Iron Roughneck Repair
We troubleshoot and repair the mechanical, hydraulic, electrical and control systems that keep iron roughnecks operating.
Mechanical, Hydraulic & Control Repair for Iron Roughnecks
Iron roughnecks take a beating.
Rollers wear. Bearings develop play. Dies wear out. Pins and bushings loosen. Control cables stretch or bind. Hydraulic hoses and lines rub, flex and fail. Cylinders leak. Valves wear. Mechanical assemblies get out of alignment.
Mondak Equipment works on the complete machine.
Brands & Models We Work On
Mondak works on iron roughnecks and make-up/break-out equipment from a variety of manufacturers and generations, including:
NOV / Varco
- ST-80
- ST-80C
- ST-80CL
- ST-80C2
- ST-100
- ST-120
- ST-160
- AR-3200
Canrig
- Torq-Matic TM80
- TM100
- TM120
Forum / FET / Blohm+Voss
- FloorHand FH-70
- FloorHand FH-80
- FloorHand FH-100
- FR120 Series
- Wrangler equipment
Cameron
- T-P
- T-P-L
- M-R
Hawk Industries
- Hawkjaw Junior
- Hawkjaw Senior
- T-Wrex Junior
- T-Wrex Senior
And other iron roughnecks and rig-floor handling equipment.
If your model is not listed, call us with the manufacturer, model and what the machine is doing.
NOV / Varco ST-80 Repair
The ST-80 family is one of the most common iron roughnecks in the field, and many have years of repairs and modifications behind them.
Mondak can repair and rebuild areas including:
- Upper and lower jaw assemblies
- Dies and die holders
- Spin rollers
- Roller bearings
- Drive plates
- Transmission and drive components
- Hydraulic motors
- Torque and clamp cylinders
- Pins and bushings
- Guide plates
- Sway-control components
- Manifolds and hydraulic valves
- Hydraulic hoses and tubing
- Control consoles
- Mechanical control cables
- HPU components
We work on the machine as it exists today.
ST-120 & Larger Roughnecks
Mondak also works on larger NOV / Varco machines such as the ST-120 and ST-160.
These machines put significant loads into the torque, backup, spinning and positioning assemblies. Mechanical condition matters just as much as hydraulic pressure.
We can inspect and repair:
- Torque and backup wrench assemblies
- Spin assemblies
- Dies
- Rollers
- Bearings
- Pins and bushings
- Positioning components
- Cylinders
- Hydraulic motors
- Valves and manifolds
- Hydraulic lines and hoses
- Sensors and controls
Hydraulic force only helps if the mechanical equipment can properly transfer it to the pipe.
Mechanical Iron Roughneck Repair
The hydraulic system creates the force.
The mechanical components still have to grip the pipe, spin it, hold the load and transfer torque.
That is why Mondak puts a lot of emphasis on mechanical condition.
Rollers & Spinner Assemblies
Worn rollers, bearings, shafts or drive components can cause slipping, vibration, slow spinning and inconsistent pipe contact.
Mondak can repair:
- Spin rollers
- Knurled rollers
- Roller bearings
- Shafts
- Drive plates
- Transmission components
- Hydraulic drive motors
- Related mounting and alignment issues
Before condemning a hydraulic motor, we want to know the mechanical assembly turns freely and can actually transfer the available torque.
Dies & Jaw Assemblies
Mondak works on:
- Dies
- Die holders
- Upper and lower jaws
- Backup jaws
- Pins and bushings
- Guides
- Jaw cylinders
- Related gripping components
New dies will not correct a jaw assembly that is loose, worn or out of alignment.
If the machine is wearing dies unevenly or struggling to hold the pipe, the entire gripping assembly deserves a look.
Bearings, Pins & Bushings
Wear in bearings, pins and bushings can create problems throughout the machine.
Symptoms can include:
- Excessive movement
- Poor alignment
- Binding
- Sagging
- Cylinder side-loading
- Uneven die wear
- Roller wear
- Repeated component failures
A little wear in several places can add up to a machine that no longer operates the way it should.
Torque & Backup Assemblies
The torque and backup sections see some of the highest loads on the machine.
Mondak can inspect and repair:
- Wrench assemblies
- Dies and gripping components
- Cylinders
- Pins and bushings
- Bearings
- Guides
- Linkages
- Worn bores
- Hydraulic valves
- Pressure controls
- Structural components
If a wrench is not holding correctly, increasing hydraulic pressure is not always the answer.
The mechanical assembly has to be sound before additional force is useful.
Control Cables
Many iron roughnecks use mechanical control cables between the operator controls and hydraulic valves.
Those cables wear.
They can become stiff, develop excessive play, bind internally or stop fully stroking a valve.
That can cause:
- Slow movement
- Weak operation
- A function working in one direction but not the other
- Different operation depending on machine position
- Inconsistent valve response
Sometimes what looks like a hydraulic problem is actually a control cable that is not fully moving the valve.
Mondak can inspect the controls, cables, adjustments, mounting hardware and valve operation as a complete system.
Hydraulic Hoses & Lines
Iron roughnecks move constantly, and their hydraulic plumbing has to move with them.
Mondak repairs and replaces:
- Hydraulic hoses
- Hose bundles
- Hard lines and tubing
- Fittings
- Clamps
- Hose guides
- Protective sleeving
We also look at why the line failed.
Chafing & Abrasion
A hose rubbing against a frame, guard, bracket or another hose may survive thousands of cycles before it fails.
Replacing the hose without correcting the wear point starts the same problem over again.
Flex-Point Wear
Some hoses flex in the same area every time the machine moves.
Repeated flexing can damage the reinforcement inside the hose even when the outside still looks acceptable.
Hard-Line & Tubing Failures
Vibration and machine movement can also cause:
- Cracked tubing
- Rub-through
- Loose fittings
- Failed clamps
- Fatigue near bends and fittings
A hydraulic leak is the symptom.
The routing, vibration or movement that caused it may be the real problem.
Hydraulic Repair
Mondak can troubleshoot and repair:
- Hydraulic cylinders
- Hydraulic motors
- Directional valves
- Proportional valves
- Relief valves
- Manifolds
- Accumulators
- Pumps
- Filters
- Hydraulic power units
- Pressure and flow problems
- Hydraulic overheating
- Internal leakage
If a roughneck suddenly needs more pressure to perform the same function, we want to know why.
Sometimes the answer is hydraulic.
Sometimes something mechanical has started binding.
Electrical & Electronic Controls
Depending on the machine, Mondak can also troubleshoot:
- Sensors
- Limit switches
- Proximity switches
- Solenoids
- Wiring
- Connectors
- Relays
- Control panels
- PLC inputs and outputs
- Safety interlocks
- Remote controls
Older cable-controlled machines and newer electronically controlled roughnecks require different approaches.
The goal is the same: determine where the function is being lost.
Worn, Modified & Obsolete Equipment
A lot of iron roughnecks have been working for years.
Components get discontinued. Machines get modified. Controls are updated. Hydraulic valves get replaced with newer designs. Mechanical wear accumulates.
That does not automatically mean the machine is finished.
Depending on the repair, Mondak can:
- Rebuild the original component
- Machine replacement parts
- Repair worn bores and shafts
- Replace or manufacture pins and bushings
- Cross-reference bearings and seals
- Adapt hydraulic components
- Update controls
- Fabricate brackets and hardware
- Repair mechanical assemblies
- Rework hose and line routing
Mondak also has machining, welding and fabrication capabilities available when the repair requires more than ordering a replacement part.
If the machine is worth repairing, we want to find a practical way to repair it.
Common Iron Roughneck Problems
Call Mondak when your roughneck is:
- Slipping on the pipe
- Wearing dies unevenly
- Not spinning correctly
- Not developing torque
- Binding
- Developing excessive play
- Wearing rollers or bearings
- Breaking or binding control cables
- Blowing hydraulic hoses
- Rubbing through hydraulic lines
- Running hot
- Moving slowly
- Stopping mid-sequence
- Working intermittently
- Having electrical or control problems
Sometimes you already know what failed.
Other times you just know the machine does not work like it used to.
Either one is a good place to start.
Field Service & Shop Repair
Some iron roughneck repairs can be handled at the rig.
Larger mechanical rebuilds, machining, fabrication, cylinder work and more extensive teardown may make more sense in the Mondak shop.
We can help determine the practical approach based on the machine and the amount of work required.
Iron Roughneck Giving You Problems?
Whether you have an NOV / Varco ST-80 or ST-120, Canrig Torq-Matic, Forum / FET FloorHand or Wrangler, Cameron roughneck, Hawk equipment, or another make or model, give Mondak a call.
Tell us:
- Manufacturer
- Model
- Serial number if available
- What function is giving you trouble
- Any unusual looseness, wear or noise
- Hose, line or control-cable problems
- Hydraulic symptoms
- Faults or alarms
- What has already been repaired
Tell us what the machine is doing. We'll start there.