Operator's

Manual 0004 Manual

OPERATOR'S MANUAL
R

Kellyguard™ Actuator, PN 3126581 PAGE

1

KELLYGUARD™ ACTUATOR
PART NO. 3126581

OPEN

CLOSE

Pressure Control Equipment

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2
Kellyguard™ Actuator, PN 3126581

CONTENTS

PAGE
SECTION 1.0 OPERATION AND INSTALLATION
1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 2.0 PHYSICAL DATA

2.1 Actuator Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Wrench Size and Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Lubrication Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 3.0 MAINTENANCE

3.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 4.0 ASSEMBLY AND DISASSEMBLY

4.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 5.0 TROUBLESHOOTING

5.1 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SECTION 6.0 DRAWINGS AND PARTS

6.1 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.2 Top Drive Conversion Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Please contact Hydril Pressure Control Equipment for any assistance or questions concerning the information in this
manual. All information contained in this manual is the exclusive property of Hydril Company.

R HYDRIL COMPANY/P.O. BOX 60458/HOUSTON, TEXAS 77205

TELEPHONE: (281) 449-2000/TELEX 168905 HYDRIL CSD HOU/
FAX: (281) 985-2828

©2000 Hydril Company Printed In The USA, August 2000. All Rights Reserved.
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SECTION 1.0 OPERATION AND INSTALLATION

1.1 Features

▼ The HYDRIL® Kellyguard™Actuator sets a new bly operations. Removal requires about 15 min-
standard for safety, performance, and ease of utes, and replacement of piston seals requires
maintenance. The pneumatically operated about an hour. The actuator can be overhauled on
Kellyguard™ Actuator remotely operates upper the rig floor with common hand tools by installing
IBOP valves on top drives and power swivels. The the replacement seal kit.
design also allows manual operation with the
actuator in place. Moving linkages are totally ▼ Fits most top drives and power swivels. The
enclosed within the rotating body. It is also the small outside envelope completely encloses all
ideal actuator for upper kelly cocks for kelly drilling mechanisms.
and ball valves with cylindrical bodies for produc-
tion manifolds. ▼ Powered by normal rig air pressure, 90 - 125
psi. The low pressure requirement allows use of
▼ Provides 600 lb-ft of torque, more than any existing pneumatic systems on virtually every drill-
other IBOP actuator. This power provides sure ing rig.
closure of the Kellyguard™ against powerful kicks,
substantially improving rig safety over earlier ac- ▼ Keeps Kellyguard™ open during drilling op-
tuator designs. erations. The weight of the piston and the friction
of the piston seals keeps the Kellyguard™ open
▼ The HYDRIL® Actuator is easy to maintain. during rough, jarring drilling such as surface hole
Very few parts are subject to wear. The simple and air drilling.
design saves time during removal and disassem-

Kellyguard™

OPEN

CLOSE
Actuator

Figure 1-1. HYDRIL® Kellyguard™ Actuator System

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Kellyguard™ Actuator, PN 3126581

1.2 Principle of Operation

The HYDRIL® Kellyguard™ Actuator (refer to Figure Open operating chamber vents out the Open port.
1-2) provides pneumatic and manual operation of a NOTE: The service life of the rotating seals is
HYDRIL® Kellyguard™ valve that is installed in a top reduced significantly if air pressure to the actua-
drive application. Connected to the top drive struc- tor is maintained while rotating at drilling RPMs.
ture by means of four tie-back blocks, the upper and With no pressure on the actuator, only the weight
lower stators remain stationary as the body of the of the piston is required to hold the valve in the
actuator turns with the Kellyguard™. open position. Therefore, it is important to mount
Operation of the Kellyguard™ valve occurs when the actuator onto the Kellyguard™ valve in the
air pressure enters the Open or Close ports of the preferred upright position as shown in Figure 1-
actuator. When the air pressure enters the Open port 2).
into the Open operating chamber, the piston moves The preferred pneumatic control circuit (refer to
down and opens the Kellyguard valve by means of a Figure 1-11) supplies air to the actuator only when rig
link connected between the piston and the crank personnel maintain operation by means of a spring
(refer to Figure 1-3). Air in the Close operating center control switch or valve. When the switch or
chamber vents out the Close port. When the air valve is released, the control circuit returns to a
pressure enters the Close port into the Close operat- neutral or vented condition. Optimum operation is
ing chamber, the piston moves up and closes the achieved when the pneumatic control valves and
Kellyguard™ valve by movement of the link and crank quick exhaust valves are located as close as possible
in the opposite direction (refer to Figure 1-4). Air in the to the actuator.

Kellyguard™ Valve
Upper Stator Tie-Back Blocks

Stationary Open Port

Open Operating
OPEN Chamber
CLOSE Crank
Link
Piston
Rotates Close Operating
Chamber
Stationary Close Port

Lower Stator

Figure 1-2. Kellyguard™ Actuator Operation

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Open
Air In

Close
Air Out

Figure 1-3. Kellyguard™ Actuator In Open Position,

and Kellyguard™ Valve Open.

Open
Air Out

Close
Air In

Figure 1-4. Kellyguard™ Actuator in Close Position,

and Kellyguard™ Valve Closed.
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Kellyguard™ Actuator, PN 3126581

1.3 Installation Top Drive Stem

Refer to Figure 6-1 in Section 6 and Figures 1-5
Hydril Spacer Ring
through 1-9 while following this procedure. CAU-
TION: Installation onto a VARCO Top Drive requires Link Adapter
installation of a spacer ring in the link adaptor before Landing Collar
installing the Hydril® Kellyguard™ actuator (refer to
Figure 1-5). The spacer ring is contained in the Hydril
Conversion Kit (kit contains two different size spacer OPEN

rings that correspond to the respective top drive) . CLOSE

Refer to the Conversion Kit Parts list in Section 6.2 for

the part number.

1.3.1 Actuator Preparation

1. Close the actuator. Refer to Figure 1-6.
2. Remove the two crank retainer lock nuts (item
Figure 1-5. Hydril Spacer Ring Installation
144), lock washers (item 145), and the crank
retainer (item 138) from the actuator assembly.
Remove the crank shafts.
3. Back out the two locating pins (item 146) far
enough so as not to obstruct the inner bore of the OPEN
actuator.

1.3.2 Kellyguard™ Preparation

1. Close the Kellyguard™. Refer to Figure 1-7.
CLOSE
1.3.3 Actuator Installation
1. Orient actuator (tie rod nuts up) to the Kellyguard™.
Witness mark
Note the rotation of the Kellyguard™ and actuator
cranks. The witness marks on the ends of the Figure 1-6. Actuator crank in Close position.
cranks of both the Kellyguard™ and the actuator
should be pointing in the same direction. If they
are not, rotate the actuator 180 degrees relative to OPEN
the Kellyguard™. Refer to Figures 1-7, 1-8, and
1-9.
2. Slide the actuator up onto the Kellyguard™.
3. Makeup the two locating pins (item 146) until they CLOSE
bottom on the Kellyguard™ body, then back out
approximately one-half turn.
4. Slide the actuator up until the two locating pins
can be made up into the receiving holes in the
Kellyguard™. Makeup the two locating pins into Indicator
the receiving holes. Mark
5. Slide the crank shafts (item 106) into the
Kellyguard™ cranks with the keys aligned with
the slots in the crank arms and the witness mark
pointing to Close. The crank shafts may be Figure 1-7. Kellyguard™ in close position. Indica-
rotated slightly to align the male hex on the crank
tor mark points to the right.
shafts with the receiving female hex on the
Kellyguard™ cranks.
6. Install the crank retainers (item 138), lock wash-
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ers (item 145), and lock nuts (item 144).

7. Secure the actuator to the top drive structure with
the four stator tie-back blocks (item 131). The OPEN
apparatus used to secure the actuator should
have 1500 pound tension load capacity. Provide
enough slack to allow for movement of the drive
structure relative to the actuator/drill stem as-
sembly. Refer to Figure 1-9.
8. Connect 125 psi maximum air supply to the 3/8- CLOSE
inch NPT Open and Close ports.
9. Cycle the Kellyguard™ actuator assembly from
close to open several times to verify proper
operation.
Witness Mark
1.3.5 Break-In Period
The new rotating inner seals (item 9A) should be run- Figure 1-8. Kellyguard™ crank in Close position.
in before using the assembly. Rotate the drill stem at
no more than 50 RPM for l0 minutes with no air
pressure applied to the actuator.
Kellyguard™

Tie Rod Nuts and

Nuts OPEN
Washers
CLOSE

Stator
Tie-Back Crank
Blocks Retainer

Spline
Actuator

Figure 1-9. Actuator in upright position.

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Kellyguard™ Actuator, PN 3126581

1.4 Removal
Refer to Figure 6-1 in Section 6 while following this
procedure.

1.4.1 Actuator Removal

1. Turn off the air supply and bleed the air pressure
from the actuator.
2. Disconnect the air supply lines from the actuator.
3. Remove the apparatus that is used to secure the
actuator to the top drive structure from the four
stator tie-back blocks (item 131).
4. Remove the nuts (item 144), lock washers (item
145), and crank retainers (item 138).
5. Slide the crank shafts out of the Kellyguard™
cranks. NOTE: A 1/4-20UNC internal thread is
provided at the bottom of the female hex on the
crankshaft for a pulling tool.
6. WARNING: SUPPORT THE ACTUATOR BE-
FORE CONTINUING. Back out the two locating
pins (item 146) from the receiving holes in the
Kellyguard™ far enough so that they do not
contact the Kellyguard™. Slide the actuator
down until it is off of the Kellyguard™.

VENT
CLOSE OPEN

OPEN
Quick Exhaust

OPEN

CLOSE

CLOSE
Quick Exhaust

RIG AIR IN

Figure 1-11. Preferred Pneumatic Control Circuit

Control Switch on Driller's Panel: 3-Position, Spring-Centered
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SECTION 2.0 PHYSICAL DATA

2.1 Actuator Operating Data

Table 2-1

Bore 8 1/2 In

Operating Pressure 125 PSI Air

Tension Load Capacity of Securing Apparatus 1500 Lb

Open/Close Air Supply Port Size 3/8" NPT

Operating Torque 600 Lb-Ft

Operating Temperature Continous Service –20o to 180o F/-29o to 82o C

Storage/Handling –40o to 212o F/–40o to 100o C

Weight-Single (Approximate) 150 Lb

2.2 Wrench Size and Torque Data

Table 2-2

ITEM PART THREAD WRENCH TORQUE

NO DESCRIPTION NUMBER SIZE SIZE LB-IN (N•m)

121 Button Head Cap Screw 1900388-0303 10-24 1/8 Hex Key Tight

125 Hex Nut 1900389-5020 1/2-20 UNF 3/4 Hex 320 (36)

124 Hex Head Cap Screw 1900044-04014 1/4-20 UNC 7/16 Hex 32 (3.6)

132 Hex Head Cap Screw 1900186-06012 3/8-16 UNC 9/16 Hex Tight

144 Lock Nut 40-507033 3/8-24 UNF 3/8 Hex Tight

a Item number refers to parts list and Figure 6-1 in Section 6.

2.3 Lubricant Data

Table 2-3

Internal/External Surfaces Teflon® Base Grease

Seals Teflon® Base Grease

Threadsa Never Seezb

a For screw and nut threads requiring torque.
b A thread lubricant with a coefficient of friction of 0.069 may be substituted.
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Kellyguard™ Actuator, PN 3126581

2.4 Dimensional Data

Figure 2-1

A
B

OPEN

CLOSE

D C

Table 2-4

Size
Dimension
(In)

A Actuator Width, Rotating 14- 3/4

B Actuator Width, Non-Rotating 13 -11/16

C Actuator Height, Non-Rotating 13- 7/32

D Actuator Height, Rotating 8 -9/32

E Crank Centerline 8

F Bore, Rotating (Not Shown) 8- 1/2

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SECTION 3.0 MAINTENANCE

3.1 Maintenance Schedule

Periodic maintenance is a very important part of 3-1) that is designed to help maintain the Kellyguard™
keeping the HYDRIL® Kellyguard™ Actuator in good Actuator by displaying in tabular form the recom-
operating condition. Not only will regular mainte- mended service interval for each required mainte-
nance extend the service life of the equipment, but it nance operation. In addition, the paragraph where
will also help to eliminate unnecessary down time. the maintenance procedure can be found in this
This section contains a maintenance schedule (Table section is also included.

TABLE 3-1
MAINTENANCE SCHEDULE

Maintenance Operations
I = Inspect; L = Lubricate;
R = Replace

Item No.a Equipment/Component Service Interval & Maintenance Operations Ref.b

Six Weeks One Year

136 Upper & Lower Stators I,Lc 3.1.1

109-119 Seals I,R 3.1.2

128,140, Bearings I,R 3.1.2

141
a Referto Figure 6-1. b Paragraph where maintenance procedure is located. c Lubricate only when
disassembled.

3.1.1 Six Week Maintenance 3.1.2 One Year Maintenance

Inspect and lubricate the upper and lower stators of Inspect the seals and bearings after one year of
the Kellyguard™ Actuator after six weeks of opera- operation.
tion.
A. Materials Required
A. Materials Required 1. Teflon® base grease
1. Teflon® base grease 2. Standard U.S. handtools
2. Standard U.S. handtools 3. Replacement seals and bearings

B. Procedure B. Procedure
1. Disassemble the upper and lower stators. 1. Disassemble the actuator.
2. Lubricate the upper and lower stators with a small 2. Clean thoroughly.
amount of grease. CAUTION: Do not apply 3. Inspect seals and bearings. Replace as neces-
excessive amount of grease to stators. Ex- sary.
cessive grease may cause heat buildup and 4. Assemble the actuator. Apply a small amount of
damage seals. grease to upper an lower stators upon assembly.
3. Assemble the stators. CAUTION: Do not apply excessive amount of
4. Operate and observe for air leaks. If air leaks are grease to stators. Excessive grease may
present, refer to troubleshooting information in cause heat buildup and damage seals.
this manual. 5. Operate and observe the actuator for air leaks. If
air leaks are present, refer to troubleshooting
information in this manual.
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Kellyguard™ Actuator, PN 3126581

SECTION 4.0 ASSEMBLY AND DISASSEMBLY

4.1 Disassembly 4.1.3 Disassemble the Piston Subassem-

Refer to Figure 4-1 while following the procedures bly
below. 1. Remove the dowel pins (item 126) and the crank
arms (item 107) from the links (item 108).
4.1.1 Tools and Materials Required. 2. Remove dowel pins (item 126) and the links from
1. 5/16" hex key wrench the piston (item 101).
2. 7/8" hex key wrench 3. Remove the bearings (item 141) from the links.
3. Puller tool with 1/4"-20 UN thread, Hydril Part No. 4. Remove the retaining rings (item 130), piston
3117359 guide bushings (item 122), tie rod bearings (item
4. 3/4" hex wrench 140), and the T-seals (item 114) from the piston
5. 7/16" hex wrench (item 101).
6. 9/16" hex wrench
7. 1/8" hex key wrench 4.1.4 Disassemble the Upper Rotor Sub-
assembly
4.1.2 Disassemble Into Subassemblies 1. Remove the tie-back blocks (item 131) from the
1. Remove the upper rotor subassembly from the stator (item 136) by removing the screws (item
actuator as follows: 132).
a. Unscrew the tie rod nuts (item 125) as far as 2. Remove the screws (item 124) and washers (item
possible. 123) from the bearing retaining ring (item 137).
b. Lift the upper rotor subassembly up as far as Allow the ring to rest on the upper rotor (item 105).
possible. 3. Remove the stator from the upper rotor.
c. Continue steps a and b until the subassembly 4. Remove the bearing retaining ring from the upper
is free of the actuator. rotor.
2. Remove the lock nuts (item 144), lock washers 5. Remove the retaining ring (item 139) and the
(item 145), and the crank retainers (item 138) bearing (item128) from the upper rotor.
from the crank shaft openings.
3. Pull the crank shafts (item 106) from the actuator 4.1.5 Disassemble the Lower Rotor Sub-
using the puller tool.
4. Unscrew the locator pins (item 146) from the assembly
actuator. 1. Remove the tie-back blocks (item 131) from the
5. Remove the outer cylinder (item 103) and the stator (item 136) by removing the screws (item
inner cylinder (items 102). 132).
6. Unscrew the tie rods (item 127). 2. Remove the screws (item 124) and tab washers
7. Remove the piston subassembly (item 101). (item 123) from the bearing retaining ring (item
137). Allow the ring to rest on the lower rotor (item
104).
3. Remove the stator from the lower rotor.
4. Remove the bearing retaining ring from the lower
rotor.
5. Remove the retaining ring (item 139) and the
bearing (item 128) from the lower rotor.
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110 137 123 124

139 128

136

116 105

103
125
111

109 138

127 107
102 106
142
130
126
122
108
114
126
140
141

120 119

121 101

104

132 131 113 112 118 143 124 123

146
115
117

145

144

Figure 4-1. Actuator Assembly, Part No. 3126581

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Kellyguard™ Actuator, PN 3126581

4.2 Assembly 4.2.2 Lubrication

Refer to Figures 4-1 through 4-18 while following the 1. Lubricate all internal surfaces, external surfaces,
procedures below. NOTE: The item numbers refer to and seal surfaces with a Teflon® base grease
the assembly drawing, Figure 4-1. upon assembly. CAUTION: Do not apply
excessive amount of grease to stators (item
4.2.1 Tools and Materials Required. 26). Excessive grease may cause heat buildup
1. Any Teflon® base grease and damage seals.
2. Never-Seez thread lubricant (coefficient of fric- 2. Lubricate all seals with a Teflon® base grease
tion is 0.069) or equivalent upon assembly.
3. 1/8" hex key wrench 3. Lubricate capscrew threads requiring torque with
4. 5/16" hex key wrench Never-Seez thread lubricant (coefficient of fric-
5. 7/8" hex key wrench tion is 0.069) or equivalent.
6. 3/4" hex wrench
7. 7/16" hex wrench
8. 9/16" hex wrench
9. Pipe wrench

4.2.3 Assemble Upper and Lower Rotor

Subassemblies
NOTE: The upper and lower rotor subassemblies are
assembled in the same manner. Follow the proce- Rotor
dure that follows for each subassembly.
Bearing

1. Place the bearing retainer ring (item 137) in the Bearing

inside diameter of each rotor. Install the bearing Retainer
(item 128) into each rotor (items 104 and 105). Ring
Refer also to Figure 4-2.

Figure 4-2

Retaining
2. Install the retaining ring (item 139) into each rotor Ring
(items 104 and 105). Refer also to Figure 4-3.

Rotor

Figure 4-3
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3. Install the seals (item 115) into each stator (item

136). The cups or lips of the seals must face
inward toward each other. Refer also to Figure 4- Stator
4.

Seals

Figure 4-4

Screw
4. Install the stators onto the rotors, being careful not
Stator
the damage the seals. With the stators in place,
lift each retainer ring up and install it onto the Bearing
stator, using the lock washers and the screws
(items 123 and 124) for the upper stator and the
tab washers and screws (items 135 and 124) for
the lower stators. (NOTE: the lower stator is the
one installed on the rotor with threaded holes for Retainer
installation of the tie rods.) Tighten the screws Ring
using 32 lb-in (3.6 N•m) torque. Refer also to
Figure 4-5. Rotor

Figure 4-5

5. Install the inner O-ring seal (item 112) and the

outer O-ring seal (item 113) into the seal ring
grooves in each rotor (items 104 and 105). Refer
also to Figure 4-6

Rotor

Outer Seal

Inner Seal

Figure 4-6
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Kellyguard™ Actuator, PN 3126581

4.2.4 Assemble the Piston Subassembly

1. Install the piston inner seals (item 118) into the
seal grooves in the inside diameter of the piston Bearings
Link
(item 101). Install the piston outer seals (item
Dowel Pin
119) into the seal grooves in the outside diameter.
Refer to Figure 4-7 for seal orientation. Piston
2. Press two bearings (item 141) into each of the two
links (item 108). Outer
Seals

Inner
Seals

Figure 4-7

3. Install the links into the two slots in the piston by

inserting dowel pins (item 126) through the body Link
of the piston. NOTE: Orient each link so that it can Crank Arm
connect to the crank arms (item 107). Dowel
Pins
4. Install the crank arms, one on each side, onto the
links by inserting a dowel pin (item 126). Allow the
crank arms to rest on the piston for now as shown
in Figure 4-8.

Piston

Figure 4-8

Tie Rod
5. Install a tie rod bearing (item 32), T-seal (item 9H), Bushing
piston guide bushing (item 12), and retaining ring
Retaining Ring
(item 20) into each tie rod bushing bore in the
piston as shown in Figure 4-9. T-Seal
6. Turn the lower stator and rotor assembly so that Bearing
the bottom of the rotor is face up. Piston
7. Position the piston on the rotor so that the tie rod
bores in the piston align with the threaded holes in Lower Rotor
the rotor. and Stator
8. Install the tie rods (item 17) through the bushings
into the rotors and make up tight. CAUTION: Do
not use a wrench on the small diameter.
Figure 4-9
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4.2.5 Assemble the Actuator Assembly

1. Install the tie rod seal (item 9C) into the groove on
the end of each tie rod (item 18). Refer also to
Figure 4-10.

Seal

Tie Rod

Figure 4-10

2. Install the outer crank seals (item 9E) into the

groove in each crank opening in the outer cylinder
(item 3). Refer also to Figure 4-11.
Crank
Opening

Seal

Outer
Cylinder

Figure 4-11

3. Install the inner crank seals (item 110) into the

grooves in each crank opening in the inner cylin-
der (item 102). Refer also to Figure 4-12.
Seal

Crank
Opening

Inner
Cylinder

Figure 4-12
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Kellyguard™ Actuator, PN 3126581

4. Install the locating pin seals (item 115) onto each

locating pin (item 146). Refer also to Figure 4-13.
Seal

Locating Pin

Locating Pin

Figure 4-13

5. Install the dowel pin (item 143) into the hole in the
Inner Cylinder
inner cylinder. Refer also to Figure 4-14.
6. Install the inner cylinder (item 102) through the
piston and onto the lower rotor (item 104) so that
the dowel pin in the cylinder aligns with the dowel
Outer Cylinder
pin locating groove in the rotor. Push the cylinder
down until the dowel pin is engaged fully.
7. Install the outer cylinder (item 103) over the piston
Rotor
and onto the lower rotor so that the groove in the
outer cylinder mates with the orienting key slot. Orienting Key
8. Inspect the inner and outer cylinders to ensure
that the crank openings and the locating pin Dowel Pin
openings are aligned.
9. Install the orienting key (item 120) onto the lower Figure 4-14
rotor using the button head screw (item 121).

10. Install the locating pins (item 146) through the

locating pin holes in the inner and outer cylinders. Inner Cylinder
Screw in the pins until tight. Refer also to Figure Outer Cylinder
4-15.

Locating
Pin

Figure 4-15
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11. Hold the crank shaft (item 106) with the male hex
facing the crank opening in the outer cylinder.
With the witness mark pointing up, insert the Retainer
parallel key (item 142) into the slot. If positioned
Crank Shaft
with the link on the left, insert the key into the slot
pointing down and to the left. Refer also to Figure
Key
4-16.
12. Insert the crank shaft (item 106) through the Crank Arms
opening. Pickup the crank arms (item 107) and
slide the crank shaft through. Continue to push
the crank shaft through until the crank shaft bot-
toms. Repeat for the other side.

Figure 4-16

13. Install the crank retainers (item 138), the lock

washers (item 145), and the lock nuts (item 144) Lock Washer
on both sides. Refer also to Figure 4-17.
Nuts

Crank
Retainer

14. Install the dowel pin (item 143) into the hole in the
inner cylinder (item 102). Refer also to Figure 4-
18. Figure 4-17
15. Install the upper stator and rotor subassembly
with the upper rotor (item 105) down onto the
cylinders (items 102 and 103) so that the dowel
pin groove in the upper rotor aligns with the dowel
pin. Position the hex tie rod nuts (item 125) in the Upper Stator & Rotor
openings where the tie rods (item 127) will fit
through prior to final positioning of the rotor. Start
Tie Rod & Nut
the nuts onto the tie rods. Finally, push the rotor
down into position on the cylinders. Tighten the tie Key
rod nuts. Dowel Pin
16. Install the orienting key (item 120) and the button Inner Cylinder
head screw (item 121) into the upper rotor. The
Outer Cylinder
key should mate with a slot in the outer cylinder.
17. Install the stator tie-back blocks (item 131) and
screws (item 132).
Stator
18. Manually function the actuator with a 7/8" hex Tie-Back
wrench in the female hex in the crank (item 106)
several times. NOTE: It may be necessary to use Figure 4-18
two wrenches.
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20
Kellyguard™ Actuator, PN 3126581

SECTION 5.0 TROUBLESHOOTING

Problem Probable Cause

1. Actuator fails to operate in either direction. Inadequate air supply to actuator.

Actuator installed on IBOP 180o out of proper

orientation.

Crank arms or keys are not engaged with crank

shafts.

Links and crank arms are not oriented correctly

inside actuator.

2. Actuator opens but only closes half way. Crank shaft is not installed through at least one
crank arm.

3. Motion is erratic or slow. Exhaust on opposing chamber is restricted.

Inadequate air supply to actuator.

Excessive operating torque required by IBOP.

4. Motion stops before reaching full open or Excessive operating torque required by IBOP.
full close.

5. Air Swivel requires excessive torque to New rotating seals need to be "run in."
rotate or runs hot.

Air is maintained on chamber.

Interference exists in swivel rotating elements.

Bearings are worn.

6. Link adapter on top drive stem hitting Hydril spacer ring not installed in link adapter of
top of actuator. top drive stem (see Figure 1-5).
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Kellyguard™ Actuator, PN 3126581 PAGE

21

SECTION 6.0 DRAWINGS AND PARTS

6.1 Parts List – Refer To Figure 6-1.
Item Part Name No. Part
No. Req. Number

Actuator Assembly 1 3126581

101 Piston 1 3116041
102 Inner Cylinder 1 3126314
103 Outer Cylinder 1 3123289
104 Lower Rotor 1 3116044
105 Upper Rotor 1 3116045
106 Crank Shaft 2 3117773
107 Crank Arm 4 3124238
108 Link 2 3115116
▼109 Tie Rod Seal, O-Ring 4 1900002-112
▼110 Inner Crank Seal, O-Ring 2 1900002-122
▼111 Outer Crank Seal, O-Ring 2 1900002-031
▼112 Inner Cap Seal, O-Ring 2 1900002-373
▼113 Outer Cap Seal, O-Ring 2 1900002-381
▼114 Tie Rod Seal, T-Seal 4 1920070-208
▼115 Locating Pin Seal, O-Ring 2 1900002-016
▼116 Rotating Inner Seal, Polypak 4 1920635-1
▼117 Inner Cylinder Pin Seal, O-Ring 2 1900001-116
▼118 Piston Inner Seal 2 1920701
▼119 Piston Outer Seal 2 1920702
120 Orienting Key 2 3116432
121 Screw, Button Head 2 1900388-0303
122 Piston Guide Bushing 4 3116433
123 Washer, Lock 8 1900296-09
124 Screw, Hex Head 16 1900044-04014
125 Nut, Hex, Tie Rod 4 1900389-5020
126 Pin. Dowel 4 1900151-1224
127 Tie Rod 4 3115119
128 Bearing, Ball 2 1920574-13
129 Nameplate 1 3108362-03
130 Ring, Retaining 4 1900103-125
131 Block, Stator Tie-Back 4 3116436
132 Screw, Hex Head 8 1900186-06012
133 Plug, Hex Socket (Not Shown) 4 1900126-04
134 Screw, Drive 9 1900061-06
 Operator's Manual R

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Kellyguard™ Actuator, PN 3126581

(Parts List Continued. Refer To Figure 6-1.)

Item Part Name No. Part
No. Req. Number

135 Washer, Tab 8 1920638-1

136 Stator 2 3116042
137 Ring, Bearing Retainer 2 3116043
138 Crank Retainer 2 3123297
139 Ring, Retaining 2 1900135-196
140 Bearing, Tie Rod 4 3117715
141 Bearing, Spherical 4 1900362-04
142 Key, Parallel 2 1900161-0812
143 Pin, Dowel 2 1900151-0507
144 Locknut, Crank Retainer 4 40-507033
145 Lockwasher, Crank 4 1920638-2
146 Locating Pin 2 3126315
▼ Seal Kit 3126601. Recommended Spare Parts for 1-Year Service

6.2 Conversion Kits

Kellyguard Description 5 1/4-10,000 5 1/4"-10,000 5 1/4"-15,000 5 1/4"-15,000

With Without With Without
Load Shoulder Load Shoulder Load Shoulder Load Shoulder
Conversion Kit* 3116102 3116104 3116103 3116105
1 Plate Mods, VARCO TD S-3 3115324 3115324 3115324 3115324
2 Spacer Ring- 7.5" ID VARCO SP 3116999 3116999 3116999 3116999
3 Spacer Ring- 9.1" ID VARCO TD 3117554 3117554 3117554 3117554

4 Kellyguard Actuator Assembly 3121269 3121269 3121269 3121269

5 Kellyguard Actuator Seal Kit 3123112 3123112 3123112 3123112
6 Kellyguard Assembly 3109790 3116090 3116080 3116100
7 Repair Kit for 5.25"-15M Top Drive 3109779 3109779 3109779 310779
8 Installation Kit for Kellyguard Top 3116229 3116229 3116229 3116229
Drive VARCO
* Items 1 through 8 are contained in coversion kit.
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Kellyguard™ Actuator, PN 3126581 PAGE

23

110 137 123 124

139 128

136

116 105

103
125
111

109 138

127 107
102 106
142
130
126
122
108
114
126
140
141

120 119

121 101

104

132 131 113 112 118 143 124 135

146
115
117

145

144

Figure 6-1. Actuator Assembly, Part No. 3126581

 Operator's Manual
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OPERATOR'S MANUAL
OPERATOR'S MANUAL
Kellyguard™ Actuator, PN 3126581
R

Pressure Control Equipment