Eckel Manufacturing Co. Inc.

Hydraulic Power Tongs — "World Wide"

13-3/8 Standard Hydraulic

Power Casing Tong

OPERATION
and SERVICE
INSTRUCTIONS
Copyright

© Copyright 1989, Eckel Manufacturing Co., Inc. All rights reserved. No part of this manual may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written
permission of Eckel Manufacturing Co., Inc.

Trademarks

Eckel is a registered trademark of Eckel Manufacturing Co., Inc.

Loctite is a registered trademark of Loctite Corporation
13-3/8 Standard Hydraulic Power Tubing Tong is covered by U.S. and Foreign Patents and Pending Patent Applications

First Editon

April 1989
Printed in U. S. A.

Main Offices and Plant: International Sales Office:

8035 West County Road 480 N. Beltway 8 East, Suite 200
Box 1375, Odessa, Texas 79760 Houston, Texas 77060
Phone (432) 362-4336 Phone (713) 999-6680
Telex 74-5434 (ODS) Telex 77-4644 (HOU)
FAX 432-362-1827 FAX 713-999-8707
 Contents
Section 1 - General Description ................................................................................1
Introduction .........................................................................................................2
Functional Description ........................................................................................3
Specifications ......................................................................................................7
Options and Accessories .....................................................................................7

Section 2 - Installation .................................................................................................... .11

General Considerations .......................................................................................12
Connecting Hydraulic Hoses ..............................................................................14

Section 3 - Operation ...................................................................................................... .17

General Operation ...............................................................................................18
Operating Controls and Gauges ..........................................................................18
Pre-Operating Checks .........................................................................................18
Typical Operating Sequence ...............................................................................20
Section 4 - Servicing ........................................................................................................ .23
Daily Inspection ..................................................................................................24
Maintenance After Each Job ...............................................................................24
Lubrication ..........................................................................................................25
Tests and Adjustments ........................................................................................26
Section 5 - Troubleshooting, Repair and Overhaul .................................. .29
Troubleshooting ..................................................................................................30
Repair ..................................................................................................................31
Tong Overhaul ....................................................................................................31
M4D Motor Overhaul .........................................................................................32
A35 Valve Overhaul ...........................................................................................35
Section 6 - Parts List ....................................................................................................... .37
Parts List, Eckel 13-3/8 Standard Tong ..............................................................38
Parts List, Clutch Assembly ................................................................................42
Parts List, Pinion Idler Assembly .......................................................................43
Parts List, Pinion Assembly ................................................................................44
Parts List, Rotary Idler Assembly .......................................................................45
Parts List, M4D Motor Assembly .......................................................................46
Parts List, A35 Valve Assembly .........................................................................48
Parts List, Hydraulic Cam Backup ......................................................................59
Parts List, Tong Suspension ................................................................................56
Parts List, Door Interlock Assembly ...................................................................57
Microswitch Assembly .......................................................................................60

iii
 Section 1
General Description

1
 INTRODUCTION
This manual describes the function, operation and maintenance of the Eckel 13-3/8
Standard Hydraulic Power Casing Tong. This section provides a functional description,
system specifications, and a description of options and accessories available. Section 2
through 5 present the operating and maintenance aspects of the tong and Section 6
provides a fully illustrated parts list.
The 13-3/8 Standard Tong, Figure 1-1, handles casing sizes as small as 4 inch and as
large as 13-3/8 inches diameter. The open-throat design, combined with high-speed
operation, assures both ease and speed in tubular handling. A safety door on the open
throat helps insure against accidents. The following paragraphs describes the functions
of the tong during tubular make-up or break-out operations.

HYDRAULIC
DRIVE SYSTEM

CAGE PLATE
WITH PIVOT HEADS

SAFETY
DOOR

3/8
L 13
E
E CK GEAR TRAIN,
CLUTCH DETAILS
(INSIDE HOUSING)

Figure 1-1
Functional Elements of the 13-3/8 Standard Tong
13-3/8 Standard Tong is covered by U.S. and Foreign
Patents and Pending Patent Applications

2
FUNCTIONAL DESCRIPTION
Operating from a hydraulic power unit, the power tong provides torque of 22,000 ft-lbs.
The heart of the unit is a head-closing system which forces the heads together and rotates
them by means of a cam-type rotary gear. The rotary gear is driven by a two-speed gear
train powered from a vane-type hydraulic motor.
In operation, the tong is suspended over the well bore on a chain bridle. Snub lines
restrain the tong from moving around the pipe as torque is applied.
HYDRAULIC DRIVE SYSTEM. Figure 1-2 is a hydraulic schematic of the drive
system. Hydraulic pressure from a separate power unit is applied through screw-type
hose connectors having built-in check valves. To prevent cross-connection of the hoses,
the pressure hose from the power unit is designed to mate with a 1-inch connector and the
return hose mates with a 1-1/4 inch connector. Connection of the hoses opens the check
valves to provide hydraulic pressure to the tong.
The tong control levers acts as a throttle valve for the unit. Pushing the lever applies
pressure to drive the motor in a forward direction (for make-up operation) and pulling the
lever applies pressure in a reverse direction (for break-out operation). While the lever is
in a neutral position, fluid circulates freely through the valve and back to the return line.
Refer to Section 3 for tong control lever positions.

1-1/4" COUPLING REVERSIBLE

RETURN MOTOR 1-1/4" COUPLING REVERSIBLE
RETURN MOTOR

PRESSURE
RELIEF PRESSURE
VALVE RELIEF
VALVE

M
PRESSURE
M
PRESSURE

1" 1"
COUPLING MAKE-UP COUPLING
BREAK-OUT MAKE-UP
BREAK-OUT

CONTROL VALVE CONTROL VALVE

Open Center Valve Closed Center Valve

Figure 1-2
Hydraulic Drive System Schematic Diagram
An adjustable relief valve permits adjustment of the operating pressure at the tong if
desired, and a built-in pressure gauge indicates the operating pressure at all times. The
maximum pressure available, of course, depends upon the power unit. A power unit
capable of delivering 2,500 PSI and 30 GPM and 1000 PSI at 65 GPM is necessary in
order to obtain the maximum rated output of the power tong.
A hydraulic motor is mounted on the top tong plate through a motor adaptor, and the
other hydraulic plumbing components are also mounted on the top tong plate.
GEAR TRAIN AND CLUTCH FUNCTION. Closure and rotation of the pipe-gripping
heads are accomplished by means of a large rotary gear having its inner diameter formed
into a double cam surface. This topic explains how mechanical power is transmitted
from the hydraulic motor to turn the rotary gear in either direction.
Gear Train Elements. The gear train, Figure 1-3, comprises a motor gear, the clutch
assembly, pinion assembly, pinion idler, two rotary idlers and the rotary gear. The rotary
gear rides within a circle of dumbbell rollers that support the gear. The selected high- or
low-speed clutch gear engages the corresponding high or low-speed pinion gear, and the

3
 ROTARY PINION PINION CLUTCH SPEED
IDLER IDLER ASSEMBLY ASSEMBLY SHIFT

CLUTCH
ASSEMBLY

SHIFTING
YOKE ADJUSTABLE
SHIFTING DETENT
COLLAR
HIGH
SPEED LOW
SPEED

DUMBBELL PINION
ROLLER ASSEMBLY
NOTE

CLUTCH SHOWN IN NEUTRAL OF SHIFTING LEVER. CUTS

SHOW HIGH-SPEED AND LOW-SPEED POSITIONS.

Figure 1-3
Clutch Details
pinion output gear drives the two pinion idlers gears whin in turn drives the two rotary
idlers. In driving the rotary gear, two rotary idler gears are necessary to bridge throat cut
out gap.
Clutch. The clutch assembly (Figure 1-3) provides high- or low-speed operation,
allowing faster operation when high torque is not required. When higher torque is
needed, the low-speed gear permits the operator to slow the speed down and increase the
torque.
The operator shifts the speed by raising or lowering a shifter lever on top of the tong. As
shown in the illustration, lifting the shift lever lifts the shifting yoke, which lifts the
shifting collar. In this position, the shifting collar mechanically couples the clutch shaft
with the high-speed clutch gear. Lowering the shifting lever lowers the shifting yoke
which lowers the shifting collar, thereby mechanically coupling the clutch shaft with the
low-speed clutch gear. Then the selected clutch gear drives the corresponding pinion
gear as previously described. An adjustable spring detent on the shifting shaft holds the
yoke and shifting lever in the selected position until again moved by the operator.
HEAD OPERATIONS. The sliding heads are enclosed within the rotary gear by the top
and bottom cage plates. The heads are closed, rotated and opened by the combined
actions of the rotary gear, brake bands and backing pin.
Rotary Gear/Head Functions. During make-up operations, the pipe to be turned is
first enclosed in the tong, and the throat safety door is closed. Then with the backing pin
in the make-up position (described later) the operator pushes the tong control lever
forward to cause the heads to bite and rotate the pipe. To release the heads and back off
from the pipe, the operator pulls the tong control lever outward.
During break-out operations, the backing pin is placed in the break out position so that
the heads bite in the reverse direction (see Backing Pin Function). Then the operator
pulls the tong control lever to cause the heads to bite and break out the pipe. Finally, he
pushes the lever forward to release the heads and back them off the pipe.
As illustrated in Figure 1-4, the head-biting action is a function of the rotary gear inner
surface cam design. When the rotary gear begins to rotate, the head rollers roll up on the
cam surface and force the sliding heads inward until the heads bite the pipe. Further
rotation then turns the pipe to make-up (or break-out) the joint.
4
 ROLLER
ONE IN EACH ROTATION
PIVOT HEAD
POINTS

PIPE

HEADS OPEN
HEADS CLOSED

Figure 1-4
Head Biting Action, Makeup

Rotary Gear and Head Cage Rotation. Figure 1-5 illustrates the cam follower
rollers that permit the semi-independent rotation of the cage plates and rotary gear. The
figure illustrates how the top cage plate is free to rotate on a ring of cam follower rollers
following a groove in the rotary gear. The rotary gear is turned independently within a
circle of dumbbell rollers.. The bottom cage plate rotates on a ring of cam follower
rollers identically with the top cage plate. This plate is bolted to the top cage plate to
enclose the heads. The heads are forced in to bite the pipe as brought about by the cam
action of the rotary gear on the head rollers.
Brake Band Function. Consider again the actions of the rotary gear cam and heads in
view of the freedom that the cage plates have to rotate. It becomes evident that, if the

BACKING PIN HOLE RETAINER SCREW

(MAKE-UP POSITION) AND WASHER

BACKING PIN
RETAINER
BACKING PIN
(BREAK-OUT POSTION)
CAM FOLLOWER
NUT AND WASHER
BACK CAGE
PLATE BOLT CAM FOLLOWER
TOP TONG PLATE
TOP
CAGE PLATE

BOTTOM
CAGE PLATE ROTARY
GEAR

DUMBBELL
BACKING ROLLER
LUG

CAM FOLLOWER

Figure 1-5
Head Cage Plate and Rotary Gear Details

5
 BACKING PIN ROTARY
HEADS GEAR CAM
SURFACE

HEAD
PIVOT HEAD
BOLT ROLLERS

BRAKE
BAND
ADJUSTMENT
BRAKE BAND

PIPE THROAT
SAFETY
DOORS

Figure 1-6
Brake Bands and Safety Door
cage plates have unrestrained freedom to rotate, the heads will simply move with the
rotary gear and will not cam up on the rotary cams to force the biting action. Figure 1-6
illustrates how brake bands are placed around the cage top and bottom plates to exert
continuous friction on these plates and to restrict their freedom to move.
Thus it is evident that the brake bands do not permit the cage plates (and heads) to turn
freely when the rotary gear turns. Rather, the cage plates are held stationary as the head
rollers roll up onto the cam surfaces to force the heads in against the pipe. As the heads
bite the pipe, the friction of the brake bands is overcome. Then the cage plates begin to
rotate with the rotary gear, thus turning the pipe that is now gripped firmly by the heads.
Backing Pin Function. The backing pin shown in Figure 1-5 permits the heads to bite
in the forward direction for make-up and in the reverse direction for break-out.
When the pin is placed in the left-hand hole, forward operation causes the heads to bite
and rotate to make up the joint. However, reverse operation causes the backing lug to
strike the backing pin and force the cage plates around with the rotary gear. Thus, in the
reverse direction, the head rollers cannot cam up on the rotary cam and the heads do not
bite.
If the backing pin is placed in the right-hand hole, the opposite action occurs and reverse
operation causes the heads to bite, while forward operation causes the backing lug to
strike the backing pin and force the head cage around with the rotary gear, thus inhibiting
the heads from biting in the forward direction.
In summary then: for make-up, the backing pin is placed in the left-hand hole and the
heads bite in forward direction; and for break-out, the backing pin is placed in the right-
hand hole and the heads bite in the reverse direction.
Open Throat and Safety Door. The open throat design permits ease of operation
by permitting entry of vertical pipe that projects above the level of the tong. For safety
purposes it is necessary that the throat opening be closed during operation to prevent
personnel injuries or damage to the equipment. A safety door (Figure 1-6) serves both
to close off the front during operation and to provide an extra margin of support for the
housing during high-torque operation. An optional Door Interlock (Figure 6-9) device
adds additional margin of safety, preventing the tong from operating while the tongs
door is open.

6
 SPECIFICATIONS
The specifications for an operating tong must consider the hydraulic power unit as well as
the tong itself.
HYDRAULIC POWER UNIT SPECIFICATIONS. The power tong is designed to be
powered by a hydraulic power unit capable of delivering at least 2500 pounds per square
inch (PSI) for maximum rated operating torque.
At least 65 gallons of hydraulic oil per minute, depending upon the power unit used, are
required to operate the tong at maximum RPM.
TONG SPECIFICATIONS. Table 1-1 list the specifications for the Eckel 13-3/8
Standard Casing Tong.

OPTIONS AND ACCESSORIES

Options for the 13-3/8 Standard Tubing Tong include lift cylinder with lift cylinder
control, spring hanger, torque gauge, manual backup and door interlock. The optional
items are described in the following paragraphs.
LIFT CYLINDER AND CONTROLS. A lift cylinder as illustrated in Figure 2-3 is
optionally supplied with the 13-3/8" tong. This cylinder provides a means for raising and
lowering the tong during operations.
Lift Cylinder. While the lift cylinder may be connected directly to the tong bridle, it is
suggested that the optional spring hanger be inserted between the lift cylinder and the
Table 1-1
Specifications Eckel 13-3/8 Standard Tong

Torque:
High Gear (Range) ...................... 4,400 ft/lbs
(5,966 nm)
Low Gear (Maximum) ............... 22,000 ft/lbs
(29,828 nm)
Torque Handle Lengths:
Standard .................................. 36" (914 mm)
RPM:
High ..................... 85 at 65 GPM (250 L/min)
Low ...................... 16 at 65 GPM (250 L/min)
Hydraulic Requirements:*
65 G.P.M. (250 L/min) at 1,000 P.S.I. (68 bar)
30 G.P.M. (113 L/min) at 2,500 P.S.I. (172 bar)
Hyd. Oil Operating Temperature:
Normal .................................. 130° F. (54° C)
Maximum .............................. 180° F. (82° C)
Dimensions:
Length ........................ 61 inches (1549 mm)
Overall Width ..................34 Inches (864mm)
Pipe Space Required ... 7.5 inches (191 mm)
Max. Elevator Diameter ............... (Unlimited-
Tong comes off Pipe)
Pipe C.L. to Anchor C.L. 36 Inches (914 mm)
Weight:
Approximately ......... 1,260 Pounds (571 kg.)
Heads Available:
For Tubing Size O.D.: .... 4", 4-1/2", 5", 5-1/2"
6-5/8", 7", 7-5/8", 8-5/8"
9-5/8", 10-3/4",11-3/4",13-3/8"
NOTE: Any size head between 4" and 13-3/8" may
be specified as needed.
* These are average requirements for a new tong.
There may be some variations from tong to tong.

7
 bridle to permit tong movement during make-up or break-out operations without exerting
undue stress on the bridle and dies.
Lift Cylinder Controls. When a lift cylinder is ordered with a tong, the tong contains
an additional control lever for controlling the lift cylinder movement. The control lever-
operated valve is identical to the tong operating control lever. This lever is illustrated in
Figure 3-1 and its operation is shown in Figure 3-2 and Table 3-1. Pulling the control
lever outward provides hydraulic pressure from the hydraulic power unit to operate the
lift cylinder upward, and thus raise the tong. While pushing the control lever forward
operates the cylinder downward to lower the tong. The center lever position is the neutral
position and does not operate the cylinder in either direction. The maximum travel of the
lift cylinder is 6 feet.
SPRING HANGER. The optional spring hanger (Figure 2-3) is designed to permit the
tong to move up or down to allow for thread length in make-up and break-out operations.
When used, the spring hanger should be attached directly to the tong bridle ring and used
as a hanger for the tong.
TORQUE GAUGE ASSEMBLY. The optional torque gauge assembly (Figure 2-2) is
used to measure the torque exerted in make-up or breakout operations. Consisting of a
hydraulic cylinder and torque gauge connected together by a pressure hose, the torque
gauge assembly senses and indicates the torque developed during an operation. For
operation, the hydraulic cylinder is connected by a shackle to the rear of the tong; and a
snub line is connected to the cylinder. The snub line is tied off to a solid part of the rig
structure to form an angle of 90° in order to indicate accurate torque readings.
HYDRAULIC CAM BACKUP AND CONTROLS. A hydraulic backup tool as
illustrated in Figure 1-8 is optionally supplied with the 5-1/2 Standard Tong. In opera-
tion this tool provides a backup when in break-out or make-up situations. The specifica-
tions for the hydraulic backup are supplied in Table 1-2.

Table 1-2
Pressure / Torque Data Specifications

PRESSURE TORQUE RANGE

HIGH LOW
PSI BAR Ft-lbs Nm Ft-lbs Nm

100 7 176 238 880 1193

200 14 352 477 1760 2386
300 21 528 715 2640 3579
400 28 704 954 3520 4772
500 34 880 1193 4400 5965
750 52 1320 1789 6600 8948
1000 69 1760 2386 8800 11931
1250 86 2200 2982 11000 14913
1500 103 2640 3579 13200 17896
1750 121 3080 4175 15400 20879
2000 138 3520 4772 17600 23862
2250 155 3960 5369 19800 26845
2500 172 4400 5965 22000 29827

These figures are estimated average torque with mechanical and hydraulic losses taken into account.
Actual performance will depend upon the condition of the tong.

8
Table 1-3
Specifications Eckel 13-3/8 Hydraulic Cam Backup

Capacity ........... 4" - 14-3/8" (101.6 - 365.1 mm)

Max. Holding Torque 22,000 ft-lbs (29,827 Nm)
Max. Pressure ................ 3,000 P.S.I. (207 Bar)
Handle Length ....................... 36 inch (914 mm)

Dimensions (Tong and Backup):

Length ......................... 61 inches (1550 mm)
Height ..................... 58.5 inches (1486 mm)
Overall Width .............. 43 inches (1092 mm)

Weight:
Approximately
(Tong and Backup) .... 2,950 lbs (1,338 kgs)

Heads Available:
For Tubing Size O.D. ........ 4", 4-1/4", 5-1/4",
5-1/2", 5-3/4", 6-1/2", 6-5/8", 7-3/8", 8-5/8",
9-5/8", 10-3/4", 11-3/4",13-3/8",14-3/8

NOTE: Any size between 4" and 14-3/8" may

be specified as needed.

HYDRAULIC CAM BACKUP. The hydraulically operated backup tool, in utilizing the
same biting principal as the power tong, uses a cam and pivot head arrangement to insure
slip-free operation.
The stinger part of the backup, extending from the rear of the unit is inserted into the
torque bracket mounted on the underside of the tong. This method of hook up prevents
movement of the tong about the pipe during torquing operation. Between the stinger and
bracket is located the torque gauge compression load cell. During make-up or break-out
operations, the tong unit rotates slightly causing the stinger to compress the load cell,
torque readings are available in make-up or break-out, depending on position of load cell
in bracket. The load cell should be on the operator side of the backup stinger for make-up
and for break-out the load cell would be inserted on the opposite side of the backup
stinger to register the torque. The compression force is translated to torque which is
indicated on the torque gauge connected to the load cell. The hydraulic cam type backup
requires a 36-inch torque gauge handle which offers direct reading of torque between the
backup and the tong.
The hydraulic backup is suspended at an adjustable level below the power tong by means
of three hanger legs and springs. This set up allows the backup to remain stationary
while the power tong moves vertically to compensate for thread travel of the connection.
Hydraulic Backup Controls. When a hydraulic backup is ordered with a tong, the
tong contains an additional control lever for controlling the backup and a directional
valve for controlling the rotation of the backup. These levers are illustrated in Figure 3-1
and its operation is shown in Figure 3-2 and Table 3-1. Pushing the control lever inward
provides hydraulic pressure from the hydraulic power unit to rotate the backup cage
plates clockwise for make-up or counter-clockwise for break-out and engages the heads
on the pipe. Pulling the control lever disengages the backup heads from the pipe. The

9
 Make-up Break-out

Tong Dies
Tong Dies Tong Dies

Non Upset & External Upset Integral Joint Connections

Tong and Cam-Type Backup Cam-Type Tong and Cam-Type Backup
Biting Locations Backup Dies Biting Locations

Make-up and Break-out

Cam-Type
Backup Dies Cam-Type Backup Dies

Figure 1-9
Make-up and Break-out Biting Locations
backup cage plates are always rotated in the direction that the tong will turn and by using
the directional control lever the operator controls which direction the backup rotates.
Adjusting Backup Spacing. The vertical spacing between the backup and tong is
adjustable in steps using different sets of holes in the hanger legs for the bolts which hold
the backup hanger springs in position. There are four sets of holes located at various
distances below the tong. The distance of these holes from the midpoint of the tong dies
to midpoint of backup dies is described in Table 1-4.
Close spacing between the backup and tong is desirable from the standpoint of insuring
the closest possible length of contact between the dies and pipe. This is particular
important with drill pipe where short upsets may be encountered. Also, close spacing is
beneficial in reducing twisting forces in the tong and backup structures. On the other
hand, the design provides spacing when it is necessary to straddle extra long couplings or
upsets as is required in make-up operations. Figure 1-9 illustrates the proper biting
locations for make-up and break-out.
DOOR INTERLOCK. The door interlock device is an optional added safety feature that
Eckel Manufacturing Co., Inc. offers with its tongs. The door interlock device impedes
hydraulic •uid from reaching the motor when the tongs door is open thus preventing tong
operation.
RPM CONTROL. The RPM Control is a •ow divider that decreases the amount of
hydraulic •uid that reaches the tong, the remaining •uid is returned to the reservoir. By
decreasing the amount of •uid reaching the tong the operator is able to control the
maximum RPM's the tong will deliver.

Table 1-4
Midpoint of Backup Dies to Midpoint of Tong Dies

Hole Set Distance

Top (First) 9.75"
Second 14.75"
Third 19.75"
Fourth 24.75"

10
 Section 2
Installation

11
 GENERAL CONSIDERATIONS
Installation of the power tong requires consideration of the tong itself, the hydraulic
power unit to be used, and the accessories that will be required.
TONG CONSIDERATIONS. The 13-3/8 Standard Tubing Tong is capable of handling
pipe sizes from 4 inch to 13-3/8 inch in outside diameter. The heads to be used with the
tongs, of course, depend upon the size pipe being used. Refer to Table 1-1, Specifica-
tions for the various heads provided with the tong.
Head Installation. Install the correct size heads according to the following procedure.
! WARNING: Do not attempt to change heads with power unit in operation. Failure to
Warning observe proper precautions could be extremely hazardous and result in loss of a hand or
arm.
1. Remove two head pivot bolts, Figure 1-6.
2. Swing in and lift out the heads.
3. Select proper heads for pipe to be worked and install in head cage in reverse
order of steps 1 and 2.
Tong Space Requirements. You should consider the space requirements of the tong,
both in storage and in operation. Figure 2-1 give the tong dimensions.
POWER CONSIDERATIONS. Before installing the tong for field operations, you
must be sure that an appropriate power unit is available and that the power unit is
adjusted for use with the tong. To operate the tong within its full capability, the relief
valve on the hydraulic power unit should be adjusted to 3000 pounds per square inch.
Refer to power unit manual for the procedure on power unit valve adjustments.
Accessory Considerations. Tong installation requires that the necessary accessories
be available for the type of operation to be performed.

22.5 IN
571.5 MM 34 IN 13.625 IN
863.6 MM 346 MM

59 IN
1498 MM

A. TONG LENGTH & HEIGHT B. TONG WIDTH & THROAT WIDTH

61 in.
1550 mm

43 in.
58.5 in. 1092 mm
1486 mm

36 in.
914 mm
Torque Handle

Figure 2-1
Tong Dimensions
12
 TORQUE
LIFT GAUGE
CYLINDER

SPRING
HANGER
HYDRAULIC
CYLINDER
TURN

KEL
BUCKLES
(3)
SNUB LINE

TONG

Figure 2-2
Torque Gauge Installation
Figure 2-3
Tong Installation Installation of Torque Gauge Assembly. Measurement of the applied torque
requires a torque gauge assembly installed on the equipment. Once installed, the torque
gauge assembly becomes an integral part of the unit. To install the torque gauge on the
tong, proceed as follows:
1. Using three mounting screws, mount torque gauge into position on torque
gauge plate, Figure 2-2.
2. Route hose to avoid interference with tong operation.
3. Secure one side of hydraulic cylinder to snub line eye on rear of tong.
WARNING: The tong should be secured for both make-up or break-out operation, by
! Warning utilizing the snub line. If this is not done, the tong may be thrown against operator
causing physical harm.
4. Attach the other end of the snub line to a part of the rig structure that is rigid
enough to withstand the line-pull. Please note that an angle of 90° must be
maintained between the tong and snub line for the gauge to indicate accurate
torque readings.
Lift Cylinder Considerations. If the tong suspension line is not counter balanced, a
lift cylinder should be used. Also, if an Eckel lift cylinder is to be used, the tong must be
equipped with an additional control valve and lever. The lift cylinder should be sus-
pended from the line that will hang the tong as shown in Figure 2-3.
Spring Hanger Consideration. A typical spring hanger installation is shown in
Figure 2-3. For a counter-balanced support line, the spring hanger is suspended from the
line. When a lift cylinder is used, the spring hanger may be installed above or below the
lift cylinder as described.
HYDRAULIC BACKUP CONSIDERATIONS. The hydraulic backup is capable of
handling pipe sizes from 4 inch to 14-3/8 inch in outside diameter. Any significant
difference between actual pipe diamter and design diamter may result in failure of the
heads to take an initial bite, slipping under torque, and other problems.
HANGING THE TONG. The tong is transported to the well site and hung into position
as illustrated in Figure 2-3 and as follows:
CAUTION: Do not hook lift-line on turnbuckels. Be sure bridle chains are clear of valves
Caution and controls.
1. Connect bridle to tong and verify tong is snubbed for both make-up and break-
out operations.
13
 2. Using the cat line on drilling rig, or a specially rigged line, lift tong to desired
height in the work area and secure. Be sure the lift cylinder or counter-balance
system is properly in place and functioning.
3. Adjust the turnbuckles as necessary to level the tong to ensure an even bite on
the casing. This is done by first placing tong on pipe, and taking all slack out of
the snub line.
4. Connect snub line to hydraulic cylinder of torque gauge assembly to restrain
tong roation and to provide torque readings for make-up or break-out opera-
tions.
5. Secure other end of snub line to a solid part of rig at a 90-degree angle from the
tongs center line.

CONNECTING HYDRAULIC HOSES

The hydraulic couplings, Figure 2-3, contain check valves to prevent loss of hydraulic
fluid when the lines are disconnected. The check valves are closed until the hydraulic
hoses are connected. Proper tightening of the hydraulic hose connectors opens these
check valves. However, pressure may be in the tong when the lines are disconnected so
that the valves resist opening. In such case, the connectors may seem to reach the end of
thread travel when, in reality, the check valve operation is restricting further tightening.
When making up these connections you should be sure that you have tightened the
couplings tight and have not simply reached a "false" tightening due to the resistance of
the check valves.
Connect the hoses as follows:
1. Disable power unit, never connect or disconnect hoses when unit is in opera-
tion.
CAUTION: To be sure connectors are completely tight, first tighten them until travel is
restricted and the end of the thread travel appears to be reached. Then try to tighten the
Caution connector further to be sure first restriction was not a false tightness. Then continue to
tighten the fitting until connection is tight.
2. Hook up pressure hose to one-inch fitting on tong by forcing connectors
together while turning the wing nut.
3. Hook up return hose from power unit to 1-1/4 inch connector on tong, as
described in step 2.
4. If a lift cylinder is used, hook up the hose from lift cylinder to connector
provided on tong.
5. Start power unit and allow hydraulic fluid to circulate through tong until fluid
reaches operating temperature. Refer to Table 1-1 for operating temperatures.

Important NOTE: This period will vary according to the ambient temperature. In severe weather
conditions, you may need to operate system for several minutes before using tong. On the
other hand, in warm climates a very brief warm-up period will be adequate.
6. While system warms up, check connections to be sure that no leaks occur.
Retighten connection if leaking.
Important NOTE: Refer to Table 4-2 under lubrication for recommended hydraulic fluid.
WARNING: When replacing hydraulic hoses, piping and fittings, be sure replacement
components are rated at no less than 3,000 PSI working pressure and 10,000 PSI burst
! Warning pressure.

14
 CONNECT HYDRAULIC
PRESSURE LINE
FROM POWER UNIT

CONNECT HYDRAULIC
RETURN LINE FROM
POWER UNIT

Figure 2-4
Hydraulic Connections

15
16
 Section 3
Operation

17
 GENERAL OPERATION
Before operating the unit, you should become thoroughly familiar with the operating
controls and gauges; then, before initial operation and daily thereafter you should
preform the recommended adjustments and operational checks.

OPERATING CONTROLS AND GAUGES

Figure 3-2 Illustrates the operating controls and gauges. For the functions of the controls
and gauges refer to Table 3-1.

(A) (B) (C) (D) (E)

A. Tong control lever.
B. Cam type backup control lever.
C. Lift cylinder control lever.
D. Backup direction control lever.
E. Speed shift lever.

Figure 3-1
Tong Control Lever Locations
PRECAUTIONS TO OBSERVE. The following precautions should be observed to
ensure safe operation.
1. Be sure that the operating personnel are checked out on proper operation of
tong, and be sure that they are aware of safety requirements.
2. Be sure that all lines and equipment associated with hanging and securing tong
are of adequate size and good condition.

PRE-OPERATING CHECKS
After installation, you should check out the system to be sure that any necessary adjust-
ments are made and that the system is functioning correctly. Before attempting opera-
tion, verify that the following initial adjustments have been made.
POWER UNIT OUTPUT PRESSURE. Determine that the power unit output pressure
has been properly adjusted. If you do not know, refer to the instruction manual on the
power unit and perform the output pressure adjustment procedure for the required
pressure.
TONG PRESSURE RELIEF VALVE. If a relief pressure is to be set on the tong,
verify that the setting has been made previously; or if you do not know, refer to the
maintenance section for the proper procedures.
BRAKE BANDS. Determine if the brake bands have been adjusted properly. If
necessary perform the pre-operational check to make this determination. Refer to the
Maintenance Section for adjustment of the brake bands.

18
Table 3-1
Operating Controls and Gauges
Control or Gauge Function

Backing Pin
In Make-up Hole Allows tong to bite when operated clockwise for makeup.
In Break-out Hole Allows tong to bite when operated counter-clockwise for breakout.
Shifting Lever
Up Position Shifts tong gear train into high-speed position.
Center Position Neutral position-motor and clutch shaft turn but rotary gear does not rotate.
Down Position Shift tong gear train to low speed.
Control Levers
Forward Position Operates rotary gear and cage plates clockwise. For make-up, heads bites and for
break-out head releases.
Back Position Operates rotary gear and cage plates counter-clockwise. For break-out head, head
bites and for make-up head releases.
Manual Relief Valve Permits operator to set hydraulic pressure to desired setting.
Pressure Gauge Measures pressure applied to hydraulic motor.
Lift Control Lever
(not shown)
Forward Position Operates lift cylinder to lower tong.
Back Position Operates lift cylinder to raise tong.

PRESSURE
MANUAL RELIEF
GAUGE
VALVE

TONG CONTROL
BREAK-OUT LEVER

SHIFTING
LEVER
MAKE-UP BACKING 3/8
PIN L 13
KE
EC

Figure 3-2
Operating Controls and Gauges

19
 OBSERVING THE OPERATING FUNCTIONS. Before starting a new job and each
day before the work begins, perform the following operations and be sure the tong
responds correctly.
WARNING: Before operating tong, verify the handle locations below apply to your
! Warning specific tong. Inadequate pre-operational check of tong could result in injury.
The tong should be secured for both make-up or break-out operation, by utilizing the
snub line. If this is not done, the tong may be thrown against operator causing physical
harm.
The following steps refer to handle locations identified in Figure 3-1 and 3-2.
1. Verify tong is snubbed for both make-up and break-out operations.
2. Place backing pin in left-hand hole.
3. Move shifting lever to high-speed (up) and push tong control lever forward and
verify that heads bite and cage plates turn at high speed.
4. Return control lever to neutral and move the shifting lever to the low speed
position (down).
5. Push tong control lever forward and verify that heads bite and cage plates turn at
low speed.
6. Return control lever to neutral.
7. Use tong control lever to operate tong so that cage plates and rotary gear
openings are aligned with the throat openings.
8. Place backing pin in right-hand (break-out position) hole. Repeat steps 2
through 6 to check break-out operation.
NOTE: If the heads fail to bite, the brake bands probably need adjustment. Adjust the
Important bands as described in the topic on Initial Adjustments in the Maintenance Section.
9. If lift cylinder option is installed, pull lift cylinder control lever (B) Figure 3-1,
back and verify that cylinder operates to lift tong.
10. Push lift cylinder control lever (B) Figure 3-1, forward and verify the cylinder
lowers the tong.
11. If a hydraulic backup is installed, push the directional control lever (D) forward
and operate backup control lever (B) forward and verify backup heads bite in
make-up position.
12. Pull lever (B) to release heads. Return to netural.
13. If a hydraulic backup is installed, pull the directional control lever (D) back and
operate backup control lever (B) forward and verify backup heads bite in break-
out position.
14. Pull lever (B) to release heads, Return to neutral.

TYPICAL OPERATING SEQUENCE

INITIAL OPERATIONS. After the tong is transported to job site, hoisted into operating
position, snubbed, leveled, and connected with power unit as described in Installation
Section, proceed as follows.
1. Be sure shifting lever and control lever(s) are in neutral position.
2. Start hydraulic power unit.
3. Perform a pre-operational check and make any required adjustments before
operation.

20
 4. Place backing pin in make-up hole for make-up operation or in break-out hole
for break-out operation (See Figure 3-2.)
POSITIONING TONG AND ENCLOSING TUBING. After performing the initial
operations, position the tong for the make-up or break-out work to be done.
1. Position the tong at proper height for griping tubing as follows:
a. If tong is installed using a counter balance system, lift or lower tong to
desired position.
b. If a lift cylinder is used, operate the lift cylinder control lever (B) on the
tong to position tong.
2. Place tong on tubing section positioned for make-up or break-out.
3. Close throat safety door, then perform operation as described in next topic.
4. After operation, open front safety door, remove tong from tubing, and push tong
off tubing, then close door.
OPERATING THE TONG. To operate the tong, proceed as follows:
WARNING: Be sure no part of the body or clothing is in tong head area and be sure no
! Warning cables or equipment other than tubing are enclosed in throat.
Make-up Operation: Refer to Figure 3-1 and 3-2 for control lever locations.
1. Verify tong is snubbed for both make-up and break-out operations
2. Place backing pin in make-up (left hole) position (Figure 1-5).
3. Shift the hydraulic cam backup tool (if used) into the make-up mode by pushing
the backup directional control lever (D) forward.
4. Begin the operation with the power tong in the low speed mode. In make-up
operation, low speed is required to insure a good start on the threads. Select
low-speed mode by pushing down on the shifting handle (E).
5. Position the tong on the pipe. The tong unit may be raised or lowered by
operating the lift cylinder control (C). Pushing in on the lever lowers the tong
while pulling out on the lever raises the tong. After positioning, close and latch
the safety door.
6. Engage the cam backup heads by pushing forward on the backup control lever
(B).
7. Grip the pipe with the power tong heads and begin rotation by pushing forward
the tong control lever (A).
8. After insuring a good start on the threads. Shift the tong to high speed by pulling
up on the shifitng lever (E) and continue the make-up operation.
NOTE: When using the shift lever (E) to change speeds, the power tong must first
come to a complete stop before shifting.
9. Once tong stalls, shift to low speed - high torque mode by pushing down on the
shifting lever (E) and continue torquing operation while observing the torque
gauge reading.
10. When maximum required torque is reached, release the tong control lever (A) to
stop the tong. The control lever is spring returned to center neutral position.
11. To release the pipe and align the door openings, pull back on tong control lever
(A). When the openings are aligned, release the control lever.
12. Disengage the cam backup by pulling out on the backup control lever (B).
13. Unlatch and open the safety door. Remove the tong from the made-up joint and
close the safety door.

21
 14. Reposition the pipe and repeat the operation.
Break-out Operation: Refer to Figure 3-1 and 3-2 for control lever locations.
1. Verify tong is snubbed for both make-up and break-out operations.
2. Place the backing pin in break-out (right hole) position.
3. Shift the hydraulic cam backup tool (if used) into the break-out mode by pulling
back on the backup directional control lever (D).
4. Begin the operation with the power tong in the low speed mode. In break-out
operation, the low speed mode is required due to the high torque associated with
this mode. Select low speed mode by pushing down on the shifting lever (E).
5. Position the tong on the pipe. The tong unit may be raised or lowered by
operating the lift cylinder control (C). Pushing in on the lever lowers the tong
while pulling out on the lever raises the tong. After positioning, close and latch
the safety door.
6. Engage the cam backup heads by pushing forward on the backup control lever
(B).
7. Grip the pipe and begin rotation by pulling back on the tong control lever (A).
8. After breaking the connection and when torque requirements have fallen off,
shift the tong into high speed by pulling up on the shifting lever (E).
NOTE: When using the shift lever (E) to change speeds, the power tong must first
come to a complete stop before shifting.
9. When the joint has been fully broken apart, release the tong control lever (A) to
stop the tong. The control lever is spring return to center neutral position.
9 Disengage the cam backup by pulling out on the backup control lever (B).
10. To release the pipe and align the door openings, push forward on the tong
control lever (A). When the openings are aligned, release the control lever.
12. Unlatch and open the safety door. Remove the tong from the broken-apart joint
and close the safety door.
13. Reposition the pipe and repeat the operation.
CROSS THREADED PIPE. The following steps are to be followed when twisting off
cross threaded pipe.
1. Verify tong is snubbed for both make-up and break-out operations.
2. Place backing pin in break-out position.
3. Pull control lever (A), to reverse tong until threads are uncrossed.
4. Inspect threads to see if joint replacement is necessary.
5. Operate tong in make-up mode to complete joint connection.

22
 Section 4
Servicing

23
 Servicing the tong consists of inspection, lubrication, tests and adjustments. Should
servicing reveal requirements for repairs, refer to the appropriate portions of Sections 5
and 6.

DAILY INSPECTION
Figure 4-1 illustrates the points that should be inspected at the start of every job and once
every day thereafter.
OVERALL INSPECTION. Inspect the unit and its accessories for obvious damage,
evidence of hydraulic leaks, etc. Refer to the overhaul procedures for removal and
replacement of any faulty parts.

DIES
(2 PER HEAD)

3/8 CLUTCH
13
K EL DOOR
EC
BRAKE
BANDS
Figure 4-1
Tong Inspection Points

BRAKE BAND INSPECTION. Inspect the brake bands to be sure that each band is
intact and not excessively worn. If a brake band begins to wear into the rivets, the band
should be replaced.
CHECK HEAD DIES. Inspect head dies to be sure that biting edge is not worn
excessively and is capable of biting effectively. Change the dies if required.
TIGHTEN BOLTS. Tighten three cage plate bolts.
INSPECT HEAD ROLLERS. Inspect head rollers to be sure they turn freely. Lubri-
cate as outlined under Head Roller Lubrication procedure.

MAINTENANCE AFTER EACH JOB

After each job make the following checks and take appropriate corrective action.
1. Check dumbbell rollers for wear or breakage, and replace if necessary.
2. Check cam follower rollers for wear or breakage, and replace if necessary &
lube. (Applies to a hydraulic backup also if installed)
3. Clean heads and head sliding areas of foreign debris and grease head rollers.
4. Check grease in tong case, repack if necessary.

24
Table 4-1
Recommended Lubricants
Grease Specifications
Gear Grease * NLGI Grade 3 - Heavy Duty Wheel Bearing Grease
Bearing Grease * NLGI Grade 2 - Extreme Pressure Heavy Duty Lubricant

* Specifications are listed for average conditions. For applications involving

extreme heat and cold, consult Eckel for recommendations.

6
7 2 8 3 11

1
9
5 10
4
12

TOP BOTTOM

Figure 4-2
Tong Grease Points

MOTOR MAINTENANCE. Since the motor is self-lubricating, preventative mainte-

nance is limited to keeping the system clean by changing filters frequently. Do not allow
dirt to accumulate on the motor, especially around the shaft seal. Keep all fittings and
screws tightened. Do not operate the motor at pressures or speeds in excess of the
recommended limit

LUBRICATION
Proper lubrication is important to the operation and long life of the tong. This topic
describes both the lubricating grease and the hydraulic fluid requirements for the tong.
HYDRAULIC FLUID. Under normal operation the tong should remain charged with
hydraulic fluid even when the hydraulic hoses are disconnected. This is because check
valves at the disconnect points retain the hydraulic fluid within the tong when the
connection is separated. However, should hydraulic fluid be lost from the tong due to
leaks or during maintenance, you should recharge the tong by connecting the hoses from
the hydraulic power unit and operating the tong to purge all air from the system.
GREASE ZERTS. At the beginning of each job and daily thereafter while job is in
progress, you should use a grease gun to grease the various grease zerts. Over greasing
will do no harm, while under greasing can result in excessive wear. Figure 4-2 shows the
lubrication points and Table 4-1 gives information on the type of grease to be used.
Numbers enclosed in parenthesis refer to grease points identified in Figure 4-2.
1. On top of tong, grease shifting shaft (7) and motor gear (9).
2. Grease two idler bearings (6) and pinion idler (8).
3 Grease all upper cam follower bearings (3) and the upper dumbbell rollers zerts (4).

25
 4. Beneath tong, grease clutch assembly (10).
5. Grease all the lower cam follower bearings (11) and the lower dumbbell roller
zerts (12).
6. Grease upper and lower cam followers in backup.
NOTE: You must rotate cam and cage plates as necessary to obtain access to bearings.
Important At the same time you should grease outside of cam followers as described on the follow-
ing page.
CAM FOLLOWERS. When greasing cam follower, lubricate outside of cam follower
rollers as listed below.
1. Use gear grease as described in Table 4-1.
2. Apply grease liberally to outside of each roller.
HEAD ROLLERS. Lubricate head rollers as follows (Tong and Backup).
1. Knock out head roller pins and grease with gear grease, then replace rollers on
heads. Be sure rollers turn freely.
2. Apply gear grease liberally to outside of head rollers.
GEAR GREASE. To pack the tong with grease refer to Figure 4-2 and Table 4-1, and
proceed as follows.
! Warning WARNING: Packing the gears while power unit is operating is extremely dangerous.
Failure to observe proper precautions in maintaining this unit could result in extreme
personnel hazard.
1. With power unit connected and operating, rotate rotary gear so that opening is
turned to back of tong, Figure 4-2 (1).
! Warning 2. Disable tong by both of the following methods.
WARNING: Keep hands out of the head area while the power unit is operating.
a. Disconnect power from the power units electrical motor or turn off diesel
engine as applicable.
b. Disconnect hydraulic pressure line (1-inch line) from tong at hose connec-
tor.
3. Remove cover from inspection door.
4. Pack the unit with specified gear grease (see Table 4-1) as follows:
a. Apply grease liberally through opening at back of cage plates, Figure
4-2 (1).
b. Apply grease liberally through inspection door to gear, Figure 4-2 (2).
! Warning WARNING: Failure to disable hydraulic system after operating tong could result in
serious personnel injury.
c. Operate tong to distribute grease, then disable hydraulic power unit and
repeat steps a and b.
5. Replace cover on inspection door.

TESTS AND ADJUSTMENTS

The following test should be made and the adjustments performed as indicated.
BRAKE BANDS. At the beginning of a job and at the start of each shift thereafter,

26
 RELIEF
VALVE

BRAKE BAND
ADJUSTING NUTS
(UPPER)

3/8 CLUTCH
13
KEL
EC
SHIFTING
DETENT
BRAKE BAND
ADJUSTING NUTS
(TWO UNDERNEATH)
Figure 4-3
Tong Adjustment Points

perform the brake band test and brake band adjustment as required.
Brake Band Test. Check each brake band adjustment according to the following steps.
1. Place backing pin in Make-up position.
2. Operate the tong several times and verify that the heads bite at each operation.
3. Place backing pin in Break-out position.
TORQUE CHECK ADJUSTMENT. The relief valve for the tong may be set to
achieve the maximum torque desired. The following procedures describe the method for
checking and adjusting the relief valve to obtain the torque desired (up to the maximum
torque of the tong). Refer to Figure 4-3 for the adjustment point.
Important
NOTE: Refer to the manual on the power unit and be sure unit is adjusted to provide the
required operating pressure.
Maximum Torque Adjustment. Adjust the maximum torque to the desired value
according to the following steps.
1. Verify tong is snubbed for both make-up and break-out operations.

2. Set up tong on tong test stand with tubing coupled or installed so that it can not
turn.
3. Be sure the torque gauge is correctly installed and is in proper operation.
Important 4. Back off relief valve to minimum torque setting.
NOTE: Adjustment is extremely difficult to turn when pressure is applied.
5. Incrementally adjust relief valve, then apply pressure and read torque value.
Continue until desired maximum torque value is obtained.
4. Operate tong several times and verify that heads rotate out of cam.
5. If heads fail to bite in either Make-up or Break-out position of backing pin,
adjust brake bands.
Brake Band Adjustment. When inspection or test indicates the brake bands require

27
 adjustment, then adjust the brake bands according to the steps given below. Refer to
Figure 4-3 for the adjustment points.
1. Turn each of four brake band adjusting nuts one-fourth turn.
2. Check brake operation as in preceding topic.
Important 3. Repeat steps 1 and 2 as necessary until heads extend from cage plate smoothly.
NOTE: A total of one-half to one turn should normally be sufficient.
SHIFTING DETENT. The shifting detent that holds the shifting mechanism in the
selected speed is adjustable. This adjustment should be checked at the beginning of a job
and at the start of each shift thereafter, and the detent should be adjusted if required.
Detent Operation Check. Check the operation of the shifting detent as follows.
1. Raise shifting handle to High Speed position and verify that the control snaps
into position.
2. Exert force on shifting lever and verify that lever remains in High Speed
position until considerable force is exerted, then gives way to slide freely to
next position.
3. Repeat steps 1 and 2 for Low Speed position.
4. Repeat steps 1 and 2 for Neutral position.
5. If above steps indicate need for adjustment, adjust detent.
Detent Adjustment. When an operation check indicates the need to adjust the shifting
detent, refer to Figure 4-3 and adjust the detent as outlined below.
1. Loosen the stop nut on adjusting bolt.
2. Tighten bolt one-half turn.
3. Repeat Detent Operation Check.
4. If mechanism operates properly, tighten stop nut while holding adjusting bolt at
setting obtained in step 2.
5. If additional adjustment is indicated, repeat steps 1 and 3 until proper operation
is achieved.

28
 Section 5
Troubleshooting, Repair
and Overhaul

29
 This section contains instructions for troubleshooting, repair and overhaul of the tong.
After any major repair or overhaul, the tong should be serviced as outlined in Section 4.
TROUBLESHOOTING
Tong troubleshooting consists of locating observed symptoms on the Troubleshooting
Chart 5-1, determining the probable cause, and correcting the problem as suggested.
Table 5-1
Troubleshooting Chart
SYMPTOM PROBABLE CAUSE
TONG FAILS TO GRIP Wrong size heads in tong
or wrong rollers in tong
heads
Heads come out of neutral Undersize pipe
but will not grip pipe.
Tong not hanging
perpendicular
Heads do not come out of Brake bands not tight
neutral cam enough
Oversize pipe
Faulty cam followers
TONG DOES NOT RELEASE Brake bands not tight
(BACK BITES) enough
Faulty cam follower
bearings in cage plates
Head roller & pin dry of
TONG DOES NOT DEVELOP Power unit pressure not set
SUFFICIENT TORQUE
Power unit properly set but
relief valve on tong not set
high enough
Faulty tong valve or motor
Faulty torque gauge
MOTOR RUNS BUT TONG Broken gear or shaft
DOES NOT ROTATE
Motor drive gear and/or key
has dropped off
TONG HANGS UP UNDER Excessively worn or
LIGHT LOAD broken cam follower or idler
bearing
TONG ROTATES WHEN Faulty control valve
CONTROL LEVER IS IN
NEUTRAL
MOTOR LEAKING Faulty shaft seal
OIL COMING FROM MOTOR Blown shaft seal
CHRONIC SEAL PROBLEM Plugged case drain or plugged
return line or worn shaft
30
CORRECTIVE ACTION
Install correct head and roller
assemblies.
Install oversize rollers (1/16" OD larger).
Adjust hanging bridle turnbuckles
until tong hangs level while on pipe.
Tighten brake band adjustment nuts
1/4 turn intervals until tong grips.
Install undersize rollers (1/16" OD
smaller).
Replace cam followers.
Tighten brake band adjustment nuts
1/4 turn intervals until tong releases.
Replace cam follower bearings.
Grease per lubrication procedure.
grease
Refer to instruction manual
for proper setting.
With pressure gauge in the high
pressure line, turn
relief valve screw adjustment
clockwise and stall tong, repeat until
pressure is set correctly.
Repair or replace valve or motor.
Repair or replace torque gauge.
Check for broken gear and replace if
necessary.
Replace motor drive gear and/or key.
Replace cam follower or idler
bearing.
Replace control valve.
Replace motor seal.
Replace motor seal.
Disconnect end of case drain
connected to valve and clear line.
REPAIR
In general, repair consists of replacing worn or broken parts. When a part is determined
to be faulty, either through inspection or through an operational check, you should
remove the part and replace it with a new part according to the procedures and instruc-
tions in the following topics. The component parts are illustrated and identified in
Section 6.

TONG OVERHAUL
Overhaul consists of disassembling the tong, examining each part, replacing any worn or
damaged parts and then reassembling the tong. All damaged or worn parts are to be
replaced with identical parts as identified in Section 6.
DISASSEMBLY. During overhaul, the tong should be completely disassembled. For
replacement of a faulty part, components need be removed only as required to obtain
access to, and remove, the faulty part. In general, disassembly requirements become
obvious from the figures in the illustrated parts list; however, procedures for performing
disassembly necessary for servicing as well as replacement of certain worn parts are
presented in the parts replacement topic.
REASSEMBLY. Reassembly of a component or of the entire tong consists of replacing
the parts in the reverse order of disassembly, by performing the service outlined in
Section 4. However, certain procedures for performing reassembly after service or during
replacement of certain worn parts are presented in the following topic.
PARTS REPLACEMENT. In general, parts replacement consists of disassembly as
necessary to obtain access to the part to be replaced. However, replacement of certain
parts as required for service and indicated by the functional test is described in this topic.
Brake Band Replacement. Should the brake band become broken or excessively
worn, they are to be replaced in accordance with the following procedure. Numbers in
parenthesis refer to item numbers in figure 6-1.
1. Remove brake band retainer (8) for the top brake band (4).
2. Remove adjusting nuts (6) and bolts (5).
3. Remove brake band (4). Refer to parts list, item 4, for part no. of new band.
4. Grease new brake band before replacement.
5. Place new brake band around cage plate and replace two bolts (5) and adjusting
nuts (6) through brake band lugs (7).
6. Tighten the adjusting nuts snug but not too tight.
7. Replace brake band retainer (8).
8. Remove brake band retainer (8) from bottom brake (4).
9. Repeat steps 2 through 7 for bottom band.
10. Adjust both brake bands in accordance with brake band adjustment procedure
under Tests and Adjustments.
Cage Plate Removal and Replacement. Cleaning and service requires the periodic
removal and replacement of the top and bottom cage plates. To remove and replace these
plates, proceed according to the following steps. The numbers in parenthesis refer to item
numbers in Figure 6-1.

31
 WARNING: Keep hands out of the head cage area while the power unit is operating.
! Warning 1. Remove heads as described in Section 2.
2. Loosen brake bands as necessary to free two cage plates (11) and (12).
3. Remove back cage plate bolt (21), and remove two side cage plate bolts (13).
4. Remove top cage plate (11).
5. Remove bottom cage plate, taking care not to damage three cage plate spacers
(14).
6. Perform necessary cleaning or other maintenance.
7. Replace both cage plates in reverse order of steps 3 through 5.
8. Adjust brake bands as outlined in Test and Adjustments.
9. Replace heads as described in Section 2.

M4D MOTOR OVERHAUL

GENERAL. The instructions contained in this section cover a complete disassembly,
inspection and assembly of the vane type fluid motor.
Drain all fluid from the motor and thoroughly clean the exterior surface. Prepare a clean,
lint-free surface on which to lay the internal parts of the motor.
SPECIAL TOOLS. No special tools, other than shaft seal tools, are required to repair
these motors. These tools must be used to install the shaft seal properly. Figure 5-1
illustrates the making of these tools.
Disassembly. Numbers in parenthesis refer to item numbers in figure 6-6.
1. Secure the motor in a vise or other suitable holding fixture with the shaft (14)
extended down.
2. Remove screws (1) and remove the end cap (2) from the center housing.
3. Remove the rubber seal ring (3) from the end cap (2).
4. Check the needle bearing (4) in the end cap. If it is worn or damaged, remove it.
5. Remove the dowel pin (5) from the cam ring assembly (6).
6. Thread two 1/4 N.C. screws in the two tapped holes provided as puller holes in
the cam ring (6a) and remove the cam ring assembly (6) as a unit (6a,6b,6c,6d).
NOTE: If resistance is encountered when lifting the cam ring assembly, lightly tap the
Important outside of the body while lifting the assembly. This will help in removing the cam ring,
rotor, vanes and springs as a unit.
WARNING: The vanes are held against the cam ring by tension from the springs in the
! Warning rotor. If the rotor is pulled from the cam ring with no protection, tension from the springs
will throw the vanes out in all directions. The following procedure must be followed when
disassembling the rotor and vanes from the cam ring:
Place the cam ring assembly on a clean, flat surface. Push the rotor and vanes from the
cam ring far enough to secure a piston ring compressor over the vanes and around the
rotor.
After the compressor is in place, push the rotor and vanes the remainder of the way out of
the cam ring.
7. Release the tension on the compressor and remove the vanes (6c) and vane
springs (6d) from the rotor (6b).
8. Remove dowel pin (7) from the port plate assembly.

32
 SEAL DRIVER
NOTES:
1) REMOVE ALL BURRS AND BREAK SHARP EDGES .010/.005 R.
2) LENGTH TO BE HEAD TREATED TO RC 50-55
3) LENGTH TO HAVE A 10-20 FULL LENGTH WITH A SMOOTH
INTERSECTION BETWEEN CHAMFER AND DIA. 'A'
4) GREASE O.D. OF LENGTH BEFORE INSTALLING SHAFT SEAL ONTO
TOOL TO PREVENT DAMAGE TO THE SEAL

MATERIAL 4140 OR EQUIVALENT

PROTECTIVE CONE
NOTES:
1) REMOVE ALL BURRS AND BREAK SHARP EDGES .010/.005 R.
2) TEFLON PREFERRED, ALTERNATE 4140 TREATED AFTER MACHINING TO
RC 50-55
3) INSTALL PROTECTIVE CONE OVER SHAFT EXTENSION AND GREASE O.D.
TO PREVENT DAMAGE TO SHAFT SEAL

Figure 5-1
M4D Special Tools

9. Thread two #10-24 screws into the puller holes in the port plate assembly (8)
and remove it from the center housing (18).
a Port plate assembly teardown:
Remove the special set screws in the side. Remove the shuttle spool from
the drilled passage. The drilled holes in the port plate must be clean and
free from burrs.
10. Remove the seals (8 and 9).
11. Remove the snap ring (7) from the housing (2).
12. Press on external end of the shaft (4c) and remove shaft and bearing (4b) from
the body.
13. Remove the external snap ring (4a) and press the bearing from the shaft.
14. Remove the felt wiper (5) and shaft seal (6) from the body.
Cleaning and Inspection:
1. Wash all metal parts in cleaning solvent (Stoddard Solvent or equal) and dry
thoroughly.
2. Inspection of Parts.
a. Inspect the seals for wear, breaks, cuts and brittleness. Check closely the
shaft seal for scratches and cracks. Discard and replace all defective seals.
b. Inspect all springs for wear on the O.D., for cracks or permanent set.
Replace all defective springs.

33
 c. Inspect bearings for wear or flat spots. If the bearings are rough or loose
they must be replaced.
d. Inspect the cam ring for excessive wear (ripples or washboard marks on the
contour). Replace a badly worn or defective cam ring.
e. Inspect the rotor for scored, marred or scratched (faces and vane slots)
surfaces. Replace a defective rotor.
f. Inspect the vanes for excessive wear marks (burrs, nicks and scoring).
Replace defective vanes.
g. Inspect the wear surfaces of the port plate and end cap for deep scratches.
Replace if defective.
h. Inspect the body and end cap for cracks or other casting damage. Replace
all damaged castings.
i. Inspect the shaft for excessive wear (internal spline, bearing surface and
drive end). Replace if defective.
CAUTION: Dirt is a major cause of wear and motor failure. Cover all parts after
Caution cleaning to prevent dust and dirt from settling on them. All surfaces should be coated
with a film of hydraulic lubricating oil after they have been cleaned.
LUBRICATION. No external lubrication is required. The hydraulic fluid which
operates the motor provides adequate internal lubrication.
REASSEMBLY. Immerse the seals and bearings in clean hydraulic fluid to make the
reassembly easier and to provide initial lubrication.
Shaft End:
1. Position the body (18) on a clean flat surface with the small open end facing up.
Press the felt wiper (17) in the 2-1/16" hole. The wiper must be flush with the
bottom of the counterbore. Turn the body (18) over with the large open end
facing up. Use the shaft seal drive (Figure 5-1) and drive the shaft seal (16) into
the body (18) until it seats in the counterbore. Make certain that the open side of
the seal is toward the inside of the body. The shaft seal driver will prevent
damage to the seal during installation.
2. Press bearing (13) on the shaft (14) to the shoulder and install external snap ring
(12). Be certain that the ring is seated in the snap ring groove.
3. Apply lubricating fluid to the inside of seal (16) and wiper (17). Press the shaft
and bearing assembly (12, 13 and 14) into the body (18).
4. Install snap ring (11) in the body (18) and against bearing (13) to hold the shaft
assembly in place. Make certain snap ring (11) is fully seated in the groove.
Port Plate Sub-Assembly:
The special screws and the port plate including the internal threads must be degreased.
Apply a very small amount of Loctite #242 to the special screws only. An excessive
amount of Loctite on the screws would be forced into the shuttle spool bore when the
screws are installed. Allow the Loctite to cure for one hour after installing the screws.
1. Install one of the special screws in the shuttle spool bore of the port plate.
Torque screw to three to five ft. lbs. maximum. Insert the shuttle spool in the
shuttle bore and install the other special screw and torque. Tilt the port plate
sub-assembly back and forth to be certain that the spool travels the full length of
the bore.
2. Lubricate seals (9) and (10) and install on back of port plate.
3. Insert dowel pin (7) in hole in face of port plate assembly.

34
 4. Thread two #10-24 screws in the tapped holes in face of the port plate assembly
(8) and install in the body. See Figure 6-6 for correct positions.
Cam Ring Sub-Assembly:
1. Place the cam ring (6a), rotor (6b), vanes (6c) and vane springs (6d) on a clean
flat surface. Arrange the vanes side by side with the three spring holes up.
Insert the vane springs in the vanes. Install the vanes with the springs in the
slots in the rotor.
! WARNING: Be certain that the springs are started in the holes in each rotor slot.
Warning
a. Place a ring compressor around the vanes and tighten the compressor
gradually until the springs and vanes are in the position they will occupy
while in the cam ring. Place a back up plate, slightly smaller than the
outside diameter of the rotor in the ring compressor and push the rotor,
springs and vanes into the cam ring. The back up plate will prevent the
vanes from sliding end wise in the rotor slots and damaging the slots and
springs.
WARNING: Be certain that the rotor and vane assembly is inserted far enough in the cam
! Warning
ring to prevent the vanes from flying out of position when the ring compressor is re-
moved.
2. Thread two #10-24 screws into the cam ring assembly on the same side of the
ring that indicates the cam size. Insert the dowel pin (5) in the cam ring and
position the complete assembly in the body over the dowel pin (7).
End Cap Sub-Assembly:
1. Lubricate the rubber seal (3) and install on the cap (2)
Press the needle bearing (4) into the end cap (2) with markings on the bearing
1/16" below the face of the cap.
3. Position the end cap (2) over the dowel pin (5). Hole the end cap firmly against
the cam ring assembly and rotate to line up the bolt holes.
4. Insert screws (1) and tighten evenly to 130 ft. lbs. torque.

A35 VALVE OVERHAUL

Remove the valve bank from the equipment and thoroughly clean its exterior surface
before beginning disassembly. Mark each section in sequential order from inlet to outlet
to ensure that it will be properly reassembled. If individual sections are to be disas-
sembled, tag each spool with the number of the section from which it was taken. Spools
are hone-fitted to their housings and are not interchangeable. All work should be
performed in a clean area.
Figure 6-7, illustrates the proper relationship of parts in a typical valve bank, and should
be used as a guide for reassemble.
Disassembly:
1. Remove all control handles and linkage connectors attached to the spool clevis.
2. Remove the four tie bolts which hold the bank together, and separate the
sections.
3. Remove the two screws (11) which fasten the backcap to the housing and
remove the backcap.
4. Grasp the spring end of the spool with a clean rag and pull the spool from the
housing with a steady, twisting motion. The retaining plate, back-up ring and
spool seal (3,4,5) will generally come out with the spool.

35
 CAUTION: For detented spool models, be careful not to remove the detent poppet sleeve
Caution (9) unless it is to be serviced. Without the sleeve, the spring-loaded steel balls (8) can
pop free and be lost.
5. Remove and discard rubber spool seals.
6. These parts should not be removed from the spool unless they are to be replaced.
Once the spool is free of the housing, it must be carefully handled to avoid
damage. If it is necessary to remove the spring, place the spool in a soft-jawed
vise and remove the stripper bolt with a wrench.

Important NOTE: Cautious applications of heat may be required to free the stripper bolt or detent
retainer as an anaerobic thread adhesive is used in their assembly.
7. Remove items (8,9,15) by placing a rag around the sleeve to keep the parts from
springing loose, and pulling firmly to free them from the poppet retainer.
Cleaning, Inspection Repair:
1. Inspect the spool bores and spools for deep scratches, gouges or excessive wear.
If any of these conditions exist, replace the section. Minor surface damage on
the spool may be polished away with very fine crocus cloth.
2. Examine the machined surfaces of the valve housings for nicks or burrs that
could cause leakage between sections. Lightly stone these surfaces to remove
any rough spots.
Caution CAUTION: A shallow, machined relief band extends across the "O" ring face of the valve
housing and should not be stoned or ground off.
3. Wash all parts thoroughly in clean solvent and blow dry before beginning
reassemble.
Assembly:
1. Clamp the spool in a soft-jawed vise. Apply a small amount of Loctite™ 262 or
equivalent anaerobic adhesive to the stripper bolt (16) before assembly.
NOTE: Follow the adhesive manufacturer's instructions for proper curing. Assemble the
Important spring (15), spring guide (14) and stripper bolt (16) on the spool. The detent poppet
retainer (6) is assembled in similar fashion.
2. Apply a light coating of clean hydraulic oil to the valve spool. Place the
retaining plate (5), back up ring (4) and spool seal (3) over the spool. These
items rest against the spring guide or poppet retainer in the order illustrated in
Figure 6-7. Install the spool seal (3) into the groove at the clevis end of the
valve body. Carefully insert the spool guides should be lightly coated with a
high temperature grease to prevent rusting. The detent mechanism should be
packed with a high temperature, extreme pressure grease for lubrication and ease
of operation. Place Loctite™ 262 or its equivalent on the valve cap screws prior
to attaching the cap to the valve body.
3. Coat the section seals (1 and 2) with grease to help keep them in place during
assembly. Place the valve sections on the tie bolts in their numbered sequence.
Torque the tie bolts nuts to 33 ft. lbs.

36
 Section 6
Parts List

37
 This section contains a complete illustrated parts list for the Eckel 13-3/8 Standard Tubing
Tong. Figure 6-1 is the top assembly drawing and Table 6-1 is the top assembly parts list.
Figure 6-2 through 6-8 illustrate the subassemblies not broken down in the top assembly
illustrated, and Table 6-2 through 6-8 list the parts for the subassemblies. Figures 6-9
through 6-11 illustrate the accessories available, and Table 6-9 - 6-10 list the parts for these
accessories.
Table 6-1
Parts List, Eckel 13-3/8 Standard Tong – Figure 6-1
INDEX PART NO. DESCRIPTION QUANTITY
REF 100689 13-3/8 Inch Tong 1
1 103481 Top Tong Plage 1
2 101539 Tong Plate Bolt - 3/8" N.C. x 1-1/4" Hex Head 62
3 101643 Tong Plate Bolt - 3/8" N.C. x 1-1/4" Flat Socket Head 4
4 100232 Brake Band 2
5 101543 Brake Band Adjustment Screw - 3/8" N.F. x 1-3/4" Hex Head 4
6 101741 Nut for Adjustment Screw - 3/8" N.F. Full Lock Nut 4
7 100437 Brake Band Lug 4
8 100439 Brake Band Retainer 4
9 101764 Roller Shaft Nut - 7/8" N.F. Thin Lock Nut 28
10 101183 Roller Shaft Grease Zert - 1/4-28 Thd. 28
11 100226 Top Cage Plate 1
12 100228 Bottom Cage Plate 1
13 101570 Cage Plate Bolt - 1/2" N.C. x 6" Hex Head 2
14 100446 Cage Plate Spacer 3
15 100432 Head Pivot Bolt 2
16 101537 Retainer Screw - 3/8" NC x 3/4" Hex Head 1
17 101699 Retainer Washer - 3/8" Lock Washer 1
18 101698 Retainer Washer - 3/8" Flat Washer 1
19 100453 Backing Pin Retainer 1
20 100449 Backing Pin 1
21 100443 Back Cage Plate Bolt 1
22 100563 Door Spring Plunger 2
23 101095 Overcenter Spring 2
24 100545 Door Spring Sleeve 2
25 101539 3/8" x 1-1/4" NC Hex Head 4
26 100566 Door Spring Bushings 4
27 101786 Cam Follower - Torrington Smith H35X 18
28 101714 Cam Follower Washer - 5/8" Lock Washer 18
29 101753 Cam Follower Nut - 5/8" N.F. Jam Nut 18
30 101186 Cam Follower Grease Zert - Drive Zert 18
31 103371 Head Roller Pin 2
32 100918 Head Roller 2
33 100507 Dumbbell Roller Shaft 12
34 100561 Dumbbell Roller 16
35 100513 Dumbbell Door Roller Shaft 2
36 100550 Dumbbell Roller Bushing 32
37 100223 Rotary Gear 1
38 100412 Backing Lug 1
39 101638 Backing Lug Screw - 3/8" N.C. x 3/4" Socket Head 1

38
 100,101
80

25 55
22,23,24
84
26 60
82
64
16 85 62
83 63
17
81
18 19 66 65
29
30 15 96
99 61
13 67
98 97
21
90 68
11
88
20
2
14 92 69
1 70

41 87
89
93 86
91 79

10 94,95
42

8
28 3
9,10
4 78
27
5
6 7
31
117
36 71
102
32
74
33 77
35 39

44 76

37 75 72
57

56 73

34 52
53
40 50 38

76
45
51 12
75
54
46
50
47
59
48 58
49

Figure 6-1
Eckel 13-3/8 Standard Tong, Exploded View

39
Table 6-1
Parts List, Eckel 13-3/8 Standard Tong - Figure 6-1 (Cont.)
INDEX PART NO. DESCRIPTION QUANTITY
40 100236 Tong Door (Round Body) 1
113410 Tong Door (Flat Body) 1
41 101944 A35 Control Valve Handle 1
42 102404 Door Ear 2
44 100511 Dumbbell Leg Roller Shaft 2
45 101094 Latch Spring No. 316 1
46 101809 Door Bearing 1-Z99R14 2
47 100543 Door Washer 4
48 101764 Door Shaft Nut - 7/8" N.F. Think Lock Nut 4
49 101183 Door Shaft Grease Zert - 1/4-28 Thd. 4
50 100542 Door Bearing Spacer 8
51 100544 Door Handle Latch 1
52 100535 Rear Tong Leg 1
53 100234 Tong Body 1
54 100529 Side Hanger 2
55 100531 Back Hanger 1
56 100536 Clutch Door (Round Body) 1
114298 Clutch Door (Flat Body) 1
57 101621 Clutch Door Bolts - 1/4" N.C. x 1" Socket Head 2
58 103482 Bottom Tong Plate 1
59 100534 Front Tong Leg 2
60 100476 Shifting Handle 1
61 100478 Pivot Arm 1
62 101172 Shifting Shaft Connecting Link #80 Chain Link 1
63 101534 Connecting Link Bolts 5/16" N.F. x 1-1/4" Hex Head 3
64 101734 Connecting Link Nuts 5/16" N.F. Lock Nuts 3
65 100473 Shifting Shaft 1
66 101185 1/8 N.P.T. Grease Zert 1
67 101091 Shifting Ball 1
68 101090 Shifting Spring 1
69 101744 7/16" NF Jam Nut 1
70 101551 Shifting Ball Screw - 7/16" x 1-1/4" NF 1
71 100472 Shifting Yoke 1
72 101714 Shifting Shaft Washer - 5/8" Lock Washer 1
73 101753 Shifting Shaft Nut - 5/8" N.F. Jam Nut 1
74 101756 5/8" N.F. Full Lock Nut 1
75 105589 Rotary Idler Assembly (See Figure 6-5 for Breakdown) 2
76 105590 Pinion Idler Assembly (See Figure 6-3 for Breakdown) 1
77 105591 Pinion Assembly (See Figure 6-4 for Breakdown) 1
78 105592 Clutch Assembly (See Figure 6-2 for Breakdown) 1
79 105071 Motor Gear 1
80 13375-CT-1026 Tong Suspension (See Figure 6-8 for Breakdown) 1
81 100525 Motor Box 1
82 101661 Motor Box Bolts - 1/2" N.C. x 2" Socket Head 4
83 101709 1/2" High Collar Lock Washer 4
84 101946 Denison Motor Flange 1-1/4" x 1-1/4" 2
85 107893 Hydraulic Motor - Denison M4D 1
(See Figure 6-6 for Breakdown)
86 100547 Torque Gauge Stand 1
87 100564 Torque Gauge Plate 1

40
Table 6-1
Parts List, Eckel 13-3/8 Standard Tong - Figure, 6-1 (Cont)
INDEX PART NO. DESCRIPTION QUANTITY
88 101555 Gauge Plate Mount Bolt 1/2" NC x 3/4" Head 1
89 109293 Torque Gauge 36" Handle 1
90 101524 1/4" x 3/4" N.C. Hex Head 3
91 100548 Valve Stand 2
92 101876 Control Valve - Standard
Commercial A35-AA4-MA53-Z16
(See Figure 6-7 for Breakdown) 1
101878 Control Valve - W/Lift Cylinder
Commercial A35-AA4-MA53-MA53-Z16 1
110743 Control Vlave - Standard - Closed Center
Commercial A35-AA4-MA53-Y5505 1
93 101568 Valve Mount Bolts - 1/2" N.C. x 4" Hex Head 2
94 100551 Microswitch Base 1
95 13375-CT-1025 Microswitch Assembly (See Figure 6-11 for Breakdown) 1
96 101041 1-1/4" Male Coupling - Aeroquip 5100-S2-20 1
97 101076 Dust Cap - Aeroquip 5100-32-20S 1
98 101038 1" Male Coupling - Aeroquip 5100-S2-16 1
99 101075 Dust Cap - Aeroquip 5100-32-16S 1
100 102369 3/8" Hose x 18" O.A.L. M.P. Ends 1
101 102370 3/8" Hose x 22" O.A.L. M.P. Ends 1
102 100860 S - 4" Die Head 2
100861 S - 4-1/2" Die Head 2
100862 S - 5" Die Head 2
100863 S - 5-1/2" Die Head 2
100864 S - 6" Die Head 2
100865 S - 6-5/8" Die Head 2
100866 S - 7" Die Head 2
100867 S - 7-5/8" Die Head 2
100868 S - 8-5/8" Die Head 2
100869 S - 9-5/8" Die Head 2
100870 S - 10-3/4" Die Head 2
100873 S - 13-3/8" Die Head 2
103§ 100968 1" x 1-1/4" Bushing 2
104§ 101498 Swivel W/O-Ring 1
105§ 101361 1" x 12" Nipple 2
106§ 100990 1-1/4" x 3/8" Bushing FS 1
107§ 101370 1-1/4" x 4" Nipple 1
108§ 101470 90° Street Ell 4
109§ 101344 1" x 3-1/2" Nipple 2
110§ 101495 Swivel Union 1 M/F 16 x 16 60SA 2
111§ 101353 1" x 7" Nipple 1
112§ 101412 3/8" 90° Swivel Ell 2
113§ 101432 90° Ell 2
114§ 101473 90° Street Ell 2
115§ 105070 Motor Gear Key 1
116§ 101109 Snap Ring, MTR F/M77 1
117 101251 Rig Dies (2 per head) 2

§ - Not Illustrated in Figure 6-9

41
Table 6-2
Parts List, Clutch Assembly – Figure 6-2
INDEX PART NO. DESCRIPTION QUANTITY
REF 105592 Clutch Assembly 1
1 100468 Clutch Shaft Drive Gear 1
2 100466 Top Clutch Bearing Bushing 1
3 101799 Top Clutch Shaft Bearing 1
4 100464 Top Clutch Shaft Bearing Retainer 1
5 100458 High Clutch Gear 1
6 101792 Clutch Gear Needle Bearing 4
7 100470 Shifting Collar 1
8 100454 Clutch Shaft 1
9 100460 Low Clutch Gear 1
10 101796 Bottom Clutch Shaft Bearing 1
11 100461 Bottom Clutch Bearing Cap 1
12 101699 Bearing Cap Lock Washer 3/8" Lock Washer 4
13 101538 Bearing Cap Bolt 3/8" N.C. x 1" Hex Head 4
14 101061 Bearing Cap Pipe Plug - 1/8 N.P.T. 2
15 101185 Bearing Cap Grease Zert - 1/8 N.P.T. 1

1
8

3
6
4
TOP TONG 9
PLATE

5 10 BOTTOM TONG
PLATE

11

12
6
14 13
7
15

Figure 6-2
Clutch Assembly, Exploded View

42
Table 6-3
Parts List, Pinion Idler Assembly – Figure 6-3
INDEX PART NO. DESCRIPTION QUANTITY
REF 105590 Pinion Idler Assembly 1
1 101185 Pinion Idler Grease Zert 1/8" N.P.T. 1
2 101772 Pinion Idler Shaft Nut 1-1/2" NF Hex Nut 1
3 101726 Idler Shaft Lock Washer 1-1/2" Lock Washer 1
4 101583 Idler Pad Bolt 5/8" NC x 2" Hex Head 3
5 101714 Idler Pad Lock Washer 5/8" Lock Washer 3
6 100594 Pinion Idler Pad 1
7 100495 Pinion Idler Shaft 1
8 101145 Bearing Seal 2
9 101099 Bearing Retainer Ring 2
10 101805 Idler Gear Bearing 1
11 100492 Pinion Idler Gear 1
12 101103 Idler Shaft Snap Ring 1

4
9
2
5

3 11

TOP TONG
PLATE
10

1
7
9

12
8

Figure 6-3
Pinion Idler Assembly, Exploded View

43
Table 6-4
Parts List, Pinion Assembly – Figure 6-4
INDEX PART NO. DESCRIPTION QUANTITY
REF 105591 Pinion Assembly 1
1 101558 Bearing Cap Bolt 1/2" NC x 1-1/4" in. HH 8
2 101708 Bearing Cap Lock Washer 1/2 in. Lock Washer 8
3 101061 Bearing Cap Pipe Plug 1/8 in. NTP 4
4 100488 Pinion Bearing Cap 2
5 101801 Pinion Bearing 2
6 100486 High Pinion Gear 1
7 100482 Pinion Gear 1
8 100487 Low Pinion Gear 1

1 3
2

4
5
TOP TONG
PLATE

BOTTOM TONG
PLATE

5
4
3
2
1

Figure 6-4
Pinion Assembly, Exploded View

44
Table 6-5
Parts List, Rotary Idler Assembly – Figure 6-5
INDEX PART NO. DESCRIPTION QUANTITY
REF 105589 Rotary Idler Assembly 2
1 101772 Rotary Idler Nut 1-1/2" NF Hex Nut 2
2 101726 Rotary Idler Lock Washer - 1-1/2" Lock Washer 2
3 100505 Rotary Idler Pad 2
4 100504 Rotary Idler Gear Spacer 2
5 101145 Bearing Seal Nilos 6212 AV 2
6 101099 Bearing Retainer Ring - RR 433 2
7 101805 Idler Gear Bearing - SKF 5212 H 1
8 100492 Rotary Idler Gear 1
8a 100233 Rotary Idler Gear W/Micro Cams 1
9 101185 Rotary Idler Grease Zert - 1/8 N.P.T 1
10 100498 Rotary Idler Shaft 1

9
1

2
3 10
TOP TONG
PLATE

4 6

5 5

6
4

7 BOTTOM TONG
PLATE

3
8
2

Figure 6-5
Rotary Idler Assembly, Exploded View

45
Table 6-6
Parts List, M4D Motor Assembly – Figure 6-6
INDEX PART NO. DESCRIPTION QUANTITY
REF 107893 Hydraulic Motor - Denison M4D "B" Mod 1
1 358-24300 Socket head cap screw 5/8-11 x 2-1/2" lg. 4
2 034-59694 End cap with SAE-4 bolt 1
3 691-10250 Square section seal #250 1
4 230-82002 Needle bearing BH-1212 1
5 324-22414 Dowel pin 3/8" x 7/8" 1
6 S14-26714 Cam Ring Assembly 1
6a 034-59686 Cam Ring M4D-138 1
6b 034-49747 Rotor 1
6c 034-49746 Vanes 10
6d 034-49743 Vane Springs 30
7 324-21612 Dowel pin 1/4" x 3/4" 1
8 S24-10905 Front port plate assembly 1
034-60852 Front port plate 1
034-53346 Valve Adaptor 1
312-35056 Set screw 3/8-24 x UNF x 3/8 1
201-06001 Chrome Ball 3/16" dia. 1
9 691-00246 "O"-ring #246 1
10 691-10335 Square section seal #232 1
11 356-32283 Internal snap ring 5008-283 1
12 034-70853 External snap ring 5100-137 1
13 230-00207 Shaft ball bearing ND#3207 1
14 034-70982 Shaft with 5/16" key way 1
15 034-49676 Shaft key 1
16 637-00003 Shaft seal 1
17 605-10020 Felt wiper 1
18 034-49756 Body 1
19 034-59843 Bollevell washer 1

S24-10916 M4D Seal Kit 1

46
Figure 6-6
M4D Motor Assembly, Exploded View

47
Table 6-7
Parts List, A35 Valve Assembly – Figure 6-7
INDEX PART NO. DESCRIPTION QUANTITY
REF 101876 Control Valve - Standard - Open Center
(Comm. A35-AA4-MA53-Z16) 1
110743 Control Valve- Standard - Closed Center
(Comm. A35-AA4-MA53-Y5505) 1
1 391-2881-403 Section Seal 1
2 391-2881-200 Section Seal 3
3 391-2881-101 Spool Seal 2
4 391-2681-001 Back-up Ring 1
5 391-2183-005 Retaining Plate 1
6 391-2581-006 Detent Popper Retainer 1
7 391-3581-015 Poppet Spring 1
8 391-0282-009 Steel Ball 2
9 391-3283-008 Detent Poppet Sleeve 1
10 342-6000-100 End Cap 1
11 391-1433-009 Fillister Head Screw 2
12 391-2881-095 O-Ring Seal 1
14 391-1642-013 Spring Guide 2
15 391-3581-124 Spring 1
16 311-1432-021 Stripper Bolt 1
17 391-2483-003 Check Valve Poppet 1
18 391-3581-114 Check Valve Spring 1
19 391-0581-004 Check Valve Cap 1
20 101950 Main Relief Valve Assembly - BL6625K 2
21 391-1583-012 Gasket Washer 1
22 391-2681-165 Back-up Ring 1
23 391-2881-137 O-Ring 1
24 391-2881-260 O-Ring 2

48
 tral
Neu
n to
e tur roup 11
R G
r ing ap
p C
a l S End 14
pic
Ty
on 10
e cti ) 16
l e t S 128
In (CA 1 15
5
34
Spool—
m 4-Way. 3-Position
steve 1 Work Ports Blocked
y
S l
a in f Va 2 in|Neutral-Parallel
M elie Circuit
R
alve 3)
V 5 3 17
b oy (MA 18
o w ing
L us 12 2 on
Ho 19 e cti
S
t l et 16)
Ou (Z
Poppet Assembly Snubber Floating Displacement Locking Nut
Crimped In Cartridge. Seat Plunger

24 21 24
23 22 Adjusting Screw
A35 Main Relief Valve (BL6625K)

Figure 6-7
A35 Valve Assembly

49
Table 6-8
Parts List, Hydraulic Cam-Type Backup Assembly – Figure 6-8 through Figure 6-11
INDEX PART NO. DESCRIPTION QUANTITY
REF Hydraulic Cam-Type Backup Assembly 1
1 112429 Backup Plate Assembly 1
2 112427 Cam Ring 1
3 107196 Bolt, Socket Head, 3/4” NC x 2-1/2” 27
4 101719 Lockwasher, 3/4” Hi-Collar 34
5 101685 Bolt, Flat Socket Head, 3/4” NC x 2-1/2” 1
6 112432 Top Cage Plate 1
7 112431 Bottom Cage Plate 1
8 112593 Cage Plate Spacer 3
9 106870 Bolt, Hex Head, 1/2” NC x 7” 3
10 101708 Lockwasher, 1/2” 5
11 101786 Cam Follower, 1-1/8” 26
12 101753 Jam Nut, 5/8” NF 26
13 101714 Lockwasher, 5/8” 26
14 101186 Grease Zert, 3/16” Drive 26
15 112598 Torque Link Assembly 1
16 107183 Torque Link Washer 2
17 101537 Bolt, Hex Head, 3/8” NC x 3/4” 9
18 101699 Lockwasher, 3/8” 5
19 112599 Head Pivot Bolt 2
20 107119 Cylinder Anchor Post 1
21 107120 Pivot Arm Post 1
22 112434 Pivot Arm 1
23 106669 Pivot Arm Washer 1
24 112430 Front Hanger Leg 2
25 112420 Front Leg Bracket 2
26 112601 Bolt, Hex Head, 3/4” NC x 4-1/2” 2
27 101760 Locknut, 3/4” NC 4
28 104188 Spring Assembly 3
29 101606 Bolt, Hex Head, 3/4” NC x 7” 2
30 112412 Load Cell Bracket Mounting Plate 1
31 113323 Load Cell Bracket 2
32 107910 Bracket Cap 1
33 101583 Bolt, Hex Head, 5/8” NC x 2” 4
34 101714 Lockwasher, 5/8” 4
35 108706 Two Position Load Cell Retainer 1
36 101555 Bolt, Hex Head, 1/2” NC x 3/4” 2
37 107920 Rear Spring Retaining Plate 2
38 107808 Bolt, Hex Head, 5/8” NC x 12” 2
39 101757 Lock Nut, 5/8” NC Full 2
40 107194 Hydraulic Cylinder 2
41 106253 Cylinder Rod Eye 2
42 112421 Cylinder Rod Extender 1
43 106254 Clevis Pin 2
44 101947 Valve Section, Commercial A35-DA53 1
45 101944 Valve Handle, Commercial A35 1
46 104173 Directional Valve, 1/4” 1
47 101963 Subplate w/ Bolt Kit for 1/4” Directional Valve 1
48 106317 Shuttle Valve, 1/4” 2
49 101058 Q.D. Coupling Half, 1/4” Male 2

50
Table 6-8
Parts List, Hydraulic Cam-Type Backup Assembly – Figure 6-8 through Figure 6-11
INDEX PART NO. DESCRIPTION QUANTITY
50 101059 Q.D. Coupling Half, 1/4” Female 2
51 103823 Q.D. Coupling Half, 3/8” Male 1
52 103820 Q.D. Coupling Half, 3/8” Female 1
53 113326 Right Side Cover 1
54 113325 Left Side Cover 1
55 112046 Torque Gauge, Compression Load Cell, 1
56 112742 “SB” 4” Pivot Head 2
57 112708 “SB” 4-1/2” Pivot Head 2
58 113247 “SB” 5-1/2” Pivot Head 2
59 112706 “SB” 6-5/8” Pivot Head 2
60 113293 “SB” 7” Pivot Head 2
61 113321 “SB” 7-5/8” Pivot Head 2
62 112706 “SB” 8-5/8” Pivot Head 2
63 111954 “SB” 9-5/8” Pivot Head 2
64 113296 “SB” 10-3/4” Pivot Head 2
65 111956 “SB” 11-3/4” Pivot Head 2
66 113299 “SB” 13-3/8” Pivot Head 2
67 111959 “SB” 14-3/8” Pivot Head 2
68 111017 Grab Hook Bracket, Left Side 1
69 110726 Grab Hook Bracket, Right Side 1
70 101161 Grab Hook 2
71 112433 Brake Band 1
72 112602 Brake Band Lug 2
73 101543 Bolt, Hex Head, 3/8” NF x 1-3/4” 2
74 101741 Lock Nut, 3/8” NF Full 2
75 101727 Nut, 1/4” NC 2
76 101525 Bolt, Hex Head, 1/4” NC x 1” 2
77 101694 Lockwasher, 1/4” 2
78 101684 Bolt, Socket Head, 3/4” NC x 2” 7
79 101538 Bolt, Hex Head, 3/8” NC x 1” 2
80 112662 Head Roller 1/Hd
81 112663 Roller Pin 1/Hd

51
 25 30
4,78
26,27

36
35

28 (Not Shown)
28 53,54 37
27,29
38,39
31
24
33,34
32

Figure 6-8
Hydraulic Cam-Type Backup Assembly (Side Views)

52
 Figure 6-9
5,79 80 81 68
54 55
72
2
35

Hydraulic Cam-Type Backup Assembly (Top View)

36
8,9
8,9 8,9

1
17 53

73,74 71 69 75,76,77
70

53
54
3,4 41
15 42 40

Figure 6-10
43
22
1
48
21
19 17,18,23
3,4
16 5
35
48 45

Hydraulic Cam-Type Backup Assembly (Bottom View)

44
51
40
50
17,18
20 3,4 49
49 52
47 46 50 51 44

46
 40

48

48

49,50

40
49,50
51,52
a b

t p

46,47

45
44

t p

Figure 6-11
Hydraulic Cam-Type Backup Assembly (Schematic)

55
Table 6-9
Parts List, Tong Suspension – Figure 6-12
INDEX PART NO. DESCRIPTION QUANTITY
REF 13375-CT-1026 Tong Suspension 1
1 101985 Lift Cylinder 1
2 100721 Spring Hanger Assembly 1
3 102373 Lift Cylinder Hose Assembly 1
4 101885 Pilot Operated Check Valve 1
5 100675 Bridle Assembly 1
6 101241 3/4" Clevis 2
7 101168 5/16" Clevis 3
8 101042 1/2" Male Quick Disconnect 1
9 101878 Control Valve Comm. A35-AA4-MA53-MA53-Z16 1
10 101065 3/4" Pipe Plug 1
11 100980 1/2" x 3/4" FS Bushing 1

6
3
2

10
5 4
9
11

Figure 6-12
Tong Suspension

56
Table 6-10
Parts List, Door Interlock Assembly – Figure 6-13 and 6-14
INDEX PART NO. DESCRIPTION QUANTITY
REF 107259 Door Interlock Device (Double Door Tongs) 1
1 106882 1" Relief valve R4V-06-513 1
2 101472 1" Ell 2
3 101495 Straight Swivel M/F 2
4 101342 1" x 2-1/2" Nipple XH 1
5 101437 1" 90° Ell 2
6 101284 1" Tee Steel 3
7 101343 1" x 3" Nipple XH 1
8 101344 1" x 3-1/2" Nipple XH 1
9 104313 0-5000 PSI Pressure Gauge 1
10 106716 1-1/4 x #65 Check Valve 1
11 101340 1" Nipple AT XH 6
12 100968 1-1/4" X 1" Bushing 1
13 100963 1" x 1/4" Bushing 1
14 101273 1/4" Tee Steel 1
15 101300 1/4 Nipple AT 1
16 101409 1/4" 90° Swivel 1
17 101352 1" x 6-1/2" Nipple XH 1
18 101039 1-1/4" Coupling 1
19 101040 1" Coupling 1
20 102395 1/4" NPT Hose Ends 8
21 101485 1/4" Straight Swivel M/F 5
22 101409 1/4" x 90° Swivel M/F 4
23 104378 1/4" Deltrol Plunger Valve CH V MOC20 4
26 107529 Door Cam 2
28 107257 Valve Bracket (Right Side) 1
111918 Valve Bracket (Left Side) 1
29 102366 1/4" x 60" Hose Assembly 4
30 101301 1/4" x AT XH Nipple 1

57
 2 6 11
7

10 9
13
12 11

6
8

11

7
RETURN LINE

PRESSURE LINE

Rear View Front View

2
5
5 4 3

26
28 11 1
30
23 21
12 11 14
21
RETURN LINE
13 15
5
19

26 28 23 18

A
PRESSURE LINE
B

6 17 14 16
5
21

Side View
21
23

B
APPLIES TO LEFT AND
RIGHT SIDE TONG DOORS
A

20 22

APPLIES TO LEFT AND

RIGHT SIDE TONG DOORS
Figure 6-13
Door Interlock Assembly and Hydraulic Components

58
 DOOR INTERLOCK
PLUNGER VALVE DOOR INTERLOCK
RELIEF VALVE
PRESSURE

RETURN

TONG
MOTOR

DOOR INTERLOCK
PLUNGER VALVE

TONG CONTROL
VALVE

Figure 6-14
Door Interlocking Schematic

59
Table 6-11
Parts List, Microswitch Assembly – Figure 6-15.
INDEX PART NO. DESCRIPTION QUANTITY
REF 13375-CT-1025 Microswitch Assembly 1
1 101192 Micro Switch BZ-2RN 702 1
2 100553 Micro Bushing Housing 1
3 100565 Micro Switch Push Rod 1
4 101811 Micro Bushing Consolidated A4812 3
5 103689 1/4" x 3/4" NF HH 2

Figure 6-15
Microswitch Assembly

60