P15026-Actuator Manual

HI-KALIBRE ACTUATOR MANUAL
4186-TDA-SER-F
HI-KALIBRE EQUIPMENT LTD

EDMONTON ALBERTA
CANADA
(780) 435-1111
C
DIMENSION: SIZE (in)
A STEM DEPTH 4.87

E
B STEM HEIGHT 7.81
F
C ROTATING Ø 11.63
D NON-ROTATING Ø 12.00
E ROTATING DEPTH 9.68
F OVERALL LENGTH 12.68

B
SPECIFICATION: SCALAR (U)

MAX HYDRAULIC PRESSURE 1500 PSI
TORQUE @ MAX 660 FT-LB
HYDRAULIC PRESSURE
WEIGHT 224 LB
THIS DRAWING IS PROPERTY OF HI-KALIBRE

EQUIPMENT LTD AND MUST BE RETURNED ON
HI-KALIBRE
DEMAND. THIS PRINT IS LOANED EQUIPMENT LTD.
IN CONFIDENCE WITH UNDERSTANDING THAT 9816-45 AVENUE
IT IS NOT TO BE REPRODUCED OR DISCLOSED,
IN THE WHOLE OR IN PART, WITHOUT WRITTEN EDMONTON, AB T6E 5C5
CONSENT FROM HI-KALIBRE EQUIPMENT. TEL: (780) 435-1111
HI-KALIBRE EQUIPMENT LTD RESERVES ALL FAX:(780) 436-5164
FIGURE 1: 4186 SERIES TOP DRIVE ACTUATOR - OVERALL DIMENSIONS
RIGHTS OF DESIGN AND INVENTION
DOCUMENT NO:
HI-KALIBRE EQUIPMENT LTD. PS-02-002
MAINTENANCE MANUAL REV: DATE:

HI-KALIBRE ROTARY ACTUATOR –
4186-TDA-SER-F OPERATING MANUAL
0 12/05/2008
1. OVERVIEW
This document will provide the operating instructions and data for the 4186-TDA-SER-F
Rotary Actuator design featuring the new bearing hub configuration.
CAUTION: The actuator gets hot while it is running. Stand clear from the actuator while it is
rotating. After removing the actuator from service, allow 2 to 3 hours of cool down time
before handling or servicing an actuator that was rotating.
The actuator should have an open center port control valve installed in the hydraulic lines.
This will allow pressure to return to tank after the function cycle is completed. In order to
insure full opening/closing of the valve the actuator must be held under pressure for 3-5
seconds before it returns to the neutral position. Once functioned, there should be a delay
programmed into the controller so that the top drive does not begin rotating while the
hydraulics are being energized. The controller must still allow the actuator to function while
rotating in the event of a well control emergency.
2. TECHNICAL SUPPORT
For technical support or troubleshooting help, contact your supplier or Hi-Kalibre Equipment
Ltd’s 24 hour service line at (780) 435-1111. Before calling for support please make sure to
have the actuator serial number ready. It can be found in the large milled ID window located
on the OD of the actuator on the lower cylinder. i.e. 4186-TDA-850F
3. SHIPPING AND HANDLING INSTRUCTIONS

Actuators that are shipped mounted to the valve should be shipped laying down with the
ends of the valve blocked up so no weight is resting on the rotary hub on the actuator.
Actuators that are shipped not mounted to a valve body should be shipped in the upright
position, making sure that nothing comes into contact with the rotary hub.
4. TROUBLE SHOOTING
Refer to the Exploded view drawing and Table for corresponding part numbers and
diagram.
1. Oil is leaking from the 1/8” NPT vent fittings (25) on the upper cylinder housing (2)
indicates worn seals on the piston racks (9). Refer to section 9 on complete seal kit
replacement.
HEAD OFFICE: 9816 – 45 Avenue, Edmonton, Alberta T6E 5C5

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http:\\www.hikalibre.com email: hke@hikalibre.com 1 OF 8
DOCUMENT NO:

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2. Oil is leaking from between the sleeve (4) and the rotary hub (5), or between the sleeve
(4) and lower end cap (6) indicates that the hub seal set (20) is worn and needs to be
replaced. A small amount of oil is normal due to the self-lubricating nature of the seals.
Refer to section 7 on rotary hub seal set replacement.
3. Actuator/Valve fails to rotate when functioning the hydraulics, check the following:
a) The hex drives are installed correctly.
b) The main window of the valve is aligned on the same side as the main window on
the actuator.
c) Both the valve and actuator are in the open position when the hex drives are
installed.
d) The hydraulic lines are connected properly.
If none of these correct the problem then check the timing of the racks to the pinion inside
the actuator. All mounted units are tested for operation before shipping, check timing of the
unit if it has been field serviced. Refer to section 9 for proper timing of the racks and pinion.
4. Never plug any holes with leaking vent fittings as this could cause a pressure buildup
and severe personal injury to yourself or co-workers.
5. Actuator is extremely hot (more than 37°C / 100° F over ambient temperature). Insure
that there is no residual back pressure on the actuator lines that could be energizing the
seals as the unit is rotating.
5. STRIPPING THE ACTUATOR

1. Make sure that the actuator and valve are in the open position. Remove the hydraulic
lines after making sure that there is no pressure in the lines. Failure to do so could result
in serious injury.
2. Remove both the internal snap rings (27) from inside the pinions (7 & 8). There is a pair
of snap ring pliers included in the actuator strip kit (P/N: HK-TDA-STRIPKIT).
3. Pull both of the hex drive shafts (12) from inside of the hex in each pinion. To make this
easier, there is a slide hammer included with the strip kit as well.
4. Remove both the upper and lower worm ring clamps (37) from the cylinder housings.
They are used to cover the eight lock pin retaining screws.
5. Remove two of the upper set of lock pin retaining assemblies, 180° apart from each
other. The lock pin assemblies include a 1” set screw (24), a coil spring (26), and a lock
pin (10).
6. Install the two lifting handles into the two empty holes. The lifting handles are included in
the HK-TDA-STRIPKIT. Secure a lifting apparatus onto the lifting handles as the
actuator is heavy (250 lbs).
7. Loosen the six remaining lock pin assemblies. Back off each assembly roughly 10 to 12
full turns until they come out.
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DOCUMENT NO:

0 12/05/2008
8. Lift the actuator off the valve body.
6. RE-INSTALLING THE ACTUATOR

1. Orient the valve and actuator for installation. Double check to make sure that the valve
and actuator are both in the OPEN position.
2. Slide the actuator onto the valve body. Align the main stamping window of the actuator
with the main stamping window of the valve body. Rotate the actuator 45° to the right
and lower it until the actuator passes the first stem hole.
3. Insert the lower lock pin assemblies. They consist of a lock pin (10), coil spring (26), and
a 1” set screw (24).
4. Pre-load the lock pin assemblies. Place a slight load on the coil springs by hand
tightening the set screws of each assembly.
5. Lower the actuator to the locator groove on the valve body. The pre-loaded lock pin
assemblies will pick up the locator groove on the body. Rotate the actuator 45° left to
engage the lock pins into the valve detents.
6. Shim the actuator with brass shim stock found in the HK-TDA-STRIPKIT. Insert a total
of eight pieces, four at the top and four at the bottom spaced equally apart.
7. Torque the four lower lock pin assemblies to 100 ft-lbs.
8. Remove the two lifting handles and install the four upper lock pin assemblies. Torque
those four to 100 ft-lbs as well. ***After the first 12 hours of drilling, make sure the re-
torque all eight lock pins to 100 ft-lbs.
9. Periodically check the lock pins as part of the routine maintenance checks on the rig.
10. Remove the brass shim stock and place it back in the HK-TDA-STRIPKIT.
11. Install the hex drives (12) into the pinions (7 & 8) and secure them with the internal snap
rings (27).
12. Install the upper and lower worm ring clamps (37) and the dust seal o-ring (21) and you
are finished.
7. ROTARY HUB SEAL SET REPLACEMENT

The seals are self-lubricating and will show small amounts of weeping, this is normal and
the seals should only be replaced when an actual leak occurs. The rotary hub seals should
be replaced after the actuator has been stripped off the valve body. The work area should
be clean so as to avoid contaminating the seals or sealing surfaces.
1. Function the actuator to the OPEN position. Disconnect the hydraulic lines, making sure
the release any pressure before disconnecting them so you avoid potential injury.
Remove the eight locking pins (10) from the actuator and take the actuator off the valve
body. Take the actuator to a clean work area, carefully as the actuator weighs up to 250
lbs.
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DOCUMENT NO:

0 12/05/2008
2. Flip the rotary actuator so that the lower end cap (6) faces up.
3. Remove the 5/16” x 3-3/4” NF socket head cap screws (33) from the lower end cap (6).
4. Take out the two 5/16” orbital plugs (39) located on the end cap.
5. Thread two of the 5/16” x 3-3/4” NF socket head cap screws into the orbital plug bores:
tighten until the lower end cap gently lifts off from the locating dowel pins (15).
6. Remove the lower end cap from the rotary actuator.
7. Separate the hub (5) from the rotary sleeve (4) by gently tapping up on the anchor block
(13) with a rubber mallet. In order to ensure the hub comes off straight, apply hand
leverage on the side opposite of the anchor bracket as you tap.
8. Clean all surfaces on the rotary sleeve (4) and lower end cap (6). Remove the three hub
seals and discard them. Clean the rotary hub, pay special attention to the seal grooves
and make sure that they are clean and dry.
9. Install the new hub seal set (20). The new hub seal set will consist of three rubber seals
with a self lubricating wave pattern on them. Install them into the three seal grooves
making sure not to get oil or grease behind them and that the grooves were clean and
dry before you installed them. Failure to do this will result in pre-mature seal failure.
10. Apply liberal amounts of Metalon Hi-Tech EP 1.5 grease to the exposed inner bore of the
sleeve and seal faces of the hub as well as to the mating surface on the rotary sleeve.
11. Ensuring that the hub “closed” and “open” hydraulic ports are on the right and left
respectively, slide the hub into place on the rotary sleeve. A rubber mallet may be used
to gently tap the hub into place.
12. Place the lower end cap on the hub ensuring that the dowel pins are properly aligned.
13. Thread the eight 5/16” x 3-3/4” SHCS (33) through the lower end cap into the sleeve:
torque to 27 ft-lbs.
14. Re-install the orbital plugs (39) removed during disassembly.
At this point the Rotary Actuator is complete and ready for service.
8. DISASSEMBLY
1. Function the actuator to the OPEN position. Disconnect the hydraulic lines, making sure
the release any pressure before disconnecting them so you avoid potential injury.
Remove the eight locking pins (10) from the actuator and take the actuator off the valve
body. Take the actuator to a clean work area, carefully as the actuator weighs up to 250
lbs.
2. Flip the rotary actuator so that the lower end cap (6) faces up.
3. Remove the 5/16” x 3-3/4” NF socket head cap screws (33) from the lower end cap.
4. Take out the two 5/16” orbital plugs (39) located on the end cap.

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DOCUMENT NO:

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5. Thread two of the 5/16” x 3-3/4” NF socket head cap screws into the orbital plug bores:
tighten until the lower end cap gently lifts off from the locating dowel pins (15).
6. Remove the lower end cap from the rotary actuator.
7. Separate the hub (5) from the rotary sleeve (4) by gently tapping up on the anchor block
(13) with a rubber mallet. In order to ensure the hub comes off straight, apply hand
leverage on the side opposite of the anchor bracket as you tap.
8. Remove both threaded bushings (14) from the rotary hub (5) and inspect them for wear.
Discard the o-rings from the threaded bushings.
9. Remove the five bearing housings (17) from the hub by taking out the two ¼” bolts (35)
from each housing.
10. Be careful when removing the pins (18), bearings (28), and springs (30). Take them out
slowly and carefully so as to not injure anyone. Inspect the bearings, pins, and springs
for wear. Replace parts as required.
11. Remove the rotary sleeve (4) from the lower cylinder housing (3) by taking out the ten
5/16” NF x ¾” long SHCS (31) socket head cap screws. Inspect the sleeve for damage
and discard all the seals.
12. Flip the actuator over so that you can remove the upper end cap (1). Remove all twelve
5/16” x ¾” NF socket head cap screws (31) from the upper end cap (1).
13. Take out the two 5/16” orbital plugs (39) located on the end cap using the Allen wrench
supplied in your HK-TDA-STRIPKIT.
14. Thread two of the 5/16” x 3/4” NF socket head cap screws into the orbital plug bores:
tighten until the upper end cap gently lifts off from the locating dowel pins (36). Inspect
the upper end cap and discard the seals.
15. To separate the two cylinder halves (2 & 3), begin by taking out the eight ½” x 4-1/2” NF
socket head cap screws (32).
16. Pull the upper cylinder directly up. Take out the two ½” dowel pins (36) and discard the
o-rings.
17. Remove the racks (9) and pinions (7 & 8) from each side of the actuator. Take off the
plastic pinion riders (11), the Teflon face seals (16), and the o-rings from the racks and
discard them.
18. Inspect and thoroughly clean all the hard parts from the actuator. Make sure to make a
record of the parts that you will need to order for replacement along with the seal
kits/seal sets.
9. ASSEMBLY
1. Make sure that all the parts have been thoroughly cleaned and are free from
contamination. If the actuator is contaminated during assembly it can lead to pre-mature
failure in the field.
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DOCUMENT NO:

0 12/05/2008
2. Install all of the o-rings, back-ups, and other seals onto all the required parts being
careful not to twist them on.
3. Prepare the racks (9) and pinions (7 & 8) for assembly. Make sure that there are two o-
rings and four back ups on each rack. Apply a light coat of grease to the racks. Press
one Teflon pinion seal (16) into both faces on each pinion. Apply another light coating of
grease to the pinion teeth and inside the pinion riders (11). DO NOT grease the outside
surfaces of the pinion riders. Slide the pinion riders onto the pinions; it is the same
procedure for both pinions.
4. Refer to Figure 2 for proper timing of the racks and pinions. To maintain proper timing
of the racks and pinions so that the actuator will function properly, start by orienting the
main window on the lower cylinder housing (3) as shown in Figure 2.
5. Ensure that the master pinion (8) is on the right side and the slave pinion (7) is on the left
hand side.
6. With the pinion indicators (small milled grooves from hex) facing out and in the upright
position, place the master pinion (8) and rack (9) into the pinion cavity so that the pinion
and rack are as shown in Figure 2. Do the same thing for both cavities on the actuator.
7. When the racks and pinions are installed and timed properly, the racks should bottom
out when the pinion indicators are pointing directly up as shown in Figure 2, if not then
go back and start over so you prevent the actuator from malfunctioning and damaging
the valve.
8. Install the two ½” dowel pins (36) and all the o-rings into the lower cylinder (3). Line the
upper cylinder (2) and lower cylinder up and mate them together. Tighten the eight ½”
NF x 4-1/2” long socket head cap screws (32) to 100 ft-lbs.
9. Install the ½” dowel pins (36) and o-rings in the upper end cap (1). Align the dowel pins
with the holes in the upper cylinder and fasten it down with twelve of the 5/16 NF x ¾”
long socket head cap screws (31). Torque them to 27 ft-lbs to make sure they stay
tight.
10. Flip the actuator over and prepare to install the rotary sleeve (4). Install the two ½”
dowel pins (36) and the o-rings into the sleeve. Attach it to the lower cylinder (3) by
lining up the dowel pins and tightening it down with ten of the 5/16” NF x ¾” long socket
head cap screws (31). Torque them to 27-ft-lbs as well.
11. Install the five bearing assemblies into the rotary hub. Begin by installing the spring (33),
bearing shims (29), and bearings (28). A spring compression tool (HK-4186-23) can be
purchased (it also comes in an actuator service kit (ASK) or the rotary bearing hub major
repair kit (HK-ROTOHUB-MRK)). Install a pin in each hole, place the spring in between
making sure the flats on the pins are lined up. Compress the spring slightly so the pins
will go into the two holes. Remove the tool, add the bearings (28) and shims (29). Once
they are in, place the bearing housing (17) over top, install the bolt retainer strips (19),
and the two ¼” bolts (35). Torque the bolts to 6 ft-lbs. Bend the ends of the retainer
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DOCUMENT NO:

0 12/05/2008
strips up against the bolt heads so the bolts do not work loose. Repeat this step for all
five bearing housings on the rotary hub refer to FIGURE 3.
12. Install the new hub seal set (20). The new hub seal set will consist of three rubber seals
with a self lubricating wave pattern on them. Install them into the three seal grooves
making sure not to get oil or grease behind them and that the grooves were clean and
dry before you installed them. Failure to do this will result in pre-mature seal failure.
13. Apply liberal amounts of Metalon Hi-Tech EP 1.5 grease to the exposed inner bore of the
hub and seal faces of the hub as well as to the mating surface on the rotary sleeve.
14. Ensuring that the hub “closed” and “open” hydraulic ports are on the right and left
respectively, slide the hub (5) into place on the rotary sleeve (4). A rubber mallet may be
used to gently tap the hub into place.
15. Place the lower end cap (6) on the hub ensuring that the ¼” dowel pins (15) are properly
aligned.
16. Thread the eight 5/16” x 3-3/4” socket head cap screws (33) through the lower end cap
into the sleeve; torque them to 27 ft-lbs.
17. Re-install the 5/16” orbital plugs (39) removed during disassembly.
The actuator is now complete and ready for service. Hook up your hydraulic lines to the
proper port and make sure to function the actuator from open to closed and back several
times to lubricate the seal running surface. Make sure that the direction of rotation is proper
and that the rack and pinions do not bind inside the housings.
10. REPAIR AND SERVICE KITS

1. Hub Seal Kit:
HK-4186-HDS-KIT – c/w 3 rubber hub seals.
2. Internal soft seal kit:

HK-4186-SK-F – c/w all internal o-rings, pinions seals, and plastic pinion riders.
3. Complete Service Kit:

HK-4186-ASK-F – c/w 3 hub seals, internal seal kit, various fittings, and tools.
4. Bearing Repair Kit:

HK-ROTOHUB-MRK – c/w 10 bearings, pins, springs, shims, extra springs and shims,
as well as the pin/spring installation tool.
5. Actuator Removal/Installation Kit:

HK-TDA-STRIPKIT – c/w lifting handles, hex drive pullers, tools for hardware, etc.
PAGE
Phone: (780) 435-1111 Fax: (780) 436-5164
EXP
LOD
ITEM NO. PART NUMBER DESCRIPTION
ED/ 21
QTY.
1 HK-4186-1 UPPER END CAP 1 31
2 HK-4186-2 UPPER CYLINDER 1 1

3 HK-4186-3 LOWER CYLINDER 1
4 HK-4186-4A ROTO SLEEVE 1
5 HK-4186-5D HUB 1 21 32
6 HK-4186-6 LOWER END CAP 1
24
7 HK-4186-7-S SLAVE PINION 1
8 HK-4186-7-M MASTER PINION 1 2
9 HK-4186-8 PISTON RACK 2
10 HK-4186-9 LOCKPIN 8 10
26
11 HK-4186-10-DEV PINION RIDER 4
11
12 HK-4186-11A HEX DRIVE SHAFT 2
13 HK-4186-12 ANCHOR BLOCK 1 25
22
14 HK-4186-13 THREADED BUSHING 2 16
21 21
15 HK-4186-14 DOWEL PIN 2 8
9 12
16 HK-4186-16 PINION SEAL 4
17 HK-4186-20 BEARING HOUSING 5 37
18 HK-4186-21 BEARING PIN 10 27
19 HK-4186-22 LOCK STRAP 5

20 HK-4186-HDS-KIT ROTO HUB SEAL 3 3
21 HK-4186-SK-F SEAL KIT 1
7
22 117-HS80 O-RING 2
22 HK-308693-A DECAL 2
23 HK-308692 DECAL 2
36 23
24 1NSX1-SETSCREW SETSCREW 8 4
21
25 323060 RELIEF FITTING 15-25 2
SEE FIGURE 3
26 1000-B-08 COIL SPRING 8 FOR BEARING
ARRANGEMENT
27 N1300-0087-AS INTERNAL SNAP RING 2 20
28 6001-2RS1 ROLLER BEARING 10
5
29 656-163 SHIM 10
21
30 8000-SPRING COIL SPRING 5 14
38
31 5/16NFX3/4SHCS SOCKET HEAD CAP SCREW 22 13 29
32 1/2NFX4-1/2SHCS SOCKET HEAD CAP SCREW 8
35
33 5/16NFX3-3/4SHC SOCKET HEAD CAP SCREW 8
15
34 5/16X1-3/4-SHCS SOCKET HEAD CAP SCREW 6 30
18
35 .25NCX1LBOLT BOLT (GRADE 5) 10 28
19
36 1/2X3/4-DOWEL DOWEL PIN 6 17 34
6
37 HAS-96 WORM CLAMP 4
38 O5CP-6 O-RING BOSS PLUG 2
33
39 20-ORB-127-PHH ORB PLUG 4
39
NOTES: DATE ASSEMBLY NUMBER 4186-TDA-SER-F

12/09/08 HI-KALIBRE
EQUIPMENT LTD.
DRAWN BY TS WORKING PRESSURE 1500 PSI
PHONE 780-435-1111
CHECKED BY BB MAJOR REPAIR KIT HK-4186-ASK-F FAX 780-436-5164
MADE IN CANADA 9816-45 AVENUE
PATENTS APPLY APPROVED BY TH WEIGHT 224 LB EDMONTON, ALBERTA, CANADA
RIGHT SIDE
LEFT SIDE VIEW
LEFT SIDE
RIGHT SIDE VIEW THIS DRAWING IS PROPERTY OF HI-KALIBRE

HI-KALIBRE
FIGURE 2: 4186 SERIES TOP DRIVE ACTUATOR - RACK TIMING RIGHTS OF DESIGN AND INVENTION
30
18
29
28
17
19
35
THIS DRAWING IS PROPERTY OF HI-KALIBRE

HI-KALIBRE
FIGURE 3: 4186 SERIES TOP DRIVE ACTUATOR - HUB BEARING ARRANGEMENT RIGHTS OF DESIGN AND INVENTION
DOCUMENT NO:

0 12/05/2008
REV: DATE: DESCRIPTION: PREP: REVIEW: APPR:
0 01/12/2009 INITIAL APPROVAL BB PR TH

PAGE
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HI-KALIBRE ACTUATOR MANUAL

HI-KALIBRE EQUIPMENT LTD

DIMENSION: SIZE (in)

A STEM DEPTH 4.87

E ROTATING DEPTH 9.68

F OVERALL LENGTH 12.68

SPECIFICATION: SCALAR (U)

THIS DRAWING IS PROPERTY OF HI-KALIBRE

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

3. SHIPPING AND HANDLING INSTRUCTIONS

HEAD OFFICE: 9816 – 45 Avenue, Edmonton, Alberta T6E 5C5

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

5. STRIPPING THE ACTUATOR

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

8. Lift the actuator off the valve body.

6. RE-INSTALLING THE ACTUATOR

7. ROTARY HUB SEAL SET REPLACEMENT

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

HEAD OFFICE: 9816 – 45 Avenue, Edmonton, Alberta T6E 5C5

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

10. REPAIR AND SERVICE KITS

2. Internal soft seal kit:

3. Complete Service Kit:

4. Bearing Repair Kit:

5. Actuator Removal/Installation Kit:

2 HK-4186-2 UPPER CYLINDER 1 1

19 HK-4186-22 LOCK STRAP 5

NOTES: DATE ASSEMBLY NUMBER 4186-TDA-SER-F

LEFT SIDE VIEW

RIGHT SIDE VIEW THIS DRAWING IS PROPERTY OF HI-KALIBRE

THIS DRAWING IS PROPERTY OF HI-KALIBRE

HI-KALIBRE EQUIPMENT LTD. PS-02-002

MAINTENANCE MANUAL REV: DATE:

REV: DATE: DESCRIPTION: PREP: REVIEW: APPR:

0 01/12/2009 INITIAL APPROVAL BB PR TH

HEAD OFFICE: 9816 – 45 Avenue, Edmonton, Alberta T6E 5C5

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