv

Table of Contents

Chapter 1: General Information

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Advisories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Hot Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Pinch Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Proper Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Safe Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Recommended Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Safe Equipment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
General System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Service Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Chapter 2: Description
Introduction to the ST-160 Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Equipment Operating Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fully Retracted and Fully Lowered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fully Extended and Fully Lowered Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Fully Retracted and Fully Raised Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fully Extended and Fully Raised Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Equipment Pinch Point Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
General Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Drill Pipe Head Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Jaw Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Pipe Centralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Column Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

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Rig Floor Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

Floor Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Socket Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Hydraulic Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Drill Pipe Head Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Arm and Carriage Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Hydraulic Cylinders and Hydraulic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Cylinders and Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Warning Beacon/Warning Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Junction Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Sensors and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Valve Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Wireless Remote Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

Chapter 3: Installation
Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Drill Floor Position Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Lifting Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Chapter 4: Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operating Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pre-Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Normal Sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Normal Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
General Operating Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Trip Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Destination Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Moving Between Destinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Wireless Remote Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Wireless Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Wireless Controller Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
On Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Wrench Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Mode Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Tool Joint Length Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
ST-160 Auto Teach Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Initial Teach Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

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Specific Position Teach Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Making Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Breaking Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Automated Makeup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Automated Breakout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Interlock Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Interlock Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Arm Assembly Lockout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Locking Out the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Electro-Hydraulic Pilot Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Manually Operating the Electro-Hydraulic Pilot Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Hydraulic Failure Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Rotating the Slew Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Releasing the Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Releasing the Spin Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
Moving the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Securing Equipment on a Floating Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Removal Procedure for the Shipping Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Removing the Column/Arm Assembly from the Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Removing the Head Module from the Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Installation Procedure for the Shipping Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Installing Head Module to the Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Installing the Column/Arm Assembly to the Shipping Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Removing and Installing the Head Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Transporting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Storing the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Long Term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Returning Equipment to Service After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Chapter 5: Maintenance
General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Documentation You Will Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Major Repairs and Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Spare Parts You May Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Fastener Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Safety Wiring (Lockwire) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Wireless Controller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Locking Out the Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Equipment Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Inspection Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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Table of Contents

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5 Years . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Inspection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Equipment Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
General Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Gear Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Lubrication Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Every 6 Months . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Column/Guide Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Arm Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Spin Wrench Carrier Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Spin Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Torque Wrench Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Socket Base Assembly Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Component Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Nord-Lock® Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Replacing Torque Wrench Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
Replacing Spin Wrench Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
Changing the Inlet Hydraulic Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Changing the Intensifier Hydraulic Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Removing the Spin Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Removing the Torque Wrench Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Changing Oil Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Changing Brake and Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Filling Expansion Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Chapter 6: Troubleshooting
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Service Centers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting the Iron Roughneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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Revision 01

General Information 1

Conventions
This manual is intended for use by field engineering, installation, operation, and repair personnel.
Every reasonable effort has been made to ensure the accuracy of the information contained
herein. National Oilwell Varco® (NOV) will not be held liable for errors in this material, or for
consequences arising from misuse of this material.

Advisories
Graphic symbols and bracketed text indicate advisories for a specific topic. This information
provides additional details and may advise the reader to take a specific action to protect personnel
from potential injury or lethal conditions. Advisories may also describe actions necessary to
prevent equipment damage.

Note

The note symbol indicates that additional information is

provided about the current topic.

Caution

!
The caution symbol indicates that potential damage to
equipment, or injury to personnel exists. Follow
instructions explicitly. Extreme care should be taken when
performing operations or procedures preceded by this
caution symbol.

Warning

The warning symbol indicates a definite risk of

equipment damage or danger to personnel. Failure to
follow safe work procedures could result in serious or
fatal injury to personnel, significant equipment
damage, or extended rig down time.

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Conventions
Advisories
Hot Surfaces

The hot surface symbol indicates the presence of a

hot surface or component. Touching this surface
could result in bodily injury. To reduce the risk of
injury from a hot component, allow the surface to cool
before touching.

Pinch Point

The pinch point symbol indicates that part of the body

can be caught between moving parts of the equip-
ment, between the moving and stationary parts of the
equipment, or between material being handled and
part of the equipment. Take extreme care around
equipment pinch points. Avoid these areas while the
equipment is operating.

Electrostatic Discharge

The Electrostatic Discharge (ESD) symbol indicates the

potential for static electrical discharge is present. ESD can
damage or destroy sensitive electronic components. ESD
can also set off explosions or fires in flammable environ-
ments. Always discharge static electricity prior to working
on sensitive components or in flammable environments.

Illustrations
Illustrations (figures) provide a graphical representation of equipment components or screen
snapshots for use in identifying parts, or establishing nomenclature, and may or may not be drawn
to scale.
For component information specific to your rig configuration, see the technical drawings included
with your NOV documentation.

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General Information 1

Safety Requirements
The 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
outlined in the equipment manuals are the recommended methods of performing operations and
maintenance.

!
To avoid injury to personnel or equipment damage,
carefully observe requirements outlined in this section.

Proper Use of Equipment

NOV equipment is designed for specific functions and applications, and should be used only for its
intended purpose.

Safe Lifting
When lifting and handling NOV equipment, use approved 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.

Lifting equipment improperly creates a hazardous

working environment. To avoid lifting hazards, only lift
equipment with material handling equipment rated for
the expected load and only from the designated lift
points. Failure to follow safe lifting guidelines may
result in serious or fatal injury to personnel,
significant equipment damage, and extended rig down
time.

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Safety Requirements

!
Individuals working with rig equipment must never lift
anything over 55 lb (25 kg) without assistance. Always get
help from additional rig personnel or use lifting equipment.

Always follow all federal, state and local rules, codes, and
rig-specific safety guidelines when lifting and handling
NOV equipment. Operators and maintenance personnel
should be properly trained in safe lifting procedures and
the inspection of material handling equipment and lifting
components. 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.

Personnel Training
All personnel performing installation, operations, repair, or maintenance procedures on the
equipment, or those in the vicinity of the equipment, should be trained in rig safety, tool operation,
and maintenance to ensure their safety.

!
Personnel should wear protective gear during installation,
maintenance, and certain operations.

!
Rig personnel must understand the information provided in
this manual and be thoroughly trained before operating this
equipment.

Contact the NOV training department for more information about equipment operation and
maintenance training.

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General Information 1

Safety Requirements
Recommended Tools
Service operations may require the use of tools designed specifically for the purpose described.
The equipment manufacturer recommends that only those tools specified be used when stated.
Ensure that personnel and equipment safety are not jeopardized when following service
procedures and that personnel are not using tools that were not specifically recommended by the
manufacturer.

Safe Equipment Operation

Read and adhere to the following advisories when operating the Iron Roughneck.

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.

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.

!
Shut down the equipment when it is not being used.

!
Rig personnel must understand the information provided in
this manual and be thoroughly trained before operating this
equipment.

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Safety Requirements
General System Safety
The equipment discussed in this manual may require or contain one or more utilities such as
electrical, hydraulic, pneumatic, or cooling water.

!
Read and follow the guidelines below before installing
equipment or completing maintenance activities to avoid
endangering exposed persons or damaging 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, maintenance, or
repair.

Replacing Components
 Verify that all components (such as cables, hoses, etc.) are tagged and labeled
during assembly and disassembly of equipment to ensure correct installation.
 Replace failed or damaged components with original equipment manufacturer
certified parts. Failure to do so could result in equipment damage or injury to
personnel.

Routine Maintenance
Equipment must be maintained on a routine basis. See product-specific service manuals for
maintenance recommendations.

!
Failure to conduct routine maintenance could result in
equipment damage or injury to personnel.

Service Centers
For a directory of NOV Service Centers, see NOV document number D811001337-DAS-001, titled
“Service Center Directory.” This document is located in the User Manual.
The link below provides after-hours contact information for emergencies or other equipment issues
requiring an immediate response by NOV service personnel.
www.nov.com/contact_us/24hr_EmergencyList.asp

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Description 2

Introduction to the ST-160 Iron Roughneck

This manual describes the National Oilwell Varco ST-160 Iron Roughneck. The ST-160 is an
automated drill floor tool used for make-up and break-out of drilling tubular connections. It is
designed for use on offshore drilling rigs. It allows clearance around well center and the
mousehole when in standby and parked positions.
The ST-160 Iron Roughneck comes equipped with a drill pipe module and can be provided with an
with an optional casing tong module. The ST-160 is equipped with a quick change head system to
allow for fast and easy removal or re-installation of the drill pipe or casing module.

!
This manual provides basic operation and maintenance
information for the ST-100 Iron Roughneck. Rig personnel
must be thoroughly trained and familiar with this Iron
Roughneck before operating and maintaining this or any
associated equipment.

For your particular Iron Roughneck model specification,

see section titled "Specifications" on page 2-3

Overview
The ST-160 Iron Roughneck torque wrench assembly is capable of making connections up to
140,000 ft-lbs (189,815 N-m) and breaking connections up to 160,000 ft-lbs (216,931 N-m), and
handles tubulars ranging from 3-1/2 inches outside diameter (OD) to 10 inches outside diameter
(OD).
The spin wrench can spin in and spin out connections at speeds up to 80 rpm while providing up to
3,467 ft-lb (4,701 N-m) of torque. (Spin speed will vary based on pipe size and flow rate.)
The ST-160 Iron Roughneck is installed with a single, floor-mounted socket base assembly. 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.

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Introduction to the ST-160 Iron Roughneck

Features
The ST-160 Iron Roughneck includes the following features:
 A compact design that features a mechanical hydraulic powered extend/retract
scissor-arm system which moves the ST-160 Iron Roughneck to / from Well Center
and Mousehole, and allows for clearance around Well Center and Mousehole area
during use or when placed in the parked position.
 A wireless remote control lab belt system carried by the user. The wireless remote is
equipped with an e-stop and an on/off switch. It is also equipped with a digital
screen for displaying torque, setup messages, and warnings/alerts. From the
wireless controller, the tool can be operated in auto sequence mode.
 A torque wrench that can provide up to 140,000 ft.-lbs. of makeup torque and
160,000 ft.-lbs of breakout torque.
 A single socket-mounted system installed in the drill floor that allows the Iron
Roughneck to rotate.
 A slew system that can be rotated about the center of the column via a hydraulic
slewing motor.
 A spin wench thread compensation lift circuit which allows the spin wrench to travel
with the drill pipe while spinning in and out.
 A tool joint sensing system which provides automatic positioning of the Iron
Roughneck to the tool joint center.
 A pipe centralizer located below the lower jaw assembly of the drill pipe head
assembly and is used to align the Iron Roughneck with the drill pipe.

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Description 2

Specifications
Weight

Arm Assembly 12,284 lb (5572 kg)

Head Assembly 10,060 lb (4563 kg)

Base Assembly 2,518 lb (1142 kg)

Hydraulic Requirements

Required Operating Pressure 3,000 psi (207 bar)

Required Flow Rate 65 gpm (246 lpm)

Maximum Input Pressure 3,000 psi (206 bar)

Minimum Input Pressure 3,000 psi (207 bar)

Minimum Flow Rate 55 gpm (208 lpm)

Hydraulic Supply Connections 1" pressure, 1 1/4" tank, and 1/2" drain

Spin Wrench

Speed 80 rpm on 5" OD Tubular

Torque 3,467 ft-lb (4,701 N-m) on 5" OD Tubular

Pipe Range 3-1/2" - 10"

Torque Wrench

Make-up Torque 140,000 ft-lb (189,815 N-m)

Break-out Torque 160,000 ft-lb (216,931 N-m)

Connection Range 3 1/2" - 10"

Electrical Requirements

Power (Voltage/Current) 110-240 VAC, 15-20 Amps

Optional: Normally Closed dry contact for tool shutdown

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Specifications
Equipment Operating Dimensions
Fully Retracted and Fully Lowered
Fully Retracted and Fully Lowered Top View

RIGHT SIDE
OF TOOL Numbers in brackets are millimeters
90.51
[2299] ±90°
*SEE NOTE
61.98
[1574]
R42.81
[R1087]
*Maximum slew angle as shown. For
CW SLEW R67.41
[R1712]
devaiation, consult National Oilwell
Varco Engineering.

82.62 57.00
[2099] [1448]
*Vertical dimensions vary when arm is
extended because the arm does not
BACK OF travel in a perfect horizontal path.
TOOL
Maximum connection height with
tool fully lowered could be: 35.24
FRONT OF [895].
TOOL
R44.74
[R1136] CCW SLEW CENTER OF
ROTATION
46.60 LEFT SIDE
[1184] OF TOOL

46.60
[1184]

15.78
[401]

CG CENTER OF SPIN
WRENCH ROLLERS

108.24
[2749]

*58.98
46.62 [1498]
[1184] *31.88
[810]
CONNECTION
HEIGHT

DRILL FLOOR

Fully Retracted and Fully Lowered Side View Fully Retracted and Fully Lowered Front View
ST16000009

Figure 2-1. ST-160 Fully Retracted and Fully Lowered Elevation Views

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Description 2

Specifications
Equipment Operating Dimensions
Fully Extended and Fully Lowered Dimensions

Fully Extended and Fully Lowered Top View

Numbers in brackets are millimeters

252.60
[6416]
208.60
[5298]

57.00 80.26
[1448] [2039]

103.04
[2617]
COLUMN

42.00
ARM ASSEMBLY [1067]

CG CENTER OF SPIN
WRENCH ROLLERS

*104.85
[2663]

65.59 *60.94
[1666] [1548]
46.00
86.03 [1168] 31.16 *33.84
[2185] [859]
[791] 15.56
[395]

CONNECTION
DRILL FLOOR DRILL PIPE HEIGHT
CENTRALIZER

*Vertical dimensions vary when arm is

extended because the arm does not
travel in a perfect horizontal path. Fully Extended
Maximum connection height with tool and
Fully Extended and Fully Lowered Side View fully lowered could be: 35.24 [895]. Fully Lowered Front View
ST160000010

Figure 2-2. ST-160 Fully Extend and Fully Lowered Elevation Views

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Page 2-6 of 36

Specifications
Equipment Operating Dimensions
Fully Retracted and Fully Raised Dimensions
Fully Retracted Fully Raised Top View
90.51
[2299]
61.98 Numbers in brackets are millimeters
R42.81 [1574]
[R1087] R67.41
[R1712]

*Maximum slew angle as shown. For

devaiation, consult National Oilwell
57.00 Varco Engineering.
[1448]
82.62
[2099]

*Vertical dimensions vary when arm is

extended because the arm does not
travel in a perfect horizontal path.
R44.74 Maximum connection height with tool
[R1136] 46.60 fully raised could be: 77.24 [1962].
[1184]
CENTER OF
ROTATION
46.60
[1184]
15.78
[401]

CG CENTER OF SPIN
WRENCH ROLLERS

150.24
[3816]

CONNECTION *100.98
88.62 HEIGHT [2565]
[2251] *73.88
[1877]

DRILL FLOOR

Fully Retracted and Fully Rasied Side View Fully Retracted and Fully Raised Front View
ST16000011

Figure 2-3. ST-160 Fully Retracted and Fully Raised Elevation Views

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Specifications
Equipment Operating Dimensions
Fully Extended and Fully Raised Dimensions

Fully Extended and Fully Raised Top View

Numbers in brackets are millimeters

252.60
[6416]
208.60
[5298]

57.00 80.26
[1448] [2039]

103.04
[2617]

42.00
ARM ASSEMBLY [1067]

CENTER OF SPIN
WRENCH ROLLERS

*146.85
[3730]

107.59 *102.94
[2733] 128.03
[3252] [2615]
80.81 DRILL PIPE *75.84
73.16
[2053] CENTRALIZER [1926]
[1858] 57.56
[1462] CONNECTION
HEIGHT

ARM ASSEMBLY

*Vertical dimensions vary when arm is

extended because the arm does not
travel in a perfect horizontal path. Fully Extended
Maximum connection height with tool and
Fully Extended and Fully Raised Side View fully raised could be: 77.24 [1962]. Fully Raised Front View
ST16000012

Figure 2-4. Fully Extended and Fully Raised Elevation Views

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Page 2-8 of 36

Equipment Pinch Point 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 equip-
ment, or between material being handled and part of
the equipment. Take extreme care around pinch
points. If possible, avoid these areas while the equip-
ment is operating.

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 2-5 show the locations for pinch points on the ST-160 Iron Roughneck.

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Description 2

Equipment Pinch Point Locations

Take extreme care around equipment

pinch points. If possible, avoid these
areas while the equipment is operating.

ST160000013

Figure 2-5. Equipment Pinch Points

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General Arrangement

Left Rear

ST-160
IRON ROUGHNECK
References to right or left and ASSEMBLY
front and back of the components
described in this manual assumes
the perspective of the tool, as if
you were in front and facing the
tool.

For ST-160 technical

Drill Pipe Head information see the section
Module tilted “Specifications”.

Front Front View Right

Right Front

Arm Assembly

ST-160
IRON ROUGHNECK
ASSEMBLY

For rig floor mounting

configuration, kits, and rig
floor technical layout
reference See the appropri-
ate ST-160 General
Arrangement drawing.

Socket Base
Rear Assembly Rear View Left
(See note)
ST16000001

Figure 2-6. Typical ST-160 Iron Roughneck Assembly

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Description 2

Major Components
The ST-160 Iron Roughneck consists of the following components:
 Drill Pipe Head Module — Connected to the arm assembly, the drill pipe head
module consists of the spin wrench and torque wrench assemblies. (See the section
titled "Drill Pipe Head Module" on page 2-13.)
 Torque Wrench Assembly — Supports clamping jaws that make up and break
out tubular connections. (See the section titled "Torque Wrench Assembly" on
page 2-14.)
 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 2-18.)
 Arm Assembly — Supports and provides horizontal travel for the drill pipe head
module. 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 2-20.)
 Column Guide Assembly — Provides vertical travel for the Iron Roughneck. The
column guide assembly is connected to the floor-mounted socket base assembly.
(See the section titled "Column Assembly" on page 2-22.)
 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 2-26.)
 Electrical Components — The tool is equipped with multiple I/O J-boxes
assemblies, tool mounted sensors, along with other electrical components. (See the
section titled "Electrical Components" on page 2-30.)
 Rig Floor Kit — 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 "Rig Floor
Kit" on page 2-24.)
 Wireless Remote Control System — The wireless remote control system is
specifically designed for the ST-160 Iron Roughneck. The operator station
communicates with its respective receiver using a coded radio signal. The radio
remote transmitter and receiver are a uniquely matched pair. (See the section titled
"Wireless Remote Control System" on page 2-34.)
Figure 2-7 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.

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Page 2-12 of 36

Major Components

Take extreme care around equipment

pinch points. If possible, avoid these
areas while the equipment is operating.

Junction Box Assembly

Column/Guide
Assembly

Arm Assembly

Drill Pipe Head

Module

Spin Wrench
Socket Base Assembly
Assembly
Upper Jaw
Assembly
Torque Wrench
Assembly Pipe Centralizer Lower Jaw
Assembly Assembly

For ST-160 Hydraulic assemblies and Properly lock out all energy sources
components, see Chapter 2, tilted before performing inspection, lubrica-
“Hydraulic Assemblies” for more tion, or replacement procedures.
information.
ST16000004

Figure 2-7. Major Assemblies and Components of a typical ST-160 Iron Roughneck Assembly

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Description 2

Major Components
Drill Pipe Head Module
The ST-160 Iron Roughneck drill pipe head module attaches to the scissor-arm which provides
horizontal travel to align the Iron Roughneck with Well Center or Mousehole. It consists of the spin
wrench and torque wrench assembly.
The head assembly provides two basic functions:
 Provides backup and torque capability for making up and breaking out connections.
 Provides capability for spinning in and spinning out connections.
For tubular makeup and breakout procedures refer to Chapter 4, titled "Operating Procedures"“.

Spin Wrench
Assembly
Drill Pipe Head
Frame Weldment

Torque Wrench
Assembly

ST-160 Drill Pipe Head Module

as viewed from FRONT Side

ST160000003

Figure 2-8. Drill Pipe Head Module

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Major Components
Torque Wrench Assembly
The ST-160 torque wrench is capable of making and breaking connections at 140,000 ft-lbs and
160,000 ft-lbs, respectively, and handles tubulars ranging from 3-1/2" to 10" outer diameter.
Each torque wrench consists of a three cylinder clamping system. The upper and lower torque
cylinders allow the ST-160 a full 60 degrees of rotation. The upper torque wrench rotates 30
degrees either direction of center, while the lower torque wrench remains stationary.
The clamping circuit is "dynamic", in that the clamping pressure increases as the torque setting is
increased. This is controlled automatically through the hydraulic system and requires no input from
the user, other than the desired torque setting.

See Chapter 4, titled "Operation" for more information.

Figure 2-9 shows an ST-160 Torque Wrench assembly with the upper and lower jaw
subassemblies shown to show how the subassemblies go together with the torque wrench
assembly.
Figure 2-10 shows the upper jaw and lower jaw assemblies with the internal components.

ST-160
TORQUE WRENCH
ASSEMBLY

Upper Jaw
Assembly

Lower Jaw
Assembly

Torque Wrench Assembly

as viewed from Front Side

ST160000006

Figure 2-9. Torque Wrench Assembly

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Description 2

Major Components
Torque Wrench Assembly
Jaw Assemblies
Torque Cylinders

Upper Jaw Assembly

Dies
(3 places)
Clamp Cylinder
(3 places)
Jaw Spacer
(2 places)

Center Die Guide

Jaw Spacer
(2 places)

Jaw Assembly
Cap Plates Wrench Guard
(2 places)

Link Guide
(2 places)
Torque Cylinders

Clamp Cylinder Side Die Guide

(2 places)
(3 places)

Side Die Guide Clamp Cylinder

(2 places) (3 places)

Lower Jaw Assembly

Jaw Assembly Jaw Assembly Wrench Guard

Top Cap Plate Bottom Cap Plate (2 places)
ST16000007

Figure 2-10. Jaw Assemblies

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Major Components
Torque Wrench Assembly
Pipe Centralizer
The ST-160 pipe centralizer enables the drill pipe head to be concentric around the tubular when
making or breaking connection. The pipe centralizer assembly consists of the following:
 A pair of centralizer jaw plates
 A joint finder assembly with a quick disconnect proximity switch
 A hydraulic cylinder assembly to open and close the centralizer jaw plates.
The hydraulic supply line to the torque wrench clamp cylinders also provides hydraulic pressure to
the centralizer clamp cylinder. When a torque wrench clamp command is given, the centralizer
clamps on the tubular before the torque wrench dies come in contact with the tubular. The force of
the centralizer positions the torque wrench properly about the tubular.
Integrated into the pipe centralizer is the tool joint finder. The tool joint finder is equipped with a
proximity sensor for sensing the upset on drill pipe.

See section titled "Torque Wrench Assembly" on page 2-

14, and see Chapter 4, titled "Operation" for more
information.

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Description 2

Major Components
Torque Wrench Assembly
Pipe Centralizer
Head Assembly
Reference Only Proximity Switch Slide Weldment
Cover Plate
Cable
GuideTube
Front

Cap Plate

Torque Wrench
Assembly
(Ref.) Washer

Side Plate
2 places

Joint Finder Spring

Cord Set
Rear
Pipe Centralizer Tool Joint Finder
Assembly Assembly
Jaw Plate

Tool Joint Finder

Cord Set Assembly

4 Pin Connector
(M)

4 Pin Connector
(F)

Jaw Plate

Cylinder Assembly Travel Block

Pipe Centralizer
as viewed from Rear

ST160000016

Figure 2-11. ST-160 Pipe Centralizer

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Major Components
Spin Wrench Assembly
The ST-160 Spin Wrench Assembly is hydraulically powered and contained in the drill pipe head
module. It is located above the torque wrench assembly and is used to spin a drill pipe/drill collar
connection in prior to applying makeup torque, and spin a drill pipe/drill collar connection out after
applying breakout torque.
During spin-in and spin-out operations, the thread compensation system allows the spin wrench to
move up or down slightly to compensate for the threading and unthreading of tubular sections. The
spin wrench assembly is equipped with a nitrogen-charged accumulator which allows the spin
wrench to travel with the drill pipe while spinning in and out.

Before a makeup cycle, the spin wrench must be elevated

at least six inches so the accumulator can compensate for
pipe travel. The spin wrench automatically elevates to the
proper level for drill pipe.

Figure 2-12 shows the ST-160 Spin Wrench assembly and its right and left wrench roller carrier
subassemblies.

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Description 2

Major Components
Spinner Wrench Assembly

Motor Guard
Motor Guard

Hydraulic Manifold

Spin Wrench
Roller Carrier Weldment
Hydraulic Cylinder

Bogey Arm Guard

SPIN WRENCH
as viewed from Rear Side

Objects can get caught in the rollers.

Make sure that tools, clothing, or personal Hydraulic Motor
equipment do not contact the rollers during 2 places each side
operation. These objects can get tangled in
the rollers and cause serious injury and/or
equipment damage. Upper Bearing Housing
2 places, each side
Bogey Arm Guard
Grooved Roller
Spin Wrench Strut 2 places, each side

Lower Bearing Housing

Spin Wrench 2 places, each side
Roller Carrier Weldment

SPIN WRENCH Spin Wrench

as viewed from Front Side Roller Carrier Weldment

Rear
Pinching Hazard. Make sure the power is
OFF to the spin wrench before touching it or
getting near it for maintenance and repairs.

Spin Wrench

Front 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.
Head Assembly
Reference Only ST160000015

Figure 2-12. ST-160 Spin Wrench Assembly

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Major Components
Arm Assembly
The ST-160 Arm Assembly is capable of supporting, extending, and retracting the head assembly
for positioning at well center, mousehole, and park/stand by positions.
Horizontal movement is accomplished by two (2) hydraulic cylinders mounted to the arm main
frame structure and vertical movement is accomplished by one (1) hydraulic cylinder mounted to
the column guide assembly.
The Arm Assembly consists of the following assemblies and components:
 Arm structure
 Column guide assembly
 Junction-box assembly
 Arm functions manifold assembly
The arm structure consists of three sections:
 Primary arm section
 Secondary arm section
 Front arm section

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Description 2

Major Components
Arm Assembly

Column/Guide Assembly
Upper Primary Arm
(2 places)
Upper Secondary Arm
For ST-160 Hydraulic assemblies
and components see the section
tilted “Hydraulic Assemblies”.

Upper Front Arm

(2 places)

End Link

End Link Lower Primary Arm

Front View Lower Front Arm Lower Secondary Arm

(2 places) (2 places)

Upper Primary Arm Upper Front Arm End Link

(2 places) (2 places)
End Link
Guards removed for clarity.
Upper Secondary Arm
Column/Guide Assembly

J-Box
Guard

Lower Front Arm

(2 places)

Junction Box
Lower Secondary Arm
(2 places)
Service Loop
Bracket Manifold Guard

Arm Functions
Rear View Manifold Assembly Lower Primary Arm ST16000008

Figure 2-13. ST-160 Arm Assembly

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Major Components
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 is connected to the floor-mounted socket base assembly.
The Column Assembly consists of the following welded assemblies and components:
 Column weldment
 Guide Weldment
Column weldment - The column weldment consists of two upright support plates connected by
an upper top plate and a cross beam center plate. Located on the outside of each upright plate is
the column guide roller track, and located on the lower end of each plates are the socket base pin
bores and tie-down feet.
Guide Weldment - The guide weldment is roller mounted to the column, and provides support and
vertical movement for the arm structure. A set of combined track rollers roll directly against the
inside and outside runner surface of the column guide track, allowing the arm structure to travel up
or down.
The column guide assembly also provides end support for the service loops, electrical junction
box, and the arm functions manifold assembly.

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Description 2

Major Components
Column Assembly.
Column Weldment

Column Guide Track

Linear Profibus
Transducer
Oil Tank
2 places

Track Roller
4 places

Service Loop
Support
Column Guide

Track Roller
4 places

Front

Hydraulic Cylinder

Rear

Arm Assembly
Reference Only Column/Guide Assembly

ST16000014

Figure 2-14. ST-160 Column Guide Assembly

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Major Components
Rig Floor Kit
The ST-160 Iron Roughneck is installed on the drill floor using a single, floor-mounted socket
system. The following assemblies and components make up the ST-160 floor mount system:
 Floor Socket Weldment
 Socket Base Assembly

Floor Socket
The floor socket is a female weldment member positioned and welded in the rig floor to support
both the socket base assembly and Iron Roughneck.

For specific floor socket details, refer to the appropriate ST-

160 General Arrangement and Socket Kit drawings in the
the Technical Drawing package (TDP).

Socket Base Assembly

The socket base assembly is an integrated gearbox drive. It enables the Iron Roughneck to be
rotated about the center of the column for proper alignment over the Well Center or Mousehole.
The socket base system consists of a hydraulic slewing motor, spring applied-hydraulic release
brake, and a gearbox.
The hydraulic slewing brake is used as a parking brake. It is mounted atop of the planetary
gearbox. When the slewing function is actuated, the brake is hydraulic released and the ST-160
will begin to slew in the desired direction, When the function is release, the ST-160 will stop
slewing and the brake will set.
The gearbox is powered by a low-speed high torque hydraulic motor. The hydraulic slewing motor
is mounted atop of the hydraulic slewing brake.
The slew encoder outputs a digital signal for absolute shaft position. It is mounted atop of the
hydraulic slewing motor. When the slew command is activated the encoder indicates the current
position of the tool for processing.
Figure 2-15 shows a typical ST-160 Socket Base Assembly.

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Description 2

Major Components
Rig Floor Kit
Socket Base Assembly.
ST-160
Reference Only

Iron Roughneck
(Ref.)
Encoder

Encoder Adapter

Hydraulic Motor

Front
Motor Adapter

Brake

Planetary Gearbox
Guards removed for clarity.

Rear

Socket Base Base Shims

Assembly (A/R each side)

Socket Weldment
Cover

Base

Column Pin
2 places

Turntable Bearing
Female Floor Socket

Male Socket Flange

Refer to the engineering drawings in the

Technical Drawing Package (TDP) for
rig-specific details about the floor socket kit
configuration.

ST16000017

Figure 2-15. Socket Base Assembly

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Major Components
Hydraulic Assemblies
Drill Pipe Head Manifolds
The ST-160 Drill Pipe Head Module
contains seven (7) hydraulic manifold assemblies:
 Head Functions Manifold Assemblies
 Wrench Centering Manifold Assembly
 Torque Wrench Centralizer Manifold Assembly
 Upper Torque Wrench Clamp Manifold Assembly
 Lower Torque Wrench Clamp Manifold Assembly
 Clamp Intensified Pressure Manifold Assembly
 Spin Wrench Manifold Assembly
High Pressure
Filter Assembly Spin Wrench
Manifold Assembly

Head Functions
Manifold Assembly Front

ST-160 Drill Pipe

Head Module

Rear

Clamp Intensified
Pressure Manifold
Assembly Torque Wrench
Centralizer Manifold Assembly
Upper Torque Wrench
Clamp Manifold Assembly

Lower Torque Wrench

Clamp Manifold Assembly

Wrench Centering Manifold

Assembly
(removed for clarity)
ST160000005

Figure 2-16. Torque Wrench and Spin Wrench Manifold Assemblies

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Description 2

Major Components
Hydraulic Assemblies
Arm and Carriage Manifold
The ST-160 Arm Assembly contains one (1)
Arm Assembly hydraulic manifold assembly:
Reference Only
 Arm Functions Manifold Assembly

Front

Rear

Guards removed for clarity.

Filter Assembly

Supply Shut-off
Ball Valve
Flow Switch
Motion Control Assembly
Valve Assembly

Arm Functions
Manifold Assembly

ST16000019

Figure 2-17. Arm and Carriage Functions Manifold

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Major Components
Hydraulic Assemblies
Hydraulic Cylinders and Hydraulic Motors
Mechanical movement of the ST-160 Iron Roughneck is accomplished by several sequential
hydraulic functions performed by several hydraulic cylinders and hydraulic motors.
Mounted in the torque wrench the following cylinders operate the upper and lower jaw assemblies.
 Three (3) upper jaw clamp cylinders
 Two (2) upper jaw torque cylinders
 Three (3) lower jaw clamp cylinders
 Two (2) lower jaw torque cylinders
Mounted in the spin wrench the following hydraulic cylinders and hydraulic motors operate the spin
wrench assembly.
 One (1) spin wrench lift cylinder
 One (1) spin wrench clamp cylinder
 Four (4) spin wrench roller carrier hydraulic motors
Mounted in the arm/carriage the following hydraulic cylinders operate the arm/carriage assembly:
 Two (2) arm deploy hydraulic cylinders
 One (1) carriage lift cylinder
Mounted in the socket base the following hydraulic motor operates the socket base assembly.
 One (1) carriage hydraulic slewing motor
 One (1) hydraulic slew brake.

See Chapter 4, titled "Operation", and Chapter 5, titled

"Maintenance" for more information.

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Description 2

Major Components
Hydraulic Assemblies
Cylinders and Motors

Spin Wrench
Hydraulic Motor
(4 places)

Spin Wrench
Lift Cylinder
Upper Jaw
Clamp Cylinder
(3 places)
Spin Wrench
Clamp Cylinder

Lower Torque Wrench

Cylinder
Arm (2 places)
Deploy Cylinder Lower Jaw
(2 places)
Clamp Cylinder
(3 places)
Upper Torque Wrench
Cylinder
Carriage Centralizer Cylinder (2 places)
Hydraulic Slewing Motor
Carriage
Lift Cylinder

ST16000018

Figure 2-18.

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Major Components
Electrical Components
Electrical components consists of safety devices and monitoring sensors for input to the control
system and tool-mounted solenoids for function control. Position monitoring sensors provide
feedback for slew, arm extension, vertical travel, spin wrench height, jaw rotation, and tool joint
sensing.
Electrical cabling termination for power, signal, and control circuits is accomplished by using a
derrick-mounted junction box and three separate tool-mounted junction boxes.
Figure 2-19 illustrates the electrical components and their location on the equipment.

For additional electrical component details, refer to the

TDP (Technical Drawing Package) for drawings and
electrical schematics regarding component information.

The following electrical components are installed on the ST-160 Iron Roughneck:

E-Stop
 Three emergency shot down switch devices are located on the tool. One is located
at the rear of the tool on the carriage junction box and two are located on the left and
right side of the tool. Another E-Stop switch device is located on wireless control
(see Figure 4-3).

Warning Beacon/Warning Horn

 Beacon/Strobe Light — Provides a combined visual and audible warning. The
lights flash when the ST-160 is enabled and, the horn sounds when any arm
function is activated.

Junction Boxes
 Derrick Remote I/O Junction Box — The derrick remote junction box provides a
termination interface between the rig and the ST-160 for electrical power and
control. Derrick Remote I/O junction box not shown in Figure 2-19, refer to the TDP
(Technical Drawing Package) for drawings and electrical schematics regarding
component information.
 Carriage Junction Box — The carriage junction box provides connection points to-
and-from the ST-160 electrical components: the derrick remote junction box, N.I.S.
junction box, I.S. junction box, arm functions manifold, proximity switches,
transmitters, sensors, transducers, and E-Stop devices.
 Head N. I.S. Junction Box — The head N.I.S. junction box provides I/O connection
points to-and-from ST-160 carriage junction box and head functions manifold
assembly.
 Head I.S. Junction Box — The head I.S. junction box provides I/O connection
points to-and-from ST-160 carriage junction box and head module proximity
switches.

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Description 2

Major Components
Electrical Components
Sensors and Transducers
 Deploy Extend/Retract Linear Profibus Transducer — Provides position
feedback for arm horizontal travel.
 Carriage Up/Down Linear Profibus Transducer — Provides position feedback for
vertical arm travel.
 Spin Wrench Up/Down Linear Transducer — Provides position feedback for spin
wrench vertical travel
 Slew Left/Right Profibus Encoder — Provide position feedback for slewing.
 System Pressure Transducer — Provides pressure feedback for system pressure
0-3000 psi [207 bar]. Transducer not shown in Figure 2-19, refer to the TDP
(Technical Drawing Package) for drawings and electrical schematics regarding
component information.
 Makeup/Breakout Pressure Transducer — Provides pressure feedback to
determine full make up or breakout position, 0-3000 psi [207 bar].
 Torque Pressure Transducer — Provides pressure feedback for displaying torque
torque (0 to 3,000 psi [207 bar]). Transducer not shown in Figure 2-19, refer to the
TDP (Technical Drawing Package) for drawings and electrical schematics regarding
component information.
 Clamp Pressure Transducer — Provides pressure feedback for applied clamp
pressure (0 to 6,000 psi [414 bar]). Transducer not shown in Figure 2-19, refer to the
TDP (Technical Drawing Package) for drawings and electrical schematics regarding
component information.
 Hydraulic Enable Transducer — Provides pressure feedback to determine if tool is
enabled.
 Torque Wrench Proximity Sensor (2) — Provides location feedback for wrench
center, full makeup, and full breakout positions of the upper torque wrench.
 Tool Joint Finder Proximity Sensor — Provides feedback when a tool joint is
detected.
 Object Detection Diffuse Sensors (4) — Provides feedback if an object is in the
collapse zone of the arm. Triggering this sensor shuts down all functions.
 Flow Switch — Provides feedback for determining when some spin wrench or
torque wrench functions have been completed. Flow switch not shown in Figure 2-
19, refer to the TDP (Technical Drawing Package) for drawings and electrical
schematics regarding component information.

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Major Components
Electrical Components
Valve Solenoids
 The ST-160 contains six (6) 24VDC electrical solenoids that energize the
hydraulically operated head module control valves. These valve solenoids are
located on the head functions manifold assembly.
 The ST-160 contains three (3) 24VDC electrical solenoids that energize the
hydraulically operated arm functions. These valve solenoids are located on the arm
functions manifold assembly.

Electrical Connectors
 Electrical connectors are provided for removing/re-installing the drill pipe head
module and casing tong module. The electrical connectors are located on the right
end link of the arm assembly.

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Description 2

Major Components
Electrical Components

Beacon/Strobe Light

Diffuse Sensor Column

4 places Linear Transducer

Head N.I.S. Junction Box

Valve Solenoid
6 places Head I.S. Junction Box
(Head Functions Manifold Assembly)
Diffuse Sensor
4 places

Head Module/Casing Module

Proximity Sensor Arm
2 places Linear Transducer

Spin Wrench
Linear Transducer
E-Stop

E-Stop

Carriage
Upper Torque Wrench Junction Box
Proximity Sensor
2 places
Slew Encoder

Front Valve Solenoid

Proximity Sensor 3 places
(Tool Joint Finder) Electrical E-Stop (Arm Functions Manifold Assembly)
Connectors

ST160000047

Figure 2-19. Electrical Assemblies and Components

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Wireless Remote Control System

The ST-160 wireless remote control system enables the operator to control the ST-160 without
having to stay at a fixed stationary control console.
The wireless remote control system shown in Figure 2-20 is specifically designed for the ST160
Iron Roughneck. The wireless remote controller (transmitter) communicates with its respective
receiver using a coded radio signal. The transmitter and receiver are uniquely matched pair.
The following are features of an NOV wireless remote control system:
 The controller is intrinsically safe type of protection and is certified for use in an EX
Zone 1 areas.
 The controller is battery operated and uses a rechargeable battery. Batteries may
be exchanged within the hazardous area.

!
The receiver is only to be used in a safe area. It is mounted
in the remote I/O derrick junction box.

 The wireless controller can be carried by user with a lap belt carrier.
 The wireless controller includes a display screen. It relays information to the
operator regrading feedback information, set point information. and operator
messages and prompts.
 The E-Stop button stops the tool in an emergency situation. This stop can be
initiated by manually pushing the E-Stop button located on the side of the controller
(see Figure 4-3). The button is twisted to disengage.

See section titled "Wireless Controller" on page 4-6 for

detailed wireless controller information.

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Description 2

Wireless Remote Control System

Antenna
(Remote mounted)

Remote Antenna
Cable

Remote Operator Feedback Antenna

Receiver Station
with
Digital Card

Transmitter
iON Key

RECEIVER TRANSMITTER

!
The receiver is only to be used in a safe
(Non-Hazardous) area.

The receiver is typically mounted

next to the derrick junction box. ST16000028

Figure 2-20. Wireless Remote Control System

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Installation 3

Installation Procedures
A rig-specific engineering installation procedure is required for the ST-160 Iron Roughneck. This
installation procedure is included in the equipment User Manual. Refer to the ST-160 Installation
Procedure, for rig-specific installation information.

Drill Floor Position Recommendations

The Iron Roughneck must be secured to the rig floor and the supporting structure should be able
to support the weight of the equipment. Refer to the section titled "Specifications" on page 2-3 and
the General Arrangement engineering drawing in the Technical Drawing Package (TDP) for
dimensions, weights, rig-floor loading, and rig-floor layout drawings.

Lifting Recommendations
When lifting and handling the Iron Roughneck, lift the equipment from designated lift points only.
Refer to the General Arrangement engineering drawing in the Technical Drawing Package (TDP)
for lifting arrangement information.

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Operation 4

Introduction
There are two operator interface methods typically used to control the ST-160 Iron Roughneck.
Depending on the equipment and rig configuration, one or more of these methods may be used to
access and operate the equipment.
 Wireless Remote Control
Refer to the section titled "Wireless Remote Control Operation" on page 4-5 for
operating instructions.
 Amphion™ Control System
Refer to the Amphion Operator’s Guide supplied with the NOV equipment rig
documentation package.
The following sections provide basic operating information and instructions for the Iron
Roughneck.

Operating Considerations
Please make note of the following before operating the Iron Roughneck.

Precautions

Make sure that all personnel are clear of the equipment

operating path before operating or restarting the
equipment. Failure to adhere to this precaution may
result in severe injury. If the tool moves unexpectedly,
shut down the equipment and lock out hydraulics
immediately. Inspect equipment for damage.

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.

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Operating Considerations
Precautions

!
This chapter provides basic operating information for the
ST-160 Iron Roughneck. Rig personnel must understand
the information provided in this chapter and be thoroughly
trained before operating this equipment.

!
Shut down the equipment when it is not being used.

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 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, remote control console, and, if applicable, the
Amphion™ single-board computer (SBC).

Normal Sounds
The following may occur during normal operation:
 Ticking — Ticking noise occurs when jaws have made contact with the pipe and the
intensifier is building pressure.
 Whining — Torque wrench clamp flow dividers make a whining noise when the jaws
are being clamped prior to making contact with pipe. The torque wrench also makes
a whining noise when the output is set in the lower range.
 Humming — When the Iron Roughneck slews there may be a humming sound
coming from the slewing system.

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Operation 4

Operating Considerations
Normal Occurrences
The following may occur during normal operation:
 Torque wrench may cycle left or right slowly when operating other functions.
 Torque display will drop to zero when going to the full makeup position.
 Spin rollers may rotate very slowly when other functions are operating.

Component motion may occur when operating other

functions is due to high return pressure.

General Operating Information

!
Rig personnel must understand the information provided in
this section and be thoroughly trained before operating this
equipment. Refer to the section titled "Wireless Controller"
on page 4-6 for wireless controller operating information.

Trip Mode
The two modes of operation in Trip Mode are In and Out. This mode is used by the Auto Sequence
to either make or break a connection. Select Trip In to inform the tool that you would like to makeup
connections in the Auto Sequence. Select Trip Out to inform the tool that you would like to breakout
connections in the Auto Sequence.

Destination Selector
The destination selector allows you to toggle to the activity center that the roughneck will operate
at.

Moving Between Destinations

The roughneck is only allowed to slew when it is within eight inches of its fully retracted position.
Also, it is only allowed to slew to the slew position of the destination that is selected. To slew the
roughneck:
 Retract the arm to within eight inches of the fully retracted position.
 If the home position is set such that it is further than eight inches, the Iron
Roughneck will have to be retracted further. To do so, push and hold the OVERRIDE
button while actuating the DEPLOY RETRACT lever until the Iron Roughneck is
within 8 inches of the fully retracted position.

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General Operating Information

Moving Between Destinations
 Using the DESTINATION button, toggle to the desired destination. Using the SLEW
CW/CCW lever slew in the direction of the desired destination. The Iron Roughneck
will slew towards and stop at the slew position of the selected destination. The Iron
Roughneck can only slew in the direction of the slew position of the selected
destination. If the user attempts to slew the Iron Roughneck in the opposite
direction, nothing will happen.

Start Up
Upon starting the tool up:
 Open the torque wrench and spinning wrench.
 Move the TW MAKE/BREAK lever so that the torque wrench moves in the full make
or break direction, or push then release the DEPLOY lever in the EXTEND/
RETRACT direction. Pushing the DEPLOY lever will indicate to the Iron Roughneck
control system that it should center the torque wrench and deploy in the requested
direction. If the DEPLOY lever is pushed and released before it can move, only the
wrench will center.

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Operation 4

Wireless Remote Control Operation

This section contains basic operating information for the ST-160 Iron Roughneck operated
remotely from a wireless remote controller.

The wireless remote control system shown in Figure 4-1 is

specifically designed for the ST-160 Iron Roughneck. Refer
to Chapter 2 for the description of the wireless remote
control system.

Antenna
(Remote mounted)

Remote Antenna
Cable

Remote Operator Feedback Antenna

Receiver Station
with
Digital Card

Transmitter
iON Key

RECEIVER TRANSMITTER

!
The receiver is only to be used in a safe
(Non-Hazardous) area.

The receiver is typically mounted

next to the derrick junction box. ST16000028

Figure 4-1.

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Wireless Remote Control Operation

Wireless Controller

Top View Back View

Left View Right View

ST16000029

Figure 4-2. Wireless ST-160 Control Transmitter

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Operation 4

Wireless Remote Control Operation

Wireless Controller
Right View
ON/OFF
Key Switch
ST-160

E-Stop

ST16000038

Figure 4-3. ON/OFF Key and E-STOP Pushbutton Operator Switches

 ON/OFF — The ON/OFF key switch turns the wireless controller on. After turning
the controller on, you must push the OVERRIDE button once to turn the Iron
Roughneck on. The BATTERY LED indicator lights green to indicate that the
wireless controller is on and blinks red when the battery is low.
 E-STOP — The E-STOP (Emergency Stop) button is used to stop the tool in an
emergency situation.

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Wireless Remote Control Operation

Wireless Controller
This section provides information about ST-160 wireless remote control console components.
Figure 4-2 shows the wireless remote control console in separate views for identifying location of
components used.

ST-160

ST16000027

Figure 4-4. Override, Destination, and Trip Normal Operation Pushbutton Switches

 OVERRIDE — The OVERRIDE button is used to override most of the interlocks.

Press and hold this button while overriding the interlock. This is also used to start
the unit right after switching the wireless controller on.
 DESTINATION —The DESTINATION button is used to select the destination that
the Iron Roughneck should operate at.
 W/C — The W/C green LED lamp indicator indicates that the Iron Roughneck
will operate at well center. (Note that the unit should be slewed while fully
retracted to line up with well center prior to initiating any operation sequences).
 FH1 — FH1 green LED lamp indicator indicates that the roughneck should
operate at Foxhole 1. (Note that the unit should be slewed while fully retracted
to line up with Foxhole 1 prior to initiating any operation sequences)
 FH2 — The FH2 green LED lamp indicator indicates that the Iron Roughneck
should operate at Foxhole 2. (Note that the unit should be slewed while fully
retracted to line up with Foxhole 2 prior to initiating any operation sequences)
 TRIP — The TRIP button is used to select the trip sequence that will be run during
the Auto Sequence.
 IN — The IN green LED lamp indicator indicates that the Iron Roughneck will
makeup a connection during the Auto Sequence.
 OUT — The OUT green LED lamp indicator indicates that the roughneck will
breakout a connection during the Auto Sequence.

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Operation 4

Wireless Remote Control Operation

Wireless Controller
ST-160

ST16000032

Figure 4-5. Slow and Teach Normal Operation Pushbutton Switches

 SLOW — The SLOW button steps the tool in and out of Slow mode. This mode is
used to slow down the spinners when spinning drill collars. The SLOW green
indicator lamp lights up when the tool is in Slow mode.
 TEACH — The TEACH button starts the Teach sequence and is used to step
through the sequence. The TEACH lamp indicator lights up when the tool is in Teach
mode.

ST16000033

Figure 4-6. Operator Display

 OPERATOR DISPLAY — Displays messages and other relevant information to the

operator.

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Wireless Remote Control Operation

Wireless Controller

ST-160

ST16000034

Figure 4-7. Slew, Deploy, SW/TW - Up/Down, - Clamp/Unclamp, SW In/Out, TW Make/Break

Normal Operation Linear Levers

 SLEW CW/CCW — The SLEW lever is used to rotate the Iron Roughneck in the
clockwise and counter-clockwise direction.
 DEPLOY EXTEND/RETRACT — The DEPLOY lever is used to extend and retract
the Iron Roughneck.
 SW/TW UP/DOWN — The SW/TW UP/DOWN moves the main carriage or spinning
wrench carriage up and down. The carriage that moves depends on which wrench is
selected using the WRENCH button, see page 4-13 for more details about wrench
controls.
 SW/TW CLAMP/UNCLAMP — The SW/TW CLAMP/UNCLAMP lever is used to
clamp or unclamp the spinning wrench or torque wrench. The wrench that clamps or
unclamps depends on which wrench is selected using the WRENCH button, see
page 4-13 for more details about wrench controls.
 SW IN/OUT — The SW IN/OUT lever is used to spin the spinning wrench spinners
in the in or out direction.
 TW MAKE/BREAK — The TW MAKE/BREAK lever is used to move the torque
wrench in the make or break direction.

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Operation 4

Wireless Remote Control Operation

Wireless Controller
ST-160

ST16000032

Figure 4-8. Torque ADJ/Tool Joint, Increase /Decrease Normal Operation Toggle Switches

 TORQUE ADJ/TOOL JOINT — The TORQUE ADJ / TOOL JOINT toggle switch is
used to set the required torque and to set the tool joint length of the joint that is
being made up or broken out in the auto sequence. This switch is to be used in
conjunction with the INCREASE/DECREASE toggle switch and should be
maintained in the TORQUE ADJ or TOOL JOINT direction while setting these
values.
 INCREASE/DECREASE — The INCREASE/DECREASE toggle switch increases
or decreases the torque set point or the tool joint length depending on which
direction the TORQUE ADJ / TOOL JOINT toggle switch is pressed.

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Wireless Remote Control Operation

Wireless Controller
ST-160

ST16000036

Figure 4-9. Auto, Power Slips Mode Normal Operation Pushbutton Switches

 AUTO — The AUTO button initiates the auto sequence and steps the Iron
Roughneck through the sequence. The ATUO green lamp indicator lights up when
the auto sequence is active.
 POWER SLIPS MODE — The POWER SLIPS MODE button is used to tell the
system that PS-16 power slips are installed. The POWER SLIPS green lamp
indicator lights up when the tool is in Power Slips mode.

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Operation 4

Wireless Remote Control Operation

Wireless Controller

ST-160

ST16000037

Figure 4-10. Wrench, Mode Normal Operation Pushbutton Switches

 WRENCH — The WRENCH button is used to select which wrench to use. The
wrenches that can be selected are the torque wrench or the spinning wrench.
 TW — The TW green LED lamp Indicator informs the Iron Roughneck operator
that the torque wrench is selected.
 SW — The SW green LED lamp indicator informs the Iron Roughneck operator
that the spinning wrench is selected.
 MODE — The MODE button allows the operator to select which mode to operate
the Iron Roughneck in. The modes to choose from are Normal, Spinning Wrench
Backup, and TDS Backup.
 NORMAL— The NORMAL green LED lamp indicator informs the Iron
Roughneck operator that the tool is in NORMAL mode.
 TDS — The TDS green LED lamp indicator informs the Iron Roughneck
operator that the tool is in TDS Backup mode.
 SWB — The SWB green LED lamp indicator informs the Iron Roughneck
operator that the tool is in Spinning Wrench Backup mode.
 SWAP — When the NORMAL, TDS, and SWB green LED lamp indicators are
all powered off, this status informs the Iron Roughneck operator that the tool is
in SWAP mode.

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Wireless Remote Control Operation

Wireless Controller Display
The ST-160 wireless controller display relays information to the operator regarding feedback
information, set point information, and operator messages and prompts. The display is broken
down into three sections: Graph, Numeric, and Message. A detailed explanation of the display
sections is given in Figure 4-11.

Graph

Numeric

Message

ST16000039

Figure 4-11. Wireless Screen Display

Graph
This section of the display gives a graphical representation of the torque information (see Figure 4-
11). The large bar graph (5 pixels wide) indicates actual torque, where the small bar graph below it
(1 pixel wide) indicates set point torque. As the actual torque increases, the bar will move from left
to right. The minimum and maximum torque are to the left and right respectively.

Numeric
This section of the display (see Figure 4-12) gives a numerical display of actual torque, set point
torque, and tool joint length. The value that is displayed depends on which direction the TORQUE
ADJ / TOOL JOINT return to center toggles switch is pressed. The actual torque is displayed by
default. The torque set point is displayed when the switch is pressed in the TORQUE ADJ
direction. The tool joint length is displayed when the switch is pressed in the TOOL JOINT
direction.
Min Torque Actual Torque Torque Setpoint Max Torque

ST16000040

Figure 4-12. Wireless Display Screen showing Torque Setting

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Operation 4

Wireless Remote Control Operation

Wireless Controller Display
Numeric
In Figure 4-13 below, the Numeric Value is the numeric representation of the information that is
displayed (i.e. actual torque, torque set point, or tool joint length). The unit of that value will be
displayed in the middle (Units: KFT-LB for actual and set point torque, and INCHES for tool joint
length). The information that is being displayed (Display Information. i.e. ACTLTORQ for Actual
Torque, TORQSET for torque set point, and TJL for tool joint length) is to the far right.
Displayed
Numeric Value Units
Information

ST16000041

Figure 4-13. Wireless Display Screen showing Units and numeric Information

Message
The Message portion displays messages regarding tool interlocks and operator prompts.

On Function
Turning the tool on is a two step process. First you must move the on/off switch in the on position.
Then you must push the override button.

Wrench Selector
The WRENCH button allows the user to select which wrench to operate, spinning wrench or torque
wrench. When SW is selected, the SW/TW UP/DOWN lever will raise or lower the spinning wrench
carriage and the SW/TW CLAMP/UNCLAMP lever will clamp or unclamp the spinning wrench.
When TW is selected, the SW/TW UP/DOWN lever will raise or lower the main carriage and the
SW/TW CLAMP/UNCLAMP lever will clamp or unclamp the torque wrench clamp.

Mode Selector
The MODE button allows the user to toggle between NORMAL, SWB (Spinning Wrench Backup),
TDS (TDS Backup) mode, and SWAP mode.
NORMAL MODE — In NORMAL mode, the torque wrench Clamp and Unclamp functions will
operate both the upper and lower torque wrench.
SWB MODE — In SWB mode, the torque wrench clamp and unclamp functions will operate only
the lower torque wrench.

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Wireless Remote Control Operation

Wireless Controller Display
Mode Selector
TDS MODE — In TDS mode, the torque wrench clamp and unclamp functions will operate only the
lower torque wrench. Also while in TDS mode, the operator will not be allowed to close the
spinning wrench.
SWAP MODE — When the NORMAL, TDS, and SWB mode LED’s are all deactivated to an off
state, this indicates the ST-160 is SWAP mode. In SWAP mode, all arm functions are reduced to a
slow speed for safely docking/undocking the drill pipe or casing module.
To get to the SWAP mode, toggle the mode selected switch until NORMAL, TDS, and SWB LED’s
are all OFF.

Tool Joint Length Selection

The TOOL JOINT toggle switch allows the user to input the length of the tool joint the Iron
Roughneck will operate on while in the auto sequence. If the tool joint length is set to 0, the user
will manually adjust the roughneck height in the auto sequence.
To set the tool joint length:
 Push TORQUE ADJ / TOOL JOINT toggle switch in the TOOL JOINT (Downward)
direction.
 While maintaining the toggle switch in that direction, move the INCREASE/
DECREASE toggle switch in the direction that you want to adjust the tool length.
 Once the desired tool joint length is reached, release INCREASE/DECREASE
toggle switch.
 While maintaining the TORQUE ADJ / TOOL JOINT toggle switch in the TOOL
JOINT (downward direction), verify in the display that the tool joint length is correct.
 Release the toggle switch when the length is verified.

Torque Adjustment
The TORQUE ADJ toggle switch allows the user to input the output torque of the ST-160.
To set the output torque:
 Push Torque ADJ/TOOL JOINT toggle switch in the TORQUE ADJ (upward)
direction.
 While maintaining the toggle switch in that direction, move the INCREASE/
DECREASE toggle switch in the direction that you want to adjust the torque.
 Once the desired torque is reached, release INCREASE/DECREASE toggle switch.
 While maintaining the TORQUE ADJ / TOOL JOINT toggle switch in the TORQUE
ADJ (upward direction), verify in the display that the torque is correct.
 Release the toggle switch when the torque is verified.

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Operation 4

Wireless Remote Control Operation

ST-160 Auto Teach Sequence
The purpose of the teach sequence is to allow the user to pre-set destination, duck, and home
positions for each location of roughneck operation.
Buttons involved in the teach sequence:
1. Teach – The Teach button puts the unit into teach mode, but also toggles between
the teach operations that can be taught.
2. Auto – The Auto button sets the position once the tool is in the desired location.

When in Teach mode, the remote control display will scroll

detailed instructions for teaching destinations. The
following instructions allow the user to view the complete
teach sequence instructions.

Initial Teach Instructions

The followings steps detail the initial teach setup. They should be used when no positions have
been taught.
1. Select the destination that you intend to teach by pressing the destination button
until the desired destination indicator is illuminated.
2. To put Roughneck into teach mode, press the Teach button. The teach mode
indicator should now be illuminated.
3. Destination Teach – The first operation in the teach mode is to teach the position of
the selected destination (i.e. well center, foxhole 1, or foxhole 2. Follow steps 3a -3d
to teach destination. If the destination is already set and correct, press the TEACH
button to move to the next step in the Teach sequence.
a. Position the tool at the correct destination. The tool must be completely
retracted in order to slew, but can be slewed when at the destination by pressing
the override button while activating the slew lever on the remote control.
Activate the slew lever VERY slowly when slewing while extended to the
destination.
b. Once the tool has been positioned at the desired location, press the Auto
button. The destination has now been set for arm extension and slew position.
c. If the tool needs to be repositioned more accurately, make the necessary
adjustments to slew and arm extension, then press the Auto button to set the
destination.
d. Press Teach to move to the next step in the Teach sequence.
4. Duck Teach – The second operation in the teach mode is to teach the duck position
(i.e. lower the tool to miss overhead obstructions). If the duck position is correct,
press the Teach button to move to the next step in the Teach sequence
a. Position the tool such that the head is just in front and below of the overhead
obstruction.

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Wireless Remote Control Operation

ST-160 Auto Teach Sequence
Initial Teach Instructions
b. Once the tool has been positioned at the desired location, press the Auto
button. The duck position has now been set.
c. If the tool needs to be repositioned more accurately, make the necessary
adjustments, then press the Auto button to set the duck position.
d. Press Teach to move to the next step in the Teach sequence.
5. Home Teach - The third operation in the teach mode is to teach the home position
(i.e. the arm extension position the operator wants the tool to return to after
completing a makeup or breakout sequence).
a. Position the tool in the desired Home position.
b. Once the tool has been positioned at the desired Home position, press the Auto
button. The home position has now been set.
c. If the home position needs to be adjusted, reposition the tool, then press the
Auto button to set the home position.
6. Exit Teach Sequence – Press the Teach button to exit the Teach sequence. The
teach mode indicator should now be no longer be illuminated.

Specific Position Teach Instructions

If a position is already set and is acceptable, it does not have to be re-taught. If only one position
needs to be taught, follow these instructions:
1. Put the tool in teach mode and toggle the teach button until the desired teach
operation (Destination Teach, Duck Teach, Home Teach) is displayed.
2. Press the Auto button to set the desired position.
3. Toggle the teach button until teach mode is exited.

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Operation 4

Operating Procedures
Making Connections
The following instructions detail how to perform a manual (non-automated) makeup sequence
using the wireless controller. For automated operation see section titled "Automated Makeup
Procedure" on page 4-21. Make sure the following are verified before beginning the procedure:
 The iron roughneck is fully retracted and the carriage is in its lowest position.
 The teach sequence has been performed for all required destinations (see section
titled "ST-160 Auto Teach Sequence" on page 4-17).
 The torque wrench jaws and the spin wrench are fully opened.
 The required torque has been set (see section titled "Torque Adjustment" on page 4-
16).
 The tool joint length has been set (see section titled "Tool Joint Length Selection" on
page 4-16).
 The desired destination has been selected and the ST-160 has been slewed to that
destination.
 SWB Mode is selected.
 TW LED is illuminated by toggling the WRENCH button.
Complete the following steps to make up a connection using the iron roughneck:
1. Extend the arm by holding the DEPLOY switch in the EXTEND position. The head
assembly will be deployed to the preset target destination and will stop.
2. Raise the torque wrench by holding the SW/TW switch in the UP position until the
upper and lower jaws are centered on the tool joint. If the torque wrench is already
raised, verify that the upper and lower jaws are centered on the tool joint.
3. Clamp the lower torque wrench jaw by holding the SW/TW switch in the CLAMP
position.
4. Toggle the WRENCH button until the SW LED light is illuminated, and Clamp the
spin wrench by holding the SW/TW switch in the CLAMP position.
5. Spin in the connection by holding the SW switch in the IN position until the
connection is shouldered.
6. Unclamp the spin wrench by holding the SW/TW switch in the UNCLAMP position.
7. Toggle the MODE button until the NORMAL LED light is illuminate.
8. Toggle the WRENCH button until the TW LED light is illuminated, and position the
upper torque wrench jaw by holding the TW switch in the BREAK position until it
stops rotating.
9. Clamp the upper jaw by holding the SW/TW switch in the CLAMP position.
10. Torque the connection by holding the TW switch in the MAKE position until the
desired torque is reached. If the torque setting is not reached or the torque gauge
drops to zero, repeat steps 8-10.
11. Unclamp the torque wrench by holding the SW/TW switch in the UNCLAMP
position until the upper and lower jaws fully retract.
12. Retract the arm to the home position by holding the DEPLOY switch in the
RETRACT position. Note, depressing the DEPLOY-RETRACT switch will return the
torque wrench to the wrench center position before retracting the arm.

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Operating Procedures
Breaking Connections
The following instructions detail how to perform a manual (non-automated) breakout sequence
using the wireless controller. For automated operation see section titled "Automated Makeup
Procedure" on page 4-21. Make sure the following are verified before beginning the procedure:
 The iron roughneck is fully retracted and the carriage is in its lowest position.
 The teach sequence has been performed for all required destinations (see section
titled "ST-160 Auto Teach Sequence" on page 4-17).
 The torque wrench jaws and the spin wrench are fully opened.
 The required torque has been set (see section titled "Torque Adjustment" on page 4-
16). For breakout, the torque should be set to 10% higher than the required makeup.
 The tool joint length has been set.
 The desired destination has been selected and the ST-160 has been slewed to that
destination.
 Normal Mode is selected.
 TW LED is illuminated by toggling the WRENCH button.
Complete the following steps to make up a connection using the iron roughneck:
1. Extend the arm by holding the DEPLOY switch in the EXTEND position. The head
assembly will be deployed to the preset target destination and will stop.
2. Raise the torque wrench by holding the SW/TW switch in the UP position until the
upper and lower jaws are centered on the tool joint. If the torque wrench is already
raised, verify that the upper and lower jaws are centered on the tool joint.
3. Position the upper torque wrench jaw by holding the TW switch in the MAKE position
until it stops rotating.
4. Clamp the upper and lower torque wrench jaws by holding the SW/TW switch in the
CLAMP position.
5. Break the connection by holding the TW switch in the BREAK position until the
torque wrench reaches the end of its stroke.
6. Toggle the Mode button to select SW mode.
7. Unclamp the upper torque wrench jaw by holding the SW/TW switch in the CLAMP
position.
8. Toggle the WRENCH button until the SW LED light is illuminated, and clamp the
spin wrench by holding the SW/TW switch in the CLAMP position.
9. Spin out the connection by holding the SW switch in the OUT position until the
connection is spun out. If the connections can't spin out, repeat steps 3-8.
10. Unclamp the spin wrench by holding the SW/TW switch in the UNCLAMP position.
11. Toggle the WRENCH button until the TW LED light is illuminated.
12. Unclamp the torque wrench by holding the SW/TW switch in the UNCLAMP
position until the lower jaws fully retract.
13. Retract the arm to the home position by holding the DEPLOY switch in the
RETRACT position. Note, depressing the DEPLOY-RETRACT switch will return the
torque wrench to the wrench center position before retracting the arm.

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Operation 4

Operating Procedures
Automated Makeup Procedure
The following instructions detail how to perform an automated makeup sequence using the
wireless controller. Make sure the following are verified before beginning the procedure:
 The iron roughneck is fully retracted and the carriage is in its lowest position.
 The teach sequence has been performed for all required destinations (see section
titled "ST-160 Auto Teach Sequence" on page 4-17).
 The torque wrench jaws and the spin wrench are fully opened.
 The required torque has been set (see section titled "Torque Adjustment" on page 4-
16).
 The tool joint length has been set.
 The desired destination has been selected and the ST-160 has been slewed to that
destination.
 TRIP IN is selected.
 Set mode to SWB.
Complete the following steps to makeup a connection using the auto makeup sequence:
1. Press the AUTO button on the wireless controller.
a. The ST-160 will extend to the destination and raise to the tool joint.
b. The torque wrench will then rotate to the makeup ready position.
2. Visually verify that the ST-160 torque wrench jaws are in the proper vertical position
on the tubular.
3. Once the torque wrench position is visually verified, press the AUTO button.
a. The lower torque wrench will clamp.
b. The spin wrench will clamp.
c. The spin wrench will then spin in the connection.
d. Once the connection is fully spun in, the upper torque wrench will clamp and
apply torque.
4. Visually verify on the Operator Display that the desired torque has been reached.
5. Once the makeup torque has been reached and verified, press the AUTO button.
a. The spin wrench and torque wrench will unclamp, the torque wrench will return
to the wrench center position, the arm will fully lower and retract to the preset
home position.

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Operating Procedures
Automated Breakout Procedure
The following instructions detail how to perform an automated breakout sequence using the
wireless controller. Make sure the following are verified before beginning the procedure:
 The iron roughneck is fully retracted and the carriage is in its lowest position.
 The teach sequence has been performed for all required destinations (see section
titled "ST-160 Auto Teach Sequence" on page 4-17).
 The torque wrench jaws and the spin wrench are fully opened.
 The required torque has been set (see section titled "Torque Adjustment" on page 4-
16). For breakout, the torque should be set to 10% higher than the required makeup.
 The tool joint length has been set.
 The desired destination has been selected and the ST-160 has been slewed to that
destination.
 TRIP OUT is selected.
 Set mode to SWB.
Complete the following steps to makeup a connection using the auto makeup sequence:
1. Press the AUTO button on the wireless controller.
a. The ST-160 will extend to the destination and raise to the tool joint.
b. The torque wrench will then rotate to the breakout ready position.
2. Visually verify that the ST-160 torque wrench jaws are in the proper vertical position
on the tubular.
3. Once the torque wrench position is visually verified, press the AUTO button.
a. The upper and lower torque wrench will clamp, and the upper torque wrench will
breakout the connection.
b. Once the torque wrench reaches the end of stroke, the upper torque wrench will
unclamp.
c. The spin wrench will then spin out the connection.
d. Once the connection has been fully spun out, the spin wrench and torque
wrench will unclamp.
e. The torque wrench will return to the wrench center position, and the arm will
lower and retract to the home position.

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Operation 4

Interlock Conditions
This section describes the rules within the ST-160 control system that govern the interlock
functions.
Integrated sensors and interlocks enable the ST-160 to perform several functions without operator
intervention. Interlocks also prevent an operator from inadvertently initiating inappropriate
operating sequences.
A general list of interlocks is as follows:
 Torque Wrench / Spin Wrench Clamp Interlock – If the torque wrench and/or the
spin wrench are clamped on the drill pipe, the following will be disabled: arm extend/
retract, slew CW/CCW, main carriage up/down, spin wrench clamp up/down (only
when spin wrench is clamped on drill pipe).
 Non Driven Motion Interlock – If the carriage up/down or spin wrench raise linear
transducer changes in value while the torque wrench and/or spin wrench is clamped
on drill pipe, all torquing functions will cease immediately and the torque wrench
jaws and spin wrench will be unclamped immediately. This will aid to protect the tool
from damage, as in the case when the driller inadvertently lifts the drill pipe via the
drawworks, or the drill pipe slips in the slips.
 Slewing Interlock – The slew function is interlocked when the arm is extended
beyond 18 inches. This is to protect the slewing system and ensure that the arm
does not “run away” when trying to bring it to a stop, i.e. listing drill ship/
semisubmersible.
 Torque Sequence Interlock – This interlock does not allow the torque sequence to
begin until the clamp pressure has reached a steady state.
 Wrench Center Interlock – When the torque wrench is not centered, the arm
cannot be extended/retracted.
 Unclamp Interlock – The jaws cannot be unclamped from the drill pipe unless the
make/break function has been de-energized. This minimizes damage to the dies
and scaring of the drill pipe.
 Carriage Interlock – When the ST-160 is fully raised or fully lowered, the jaws
cannot be clamped on the drill pipe. See bullets about non-driven motion in the
following scenarios: spin wrench carriage and main carriage.
 Traverse To Far Interlock – Cannot slew when the arm is extended past a certain
distance.
 Off Path Interlock – Cannot extend/retract or operate carriage when not on path of
chosen destination.
 Carriage In Obstruction Interlock – Cannot extend/retract when carriage is in
perceived obstruction.
 Traversed In Obstruction Zone Interlock – Cannot hoist spin wrench and main
carriage when extended behind a perceived obstruction.
 TDS Backup Interlock – Cannot clamp spin wrench when in TDS backup.
 Arm In Obstruction Interlock – Cannot extend/retract when the arm is in the
perceived obstruction.
 Diffuse Sensors Interlock – Extend/retract, main carriage rise/lower, slew CW/
CCW disabled.

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Interlock Conditions
 Torque Wrench Maximum Torque Interlock – Doesn't allow torque wrench make if
torque is greater than 140,000 ft-lb (4,701 Nm).
 Too Many Modules Interlock – Disables all functions if more than one module is
detected.
 Installed Illegally Interlock – Disables all functions if a module is installed and the
tool is in SWAP mode.
 Needs To BE In SWAP Mode Interlock – Disables all functions if a module is not
installed and the tool is not in SWAP mode.
 Low System Pressure Interlock – Disables all functions if there is low system
pressure.

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Operation 4

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.

Before momentarily overriding an interlock condition,

check the area of operation for rig personnel and
equipment. Failure to do so could result in severe
injury, death, and/or equipment damage.

 If the Spin Wrench is closed:

 The ST-160 is not allowed to deploy forward or reverse or slew
 The Main Carriage is not allowed to hoist or lower
 The Spin Wrench Carriage is not allowed to hoist or lower
 And the ST-160 detects non-driven motion of more than 1" up or down, or
reaches the Carriage Interlock at the end of stroke, the Spin Wrench will be
forced open 
(Note: End of stroke detection forcing the SW open is NOT override-able)
 If the Torque Wrench is closed:
 The ST-160 is not allowed to deploy forward or reverse or slew
 The Main Carriage is not allowed to hoist or lower
 And the ST-160 detects non-driven motion of more than 1" up or down, or
reaches the Carriage Interlock at the end of stroke, the Torque Wrench will be
forced open 
(Note: End of stroke detection forcing the TW open is NOT override-able)
 If the ST-160 has been taught that an Overhead Obstruction Exists:
 The Main Carriage is not allowed to hoist into the obstruction
 And if the ST-160 is above the obstruction height the ST-160 is not allowed to
deploy forward or reverse
(Note: Normal operation of the forward or reverse command will activate main
carriage lower until the ST-160 is clear of the obstruction, then it will deploy)
 If the ST-160 has been set to work with Power Slips:
 The Main Carriage is not allowed to lower into the power slips
 And if the ST-160 is below the power slips height the ST-160 is not allowed to
traverse forward into the power slips area
(Note: Normal operation of the forward or reverse command will activate main
carriage hoist until the ST-160 is clear of the power slips, then it will deploy)
 If the ST-160 has been set to backup torque from a Top Drive:
 The Spin Wrench is not allowed to close
 The upper jaws of the Torque Wrench are not allowed to close

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Interlock Considerations
 If the ST-160 has been set to backup for spinning:
 The Upper Torque Wrench Jaw will not close
 If the ST-160 has not been initialized;
 None of the automated sequences will be allowed to start
(Note: Initialization of the ST-160 means that all mechanical components of the
ST-160; deploy, Torque Wrench & Spin Wrench carriages and Torque Wrench &
Spin Wrench bodies have been moved and monitored and their current
positions and status are known by the control system. See section titled "ST-160
Auto Teach Sequence" on page 4-17 for initialization instructions.
 If the ST-160 is performing an automated sequence:
 And the non-driven motion interlock is received on main carriage, the sequence
will be aborted.
 If the ST-160 is performing any movement;
 And a ZMS Interlock is received that is directed at that movement, the
movement will be inhibited.
In addition to interlocks, the ST-160 will automatically stop movement when; it has reached its
preset travel point destinations, the main carriage or spin wrench carriage reaches its high or low
limits, and when input from the operator is required during auto sequence. If the system is not
properly configured or not fully powered up prior to attempting operation, an appropriate message
will be displayed. However, this may simply be information to the operator and not an interlocking
condition.

In addition to the interlocks, the remotely controlled ST-160

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 4

Arm Assembly Lockout Procedures

For the safety of personnel and to prevent equipment damage install arm assembly locking pins
prior to work being performed on the unit.

Properly lock out the arm assembly before performing

lubrication, inspection, or replacement procedures.
Failure to adhere to this precaution may result in
severe injury and/or equipment damage.

Arm lock pins are stored behind the arm functions manifold
guard.

Locking Out the Arm Assembly

Complete the following steps to properly lockout the arm assembly:
1. Once the hydraulic service loop has been installed, turn the ball valve on the rear of
the ST-160 to the ON position.
2. Extended the arm, by activating the DEPLOY EXTEND function to the point where
the arm assembly lock pins can be installed.
3. Install the arm assembly lock pins.
4. Turn the ball valve on the rear of the ST-160 to the OFF position.

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Arm Assembly Lockout Procedures

Locking Out the Arm Assembly

Properly lock out all energy

sources before performing
inspection, lubrication, or
replacement procedures.

Arm Assembly
Take extreme care around
equipment pinch points.

Arm Lock Pin

2X

Arm lock pin can be installed on

this component three various
positions that result in different
arm extensions.

Arm Functions
Manifold Guard

Arm lock pins are stored

behind the arm functions
manifold guard.

ST16000075

Figure 4-14. Arm Assembly Lockout

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Operation 4

Electro-Hydraulic Pilot Valve Operation

Manually Operating the Electro-Hydraulic Pilot Valve
In the event the ST-160 cannot be operated by the control system, the electro-hydraulic control
valves are equipped with a manual override button.

!
The manual override buttons should only be used in an
emergency situation and should be used with extreme
caution. The resolution of the button is low, so depressing
the button will result in full flow functionality.

Electro-Hydraulic pilot valve 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.

!
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. If
possible, avoid these areas while the equipment is
operating.

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Electro-Hydraulic Pilot Valve Operation

Manually Operating the Electro-Hydraulic Pilot Valve

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 do so could
result in severe injury, death, and/or equipment
damage.

 To manually operate an Iron Roughneck actuator component, isolate and manually

operate the respective pilot valve by using a small tool to press the pilot valve
override. See Figure 4-15 for manual override application.
 The head functions manifold assembly contains 7 (seven) electro-hydraulically
piloted proportional valve assemblies. See Figure 2-16 for head functions manifold
location.
 The arm functions manifold contains 3 (three) electro-hydraulically piloted
proportional valve assemblies. See Figure 2-17 for arm functions manifold location.

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Operation 4

Electro-Hydraulic Pilot Valve Operation

Manually Operating the Electro-Hydraulic Pilot Valve

Use a small tool to

press the pilot valve
override.

Electro-Hydraulic
Piloted Proportional Valve

Head Functions Manifold Arm Functions Manifold

Piloted Proportional Valves Piloted Proportional Valves
(6 places) (3 places) ST16000062

Figure 4-15. Manual Override of Electro-Hydraulic Pilot Valve

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Hydraulic Failure Operation

This section describes operating instructions for releasing hydraulic Iron Roughneck components
under failure conditions.

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.

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 1-3 and
section titled "Safety Precautions" on page 5-4.
 Identify all equipment pinch points as described in the section titled "Equipment
Pinch Point Locations" on page 2-8.

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 to the Iron Roughneck before
performing any of the procedures in this section. Refer to
the section titled "Hydraulic Assemblies" on page 2-26 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.

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Operation 4

Hydraulic Failure Operation

Rotating the Slew Base Assembly
In the event of hydraulic failure, the slew base assembly may need to be rotated manually by
overriding the hydraulics to the slew base assembly.

!
Procedures described in this section will result in hydraulic
fluid leaks that may expose personnel to slip-and-fall
injuries. Take precautionary measures to catch or contain
hydraulic fluid. Spilled hydraulic fluid may also cause
environmental contamination. Collect and clean up any
spilled or escaping oil. Dispose of excess hydraulic fluids,
lubricants, and cleaning material appropriately.

During operation, surfaces may become hot enough to

injure personnel. Allow surfaces to cool before
touching or working around the equipment.

Complete the following steps to override the hydraulic slew motor:

1. Extend the arm, if necessary, to allow access to the column.
2. Disconnect lines A and B of the hydraulic slew motor from the connection to the
hoses in the column.
3. Connect lines A and B of the hydraulic slew motor. These lines are equipped with
quick disconnect connections and should couple together. See Figure 4-16.
4. Next, using a hydraulic power source of no more than 500 psi, connect to the brake
release line C (#6 male JIC fitting) and release the brake.
5. Once the brake is released, the socket base assembly should be able to rotate
manually. Rotate into the position desired and release hydraulic pressure to the
brake.
6. Next, disconnect the A and B lines of the hydraulic motor and reconnect each to the
appropriate hose in the column. Disconnect hydraulic power source from the brake
and replace hose.

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Hydraulic Failure Operation

Rotating the Slew Base Assembly

Bleed all hydraulic pressure from the Iron Roughneck

before disconnecting hydraulic lines. Hydraulic oil
under pressure can penetrate skin and cause serious
injury.

ST16000024

Figure 4-16. Manual Override of Slew Hydraulic Motor

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.

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Operation 4

Hydraulic Failure 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.

During operation, surfaces may become hot enough to

injure personnel. Allow surfaces to cool before
touching or working around the equipment.

Figure 4-17 shows the location of the port plugs on the clamp cylinders.
Complete the following steps to remove plugs and manually retract the clamp cylinders:
If the torque wrench clamp cylinders need to be retracted during a hydraulic failure, please do the
following:
1. To deactivate torque wrench clamp cylinders, locate and slowly remove the plugs in
port “P” on all four forward clamp cylinders to gradually release hydraulic pressure.
2. Once all residual pressure is relieved, use a pry-bar to retract clamp cylinders from
drill pipe.

Remove clamp cylinder plugs slowly so hydraulic

pressure is released gradually. If a plug is removed too
quickly, it could be projected across the rig floor at
high velocity. Always wear protective eye wear when
working on hydraulic components.

Pressurized hydraulic oil can penetrate skin and cause

serious injury to personnel. Always wear protective
clothing when working on hydraulic components.

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Hydraulic Failure Operation

Releasing the Torque Wrench

ST-160
TORQUE WRENCH
ASSEMBLY

Upper Jaw
Assembly

Lower Jaw
Assembly

Front
“P” “P”
Hydraulic Drain Plug Hydraulic Drain Plug

Clamp Cylinder
4 places

“P”
“P”
Hydraulic Drain Plug
Hydraulic Drain Plug
ST16000056

Figure 4-17. Torque Wrench Clamp Cylinder Port Plugs

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Operation 4

Hydraulic Failure 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 cylinder. To manually retract the clamp cylinder, fittings are loosened on the
clamp cylinder to release hydraulic pressure.

During operation, surfaces may become hot enough to

injure personnel. Allow surfaces to cool before
touching or working around the equipment.

Complete the following steps to remove plugs and manually retract the clamp cylinders:
1. Slowly and carefully loosen the hose fittings on the spin wrench clamp cylinder.

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.

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 grooved rollers away from the drill pipe.
4. Once the cylinder is retracted, replace and retighten all fittings and hoses.
Figure 4-18 shows the location of the fittings on the spin wrench clamp cylinder.

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Hydraulic Failure Operation

Releasing the Spin Wrench

Pinching Hazard. Make sure the power is

OFF to the spin wrench before touching it or
getting near it for maintenance and repairs.

Clamp Cylinder
Hydraulic Fittings

Clamp Cylinder

SPIN WRENCH
as viewed from the Rear

Grooved Roller
4 places

Use pry bar here

SPIN WRENCH
as viewed from the Front

Drill Pipe
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.
ST160000057

Figure 4-18. Clamp Cylinder Hydraulic Fittings

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Operation 4

Hydraulic Failure 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-and-
fall injuries and environmental contamination. Collect and
clean up any spilled or escaping oil. Dispose of excess
hydraulic fluids, lubricants, and cleaning material
appropriately.

During operation, surfaces may become hot enough to

injure personnel. Allow surfaces to cool before
touching or working around the equipment.

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 4-19).
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.
Figure 4-19 shows the location of the test fittings on the arm assembly extend/retract cylinder.

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Hydraulic Failure Operation

Moving the Arm Assembly

Arm
Assembly

Loosen the fittings slowly so hydraulic

pressure is released gradually. If a
fitting is loosen and removed too
quickly, it could be projected at high
velocity. Always wear protective eye
wear when working on hydraulic
components.

Test Fitting 1

Arm Cylinder
 2 places; one on each arm

Test Fitting 2
ST16000058

Figure 4-19. Arm Cylinder Hydraulic Fittings

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Operation 4

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 4-21 on page 4-44).

Operating Environment

Condition Parameter

• Roll: 4° pitch, single amplitude with a 10 second period

Roll/Pitch
• Pitch: 50 foot roll center, below rig floor

Heave 2% acceleration force

Temperature -20° C to +55° C

Ice Thickness None

The following table provides the environmental limits for the Iron Roughneck secured in position
with the storage pin installed (Figure 4-21 on page 4-44).

Survival Environment

Condition Parameter

• Roll: 20° pitch, single amplitude with a 10 second period

Roll/Pitch
• Pitch: 50 foot roll center, below rig floor

Heave 30 ft. with a 10 second period

Temperature -20° C to +55° C

Ice Thickness None

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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Removal Procedure for the Shipping Skids

The ST-160 head module and column/arm assemblies are designed to be lifted and shipped
separately. Note assembly weights and ensure lifting equipment is properly rated.
Both the head and column/arm assemblies include attachment points for attaching lifting devices.
Use these lifting points to avoid damage to the components and to maintain balance during lifting.

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.

Figure 4-21 shows shipping pins and lifting points for the shipping skid and column/arm.
Figure 4-22 shows shipping pins and lifting points for the shipping skid head module.

Removing the Column/Arm Assembly from the Shipping

Skid
1. Attach lifting sling to the column/arm assembly, use the two lifting shackles and the
supplied sling (see Figure 4-20 on page 4-43), hoist the column/arm assembly
slightly so the weight is off the shipping skid.
2. Remove the two (2) front column/arm shipping pins and the two (2) rear column/arm
shipping pins (see Figure 4-21 on page 4-44).
3. After the shipping pins have been removed carefully hoist the column/guide
assembly away from the shipping skid and move it to its operating location.

See “ST-160 Field Installation Procedure” for detailed

installation instruction for positioning the column/arm
assembly to the socket base assembly.

4. Store the shipping skid and all pins for future use.

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Operation 4

Removal Procedure for the Shipping Skids

Removing the Column/Arm Assembly from the Shipping
Skid

Lift Weight
13,000 lbs.
(5897 kg.)

Lifting Sling

CL of Cloumn
Lifting Shackle Lifting Shackle
Storage Pin

Column/Arm
Assembly

Shipping Skid

ST16000060

Figure 4-20. Lifting Arrangement of Column /Arm on Shipping Skid

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Removal Procedure for the Shipping Skids

Removing the Column/Arm Assembly from the Shipping
Skid
Storage Pin

Lifting Shackle

Lifting Shackle

Column/Arm
Assembly

Rear
Shipping Pins
2 places

Column/Arm
Shipping Skid

Front
Shipping Pins
2 places ST16000059

Figure 4-21. Removing the Column /Arm from the Shipping Skid

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Operation 4

Removal Procedure for the Shipping Skids

Removing the Head Module from the Shipping Skid

The ST-160 Iron Roughneck and associated components

shall be installed, connected, fully assembled and adjusted
prior to removal of the head module from its shipping skid.

1. At the controller select SWAP MODE (see Figure 4-10, and refer to the section titled
"Mode Selector" on page 4-15 for information about SWAP MODE.

When the NORMAL, TDS, and SWB mode LED’s are all
deactivated to an off state, this indicates the ST-160 is
SWAP mode. In SWAP mode, all arm functions are
reduced to a slow speed for safely docking/undocking the
drill pipe or casing module.

2. Attach lifting sling to the head module, use the two lifting shackles and the supplied
sling (Figure 4-22 on page 4-47), hoist, and orient the head module with its shipping
skid relative to the arm assembly on a hard level surface.
3. Raise and suspend the head module so that the bottom of the shipping skid is high
enough to rotate the four (4) legs out of the shipping position and into the docking
position.
4. Rotate the legs and install the pins to fix the legs in the docking position.
5. Lower the assembly on a hard level surface and remove the lifting sling.
6. At the arm assembly end links remove the pins from the retainer links and rotate the
retainer links out of the way. The pins will be reinstalled after docking.
7. Using the remote controller, extend the arm until the arm saddles are in position
under the head module hubs.
8. Raise the carriage until the hubs are seated in the arm saddles, but don’t lift the
head off of the shipping skid.
9. Rotate and connect the retaining links and reinstall the hairpin cotters and clevis
pins.

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Removal Procedure for the Shipping Skids

Removing the Head module from the Shipping Skid
10. At the arm hydraulic end link side, connect the three (3) hydraulic service lines
(return line, drain line, supply line) connectors.
11. At the arm electrical end link side, connect the six (6) color coded electrical
connectors.
12. Remove the shipping hitch pins connecting the head module to the shipping skid.
13. Using the remote controller raise the carriage until the head module is free of the
shipping skid.
14. Retract the arm.
15. Attach lifting sling to skid and suspended the skid so that the bottom of the shipping
skid is high enough to rotate the four (4) legs out of the docking position and into the
shipping position.
16. Store the shipping skid and all pins for future use.
17. At the controller (see Figure 4-10),select which mode to operate the Iron Roughneck
in. Refer to the section titled "Mode Selector" on page 4-15 for information about
SWAP MODE.

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Operation 4

Removal Procedure for the Shipping Skids

Removing the Head Module from the Shipping Skid

Lift Weight
10,565 lbs.
(4792 kg.)

Lifting Sling

Lifting Shackle Lifting Shackle

Head Module

Legs rotated up
for shipping

Rotate legs (4X)

180° for docking
drill pipe head
assembly to arm

Shipping Skid

ST16000061

Figure 4-22. Lifting Arrangement of Head Module on Shipping Skid

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Removal Procedure for the Shipping Skids

Removing the Head Module from the Shipping Skid

Lifting Shackle

Lifting Shackle

Head Module

Rear
Shipping Pins
2 places

Locking Pin Locking Pin

4 places
4 places

i
Legs lowered for
rig operations

Shipping Skid Leg

4 places Front
Shipping Pins Locking Pin Head Module
2 places 4 places
Shipping Skid

ST160000063

Figure 4-23. Removing the Head Module from the Shipping Skid

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Operation 4

Installation Procedure for the Shipping Skids

The ST-160 head and column/arm assemblies are designed to be lifted and installed separately.
The best way to remove and install the equipment to their respective shipping skids is to use the
column/arm assembly to install the head module to its shipping skid first. However, an alternate
lifting device can be used if it is rated for the weight of the ST-160 assembly.
Both the head and column/arm assemblies include attachment points for attaching lifting devices.
Use these lifting points to avoid damage to the components and to maintain balance during lifting.

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.

Figure 4-24 shows shipping pins and lifting points for the shipping skid head module.
Figure 4-25 shows shipping pins and lifting points for the shipping skid and column/arm.

Installing Head Module to the Shipping Skid

1. At the controller select SWAP MODE (see Figure 4-10, and refer to the section titled
"Mode Selector" on page 4-15 for information about SWAP MODE.

When the NORMAL, TDS, and SWB mode LED’s are all
deactivated to an off state, this indicates the ST-160 is
SWAP mode. In SWAP mode, all arm functions are
reduced to a slow speed for safely docking/undocking the
drill pipe or casing module.

2. Attach lifting sling to the head module shipping skid, use the supplied sling, raise
and suspended the skid so that the bottom of the shipping skid is high enough to
rotate the four (4) legs out of the shipping position and into the docking position
3. Rotate the legs and install the pins to fix the legs in the docking position.
4. Place and orient the shipping skid relative to the arm assembly on a hard level
surface.
5. Remove the sling from the shipping skid.
6. Using the remote controller, extend the arm until the head module is orientated in
position over the shipping skid.

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Installation Procedure for the Shipping Skids

Installing Head Module to the Shipping Skid
7. Position the head module such that the two (2) front aliment pins of the torque
wrench are centered over the two (2) pilot tubes of the shipping skid (see Figure 4-
24 on page 4-51).
8. Lower the carriage until the head module is in contact with the shipping skid and all
four (4) shipping hitch pin holes are aligned.
9. Insert front and rear shipping hitch pins to secure the head module to the shipping
skid.
10. At the arm hydraulic end link side, disconnect the three (3) hydraulic service lines
(return line, drain line, supply line) connectors.
11. At the arm electrical end link side, disconnect the six (6) color coded electrical
connectors.
12. At the arm assembly end links, remove the pins from the retainer links and rotate the
retainer links out of the way. The pins will be reinstalled after undocking.
13. Using the remote controller, lower the carriage until the arm saddles are free of the
head module hubs.
14. Retract the arm.
15. Rotate and connect the retaining links and reinstall the hairpin cotters and clevis
pins.
16. Attach lifting sling to the head module, use the two lifting shackles and the supplied
sling, raise and suspend the head module so that the bottom of the shipping skid is
high enough to rotate the four (4) legs out of the docking position and into the
shipping position.
17. Rotate the legs and install the pins to fix the legs in the shipping position (see Figure
4-22 on page 4-47).
18. Hoist and remove the head module to the proper location. Store the shipping skid
and all pins.

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Operation 4

Installation Procedure for the Shipping Skids

Installing Head Module to the Shipping Skid

Lifting Shackle

Lifting Shackle

Head Module

Rear
Shipping Pins
2 places
Locking Pin
4 places
Locking Pin
4 places

i
Prior to moving the head and
shipping skid to storage, rotate
the legs out of the docking
position and install the four (4)
hitch pins to fix the legs in the
shipping postion (see Figure
4-21 on page 4-44).

Shipping Skid Leg Front

4 places Shipping Pins Locking Pin Head Module
2 places 4 places
Shipping Skid

ST160000064

Figure 4-24. Installing the Head Module on Shipping Skid

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Installation Procedure for the Shipping Skids

Installing the Column/Arm Assembly to the Shipping
Skid
1. Fully retract the Iron Roughneck, for column /arm removal. Disconnect all service
loops to the Iron Roughneck and disconnect all hydraulic lines connecting the
column to the socket base assembly.
2. Insert the upper column/guide storage pin.
3. Locate the shipping skid and position it relative to the arm assembly on a hard level
surface.
4. Attach lifting sling to the column/arm assembly, use the two lifting shackles and the
supplied sling (see Figure 4-20 on page 4-43),
5. Remove the two (2) socket base pins and the two (2) tie bolts connecting the socket
base assembly to the column/arm assembly, hoist the column/arm and position it
over the shipping skid.
6. Lower the column/arm assembly until the column/arm assembly is in contact with
the shipping skid and all four (4) shipping pin holes are align.
7. Insert the two (2) front column/arm shipping pins and the two (2) rear column/arm
shipping pins (see Figure 4-24 on page 4-51).
8. After the shipping pins have been installed and carefully hoist the column/arm
assembly and move it to its storage location.

!
Make sure to install the storage pin before lifting the Iron
Roughneck.

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Operation 4

Installation Procedure for the Shipping Skids

Installing the Column/Arm Assembly to the Shipping
Skid
Storage Pin

Lifting Shackle

Lifting Shackle

Column/Arm
Assembly

Rear

i Shipping Pins
2 places

Prior to moving the column/arm

and shipping skid to storage,
make sure to install the upper
column/guide storage pin, and
make sure to install all four (4)
shipping pins and insert all pin
locks .

Column/Arm
Shipping Skid

Front
Shipping Pins
2 places ST16000065

Figure 4-25. Install the Column/Arm on Shipping Skid

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Removing and Installing the Head Module

When operations require the head module be removed or reinstalled to the arm assembly, prepare
and use the supplied shipping skid for docking and undocking the head module. The supplied
shipping skid makes the change out and handling of the head module quick and safe.
 For removal of the drill pipe head module from the arm assembly refer to the section
titled "Installing Head Module to the Shipping Skid" on page 4-49.
 For installation of the drill pipe head module to the arm assembly refer to section
titled "Removing the Head Module from the Shipping Skid" on page 4-45.

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.

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 "Removal Procedure for the Shipping Skids" on page 4-42 and section titled
"Installation Procedure for the Shipping Skids" on page 4-49 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.

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Operation 4

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 60°F (16°C) ambient temperature. If high humidity is
unavoidable, an ambient storage temperature of 70°F (21°C) 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-160 Iron
Roughneck Commissioning Procedure.

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Maintenance 5

General Maintenance Information

This section provides a general guideline for maintaining the ST-160 Iron Roughneck. For a more
detailed explanation of the system, refer to the Description and Operations chapters in this
manual.

This manual cannot anticipate all possible variations in

techniques, tools, parts and in the skill level of individuals
operating or maintaining the Iron Roughneck. This manual
cannot provide advice, cautions or warning for every
potential situation. Accordingly, you must first establish that
you will not compromise crew safety or the integrity of the
equipment by your choice of methods, tools or parts.

The service intervals are based on average operating

conditions, more frequent service intervals are required if
you operate the equipment in conditions where excessive
load, dust or corrosive operating atmosphere or extreme
temperatures occur.

Schedules and procedures in this chapter relate to the Iron

Roughneck assemblies and components only. Refer to the
applicable OEM literature in the User Manual for
maintenance and repair procedures and schedules for
associated OEM equipment.

Contact NOV regarding issues that extend beyond the scope of this manual. For a directory of
NOV Service Center, see NOV document number D811001337-DAS-001, titled “Service Center
Directory” for your contact information.

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General Maintenance Information

Documentation You Will Need
 Electrical Interconnects and Hydraulic Schematics
 Iron Roughneck Technical Drawing Package
 Iron Roughneck Service Manual
 Recommended Lubricants and Hydraulic Fluids (D811000719)
 Design Specification, Design Torque Standard (DS00008)
 Safety Wiring procedure (ASP00019)

Refer to the applicable OEM literature, in the User Manual

for additional detailed maintenance information on
individual components and assemblies.

Major Repairs and Modifications

Major repairs and modifications should only be performed by NOV technicians. Contact NOV for
additional information.

Spare Parts You May Need

Refer to the recommend spare parts list in your User Manual and contact your NOV representative
or an NOV Service Center.

Cleaning
Clean the assembly with water once per day. This removes accumulated mud. No other normal
cleaning is required except as detailed elsewhere in this section.

Fastener Torque Values

Refer to the Design Torque Standard (DS00008) in the equipment User Manual for the torque
standards to follow when tightening component fastener (unless otherwise specified).

Install bolts with anti-seize compound and tighten based

on the Design Torque Standard document (DS00008). This
document is included in the equipment User Manual.

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Maintenance 5

General Maintenance Information

Safety Wiring (Lockwire) Procedures
Refer to the Safety Wiring Procedure (ASP00019) in the equipment User Manual for the
procedures required for installing safety wire (lockwire) on component fasteners.

!
Care shall be exercised when installing lockwire to ensure
that it is tight but not over stressed. Methods for the
selection and application of safety wire based on the
Safety Wiring Procedure (ASP00019). This document is
included in the equipment User Manual.

Wireless Controller Maintenance

There is no special maintenance required for the wireless controller. However, it is recommended
to store in a cool dry place and keep dry when not in use. Also, a spare fully charged battery is
recommended to ensure continuous operation.

Locking Out the Arm Assembly

Install arm assembly lock pins prior to work being performed on the unit. Refer to section titled
"Arm Assembly Lockout Procedures" on page 4-27 for arm assembly lockout instructions.

Arm assembly lock pins are stored behind the arm

functions manifold guard.

Equipment Maintenance Records

Keep a record book of all maintenance procedures performed. Date each procedure, followed by
a description and the technician who performed it. This data is valuable for fault finding and
problem solving should technical problems arise.
 All maintenance should be performed from a routine maintenance schedule that
provides a checklist of items and/or procedures to be followed and a time frame or
frequency interval that the tasks are to be performed in.
 Simple checklists or a series of checklists can be prepared for maintenance
personnel.
 Only maintenance personnel fully trained in the maintenance and servicing of this
equipment should perform any repairs or service.

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Safety Precautions
Read and understand all safety precautions before performing maintenance procedures. Do not
attempt repairs you do not understand.
Avoid equipment damage or injury to personnel by paying close attention to the important safety
notes highlighted as Warnings, Cautions, and Notes used throughout this manual.
If an item is designated a warning, failure to comply could cause serious injury or death. This
always the case whether it is implicitly stated in the text or not. In the case of a caution, personal
injury and/or equipment damage is always at stake.

Warnings
To avoid serious injury or death, read and understand the following warning advisories before
performing maintenance or troubleshooting procedures.

Under no circumstance is work to be performed on the

unit while the hydraulic lines are connected. Even with
power unit shut OFF, residual pressure may remain in
the hydraulic circuit that could cause unsafe motion
resulting in serious injury. Hydraulic power should be
removed from the unit, all operator valves cycled, and
hydraulic lines removed prior to maintenance.

Properly lock out the arm assembly before performing

lubrication, inspection, or replacement procedures.
Failure to adhere to this precaution may result in
severe injury and/or equipment damage.

Complete all appropriate job safety analysis (JSA),

permits, and crew safety briefings immediately prior to
each maintenance activity or session. If, at any point
during the maintenance session, the planned activities
change for any reason, review the job safety
requirements again to ensure the crew involved is
aware of the changes in activities. Ensure all
appropriate personal safety equipment is in good
condition and used when necessary.

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Maintenance 5

Safety Precautions
Warnings

Wear protective glasses to prevent eye injuries from

fluids under pressure, as well as other hazards.

Do not attempt any adjustments while the machine is

moving.

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.

In addition to recognition of pinch point hazards, 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 retracting back to the
park position. Refer to the General Arrangement
drawing in the Technical Drawing Package to identify
all areas of motion for the Iron Roughneck. Failure to
adhere to this precaution may result in serious injury
and/or death to personnel.

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Safety Precautions
Cautions

!
Always use caution when inspecting equipment. Begin
only when equipment is shut down, isolated and tagged,
“Out of Service.” Any unexpected start-up of equipment
during the procedure or any accidental or poorly timed
operation can cause serious injury and/or death to
personnel and/or damage to the equipment.

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 equip-
ment, or between material being handled and part of
the equipment. Take extreme care around pinch
points. If possible, avoid these areas while the equip-
ment is operating.

Power down the ST-160 Iron Roughneck and allow hot

surfaces to cool before performing inspection and
maintenance procedures.

!
Always use lifting equipment, supports and chains with a
minimum capacity of one and a half times that of the object
being lifted or supported. Serious injury or death can result
from falling or swinging equipment.

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Maintenance 5

Safety Precautions
Cautions

!
Prior to equipment operation after performing equipment
maintenance, ensure that no loose bars, tools or parts are
lying in or on parts of the unit, as they could cause serious
injury or death to personnel and/or damage to the
equipment.

!
For your own protection, do not use substitute parts.
Failure to use proper parts could result in server injury or
death to personnel and/or damage to the equipment.

!
The hydraulic tank return connector must be connected
before any system is operated; failure to do so could cause
reservoir drain, fluid starvation and equipment damage.

!
Exercise extreme caution when performing welding
maintenance on or near the Iron Roughneck System.
Connect the welder’s ground cable such that the welding
current does not flow through the Iron Roughneck’s cables
or structural assembly. This ground cable should be made
directly to or close as possible to the part being welded to
prevent electrical current from passing through bearings in
the Iron Roughneck system as this will result in bearing
damage and premature bearing failure. All power and
control cabling should be disconnected prior to performing
welding. Failure to observe this precaution will result in
damage to the equipment.

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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 5-23 for recommended
lubricants, lubrication intervals, and lubrication points.

Schedules and procedures in this section relate to the ST-

160 Iron Roughneck assemblies and components only.
Refer to the applicable OEM literature in the User Manual
for maintenance and repair procedures and schedules for
associated OEM equipment.

The following inspection intervals are based on average

operating conditions. More frequent service intervals may
be required for severe environmental conditions.

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Maintenance 5

Equipment Inspection
Inspection Schedules
Daily

Inspection

ST-160  Visually inspect equipment during operation, noting any abnormal

Overall sounds or vibrations.
 Visually investigate any fluid leaks. Check hoses, fittings, cylinders
and hydraulic motors for hydraulic oil leakage.
 Visually inspect for loose or missing hardware. Ensure all lock wire
is undamaged.
 Visually inspect that all ST-160 functions operate smoothly without
excessive noise.
 Clean unit to remove corrosive and contaminates, salt, sand, mud,
oil, and grease.

Torque  Check the die assemblies in the torque wrench jaws for wear or
Wrench damage. See the section titled "Replacing Torque Wrench Dies" on
Assembly page 5-36.

Hydraulic  Check hydraulic fluid level at hydraulic tank.

System  Monitor gauge for correct pressure.
 Check for water and / or foreign materials in hydraulic system.
Replace fluid as necessary.

All hoses are clearly labeled. Consult hose kit drawings for
proper routing and hose specification and always label
when replacing hoses on the Iron Roughneck.

When changing hydraulic cartridge valves, refer to the

hydraulic schematic for proper settings.

Electrical  Ensure all instrumentation and controls are in good working order.
System  Check that all indicators and lamps illuminate.Check for ground
faults. Repair or replace as necessary.

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Equipment Inspection
Inspection Schedules
Weekly

Inspection

ST-160  Visually inspect that all pins and cotter pins are secured and intact.
Overall  Visually inspect for loose or missing retention hardware. Make sure
that all bolts, washer and hex nuts are secured and secondary
locking device intact.

Spin  Check for worn or damaged rollers in the spin wrench assembly.
Wrench See the section titled "Replacing Spin Wrench Rollers" on page 5-
Assembly 38.

Socket  Check expansion oil tank levels. See the section titled "Filling
Base Expansion Tanks" on page 5-46.
Assembly

Hydraulic  Inspect and clean all connections and lines. Ensure that all hoses
System and quick disconnects are properly connected.
 Inspect all hoses and fittings thoroughly for any evidence of
hydraulic oil leakage.
 Inspect all hoses and lines for abrasion, pinching, kinking, cracking,
and excessive bending or twisting. Observe the hoses and lines
while operating the ST-160 through all of its functions.

Electrical  Inspect the service loop power and control cables for any signs of
System wear or damage.

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Maintenance 5

Equipment Inspection
Inspection Schedules
Monthly

Inspection

Torque  Inspect for worn or damaged jaw springs and guide spring wear
Wrench pads.
Assembly

Arm  Inspect for worn or damaged arm assembly pins, guide pins, and
Assembly arm bushings.

Column/
Guide  Inspect for worn or damaged column/guide assembly track rollers.
Assembly

Hydraulic  Check all hydraulic cylinder rod end-to-clevis connections are

System properly shouldered and tight.
 Inspect hydraulic cylinders, valves, manifolds, and motors.
thoroughly for hydraulic oil leakage or damage.
 Inspect the hydraulic inlet arm functions manifold filter. Replace the
filter if the differential pressure (DP) indicator has popped up. See
the section titled "Changing the Inlet Hydraulic Filter Element" on
page 5-40.
 Inspect the hydraulic intensifier filter. Replace the filter if the
differential pressure (DP) indicator has popped up. See the section
titled "Changing the Intensifier Hydraulic Filter Element" on page 5-
41.

Electrical  Check wiring and earth grounds are firmly in their mounting holes at
System each location.
 Inspect electrical junction boxes; ensure cover lid bolts and nuts are
tight and gasket is clean; Check for proper fit of all glands and
seals; check for excessive moisture, petrochemical residue.

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Equipment Inspection
Inspection Schedules
5 Years

Inspection

ST-160  A five year overhaul is recommended after five years of Iron

Overall Roughneck operation. Typically, the five-year service overhaul is
performed at an NOV Service Center. Contact an NOV Service
Center or representative for details. A Service Center Directory is
supplied in the equipment User Manual.
 Perform a nondestructive examination (NDE) of critical load
components.
 The following items should be checked inspected and components
replaced after five years of operation:
• Bushings in all moving connections should be replaced with
recommended replacement parts.
• Any pins or connection plates showing excessive wear should be
replaced. Excessive wear on components should be noted and
referred to NOV engineering for further investigation.
• All column/guide track rollers and bearings should be removed and
inspected for flat spots, damage, and wear. Replace track roller
components as needed.

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Maintenance 5

Equipment Inspection
Inspection Points
Daily
Overall Inspection

 Visually inspect equipment during operation,

noting abnormal sounds or vibrations. Take Properly lock out all energy sources
action as necessary. before performing inspection, lubrication,
 Visually investigate any fluid leaks. Take action or replacement procedures.
as necessary.
 Visually inspect all areas with moving parts.
Ensure they are free and clear of debris.
Remove corrosive and contaminates: salt,
sand, mud, oil, and grease. Dispose of Take extreme care around equipment
components properly. Take action as necessary. pinch points.
 Visually inspect for loose or missing hardware.
Take action as necessary.

Column/Guide Assembly
 Check column/guide unit
to ensure it travels fully up
and down, smoothly and
freely, without binding or
restrictions.
Repair as required.

Arm Assembly
 Check arm to ensure arm,
operates smoothly and
freely, and arm cylinders
can fully extended and fully
retract, without binding
or restrictions.
Repair as required.

Guards removed for clarity.

Socket Base Assembly

 Check socket base unit to
ensure it slews, smoothly
and freely, without binding or
restrictions, or without noise.
ST-160 Repair as required.
Iron Roughneck

ST16000020

Figure 5-1. Daily Inspection Points

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Equipment Inspection
Inspection Points
Daily
Overall Inspection

 Visually inspect equipment during operation,

noting abnormal sounds or vibrations. Take Unless specifically noted in this manual, properly lock
action as necessary. out the main power source before performing inspection,
 Visually investigate any fluid leaks. Take action lubrication, or replacement procedures.
as necessary.
 Visually inspect all areas with moving parts.
Ensure they are free and clear of debris.
Remove corrosive and contaminates: salt,
sand, mud, oil, and grease. Dispose of Take extreme care around equipment
components properly. Take action as necessary. pinch points.
 Visually inspect for loose or missing hardware.
Take action as necessary.

Spin Wrench Assembly

 Check spin wrench unit to
ensure it rotates, smoothly
and freely, or without
excessive noise, and spin
wrench cylinder can fully
extended and fully retract,
without binding or restrictions.
Repair as required.

Torque Wrench
 Check torque wrench to
ensure upper and lower jaws,
operate smoothly and freely,
and jaw Clamp cylinders,
hold desired torque pressure,
and jaw toque cylinders can
fully extended and fully
retract, without binding or
restrictions.
Repair as required.
 Ensure upper and lower
jaw assemblies and
clamp jaw dies are free
and clear of debris.
Take action as necessary
 Check the die assemblies for
Pipe Centralizer Assembly wear or damage. Replace as
 Check pipe centralizer unit to required.
ensure pipe centralizer-joint
finder operates, smoothly and
provides appropriate location
feedback.
ST-160 Take action as necessary.
Iron Roughneck

ST16000026

Figure 5-2. Daily Inspection Points

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Maintenance 5

Equipment Inspection
Inspection Points
Daily
Overall Inspection

 Hydraulic - Monitor gauges for correct

pressure. Take action as required. Properly lock out all energy sources
 Hydraulic - Check all fluid levels. Inspect before performing inspection, lubrication,
hydraulic fluid level at hydraulic tank. Take or replacement procedures.
action as necessary.
 Hydraulic - Check for water and / or foreign
materials in hydraulic system. Take action as
necessary.
 Electrical - Ensure all instrumentation and Take extreme care around equipment
controls are in good working order. Take action pinch points.
as necessary.
 Electrical - Check that all indicators and
lamps illuminate. Check for ground faults.
Repair or replace as necessary.
Guards removed for clarity.

Electrical
Junction Boxes
(3 places)
As viewed from
left side

Gauge

Hydraulics
 Monitor gauge for
correct pressure
Take action as
necessary.
Electrical
 Ensure all instrumentation and
controls are in good working order. Wireless
Inspect the control panel for Control Transmitter
damaged knobs and lens caps.
Repair or replace as necessary.

Wireless
Receiver
ST16000042

Figure 5-3. Daily Inspection Points

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Equipment Inspection
Inspection Points
Weekly
Overall Inspection

 Visually inspect that all pins and cotter pins are

secured and intact. Take action as necessary. Properly lock out all energy sources
 Visually inspect for loose or missing retention before performing inspection, lubrication,
hardware. Make sure that all bolts, washers or replacement procedures.
and hex nuts are secured and secondary
locking devise intact. Take action as necessary.
 Visually inspect all hoses and lines for
abrasion, pinching, kinking, cracking, and
Take extreme care around equipment
excessive bending or twisting. Observe that
pinch points.
hoses and lines while operating the ST-160
through all of its functions. Repair or replace
as required.

Torque Wrench

Jaw Assemblies
(6 places)
 Inspect upper and lower
jaw dies for wear or damage.
Replace if worn or damaged.

Upper Jaw Assembly

Lower Jaw Assembly

 Jaw Assembly cap plate and wrench

ST-160 guards removed for clarity.
Iron Roughneck  Jaw components typical both upper and
lower jaw assemblies.
ST16000021

Figure 5-4. Weekly Inspection Points

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Revision 01
Page 5-17 of 46
Maintenance 5

Equipment Inspection
Inspection Points
Weekly
Overall Inspection

 Hydraulic - Inspect all hoses and fittings

thoroughly for any evidenece of hydraulic Properly lock out all energy sources
leakage. Take action as necessary. before performing inspection, lubrication,
 Hydraulic - Inspect all hoses and lines for or replacement procedures.
abrasion, pinching kinking, cracking, and
excessive bending or twisting. Observe the
hoses and lines while operating the ST-160
through all of its functions. Take action as
necessary. Take extreme care around equipment
pinch points.

Expansion Tanks
(2 places)
 Check expansion
tanks for sufficient oil.
Fill with oil as required.
See section titled
“Filling Expansion
Tanks on page 5-46.

Service Loop
Bracket

Hydraulics
 Inspect and clean all
connections and
lines. Ensure that all
hoses and quick
disconnects are
Hydraulic properly connected.
Service Loop Take action as
required.
HPU
AC / Control

Electrical Electrical
Service Loop  Inspect power and
control service loop
ST-160 for any signs of wear
Iron Roughneck or damage.
Take action as
Guards removed for clarity. required.

ST16000043

Figure 5-5. Weekly Inspection Points

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5 Maintenance Revision 01
Page 5-18 of 46

Equipment Inspection
Inspection Points
Weekly
Overall Inspection

 Visually inspect that all pins and cotter pins are

secured and intact. Take action as necessary. Properly lock out all energy sources
 Visually inspect for loose or missing retention before performing inspection, lubrication,
hardware. Make sure that all bolts, washers or replacement procedures.
and hex nuts are secured and secondary
locking devise intact. Take action as necessary.
 Visually inspect all hoses and lines for
abrasion, pinching, kinking, cracking, and Take extreme care around equipment
excessive bending or twisting. Observe that pinch points.
hoses and lines while operating the ST-160
through all of its functions. Repair or replace
as required.
Spin Wrench
Assembly
 Inspect pipe spinner rollers,
verify that they are still within
their wear limit.
Replace if worn or damaged.

Pipe Spinner
Rollers
(4 places)

ST-160
Iron Roughneck
ST16000023

Figure 5-6. Weekly Inspection Points

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Maintenance 5

Equipment Inspection
Inspection Points
Monthly
Column/Guide Assembly
 Visually inspect column/guide track
rollers. Replace if worn or damaged.
(8 places)
Properly lock out all energy sources
before performing inspection, lubrication,
or replacement procedures.

Take extreme care around equipment

pinch points.

Due to the magnitude of replacement

requirements to replace worn or damaged
column/guide track rollers, contact an NOV
Service Center for track roller replacement.

Jaw Springs
(4 places)
 Inspect for worn or damaged
jaw springs. Replace as necessary.

Wear Pad
(4 places)
 Inspect for worn or damaged
jaw springs. Replace as necessary.

ST16000025

Figure 5-7. Monthly Inspection Points

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Page 5-20 of 46

Equipment Inspection
Inspection Points
Monthly
Overall Inspection

 Hydraulic - check all hydraulic line and

connections for any leaks. Repair as necessary. Properly lock out all energy
 Hydraulic - Check all hydraulic cylinder rod sources before performing Spin Motors
end-to--clevis connections are properly inspection, lubrication, or (4 places)
shouldered and tight. Tighten as required. replacement procedures.  Inspect hydraulic
 Hydraulic - Inspect all hydraulic cylinders spin motors
thoroughly for hydraulic oil leakage or damage. thoroughly for
Repair or replace as necessary. hydraulic oil
Spin Wrench
 Hydraulic - Inspect service loop flange Lift Cylinder
leakage or damage.
connections at service loop bracket for Repair or replace
hydraulic oil leakage or damage. Repair or as necessary.
replace as necessary. Spin Wrench
Clamp Cylinder

Carriage Upper Jaw

Lift Cylinder Clamp Cylinder
(3 places)

Service Loop
Bracket

Electrical Upper
Service Loop Torque Wrench Lower Jaw
Arm Cylinder Clamp Cylinder
Lower Centralizer
AC / Control Deploy Cylinder (2 places) (3 places)
(2 places) Torque Wrench Cylinder
HPU Cylinder
Slew Motor (2 places)
Hydraulic
Service Loop  Inspect hydraulic slew motor
thoroughly for hydraulic oil
leakage or damage.
Take extreme care around equipment
Repair or replace as necessary.
pinch points.

The ST-160 Arm Assembly The ST-160 Drill Pipe Head Module
contains one (1) hydraulic manifold contains seven (7) hydraulic manifold
assembly: assemblies:
 Arms Functions Manifold  Head Functions Manifold
Inspect hydraulic manifold  Wrench Centering Manifold
and hydraulic valves  Torque Wrench Centralizer Manifold
thoroughly for oil leakage  Upper Torque Wrench Clamp Manifold
or damage.  Lower Torque Wrench Clamp Manifold
Repair or replace as  Clamp Intensified Pressure Manifold
necessary.
 Spin Wrench Manifold
Inspect all hydraulic manifolds and
hydraulic valves thoroughly for oil
leakage or damage.
Arms Functions Repair or replace as necessary.
Manifold Assembly
ST16000044

Figure 5-8. Monthly Inspection Points

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Page 5-21 of 46
Maintenance 5

Equipment Inspection
Inspection Points
Monthly
Overall Inspection

 Electrical - Inspect all sensors for ground fault

or damage. Take action as necessary. Properly lock out all energy sources
 Electrcial - Check and tighten all terminals, before performing inspection, lubrication
plugs, and connectors to avoid loose or replacement procedures.
connections.Take action as necessary.

Take extreme care around equipment

pinch points.
Electrical Connectors
 Verify cables are
properly secure in
connectors. Tighten
or take action as
Grounding Bar Assembly
necessary.
 Check wiring and earth grounds
are firmly in their mounting
terminals. Tighten or replace as
necessary.

Junction Box
(3 places)
 Inspect electrical junction
box; ensure cover lid
is tight and gasket is
clean. Check for excesive Wireless Remote Controller
moisture, petrochemical  Ensure all instrumentation and
resdue, and for signs of controls are in good working
damage. Tighten or take order. Inspect the wireless
action as required. remote controller for damaged
knobs and lens caps. Check
that all indicators and lamps
illuminate. Repair or replace as
necessary.
Wireless
Receiver

ST1600004

Figure 5-9. Monthly Inspection Points

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Page 5-22 of 46

Equipment Inspection
Inspection Points
Monthly

Properly lock out all energy

Intensifier Filter sources before performing
inspection, lubrication, or
 Inspect the hydraulic intensifier
replacement procedures.
filter. Replace filter element as
necessary.
See the section titled "Changing
the Intensifier Hydraulic Filter
Element" on page 5-41.
Take extreme care around equipment
pinch points.

Inlet Filter
 Inspect the hydraulic inlet arm
functions manifold filter.
Replace filter element as necessary.
See the section titled "Changing the
Inlet Hydraulic Filter Element" on
page 5-40.

ST160000048

Figure 5-10. Monthly Inspection Points

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Maintenance 5

Equipment Lubrication

Properly lock out the hydraulic 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.

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.

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Page 5-24 of 46

Equipment Lubrication
Recommended Lubricants

For fluid and lubricant information, refer to Recommended

Lubricants and Hydraulic Fluids (D811000719-PRO-001)
in the equipment User Manual.

General Lubricants
To ensure maximum service life of the ST-160 Iron Roughneck, regular maintenance and
application of high grade grease on all grease points must be performed. Use a grease lubricant
product in accordance to the type of ambient service required.

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.

Gear Oil
To ensure maximum service life of the planetary gearbox equipment, regular maintenance of the
gear oil must be performed. Use an extreme pressure (EP) gear oil product in accordance to the
type of ambient service required.

For fluid and lubricant information, refer to Recommended

Lubricants and Hydraulic Fluids (D811000719-PRO-001)
in the equipment User Manual.

!
Use only recommended gear oil types. Use only fresh gear
oils that are free of contamination. DO NOT MIX GEAR
OIL. Failure to follow this caution could result in equipment
damage.

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Maintenance 5

Equipment Lubrication
Lubrication Schedules

The following lubrication intervals are based on average

operating conditions. More frequent lubrication intervals
may be required for severe environmental conditions.

Weekly

Lubrication

Spin  Grease the external fittings on the motor and roller guards, that
Wrench lubricate the upper and lower bearings.
Assembly  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
5-31 for component and grease fitting locations.

Spin  Grease the fittings on the spin wrench carrier.

Wrench  Grease the fittings on the link hanger pins.
Carrier
 Grease the track roller fittings.
Refer to the section titled "Spin Wrench Carrier Lubrication" on page 5-
30 for component and grease fitting locations.

Torque  Grease the fittings on the clamping jaws.

Wrench  Grease the fittings on the torque cylinder.
Assembly
Refer to the section titled "Torque Wrench Assembly Lubrication" on
page 5-32 for component and grease fitting locations.

Arm  Grease all fittings on the arm assembly.

Assembly Refer to the section titled "Arm Assembly Lubrication" on page 5-29 for
component and grease fitting locations.

Column  Grease the carriage guide rollers.

Assembly Refer to the section titled "Column/Guide Assembly Lubrication" on
page 5-28 for component and grease fitting locations.

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Page 5-26 of 46

Equipment Lubrication
Lubrication Schedules
Monthly

Lubrication

Socket  Grease the slew bearing in the socket base assembly.

Base Refer to the section titled "Socket Base Assembly Lubrication" on page
Assembly 5-33 for component and grease fitting locations.

Every 6 Months

Lubrication

Socket  Change brake and gearbox fluid.

Base Refer to the section titled "Changing Brake and Gearbox Oil" on page 5-
Assembly 45 and the section titled "Filling Expansion Tanks" on page 5-46 for
information to replace the brake and gearbox fluid.

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Revision 01
Page 5-27 of 46
Maintenance 5

Equipment Lubrication
Lubrication Procedures
Refer to Recommended Lubrications and Hydraulic Fluids (D811000719-MAN-001) in the
equipment User manual for recommended lubricants and hydraulic fluids for all Iron Roughneck
equipment.

Under no circumstance is work to be performed on the

unit while the hydraulic lines are connected. Even with
power unit shut OFF, residual pressure may remain in
the hydraulic circuit that could cause unsafe motion
resulting in serious injury. Hydraulic power should be
removed from the unit, all operator valves cycled, and
hydraulic lines removed prior to maintenance.

Power down the ST-160 Iron Roughneck and allow hot

surfaces to cool before performing inspection and
maintenance procedures.

!
Use only recommended lubricant and fluid types. Use only
fresh lubricants and fluids that are free of contamination.
DO NOT MIX LUBRICANTS OR FLUIDS. Failure to follow
this caution could result in equipment damage.

!
Failure to maintain adequate lubrication could result in
equipment damage. Failure to thoroughly clean grease
fittings before applying grease can cause foreign matter to
be injected into the fitting, causing equipment damage. Do
not over-lubricate parts. Over-lubricating a fitting can
cause a bearing seal to pop out. Over-lubricated parts may
also drip causing a slipping hazard.

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Page 5-28 of 46

Equipment Lubrication
Lubrication Procedures
Column/Guide Assembly Lubrication

Apply general purpose grease

to designated grease fittings Track Roller
with grease gun. Use a brush  Lube two place
when greasing other parts. Weekly
Track
Weekly

Track Roller
 Lube two place

Weekly
Track Roller
 Lube two place each side
(4 places total)
Track
Weekly Weekly

Column/Guide Assembly
as viewed from the Rear

Front

Properly lock out all energy

sources before performing
inspection, lubrication, or
replacement procedures.

Column/Guide Assembly
as viewed from the Front

Take extreme care around

equipment pinch points.

ST160000049
Figure 5-11. Lubricating the Column/Guide Assembly

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Maintenance 5

Equipment Lubrication
Lubrication Procedures
Arm Assembly Lubrication

Weekly Weekly
Deploy Cylinder Upper Pin Machining Timing Link Pin
 Lube one place each side  Lube two places each side
(2 places total) (4 places total)

Weekly
Lower Primary Arm Pin
 Lube one place each side All Timing Link Pin grease
(6 places total) fittings are accessible only
Weekly when the arm assembly is
retracted.
Upper Primary Arm Pin
 Lube three places each side
(6 places total) Upper Front Arm Pin
Weekly
 Lube two places
Upper Secondary Arm Pin each side
 Lube two places each side (4 places total)
(4 places total) Weekly

Weekly

Deploy Cylinder Lower Pin Take extreme care around

 Lube one place each side equipment pinch points.
(2 places total)
Weekly
Lower Left & Lower Right
Weekly Secondary Arm Pin Weekly
 Lube two places each side
Lower Primary Arm Pin (4 places total) Lower Front Arm Pin
 Lube two places each side  Lube two places each side
(6 places total) (4 places total)

Weekly

Locking Timing Link Pin

Properly lock out all energy  Lube two places each side Apply grease to all grease
sources before performing (4 places total) fittings prior to arm movement.
inspection, lubrication, or
replacement procedures. ST160000050
Figure 5-12. Lubricating the Arm Assembly

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Page 5-30 of 46

Equipment Lubrication
Lubrication Procedures
Spin Wrench Carrier Lubrication

Inject grease into all grease

zerks until each cavity is
complete filled.

Weekly
Link Pin
 Lube one place each side
(2 places total)
Main Roller
 Lube two places each side
(4 places total)
Properly lock out all energy
Weekly sources before performing
inspection, lubrication, or
replacement procedures.

Spin Wrench
Carrier

Weekly
Grease Bulkhead
 Lube two places each side
(4 places total)

Spin Wrench
Assembly

Head Frame
Weldment Take extreme care around
equipment pinch points.

Front ST16000077

Figure 5-13. Lubricating the Spin Wrench Carrier

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Maintenance 5

Equipment Lubrication
Lubrication Procedures
Spin Wrench Assembly Lubrication

Link Pin
 Lube one place each side
(2 places total)
Properly lock out all energy
Weekly sources before performing
inspection, lubrication, or
replacement procedures.

Upper Bearings
 Lube two places each side Take extreme care around
(4 places total) equipment pinch points.
Weekly

Inject grease into all grease

zerks until each cavity is
complete filled.

Weekly Front
Compression Spring
Strut
 Lube one place

Weekly
Lower Bearings
 Lube two places each side
(4 places total)

Weekly
Arm Hinge Pin
 Lube one place each side Rear
(2 places total)

Weekly Weekly
Arm Hinge Pin Clevis Pin
 Lube one place each side  Lube one place each side
(2 places total) (2 places total)

ST16000007

Figure 5-14. Lubricating the Spin Wrench Assembly

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Page 5-32 of 46

Equipment Lubrication
Lubrication Procedures
Torque Wrench Assembly Lubrication
Cylinder Pivot Pin
Rocker Arm Pivot Pin  Lube one place on top side
 Lube one place on top side one place on under side
one place on under side (2 places total)
Take extreme care around
(2 places total) equipment pinch points.
Weekly
Weekly
Cylinder Pivot Pin
 Lube one place on top side
Wear Pad
 Lube two place each side on top side
one place on under side
two places each side on under side
(2 places total)
(4 places total)
Weekly
Weekly

Weekly

Cap Plate
Inject grease into all grease  Lube one place each side on top side
zerks until each cavity is one place each side on under side
complete filled. (4 places total)

Guide Link Pivot Pin Side Guide Die

 Lube one place on each of  Lube one place on each of the
the two pins on top side two guide dies on top side
Properly lock out all energy one place on each of the
one place on each of
sources before performing two guide dies on under side
the two pins on under side
inspection, lubrication, or (4 places total)
(4 places total)
replacement procedures.
Weekly Guide Link Weekly
4X

Side Guide
Die
4X

Jaw Spacer
4X

Weekly
Torque Cylinder Clevis
Rotate upper jaw to MAKE
 Lube one place on each of the two clevises on top
one place on each of two the clevises on under side
or BREAKOUT positions to
Torque Wrench access grease fittings.
(4 places total)
Assembly
ST16000066

Figure 5-15. Lubricating the Torque Wrench Assembly

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Maintenance 5

Equipment Lubrication
Lubrication Procedures
Socket Base Assembly Lubrication

Apply grease to designated

grease fittings with grease
gun. Pump grease until clean
grease is seen extruding from
related componnet.

Front

Take extreme care around

equipment pinch points.

Guards removed for clarity.

Rear

Socket Base
Assembly

Weekly Weekly

Slew Bearing Grease Bulkhead

 Lube 4 places  Lube 4 places

Properly lock out all energy

sources before performing
inspection, lubrication, or
replacement procedures.

ST16000067

Figure 5-16. Lubricating the Socket Base Assembly

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Page 5-34 of 46

Component Replacement
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.

Under no circumstance is work to be performed on the

unit while the hydraulic lines are connected. Even with
power unit shut OFF, residual pressure may remain in
the hydraulic circuit that could cause unsafe motion
resulting in serious injury. Hydraulic power should be
removed from the unit, all operator valves cycled, and
hydraulic lines removed prior to maintenance.

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.

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.

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Page 5-35 of 46
Maintenance 5

Component Replacement
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

Nord-Lock
Lockwasher

Top Washer

Bottom Washer
ST16000054

Figure 5-17. Nord-Lock Washer

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Page 5-36 of 46

Component Replacement
Replacing Torque Wrench Dies

!
Once the screws are removed the die may slip out of the
die carrier. Secure the die to avoid personal injury or
equipment damage.

Replace all dies and die carriers. Use new screws if the old
screws are worn. Check associated components for wear
and replace if needed.

Complete the following steps to replace dies in the torque wrench. Figure 5-18 shows the location
of components disassembled in this procedure.
1. Using the clamp function on the operator controls, completely extend the clamp
cylinders.
2. Remove hydraulic power from the equipment.

!
Lock out hydraulics to disable equipment operation and to
avoid injury or equipment damage.

3. Clean the area around the dies and die carriers.

4. Remove the upper die keeper bolt from the die guide and remove the die. If the die
is stuck, remove the lower die keeper bolt and drive the die out the bottom.
5. Using a wire brush, clean the die groove on the guide.
6. Inspect and lightly grease the die guide.
7. Install the new die in the retainer.
8. Apply anti-seize compound to the die keeper bolt(s) and reinstall the bolts.
9. Torque bolts to 57 -81 ft-lbs.
10. Complete this procedure for the other dies and die carriers.

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Maintenance 5

Component Replacement
Replacing Torque Wrench Dies

ST-160
TORQUE WRENCH
ASSEMBLY

Upper Jaw
Assembly

Take extreme care around equipment Lower Jaw

pinch points. Assembly

Dies
3 places
(6 total)

Center Die Guide

Clamp Cylinder
(3 places)

Jaw assembly cap plate and

wrench guards removed for
clarity. Clamp components
typical both upper and lower
jaw assemblies

Side Die Guide

(2 places)

Die Keeper Bolt

Side Die Guide 2 places
(2 places) (12 total)
ST16000051

Figure 5-18. Replacing Torque Wrench Dies

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Component Replacement
Replacing Spin Wrench Rollers

Front Isometric View

Motors
(4)
• Minimum allowable Spin Roller diameter is 6.9"
Front (equates to 1/8" radial wear).
Note: Rollers have a wear groove to indicate how
much wear has occurred.
• Replace Spin Rollers with all new rollers at the
same time.
• Replace screws with all new screws if necessary.
• Clean and inspect parts and hardware for damage
and wear. Replace damaged parts and hardware.

!
Parts may slip from the Spin Wrench Assembly
once they are loosened. Secure parts and place
in a clean, safe location to avoid personal
Spin Rollers injury or equipment damage.
(4 sets)

!
Roller Torque Lock out hydraulics to disable equipment operation
Tool and avoid personal injury and equipment damage.

Procedure

1. Remove the Plug from the lower cover plate.

2. Use the Roller Torque Tool to keep rollers from turning.
3. Remove the large support screw inside the cover plate.
4. On the bottom of the Cover Plate, remove screws to
Rear Isometric View
release and remove the Cover Plate, Lower Drive Hub,
Guard and Lower Bearing Assembly.
5. Remove Spin Rollers.
Hydraulic 6. Clean the Spin Wrench Assembly.
Manifold 7. Install new Rollers interlaced as shown. Rollers
must interlace with each other and the opposing Roller
Assembly.
Clamp 8. Use Roller Torque tool to keep rollers from turning.
Cylinder 9. Install Cover Plate, Lower Drive Hub, and Lower
Bearing Assembly.
10. Slightly oil washer, and install it and the large support
screw in the bottom of the Lower Bearing Assembly.
11. Torque bolt to 430 ft-lbs.

While the Spin Rollers are disassembled, worn or

damaged Bearing Assemblies and other Spin Wrench
Assembly parts should be replaced.
Rear ST16000053

Figure 5-19. Replacing the Spin Wrench Rollers

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Maintenance 5

Component Replacement
Replacing Spin Wrench Rollers

Retaining Ring
Hydraulic Motor

Ball Bearing
(3 places)

Upper Bearing
Housing
Ring Seal

Upper Drive
Hub

Upper Bearing
Assembly
Grooved Roller
Grease Port (4 places)
(2 places) Lower Drive
Hub

Ring Seal
Roller
Carrier
Ball Bearing
Grease Port (2 places)
(2 places)

Lower Bearing Retaining Ring

Housing
Cover Plate Screw
(4 places) Lower Bearing
Cover Plate Assembly

Plug Large Support To replace ball bearings, ensure

Screw bearings align as shown below:

Seal

Ball
Bearing
Frame

ST16000052

Figure 5-20. Spin Wrench Roller Assembly - Exploded View

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Component Replacement
Changing the Inlet Hydraulic Filter Element

Procedure
Inlet Hydraulic
1. Turn off supply shut-off valve and bleed Filter Cap
residual pressure.
2. Remove hydraulic filter cap.
3. Replace filter element.
4. Install hydraulic filter cap.

Supply Shut-off Inlet

Valve Hydraulic Filter

Properly lock out all energy

sources before performing
inspection, lubrication, or
replacement procedures.

Exercise extreme care around

equipment pinch points.

Arm Functions
Manifold

ST160000068

Figure 5-21. Replacing the Hydraulic Inlet Filter Element

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Maintenance 5

Component Replacement
Changing the Intensifier Hydraulic Filter Element

Procedure

1. Turn off main ball valve and bleed residual pressure.

2. Turn off intensifier ball valve. Intensifier
3. Remove hydraulic filter cap. Ball Valve
4. Replace filter element.
5. Install hydraulic filter cap.
Intensifier
Hydraulic
Filter

Intensifier
Hydraulic
Filter Cap

Spin Wrench
Assembly

Torque
Wrench
Housing !
Lock out hydraulics to disable equipment
operation and avoid personal injury
and equipment damage.

Front
ST16000069

Figure 5-22. Replacing the Hydraulic Intensifier Filter Element

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Disassembly Procedures
Removing the Spin Wrench Assembly
ST-160 Spin Wrench
Procedure
Assembly Rear View

1. Disconnect the hydraulic connections to the

Hanger spin wrench manifold.
Link 2. Using a crane, support the weight of the
Pressure, Tank,
and Drain Ports spin wrench.
3. Disconnect the spin wrench hanger link from
the hanger.
4. Lift and remove the spin wrench.

Rear
!
Lock out hydraulics to disable equipment
operation and avoid personal injury
and equipment damage.
Spin Wrench
Hydraulic Manifold

Pinching Hazard. Make sure the power is

OFF to the spin wrench before touching it or
getting near it for maintenance and repairs.

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.

Spin Wrench

Front ST16000070

Figure 5-23. Removing the Spin Wrench Assembly

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Maintenance 5

Disassembly Procedures
Removing the Torque Wrench Assembly
Procedure

1. Disconnect all hydraulic lines to all four (4) torque 6. Attach lifting eyes to the top of the upper jaw and
cylinders. lift slightly with a crane.
2. Remove the pin retainer from the torque cylinders 7. Slide out the upper jaw from the torque wrench
and remove the pivot pin to disengage the torque frame.
cylinder from the rocker arm. 8. Attach lifting eyes to the top of the lower jaw and
3. Disconnect hydraulic lines from the swivel fittings lift slightly with a crane.
located on top of the upper jaw and beneath the 9. Slide out the lower jaw from the torque wrench
lower jaw. frame.
4. Loosen retaining cap.
Note: Spin wrench roller tool can be used
to loosen retaining cap. !
5. Once the retaining cap is completely unthreaded, Lock out hydraulics to disable
pull out the jaw locking pins . equipment operation and avoid
Note: Jaw locking pin is the component that locks personal injury and equipment
the jaw. It is installed on the bottom jaw for regular damage.
operation, and installed on the upper jaw for bit-break
operation.
Pin Retainer
 Two places on top side
Jaw Spring Two places on under side Pivot Pin
 Two places on top side (4 places total)  Two places on top side
Two places on under side Two places on under side
(4 places total) (4 places total)

Torque Wrench
Assembly

Jaw Locking Pin

 One place on each side
(2 places total)

Retaining Cap
Front  One place on each side
(2 places total)

ST16000071

Figure 5-24. Removing the Torque Wrench Assembly

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Changing Oil

!
Before performing any hydraulic or mechanical work on the
tool, ensure the hydraulic ball valve located on the rear of
the ST-160 Iron Roughneck is in the OFF position and
bleed residual pressure by actuating SW lever in either
SPIN IN or SPIN OUT.

Changing Oil Guidelines

 Gear oil must be drained and changed after the first 50/100 hours of operation and
subsequently after every 2500 hours or in any case each year. The following list provides
oil change information.
 Oil change intervals may be modified, depending on actual operating conditions.
 During oil change, we recommend that the inside of the gear case is flushed out with
flushing fluid recommended by lubricant manufacturer.
 Pay attention to oil and gear temperature during oil change, to avoid the risk of scalding.
 Oil should be changed when hot to prevent build up of sludge deposit.
 It is advisable to check oil level at least once per month. If more than 10% of total oil
capacity has to be added, check hydraulic hoses and connections for oil leaks.
 Do not mix oils of different types even if they are from the same manufacturer.
 Never mix mineral oil and synthetic oils.
 Be conscious of the pollution hazard due to oil.

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Maintenance 5

Changing Oil
Changing Brake and Gearbox Oil

Procedure

!
Lock out hydraulics to disable equipment
operation and avoid personal injury
and equipment damage.
1. Raise the ST-160 to allow space for changing oil in the gearbox
and brake oil reservoirs.
2. To ease oil drainage, remove the constant vented breather from
both oil expansion tanks located in the column assembly.
3. Turn the hydraulic ball valve located on the rear of the ST-160 to
the OFF position.
4. Carefully remove plug "A" from the gearbox and plug "A" from
the brake.
5. Once all the oil is drained and the gear case is flushed, install
the gearbox plug "A" and the brake plug "A."
6. Remove gearbox plug "B" and brake plug "B" and fill with
recommended oil. See "Recommended Lubricants" on page 5-23.

Brake Brake Plug "B"

Brake Plug "A"

Gearbox Plug "B"

Gear Box
Gearbox Plug "A"

Brake and Gear Box

(Cover removed for clarity)

ST16000072

Figure 5-25. Changing Brake and Gearbox Oil

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Changing Oil
Filling Expansion Tanks

Procedure (Continued)

8. Fill expansion tanks with oil to the specified height.

9. Install the breather plug on the tanks.

When adding oil to expansion tank,

allow time for fluid to make it´s way to
the gearbox and brake.

Constantly
Vented Breather

Sight Glass

Sight Glass

Extension Pipe

Lock Nut

Brake and Gear Box Expansion Oil Tank

ST16000073

Figure 5-26. Filling Expansion Tanks

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Troubleshooting 6

Troubleshooting
This chapter provides guidelines to inspect and troubleshoot the ST-160 Iron Roughneck.

!
Make sure all hydraulic lines are isolated and the inlet ball
valve is closed before any work is performed on the Iron
Roughneck.

!
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.

When troubleshooting the Iron Roughneck, make sure the hydraulic pressure is 2,500 psi at the
inlet of the manifold. Check the back pressure of the tank line and ensure it does not exceed 100
psi.
1. Ensure that all hoses and QDs are properly connected.
2. Check manifold, fittings, QDs, and hoses for leaks or damage.
3. Ensure the tool is lubricated per Chapter 5, titled "Lubrication Schedules
The most important things to do before operating the Iron Roughneck are:
1. Ensure that the Iron Roughneck is fully inserted in the floor socket or the floor base
as appropriate.
2. Ensure all QDs are fully engaged.
3. Ensure the operating pressures are correct.
4. Verify the condition of the filter.
5. Check all fittings for leaks.
Lubricate entire Iron Roughneck per Chapter 5, titled "Equipment Lubrication and check the
condition of the filters per section titled "Inspection Points" on page 5-22

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Service Centers
Service contact information is included in the NOV Service Centers Directory 
D811001337-DAS-001, which is included in the User Manual. The link below provides after-hours
contact information for emergencies or other equipment issues requiring an immediate response
by NOV service personnel.
www.nov.com/contact_us/24hr_EmergencyList.asp

Troubleshooting the Iron Roughneck

The troubleshooting procedures in the following tables do not necessarily cover all possible
symptoms. These table provide an insight to typical symptoms, their possible causes, and
methods of remedying the problem.

Troubleshooting Tables

Symptom Probable Cause Remedy

Check power supply flow while

Tool runs slowly. Power unit not delivering full flow spin out valve is actuated. Flow
should be 45 GPM minimum.

Power unit return line filter dirty Replace filter element of HPU.

Pressure filter dirty Replace filter element of ST-160.

Symptom Probably Cause Remedy

Vertical positioning assembly

Power supply not operating, or
moves in one direction only or Re-establish hydraulic power.
pressure too low
does not move at all.

Lift cylinder damaged or dirty Clean or repair cylinder.

Binding of carriage guide in

Lubricate or replace side rollers.
column

Pilot pressure is set too low Check pressure and adjust.

Replace, or adjust
Does not maintain vertical Counterbalance valve out of
counterbalance valve to maintain
position adjustment
vertical position.

Lift cylinder leak Replace seals.

Base assembly quick disconnect Fully connect all base assembly

Tool does not rotate (slew).
couplings are not connected quick disconnect couplings.

Ensure storage pin is removed.

Tool does not extend Obstruction Ensure arm lock pin is not locking
the arm.

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Troubleshooting 6

Troubleshooting the Iron Roughneck

Troubleshooting Tables

Symptom Probable Cause Remedy

Torque cylinders do not makeup. Torque valve set too low Increase setting.

Torque valve or pressure

reducing valve stuck closed, dirty, Check valves, clean or replace.
or damaged

Torque cylinders already at end of Recycle the upper jaw for another
stroke bite.

Torque valve damaged Check, clean, or replace.

Torque setting pressure reducing

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

Torque setting is too low Increase torque setting.

Disassemble valve, inspect for

Torque cylinders drift in makeup Sticking or worn main operating
contamination or wear, and repair
direction. valve
or replace.

Torque cylinder does not move or

Dirty return filter in power supply Replace filter element.
moves slowly.

Torque indicator does not indicate

Dirty inlet port or gage Clean inlet port or replace gage.
pressure during makeup

Torque cylinders reached end of

Reset for additional stroke.
stroke and actuated dump valve

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Troubleshooting the Iron Roughneck

Troubleshooting Tables

Symptom Probable Cause Remedy

Jaws slip on tool joint. Worn or broken dies Replace dies.

Make sure the pressure at the

Hydraulic pressure too low
manifold is set to 3,000 psi.

Ensure the intensifier ball valve is

Intensifier not operating on and inspect and replace as
necessary.

Dirty intensifier filter Check and/or replace.

Check that intensifier is doubling

Defective intensifier
pressure to the clamp circuit.

Upper torque wrench body lifts

Interference between upper and
while cycling in makeup or Check and remove interference.
lower body sets
breakout mode.

Torque wrench clamp cylinders Check valves on manifold

Clean, repair, or adjust valves.
too slow or uneven. contaminated or defective

Lack of lubrication Lube all grease fittings.

Check for damaged line and/or

Flow Divider not operating
flow divider and replace as
properly
necessary.

Symptom Probable Cause Remedy

Spin Wrench assemblies do not

Locate cause or restriction and
clamp or unclamp and/or motors Flow restricted
correct.
do not run.

Power supply defective Check power supply.

Return valve to center position

Spin Wrench Assemblies or
manually. If problem persists,
motor creep with valve in neutral Leaking or sticky valve
inspect valve spool for wear or
position.
contamination. Repair or replace.

High tank line pressure Check and correct.

Motor runs irregularly. Contaminated motor Repair motor or replace.

Bent shaft Repair motor or replace.

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Troubleshooting 6

Troubleshooting the Iron Roughneck

Troubleshooting Tables

Symptom Probable Cause Remedy

Spin rollers do not turn with motor

running, or have insufficient Damaged motor spline Check motor spline.
power.

Motor seal blown Replace motor seals.

Locate cause of restriction and

Flow restricted to motor
correct.

Defective roller bearings Replace bearings.

Defective motor Repair motor.

Motor Drive shaft broken Replace motor.

Check power supply pressure

gage for indication. Ensure that
Loss of power, torque. Power supply not operating
supply pressure remains high
with operating valve energized.

Check for pinched, clogged, or

Restricted hydraulic lines otherwise obstructed hydraulic
lines. Clear obstruction.

Worn cylinder seals Replace seals.

Drill pipe or collars rub against

Spin Wrench motor during Spin rollers worn excessively Replace spin rollers.
spinning.

Check pressure at manifold set to

3,000 psi. Check for leaks in
Spin rollers slip. Insufficient clamping pressure
clamping lines and replace as
required.

Defective seal on spin clamp

Replace seal.
cylinder piston

Slippery connection Clean connection.

Spin rollers worn Replace spin rollers.

Grease on Spin Rollers.

Spin Wrench clamp should be Remove grease.
held while spinning

Check nitrogen pre-charge on

Spin Wrench does not thread accumulator.
Accumulator pre-charge
compensate. Add nitrogen as required to 100
psi.

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