Eckel Manufacturing Co. Inc.

Hydraulic Power Tongs — "World Wide"

7-5/8 Standard Model B

Hydraulic Power Tubing Tong

OPERATION
and SERVICE
INSTRUCTIONS
Copyright

© Copyright 2004, Eckel Manufacturing Co., Inc. All rights reserved. No part of this manual may be reproduced, transmit-
ted, 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
7-5/8 Standard Hydraulic Power Tubing Tong is covered by U.S. and Foreign Patents and Pending Patent Applications

December, 2004

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 (281) 999-6680
Telex 74-5434 (ODS) Telex 77-4644 (HOU)
FAX 432-362-1827 FAX 281-999-8707
 Contents
Section 1 - General Description ............................................................................. .1
Introduction ....................................................................................................... 1
Functional Description ...................................................................................... 1
Specifications ..................................................................................................... 4
Options and Accessories .................................................................................... 4

Section 2 - Installation .................................................................................................. . 9

General Considerations ...................................................................................... 9
Connecting Hydraulic Hoses ........................................................................... 12

Section 3 - Operation .................................................................................................. .15

General Operation ............................................................................................ 15
Operating Controls and Gauges ....................................................................... 15
Pre-Operating Checks ...................................................................................... 15
Typical Operating Sequence ........................................................................... 20
Section 4 - Servicing .................................................................................................... .23
Daily Inspection ............................................................................................... 23
Maintenance After Each Job ............................................................................ 23
Lubrication ...................................................................................................... 24
Tests and Adjustments ..................................................................................... 26
Section 5 - Troubleshooting, Repair and Overhaul ........................... .29
Troubleshooting .............................................................................................. 29
Repair ............................................................................................................... 30
Tong Overhaul ................................................................................................. 30
Series 15 and Series 37 Motor Overhaul ......................................................... 31
A35 Valve Overhaul ........................................................................................ 31
Section 6 - Parts List ................................................................................................... .35
Parts List, Eckel 7-5/8 Standard Tong ............................................................. 35
Parts List, Dumbbell Roller Assembly ............................................................. 38
Parts List, Rotary Idler Assembly ..................................................................... 39
Parts List, Pinion Idler Assembly ..................................................................... 40
Parts List, Pinion Assembly ............................................................................. 41
Parts List, Clutch Assembly ............................................................................. 42
Parts List, Shifting Shaft Assembly .................................................................. 43
Parts List, Tong Hanger: Chain Bridle Assembly ............................................ 44
Parts List, Tong Hanger: Solid Hanger Assembly ........................................... 45
Parts List, Tong Suspension ............................................................................. 46
Parts List, Door Interlock System ..................................................................... 47
Parts List, Series 15 Motor Assembly .............................................................. 49
Parts List, A35 Valve Assembly ....................................................................... 51
Parts List, A35 Control Valve Assembly ......................................................... 53
Parts List, Tri-Grip Backup .............................................................................. 54

iii
 HYDRAULIC
Section 1: General Description DRIVE SYSTEM

Introduction
CAGE PLATE
This manual describes the function, operation and maintenance
of the Eckel 7-5/8 Standard Hydraulic Power Tubing Tong. This WITH HEADS
section provides a functional description, system specifications, SAFETY
and a description of options and accessories available. Section 2
DOOR
through 5 present the operating and maintenance aspects of the
tong and Section 6 provides a fully illustrated parts list.
The 7-5/8 Standard Tong, Figure 1-1, handles tubing and casing
sizes as small as 1.050 inch and as large as 7-5/8 inches diameter.
The open-throat design, combined with high-speed operation, as-
sures 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.

Functional Description GEAR TRAIN AND

CLUTCH DETAILS
Operating from a hydraulic power unit, the power tubing tong
provides torque of 15,000 ft-lbs. The heart of the unit is a head- (INSIDE HOUSING)
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 Figure 1-1
two-speed gear train powered from a vane-type hydraulic motor. Eckel 7-5/8 Standard Tong
In operation, the tong is suspended over the well bore on a chain
bridle or solid hanger. Snub lines restrain the tong from moving
1-1/4" COUPLING REVERSIBLE
around the pipe as torque is applied. RETURN MOTOR

Hydraulic Drive System

PRESSURE
Figure 1-2 is a hydraulic schematic of the drive system. Hydraulic RELIEF
VALVE
pressure from a separate power unit is applied through screw-type
hose connectors having built-in check valves. To prevent cross- PRESSURE
connection of the hoses, the pressure hose from the power unit is M
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
1"
the check valves to provide hydraulic pressure to the tong. COUPLING MAKE-UP
BREAK-OUT
The tong control levers acts as a throttle valve for the unit. Push-
ing the lever applies pressure to drive the motor in a forward direc-
tion (for make-up operation) and pulling the lever applies pres- PRESSURE CONTROL
GAUGE VALVE
sure 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 Figure 1-2
control lever positions. Hydraulic Drive System Schematic
An adjustable relief valve permits adjustment of the operating
pressure at the tong if desired, and a built-in pressure gauge indi-
cates the operating pressure at all times. The maximum pressure
available, of course, depends upon the power unit. Eckel Manu-
facturing Co., Inc. recommends a power unit that will deliver 3,000
PSI pressure; however, a power unit capable of delivering 2500
PSI and 65 GPM is necessary to maintain maximum speed and
torque output.
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.

1
Gear Train and Clutch Function
Closure and rotation of the pipe-gripping heads are accomplished
PINION
by means of a large rotary gear having its inner diameter formed ASSEMBLY CLUTCH
ASSEMBLY
into a double cam surface. This topic explains how mechanical ROTARY IDLER
ASSEMBLY
power is transmitted from the hydraulic motor to turn the rotary PIONION IDLER
ASSEMBLY
gear in either direction. ROTARY
GEAR
DUMBBELL
Gear Train Elements ROLLER

The gear train, Figure 1-3, comprises a 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 pinion
output gear drives the pinion idler which 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 PINION CLUTCH SPEED
ASSEMBLY SHIFT
operation, allowing faster operation when high torque is not re- ASSEMBLY

quired. 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
SHIFTING
with the high-speed clutch gear. Lowering the shifting lever low- YOKE ADJUSTABLE
SHIFTING DETENT
ers the shifting yoke which lowers the shifting collar, thereby COLLAR
HIGH
mechanically coupling the clutch shaft with the low-speed clutch SPEED LOW
SPEED
gear. Then the selected clutch gear drives the corresponding pin-
ion 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.
Figure 1-3
Head Operations Gear Train Elements, Clutch Details
The pivot 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 and latched. 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 heads inward until the heads bite the pipe. Further rota-
tion then turns the pipe to make-up (or break-out) the joint.

2
Rotary Gear and Head Cage Rotation
ROLLER
Figure 1-5 illustrates the semi-independent rotation of the cage ONE EACH
HEAD
plates and rotary gear. The figure illustrates how the top cage
plate is free to rotate on cam followers following a groove in the
cage plate. The rotary gear is turned independently within a circle
of dumbbell rollers.. The bottom cage plate rotates on cam fol-
lowers 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 casing as brought about by the cam action of the rotary
gear on the head rollers.
Brake Band Function
HEADS OPEN HEADS CLOSED
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 cage plates have unrestrained freedom to ro- Figure 1-4
tate, the heads will simply move with the rotary gear and will not Head Biting Action, Make-up
cam up on the rotary cams to force the biting action. Figure 1-6 TOP TONG
illustrates how brake bands are placed around the top and bottom TOP CAGE PLATE
BACKING PIN
cage plates to exert continuous friction on these plates and to PLATE (MAKE-UP POSITION)

restrict their freedom to move. BACKING PIN

(BREAK-OUT POSITION)
Thus it is evident that the brake bands do not permit the cage TOP CAGE
PLATE
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 BOTTOM BOTTOM TONG
CAGE PLATE PLATE
break-out.
ROTARY
When the pin is placed in the left-hand (make-up) hole, forward GEAR DUMBELL
ROLLER
operation causes the heads to bite and rotate to make up the joint.
Figure 1-5
However, reverse operation causes the backing pin to strike the
Head Cage Plate and Rotary Gear Details
backing lug 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 (break-out) hole, the
opposite action occurs and reverse operation causes the heads to
bite, while forward operation causes the backing pin to strike the BACKING PIN

backing lug and force the head cage around with the rotary gear,
thus inhibiting the heads from biting in the forward direction. HEAD
PIVOT
In summary then: for make-up, the backing pin is placed in the BOLT
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 BRAKE
the heads bite in the reverse direction. Please note pin holes are BANDS

indentified looking from the throat area of the tong. HEAD

ROLLERS
Open Throat and Safety Door HEADS

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 ROTARY
SAFETY GEAR
front during operation and to provide an extra margin of support DOOR
for the housing during high-torque operation. An optional Door Figure 1-6
Interlock (Figure 1-7) device adds additional margin of safety, Brake Bands and Safety Door
preventing the tong from operating while the tongs door is open.

3

Specifications
The specifications for an operating tong must consider the hy-
draulic 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 is required to oper-
ate the tong at maximum rated RPM.
Tong Specifications
Table 1-1 list the specifications for the Eckel Model 7-5/8 Stan-
dard Casing Tong.
Options and Accessories
Options for the Model 7-5/8 Standard Tubing Tong include lift
cylinder with lift cylinder control, spring hanger, torque gauge,
door interlock, and RPM control. The optional items are described
in the following paragraphs.
Lift Cylinder and Controls
A lift cylinder as illustrated in Figure 2-2 is optionally supplied
with the 7-5/8 Standard 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
to permit tong movement during make-up or break-out opera-
tions without exerting undue stress on the bridle and dies. The
maximum travel of the lift cylinder is 6 feet.
Lift Cylinder Controls
When a lift cylinder is ordered with a tong, the tong contains an
additional control lever for controlling the lift cylinder move-
ment. The control lever 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 direc-
tion.
Spring Hanger
The optional spring hanger (Figure 2-2) 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.
4
Table 1-1
Specifications, Eckel 7-5/8 Standard Tong
Specifications for 7-5/8 Standard Tong
Capacity ............................. 2-1/16 - 7-5/8 in. (52 - 194 mm)
Size ................................... 32.5 x 63.5 in. (825.5 x 1613 mm
Height ............................................................ 30 in. (762 mm)
Weight (Approximate) ................................ 1,100 lb (499 kg)
Gear Ratio
(high) ............................................................................. 16:1
(low) ................................................................................ 80:1
Handle Lengths ............................................ 36 in. (914 mm)
Available Heads (For Pipe Size O.D.): .............. 2-1/16, 2-3/8,
2-7/8, 3-1/2, 4, 4-1/2, 5, 5-1/2, 6-5/8, 7-5/8
Note: Any size head between 2-1/16 and 7-5/8 can be
specified as needed.
* These are average requirements for a new tong, there
may be some variations from tong to tong.
7-5/8:
Torque @ 2,500 PSI (172 bar):
(high) ............................................. 3,000 ft-lbs (4066Nm)
(low) ............................................ 15,000 ft-lb (20340 Nm)
Maximum RPM @ 65 GPM (246 lit/min)
(high) .................................................................... 132 RPM
(low) ......................................................................... 26 RPM
Table 1-2
Specifications, Eckel 7-5/8 STD Tri-Grip Backup
Specifications for 7-5/8 Standard Tri-Grip Backup
Capacity ................... 2-1/16 - 8-1/2 in. (101.6 - 298.5 mm)
Maximum Holding Torque .......... 15,000 ft-lbs (20337 Nm)
Operating Pressure .................................. 2500 PSI (172 bar)
Handle Length .............................................. 36 in. (914 mm)
Dimensions (Tong and Backup):
Length ................................................. 58.5 in. (1486 mm)
Width ........................................................ 29 in. (737 mm)
Height .................................................. 59.5 in. (1511 mm)
Weight (Approximately):
Tong and Backup ............................. 1,900 lbs (862 kgs.)
Available Heads (For Pipe Size O.D.): .............. 2-1/16, 2-3/8,
2-7/8, 3-1/2, 4, 4-1/2, 5, 5-1/2, 6", 7", 7-5/8", 8-1/2"
Note: Any size head between 1.050 and 8-1/2" can be
specified as needed.
Door Interlock
The door interlock is an optional safety feature that is offered with
the power tong. The system impedes hydraulic fluid from reach-
ing the tong motor whenever the tong door is open. This prevents
accidental operation of the power tong. Figure 1-7 identifies the
components of the door interlock system.

RPM Control
The RPM Control is a flow control valve that decreases the amount
of hydraulic fluid that reaches the tong, the remaining fluid is
returned to the reservoir. By decreasing the amount of fluid reach-
ing the tong the operator is able to control the maximum RPM's
the tong will deliver.

Torque Gauge Assembly (Tong without Backup):

The optional torque gauge assembly (Figure 2-3) is used to mea-
sure the torque exerted in make-up or breakout operations. Con-
sisting of a tension type load cell and torque gauge connected
together by a pressure hose, the torque gauge assembly senses and
indicates the torque developed during an operation. For opera-
tion, the load cell is connected by a shackle to the rear of the tong;
and a snub line is connected to the load cell. The snub line is tied
off to a solid part of the rig structure to form an angle of 90° in
order for this gauge to indicate accurate torque readings.

WARNING: We recommend the following wire rope snub line

for minimum safety requirements:
7-5/8 Standard ........................... 5/8" Diameter
IPS Grade, 6 x37 Class, 6 x 36 IWRC Construction

CHECK RELIEF
VALVE VALVE

DOOR
CAM

CAM
VALVE

Figure 1-7
Door Interlock System

5
Hydraulic Tri-Grip Backup
A hydraulic backup tool as illustrated in Figure 1-8 is optionally
supplied with the tong. In operation this tool provides a backup
when in break-out or make-up situations. The specifications for
POWER
the hydraulic backup are supplied in Table 1-2. TONG
The hydraulically operated backup tool, utilizes a three jaw bit-
ing system to insure slip-free operation.
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 con-
nection. The stinger part of the backup, extending from the rear of
the unit is inserted into the torque bracket mounted on the under-
side of the tong. This method of hook up prevents movement of
the tong about the pipe during torquing operation.
Hydraulic Backup Controls
When a hydraulic backup is ordered with a tong, the tong con-
tains an additional control lever for controlling the backup opera- TRI-GRIP
tion. This lever is illustrated in Figure 1-9 and its operation is BACKUP

shown in Figure 3-2 and Table 3-1. Pushing the control lever
inward provides hydraulic pressure from the hydraulic power unit
to the backup for the pipe. Pulling the control lever disengages
the backup heads from the pipe.
Torque Gauge Assembly (Tong with Backup):
Figure 1-8
Between the stinger and bracket is located the torque gauge com- 7-5/8 Standard Power Tong with Hydraulic Tri-
pression load cell (Figure 2-5). During make-up or break-out op- Grip
erations, the tong unit rotates slightly causing the stinger to com-
press 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 oppo-
site side of the backup stinger to register the torque. The compres-
sion force is translated to torque which is indicated on the torque
gauge connected to the load cell. The hydraulic cam type backup
requires a 28.5-inch torque gauge handle which offers direct read-
ing of torque between the backup and the tong.
Adjusting Backup Spacing
The vertical spacing between the backup and tong is adjustable
in 3 steps using different sets of bolt holes in the hanger legs and
load cell bracket which hold the backup hanger spring in position
(Figure 1-10). Close spacing between the backup and power tong
is desirable from the standpoint of insuring the closest possible CONTROL
distance between the tong and backup dies. This has particular LEVER
importance when running tubulars with short upsets. Also, close
spacing is beneficial in reducing twisting forces in the tong and
backup structures. Table 1-3 indicates spacing between mid-points
of the tong and backup dies for each vertical setting. Figure 1-9
On the other hand, the design provides the spacing when it is Hydraulic Tri-Grip Controls
necessary to span extra-long couplings or upsets as is required
during make-up operations. Figure 1-11 illustrates the proper bit-
ing locations for the tong and backup for make-up and break-out
operations.
A backup bridle bar (Figure 1-10) is provided with the tong and
backup unit for use in adjusting the backup vertical spacing. Us-
ing the bridle bar, the backup is raised so that the backup weight

6
 is removed form the hanger springs. Once the weight is removed, Table 1-2
the bolts supporting the hanger springs may be removed. The Midpoint of Backup Dies to Midpoint of Tong Dies
backup may then be repositioned at the desired height with the
bolts reinserted. To use the bridle bar, it is attached to a lift line Hole Set Distance
and suspended over the power tong with the side chains hanging Top (First) 13"
on each side of the unit. The chains are then attached to grab Second 16.5"
hooks located on each side of the backup. The backup assembly Third 20"
may then be raised with the lift line. Fourth 23.5"
Bottom (Fifth) 27"

BACKUP
BRIDLE BAR

POWER
TONG

LOAD CELL
BRACKET
(Vertical Adjustment
Holes Not Shown)

HANGER
LEGS
TRI-GRIP
BACKUP
GRAB
HOOK

VERTICAL
ADJUSTMENT
HOLES
Figure 1-10
Adjusting Backup Spacing

7
 Non Upset & External Upset Integral Joint Connections
Tong and Tri-Grip Backup Tong and Tri-Grip Backup
Biting Locations Biting Locations

Make-up Break-out Make-up and Break-out

Tong Dies Tong Dies Tong Dies

Tri-Grip
Backup Dies

Tri-Grip Tri-Grip
Backup Dies Backup Dies

Figure 1-11
Make-up and Break-out Biting Locations

8
Section 2: Installation
General Considerations 58.5 IN
1485.3 MM

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. 29 IN
736.5 MM

Tong Considerations
The 7-5/8 Standard Tubing Tong is capable of handling pipe sizes
from 1.050 inch to 7-5/8 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, Specifications for the various heads
provided with the tong. 30 IN
762 MM
Head Installation
22.6 IN
573 MM
Install the correct size heads according to the following proce-
dure (Applies to power tong and backup).

WARNING: Do not attempt to change heads with power unit

in operation. Failure to observe proper precau-
tions could be extremely hazardous and result in
loss or injury to hand or arm.
Figure 2-1.1
1. Disable hydraulic system by turning off power unit and dis- Tong Dimensions
connecting 1" pressure supply hose from tong.
2. Remove two head pivot bolts, Figure 1-6. 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 58.5 IN
1485.3 MM

You should consider the space requirements of the tong, both in

storage and in operation. Figure 2-1.1 give the tong dimensions.
Figure 2-1.2 gives dimension for a tong with backup.
28.9 IN
733.5 MM
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 2,500 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 avail-
able for the type of operation to be performed.
59.5 IN
Torque Gauge 1511.3 MM

Measurement of the torque applied to the pipe connection re- 52.1 IN

1324.4 MM
quires a torque gauge assembly installed on the equipment. As
described in the previous section, a power tong without an inte-
gral hydraulic backup requires a line pull or tension torque gauge
whereas a power tong with integral hydraulic backup requires a
compression type torque gauge assembly. Both types require cali-
bration to the handle length of the power tong or backup. Both
types of torque gauge units are described later in this section.
Figure 2-1.2
Tong and Backup Dimensions

9
 Lift Cylinder Considerations SPRING
HANGER
If the tong suspension line is not counter balanced, a lift cylinder
SPRING
should be used. Also, if an Eckel lift cylinder is to be used, the HANGER
tong must be equipped with an additional control valve and lever.
The lift cylinder should be suspended from the line that will hang
the tong as shown in Figure 2-2.
Spring Hanger Consideration LIFT LIFT
CYLINDER CYLINDER
A typical spring hanger installation is shown in Figure 2-2. When
a lift cylinder is used, the spring hanger may be installed above or
below the lift cylinder as described.

Hanging The Tong

BRIDLE
The power tong is transported to the well-site and hung into posi- RING
MASTER
tion as shown (Figure 2-2) using a hoist or other specially rigged LINK
line. If a spring hanger is used, it is recommended this to be hung CHAIN
SOLID
BRIDLE
first from the suspension line followed by the lift cylinder and HANGER
TONG TONG
finally the power tong. With a tong equipped with a chain bridle,
attach the lift suspension line to the bridle ring at the top of the
bridle assembly.

CAUTION: Do not hook lift-line on turnbuckels. Be sure bridle CHAIN BRIDLE SOLID HANGER
chains are clear of valves and controls.
For tongs with the solid hanger, attach lift or suspension lines to Figure 2-2
the master link installed about the leveling screw on top of the Tong Installation
hanger.

CAUTION: Shackles, suspension lines and associated hard-

ware used to suspend the power tong and acces- TORQUE
GAUGE
sories should be rated for the unit's weight as
well as expected dynamic loads.
Once the tong unit is suspended at the correct height, proceed
with attaching the snub lines as outlined in the following proce-
dure.
HYDRAULIC
CYLINDER
Installation of Torque Gauge and Snub Lines: Tong
without Backup
KEL SNUB LINE
The 7-5/8 Standard power tong without an integral hydraulic
backup uses a torque gauge system with a tension type or line-
pull load cell. As explained in the previous section, the load cell
is located on the rear of the power tong and attached to the snub Figure 2-3
line. Refer to Figure 2-3 for component location. Tong Only: Torque Gauge Installation
1. Using the three mounting screws, mount the gauge part of the
torque gauge unit to the gauge mounting plate located on the
power tong. Tong is Securred in Both
2. Route the connecting hose so that it does not interfere with Directions to Prevent Backlash.
power tong operation. (Always Utilize Two Snub Lines)

WARNING: We recommend the following wire rope snub line

for minimum safety requirements:
7-5/8 Standard ........................... 5/8" Diameter
IPS Grade, 6 x37 Class, 6 x 36 IWRC Construction.
3. Attach the tension load cell (hydraulic cylinder) to the snub
handle on the rear of the tong.
4. Attach snub line to other end of load cell. Figure 2-4
Tong Securement/Snub Line Placement

10
5. Secure the snub line to a part of the rig structure that is rigid BACKUP
enough to withstand the line-pull. BRIDLE BAR

NOTE: An angle of 90 degrees must be maintained between POWER

the power tong and snub line during operation for TONG
the gauge to indicate accurate torque readings.

Install a second snub line on the other side of the power tong to
restrain tong movement in the opposite direction (Figure 2-4).
Installation of Torque Gauge and Snub Lines: Tong with
Backup
The 7-5/8 Standard power tong with tri-grip hydraulic backup
BACKUP
uses a torque gauge system with a compression type load cell. As STINGER
explained in the previous section, the load cell is located between
BACKUP
the backup stinger and the torque bracket that extends from the
bottom of the tong.
1. Using the backup bridle bar, lift the backup slightly to re-
lieve the weight from the load cell retainer located at the rear LOAD CELL
RETAINER
of the backup.
2. Remove the two bolts holding the load cell retainer on the
backup stinger and remove the retainer.
3. Place the torque gauge load cell in the load cell retainer and
Figure 2-5
slide the unit back onto the stinger and bolt in place.
Tong and Backup: Torque Gauge Installation
4. Lower the backup and remove the backup bridle bar.
5. Route the torque gauge hose so it does not interfere with the
tong operation.
6. Using the three mounting screws, mount the gauge on the
torque gauge mounting plate.
Snub lines should always be attached to both sides of the power
Tong is Securred in Both
tong for safety considerations in case the backup back-bites or
Directions to Prevent Backlash.
slips (Figure 2-6).
(Always Utilize Two Snub Lines)
1. Attach a snub line to the snub handle at the rear of the power
tong. Secure the other end of the line to a rigid structure on
the rig that can withstand the line pull in case of backup
slipping.

NOTE: It is not necessary to maintain a 90 degree angle

between the power tong and snub line as is the
case with a tong without backup.
2. Repeat the above step and attach the second snub line on the
other side of the power tong.

WARNING: We recommend the following wire rope snub line

for minimum safety requirements: Figure 2-6
Tong with Backup Securement with Snubline
7-5/8 Standard ........................... 5/8" Diameter Placement
IPS Grade, 6 x37 Class, 6 x 36 IWRC Construction.

11
 CONNECT HYDRAULIC PRESSURE
Connecting Hydraulic Hoses LINE (1") FROM POWER UNIT

CONNECT LIFT
The hydraulic couplings, Figure 2-7, contain check valves to pre- CYLINDER HOSE (1/2")

vent loss of hydraulic fluid when the lines are disconnected. The CONNECT HYDRAULIC
RETURN LINE (1-1/4")
check valves are closed until the couplings are connect to their FROM POWER UNIT

mating ends on the hydraulic hoses. Proper connection of the

hydraulic hoses opens these valves and ensure unrestricted flow
of hydraulic fluid.

WARNING: Hydraulic suplly lines must be completely con-

nected. Failure to insure proper connect may re-
sult in personal injury and/or damage to power
tong.
Figure 2-7 Tong Hydraulic Connections

Connecting Pressure and Return Hoses

Pressure and return line connections use thread-to-connect type
couplings with the male nipple halfs of the coupling installed on
the power tong. The mating female couplers are on the hydraulic
supply hoses. Female couplers may be either wing nut or hex nut
type with wing nut the preferred coupler since no additional tools
are needed to connect the coupling.
To prevent cross connecting, the pressure and return line cou-
plings are different sizes. The pressure or inlet coupling is 1” size.
The return line coupling is 1-1/4”.
When making up these connections, you should insure that the PRESSURE AND RETURN
couplings are tightened completely and have not reached a “false” LINE COUPLINGS
tightening due to resistance of the internal check valve. A “con-
nected” line is located on the male nipple part of the coupling.
When the female coupler is tightened to this line, the coupling is
fully connected (Figure 2-8).
Connect the pressure and return hoses as follows:
CONNECTED LINE

CAUTION: Turn off power unit before attempting to connect MALE COUPLER FEMALE NIPPLE
or disconnect hydraulic supply lines. Insure that (POWER TONG) (SUPPLY HOSE)

hoses are free of kinks and are run so that power

tong movement is not hindered.

1. Align the 1” female coupler on the pressure supply hose to

the 1” male nipple on the power tong.
CONNECTED LINE
2. Force the two coupling halves together while turning the nut
on the female coupler. Threads are right-hand. Ensure that COUPLING NOT FULLY CONNECTED
threads engage and the coupler turns freely. Slight movement
or wiggling of the supply hose as the coupler is turning may
aid in connection.
3. Fully tighten the coupler. Check that coupler has reached the
“connected” line on the male nipple. If not, continue to
tighten the coupler until line is reached. Shifting the control
valve handles back and forth may aid in tightening the con-
nection by equalizing hydraulic pressure that may be trapped CONNECTED LINE

in the system.
COUPLING FULLY CONNECTED
4. Repeat steps 1 through 3 to connect the 1-1/4” return line

Figure 2-8
Connecting Pressure and Return Hoses

12
 hose.
5. Pressure and return supply hose connection is now complete.

Connecting Lift Cylinder Hoses

The lift cylinder connection uses sleeve-type quick disconnect
couplings. The coupling half of the power tong and lift cylinder is
a 1/2" male nipple with the supply hose having a 1/2" female
coupler on each end. Refer to Figure 2-7 for lift cylinder connec-
tions.
Connect the Lift Cylinder hoses as follows:

CAUTION: Turn off power unit before attempting to connect

or disconnect hydraulic supply lines. Insure that
hoses are free of kinks and are run so that power
tong movement is not hindered.

1. Align the 1/2” female coupler on the hose running from the
lift cylinder to the male nipple located on the power tong
(Figure 2-7).
2. Pull back the sleeve on the female coupler while forcing the
two coupling halves together. Once the male nipple is fully
inserted, release the coupler sleeve. Sleeve should snap back
into original position thus locking the nipple in place. If not,
the coupling is not connected and additional force is needed
to insert the nipple. Shifting the control valve handles back
and forth may aid in the connection by equalizing hydraulic
pressure that may be trapped in the system. Continue forcing
the nipple into the female coupling until sleeve snaps back
into position.
3. Lift cylinder hose connection is now complete.

Once all hydraulic hoses have been connected. Start the power
unit and allow hydraulic fluid to travel through the tong controls
to purge any trapped air or debris.

CAUTION: All personnel should stand clear of the tong dur-

ing initial start-up of the power unit after con-
necting hydraulic hoses in case of leaks or sprays
due to improper connection of hoses. Hydraulic
fluid under pressure poses a risk of personal in-
jury.

The power tong and lift cylinder should then be briefly operated
under no load to complete purging operation. Afterward, turn off
power unit and proceed with leveling the tong to finish installa-
tion.

Leveling the Tong

Chain Bridle - Once the tong is suspended in position and the
previously stated installations and connections are complete (i.e.
tong heads, torque gauge, hydraulic lines), the tong should be
checked for level. Leveling the tong is required to insure the heads
grip the pipe correctly. To level the tong, place the unit above the

13
 well bore. Using a bubble level, check the tong level from front to
back. Adjust turnbuckles (Figure 2-8) if necessary. Any time the
turnbuckles are adjusted, check level both front to back and side
to side.
Solid Hanger - As with a power tong with chain bridle, a tong
equipped with solid hanger must be checked for level prior to
operation. With the tong over the well bore, first check the level
from front to back. Leveling screws (Figure 2-8) for front to back
adjustments are located on the hanger base on each side of the
tong. Next check the level side to side. Side to side adjustment is
accomplished by turning the balance screw located at the top of
the hanger.

TURNBUCKLE TURNBUCKLE BALANCE

SCREW

LEVELING
SCREW

LEVELING
SCREW
Figure 2-9
Leveling the Power Tong

14
Section 3: Operation
General Operation
Before operating the unit, you should become thoroughly famil-
iar with the operating controls and gauges; then, before initial
operation and daily thereafter you should preform the recom-
mended adjustments and operational checks.

Operating Controls and Gauges

Figure 3-1, 3-2.1 and 3-2.2 illustrates the operating controls and gauges.
For the functions of the controls and gauges refer to Table 3-1.1 and 3-
1.2.

Precautions to Observe
The following precautions should be observed to ensure safe op-
eration.
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 (A) (B) (C) (D)

After installation, you should check out the system to be sure that
any necessary adjustments are made and that the system is func- A. Tong control lever.
tioning correctly. Before attempting operation, verify that the B. Tri-Grip backup control lever.
C. Lift cylinder control lever.
following initial adjustments have been made. D. Speed shift lever.
Power Unit Output Pressure
Determine that the power unit output pressure has been properly Figure 3-1
adjusted. If you do not know, refer to the instruction manual on Tong Control Lever Locations
the power unit and perform the output pressure adjustment proce-
dure 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 deter-
mination. Refer to the Maintenance Section for adjustment of the
brake bands.

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.

15
Table 3-1.1
Operating Controls and Gauges - Tong Only

Control or Gauge Function

Backing Pin
In Make-Up Hole Allows tong to bite the pipe when operated clockwise for make-up.
In Breakout Hole Allows tong to bite the pipe when operated counter-clockwise for breakout.
Shifting Lever
Up Position Shifts tong gear train into high-speed (low torque) mode.
Center Position Neutral position. Motor and clutch shaft turns but rotary gear does not rotate.
Down Position Shifts tong gear train into low-speed (high torque) mode.
Tong Control Lever
Backing Pin in Make-Up Hole
Forward Position Tong rotates clockwise. Heads bite and pipe turns in make-up
(clockwise) direction.
Center Position Neutral position. Tong does not rotate. Hydraulic fluid circulates through
control valve and back to the power unit.
Back Position Tong rotates counter-clockwise. Heads release. Rotary gear and
cageplate openings align. Continued operation aligns openings with door
opening in tong case.
Backing Pin in Break-Out Hole
Back Position Tong rotates counter-clockwise. Heads bite and pipe turns in break-out
(counter-clockwise) direction.
Center Position Neutral position. Tong does not rotate. Hydraulic fluid circulates through
control valve and back to the power unit.
Forward Position Tong rotates clockwise. Heads release. Rotary gear and cage plate openings
align. Continued operation aligns openings with door opening in tong case.
Lift Control Lever
Forward Position Operates lift cylinder to lower tong.
Back Position Operates lift cylinder to raise tong.
Manual Relief Valve Allows the operator to set maximum hydraulic pressure. Hydraulic
pressure determines tong torque output.
Torque Gauge Indicates tong torque output.

TORQUE
GAUGE

SHIFTING
MAKE-UP LEVER

BREAK-OUT LIFT
CONTROL

TONG
CONTROL
LEVER
MANUAL
BACKING PIN
RELIEF
VALVE
Figure 3-2.1
Operating Controls and Gauges - Tong Only

16
Table 3-1.2
Operating Controls and Gauges - Tong with Backup

Control or Gauge Function

Backing Pin
In Make-Up Hole Allows tong to bite the pipe when operated clockwise for make-up.
In Breakout Hole Allows tong to bite the pipe when operated counter-clockwise
for breakout.
Shifting Lever
Up Position Shifts tong gear train into high-speed (low torque) mode.
Center Position Neutral position. Motor and clutch shaft turns but rotary gear does
not rotate.
Down Position Shifts tong gear train into low-speed (high torque) mode.
Tong Control Lever
Backing Pin in Make-Up Hole
Forward Position Tong rotates clockwise. Heads bite and pipe turns in make-up
(clockwise) direction.
Center Position Neutral position. Tong does not rotate. Hydraulic fluid circulates through
control valve and back to the power unit.
Back Position Tong rotates counter-clockwise. Heads release. Rotary gear and
cageplate openings align. Continued operation aligns openings with door
opening in tong case.
Backing Pin in Break-Out Hole
Back Position Tong rotates counter-clockwise. Heads bite and pipe turns in break-out
(counter-clockwise) direction.
Center Position Neutral position. Tong does not rotate. Hydraulic fluid circulates through
control valve and back to the power unit.
Forward Position Tong rotates clockwise. Heads release. Rotary gear and cage plate
openings align. Continued operation aligns openings with door opening in
tong case.
Backup Control Lever
Forward Position Backup grips pipe.
Back Direction Backup releases pipe.
Lift Control Lever
Forward Position Operates lift cylinder to lower tong.
Back Position Operates lift cylinder to raise tong.
Manual Relief Valve Allows the operator to set maximum hydraulic pressure. Hydraulic
pressure determines tong torque output.
Torque Gauge Indicates tong torque output.

17
 TORQUE
GAUGE
MAKE-UP
BREAK-OUT
LIFT
CONTROL

BACKING PIN

SHIFTING
LEVER

BACKUP
CONTROL
LEVER

TONG
CONTROL
MANUAL LEVER
RELIEF
VALVE

Figure 3-2.2
Operating Controls and Gauges - Power Tong with Backup

18
WARNING: Before operating tong, verify the handle locations
below apply to your specific tong. Inadequate pre-
operational check of tong could result in injury.

The tong should be snubbed for both make-up or

break-out operation at all times, by utilizing two
snub lines. If this is not done, the tong may be
thrown against operator causing physical harm.
In the following steps A-D in parenthesis refer to handle locations
identified in Figure 3-1.
1. Close and latch safety door.
2. Place backing pin in left-hand hole and verrify tong is snubbed
for both make-up and break-out operations.

WARNING: We recommend the following wire rope snub line

for minimum safety requirements:
7-5/8 Standard ........................... 5/8" Diameter
IPS Grade, 6 x37 Class, 6 x 36 IWRC Construction.
3. Start power unit and allow hydraulic oil to come up to oper-
ating temperature.
4. Move shifting lever (D) to high-speed (up) and push tong
control lever (A) forward and verify that heads bite and cage
plates turn at high speed.
5. Return control lever to neutral and move the shifting lever to
the low speed position (down).
6. Push tong control lever (A) forward and verify that heads bite
and cage plates turn at low speed.
7. Return control lever to neutral.
8. Use tong control lever to operate tong so that cage plates and
rotary gear openings are aligned with the throat openings.
9. Place backing pin in right-hand (break-out position) hole
and verify tong is snubbed for both break-out and make-up
operations. Repeat steps 4 through 7 to check break-out op-
eration.

NOTE: If the heads fail to bite, the brake bands probably

need adjustment. Adjust the bands as described
in the topic on Initial Adjustments in the Mainte-
nance Section.
10. If lift cylinder option is installed, pull lift cylinder control
lever (C) back and verify that cylinder operates to lift tong.
11. Push lift cylinder control lever (C) forward and verify the
cylinder lowers the tong.
12. If a hydraulic backup is installed, operate control lever (B)
forward and verify backup heads bite.
13. Pull lever (B) to release heads. Return to neutral.

19
Typical Operating Sequence
Typical operation of the tong is described in the following proce-
dures.

Initial Operations
After the tong is transported to job site, hoisted into operating
position, snubbed, leveled, and connected with power unit as de-
scribed in Installation Section, proceed as follows.
1. Be sure shifting lever and control lever(s) are in neutral posi-
tion.
2. Start hydraulic power unit.
3. Perform a pre-operational check and make any required ad-
justments before operation.
4. Place backing pin in make-up hole for make-up operation or
in break-out hole for break-out operation (See Figure 3-2.1
and 3-2.2.)

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 fol-
lows:
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 (C) on the tong to position tong.
2. Place tong on pipe section positioned for make-up or break-
out.
3. Close and latch throat safety door, then perform operation as
described in next topic.
4. After operation, open front safety door, remove tong from
pipe, 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 cables or equipment
other than tubing are enclosed in throat.
Make-up Operation
Refer to Figure 3-1, 3-2.1 and 3-2.2 for control lever locations.
1. Verify tong is snubbed for both make-up and break-out op-
erations
2. Place backing pin in make-up (left hole) position (Figure 3-2.1
or 3-2.2).
3. 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 shift lever (D).
4. Position the tong on the pipe. The tong unit may be raised or
lowered by operating the lift cylinder control (C). Pushing in

20
 on the lever lowers the tong while pulling out on the lever raises
the tong. After positioning, close and latch the safety door.
5. If hydraulic backup is installed, push the backup control le-
ver (B) forward to engage the backup heads.
6. Grip the pipe with the power tong heads and begin rotation
by pushing forward the tong control lever (A).
7. After insuring a good start on the threads, pull the shifting lever
(D) up to high speed and continue the make-up operation.

NOTE: When using the shift lever (D) to change speeds,

the power tong must first come to a complete stop
before shifting.
8. Once tong stalls, shift to low speed - high torque mode and
continue torquing operation while observing the torque gauge
reading.
9. 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.
10. To release the pipe and align the door openings, pull back on
tong control lever (A). When the openings are aligned, re-
lease the control lever.
11. If hydraulic backup is installed, pull the backup control lever
(B) to release the backup heads.
12. Open the safety door. Remove the tong from the made-up
joint and close the safety door.
13. Reposition the pipe and repeat the operation.
Break-out Operation
Refer to Figure 3-1 for control lever locations.
1. Verify tong is snubbed for both make-up and break-out op-
erations.
2. Place the backing pin in break-out (right hole) position (Fig-
ure 3-2.1 or 3-2.2).
3. 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. Shift to low
speed mode by pushing down on shift lever (D).
4. 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.
5. If hydraulic backup is installed, push the backup control le-
ver (B) forward to engage the backup heads.
6. Grip the pipe with the power tong heads and begin rotation
by pulling back on the tong control lever (A).
7. After breaking the connection and when torque requirements
have fallen off, shift the tong into high speed, by pulling up
on the speed shift lever (D).

NOTE: When using the shift lever (D) to change speeds,

the power tong must first come to a complete stop
before shifting.

21
 8. 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. 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.
10. If hydraulic backup is installed, pull the backup control lever
(B) to release the backup heads.
11. Open the safety door. Remove the tong from the broken-apart
joint and close the safety door.
12. Reposition the pipe and repeat the operation.

22
Section 4: Servicing
Servicing the tong consists of inspection, lubrication, tests and CAGE PLATE
adjustments. Should servicing reveal requirements for repairs, BOLTS
refer to the appropriate portions of Sections 5 and 6.
DIES
Daily Inspection
Figure 4-1.1 and 4-1.2 illustrates the points that should be in-
spected 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 re-
moval and replacement of any faulty parts.
INSPECTION
Brake Band Inspection DOOR
Inspect the brake bands to be sure that each band is intact and not
BRAKE BANDS
excessively worn. If a brake band begins to wear into the rivets,
ADJUSTMENT
the band should be replaced.

Check Head Dies

Inspect head dies to be sure that biting edge is not worn exces- Figure 4-1.1
sively and is capable of biting effectively. Change the dies if Tong Inspection Points
required.

Tighten Bolts
Tighten three cage plate bolts.

Inspect Head Rollers

Inspect head rollers to be sure they turn freely. Lubricate as out-
lined under Head Roller Lubrication procedure.

Lift and Snub Lines

Lines used for suspending the tong as well as snub lines should be DIES
inspected each day for any signs of wear or damage. These lines
should be replaced on a periodic basis even though they may pass
a visual inspection since fatigue may not be evident. It is highly
recommended that the manufacturer supplying the lines and the
power tong user jointly establish an inspection and replacement
schedule.

Warning: Lift lines and snub lines should be inspected by

qualified personnel prior to tong installation and
daily operation. Failure to do so may result in
injury or death.

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 (Tong Only).
2. Check cam follower rollers for wear or breakage, and replace Figure 4-1.2
if necessary & lube (Tong Only). Backup Inspection Points

23
 3. Clean heads of foreign debris and grease heavily (Tong and
Backup).
4. Check grease in tong case, repack if necessary (Tong Only).

Motor Maintenance
Since the motor is self-lubricating, preventative maintenance is
limited to keeping the system clean by changing hydraulic sys-
tem 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 and hydraulic backup.

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 and backup (if installed) 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 connec-
tion is separated. However, should hydraulic fluid be lost from
the unit due to leaks or during maintenance, you should recharge
the tong and backup 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 4-2.1 and 4-2.2 shows the lubrica-
tion points and Table 4-1 gives information on the type of grease
to be used.

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 on the tong.

Head Rollers
Lubricate head rollers as follows for 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 4-2.1 and Table 4-1,
and proceed as follows.

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.

24
Table 4-1
Greasing Points and Lubricants, Figure 4-2
3
Tong Lubrication Intervals and Lubrication Points, Figure 4-2.1
8
Ref. Lubricant* Part/Location Description No. of Points Intervals †
1 A Back of Cage Plates, Tong Case Pack C
2 A Inspection Door, Tong Case Pack C
3 B Top Cam Followers 11 D
4 B Top, Dumbbell Roller Shaft 8 D
5 B Clutch Shaft 1 D
6 B Shifting Shaft 1 D 6
7 B Idler Shafts 3 D 4 2
8 B Motor Box 1 D
9 B Bottom, Dumbbell Roller Shaft 8 D 10 Top View
12
10 A Brake Lining, Top Brake Band 1 C 7
11 A Brake Lining, Bottom Brake Band 1 C
12 A Bottom Cam Followers 8 D
* B Head Roller Pin (Not Shown) 2 C,D

Backup Lubrication Intervals and Lubrication Points, Figure 4-2.2

Ref. Lubricant* Part/Location Description No. of Points Intervals †
9
1 B Pivot Pin 2 C,D 5
2 B Head Pin 3 C,D Bottom View
11
3 B Front Clevis Pin 2 C,D
4 B Rear Clevis Pin 2 C,D Figure 4-2.1
Tong Grease Points
Recommended Lubricants Descriptions
* A Gear Grease NLGI Grade 3 - Heavy Duty
Wheel Bearing Grease
MISTIK JT-6
* B Bearing Grease NLGI Grade 2 - Extreme
Pressure Heavy Duty Lubricant
ARCO LITHOLENE HEP-2
Grease Intervals
† C After Each Job
† D Daily On Job
Specifications listed are for average conditions. For applications involving 3
extreme heat and cold, consult Eckel for recommendations. 1
2 4
1. With power unit connected and operating, rotate the rotary
gear and cage plates so that opening is turned to back of tong,
Figure 4-2.1.
2. Disable tong by both of the following methods.

WARNING: Keep hands out of the head and door area while
5
the power unit is operating.
a. Disconnect power from the power unit's electrical motor
or turn off diesel engine as applicable.
b. Disconnect hydraulic pressure line (1-inch line) from tong 4
at hose connector. 2
3. Remove cover from inspection door. 1 3 Top View
4. Pack the unit with specified gear grease (see Table 4-1) as
follows: Figure 4-2.2
Backup Grease Points

25
 a. Apply grease liberally through opening at back of cage CLUTCH
plates. RELIEF
b. Apply grease liberally through inspection door to gear. VALVE

WARNING: Failure to disable hydraulic system after operat-

ing tong could result in serious personnel injury. BRAKE BAND
ADJUSTING NUTS
c. Operate tong to distribute grease, then disable hydraulic
(UPPER)
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 SHIFTING

At the beginning of a job and at the start of each shift thereafter, DETENT
perform the brake band test and brake band adjustment as re-
quired.
BRAKE BAND
Brake Band Test
ADJUSTING NUTS
Check each brake band adjustment according to the following (TWO UNDERNEATH)
steps.
1. Place backing pin in Make-up position.
2. Operate the tong several times and verify that the heads bite Figure 4-4
at each operation. Tong Adjustment Points
3. Place backing pin in Break-out position.
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 adjust-
ment, then adjust the brake bands according to the steps given
below. Refer to Figure 4-4 for the adjustment points.
1. Turn each of four brake band adjusting nuts one-fourth turn.
2. Check brake operation as in preceding topic.
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 se-
lected 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.

26
 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 4-4 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 hold-
ing adjusting bolt at setting obtained in step 2.
5. If additional adjustment is indicated, repeat steps 1 and 3
until proper operation is achieved.

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 de-
sired (up to the maximum torque of the tong). Refer to Figure 4-4
for the adjustment point.

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 in-
stalled so that it can not turn.
3. Be sure the torque gauge is correctly installed and is in proper
operation.
4. Back off relief valve to minimum torque setting.

NOTE: Adjustment is extremely difficult to turn when pres-

sure is applied.
5. Incrementally adjust relief valve, then apply pressure and
read torque value. Continue until desired maximum torque
value is obtained.

27
28
Section 5: Troubleshooting, Repair, and
Overhaul
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
Head roller & pin dry of
grease
Undersized Pipe
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
TONG HANGS UP UNDER Excessively worn or
LIGHT LOAD broken cam follower or idler
bearing
TONG ROTATES WHEN Striper bolt is loose, handle
CONTROL LEVER IS IN NEUTRAL will not return to neutral or
Faulty control valve
MOTOR LEAKING Faulty shaft seal
OIL COMING FROM MOTOR Blown shaft seal
CHRONIC SEAL PROBLEM Plugged case drain or plugged
return line
Worn shaft
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.
Grease per lubrication procedure.
Install oversize rollers (1/16" OD Larger)
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 cam follower or idler
bearing.
Tighten stripper bolt (Fig. 6-7, Item 16)
or Replace control valve.
Replace motor seal.
Replace motor seal.
Disconnect end of case drain
connected to valve and clear line.
Replace Motor Shaft
29
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.

Disassebmly
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 fig-
ures in the illustrated parts list; however, procedures for perform-
ing 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 re-
placing the parts in the reverse order of disassembly, by perform-
ing the service outlined in Section 4. However, certain proce-
dures for performing reassembly after service or during replace-
ment of certain worn parts are presented in the following topic.

Parts Replacement
In general, parts replacement consists of disassembly as neces-
sary to obtain access to the part to be replaced. However, replace-
ment 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 (24) for the top brake band (23).
2. Remove adjusting nuts (20) and bolts (22).
3. Remove brake band (23). Refer to parts list, item 22 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
(22) and adjusting nuts (20) through brake band lugs (21).
6. Tighten the adjusting nuts snug but not too tight.
7. Replace brake band retainer (24).
8. Remove brake band retainer (24) from bottom brake (23).
9. Repeat steps 2 through 7 for bottom band.
10. Adjust both brake bands in accordance with brake band ad-
justment procedure under Tests and Adjustments.

30
 Cage Plate Removal and Replacement
Cleaning and service requires the periodic removal and replace-
ment of the top and bottom cage plates. To remove and replace
these plates, proceed according to the following steps. The num-
bers in parenthesis refer to item numbers in Figure 6-1.

WARNING: Keep hands out of the head cage area while the
power unit is operating.
1. Remove heads as described in Section 2.
2. Loosen brake bands as necessary to free two cage plates (1)
and (2).

WARNING: Bottom cage plate should be supported to pre-

vent it from dropping or falling when the cage
plate bolts are removed.
3. Remove three cage plate bolts (3).
4. Remove top cage plate (1).
5. Remove bottom cage plate, taking care not to damage three
cage plate spacers (4).
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.

Series 15 Motor Overhaul

Manufacturer suggest returning the motor for repair. Contact Eckel
for motor overhaul manual. If you decided to disassemble the
motor note the following warning statement.

WARNING: The vanes are held against the cam ring by ten-
sion from the springs in the rotor. If the rotor is
pulled from the cam ring with no protection, ten-
sion from the springs will throw the vanes out in
all directions.

A35 Valve Overhaul

Remove the valve bank from the equipment and thoroughly clean
its exterior surface before beginning disassembly. Mark each sec-
tion 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
Refer to A35 Exploded View drawing (Figure 6-13).
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

31
 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 (5,4,3) will gen-
erally come out with the spool.

CAUTION: For detented spool models, be careful not to re-

move the detent poppet sleeve (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 neces-
sary to remove the spring, place the spool in a soft-jawed vise
and remove the stripper bolt with a wrench.

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 assem-
bly.
7. Remove items (9,15,8) 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: 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 be-
fore beginning reassembly.
Assembly:
1. Clamp the spool in a soft-jawed vise. Apply a small amount
of Loctite™ 262 or equivalent anaerobic adhesive to the strip-
per bolt (16) before assembly.

NOTE: Follow the adhesive manufacturer's instructions

for proper curing. Assemble the spring (15), spring
guide (14) and stripper bolt (16) on the spool.
The detent poppet retainer (6) is assembled in simi-
lar 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 6-6. In-
stall the spool seal (3) into the groove at the clevis end of the
valve body. Carefully insert the spool guides should be

32
 lightly coated with a high temperature grease to prevent rust-
ing. 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.

33
34
Section 6: Parts List
Table 6-1
7-5/8 Standard Exploded View, Figure 6-1
REF 7-5/8” Standard Tong 1
1 108996 Top Cage Plate 1
2 108997 Bottom Cage Plate 1
3 101570 1/2” NC x 6” Hex Head Bolt 2
4 100445 Cage Plate Spacer 3
5 100432 Head Pivot Bolt 2
6 103475 Top Tong Plate 1
7 101539 3/8” NC x 1-1/4” Hex Head Bolt 43
8 100089 Backing Pin 1
9 100450 Backing Pin Retainer 1
10 100088 Back Cage Bolt 1
11 101537 3/8” NC x 3/4” Hex Head Bolt 1
12 101699 3/8” Lock Washer 1
13 101698 3/8” Flat Washer 1
14 100563 Door Spring Plunger 1
15 101095 Spring For Door Spring Assembly 1
16 100545 Door Spring Sleeve 1
17 100566 Door Spring Bushing 2
18 102701 Door Plunger Mount 2
19 101538 3/8” NC x 1” Hex Head Bolt 2
20 101741 3/8” NF Full Lock Nut 4
21 100437 Brake Band Lug 4
22 101543 3/8” NF x 1-3/4” Hex Head Bolt 4
23 108994 Brake Band 2
24 100439 Brake Band Retainer 4
25 101764 7/8” NF Thin Lock Nut 20
26 101183 1/4-28 Grease Zert 20
27 101643 3/8” NC x 1-1/4” Flat Socket Head Bolt 15
28 101789 Cam Follower - Torrington CF 1-1/2” SB 22
29 101714 Cam Follower Washer – 5/8” Lock Washer 22
30 101753 Cam Follower Nut – 5/8” NF Jam Nut 22
31 100404 Rotary Gear 1
32 100410 Backing Lug 1
33 101640 3/8” NC x 1” Socket Head Bolt 1
34 103476 Bottom Tong Plate 1
35 100513 Door Shaft 1
36 100542 Door Bearing Spacer 4
37 102404 Door Ear 2
38 101809 Door Bearing, 1-Z99414 2
39 100543 Door Washer 2
40 114881 Tong Door 1
41 103361 Door Latch 1
42 100626 Door Latch Pin 1
43 102796 Latch Spring 1
44 103067 3/16” x 2-1/2” Spring Pin 1
45 103068 5/32” x 1” Spring Pin 1
46 106858 Latch Handle 1
47 103767 Door Latch Lug 2
48 103892 Door Hook 2
49 106859 Door Handle 1
50 103749 Door Stop 2
51 REF Dumbbell Roller Assembly (Figure 6-2) 8
52 REF Rotary Idler Assembly (Figure 6-3) 2
53 REF Pinion Idler Assembly (Figure 6-4) 2
54 REF Pinion Assembly (Figure 6-5) 1
55 REF Clutch Assembly (Figure 6-6) 1

35
 26

25

24

23

20 22
11
12
10 13
64 9
62 8
65
63
3 5

82
81

1
80
4 28 79
93
7
78
61

6
76

29 30
21 77 66
90 91 50 27
55 74
89 54
92 33 84 56 75
88 32
52
83 73
85 57
70 71
68 59
51 72
60
69 58
53
86
47
42 26
25
45 39 31
48 36 36
41 7 67
38
46 37 34 87
19
35 27
16 17
44
36
40 14 18
94 38 15
43
36
39
25
49 26 2

Figure 6-1
7-5/8 Standard Exploded View

36
Table 6-1
7-5/8 Standard Exploded View, Figure 6-1
56 REF Shifting Shaft Assembly (Figure 6-7) 1
57 112030 Motor Gear 1
58 101555 1/2” NC x 3/4” Hex Head Bolt 1
59 101707 1/2” Flat washer 1
60 101708 1/2” Lock washer 1
61 104326 Torque Gauge Stand 1
62 100564 Torque Gauge Plate 1
63 112046A Torque Gauge, 0 – 25,000, 36” Handle, US/Metric Scale 1
109293A Torque Gauge, 0 – 25,000, 36” Handle, US Scale 1
64 101555 1/2” NC x 3/4” Hex Head Bolt 1
65 101524 1/4” NC x 3/4” Hex Head Bolt 3
66 118033 Hydraulic Motor, Rineer GA9.5-15 Series with Splined Shaft 1
67 100525 Motor Box 1
68 101661 1/2” NC x 2” Socket Head Bolt 4
69 101709 1/2” High Collar Lock Washer 4
70 106338 Motor Port Flange 1-1/4” NPT x 90 Degrees 2
71 101652 7/16” NC 1-3/4” Socket Head Bolt 8
(Part of Motor Port Flange Package Part No. 106338)
72 101706 7/16” Hi-Collar Lock washer 8
(Part of Motor Port Flange Package Part No. 106338)
73 103680 O-Ring (Part of Motor Port Flange Package Part No. 106338) 2
74 101558 1/2” NC x 1-1/4” Hex Head Bolt 4
75 101708 1/2” Lock Washer 4
76 101876 Control Valve, One Lever (Tong Only) 1
101878 Control Valve, Two Lever (Tong with Lift) 1
110170 Control Valve Three Lever (Tong with Lift and Backup) 1
77 100548 Control Valve Stand 2
78 101568 1/2” NC x 4” Hex Head Bolt 2
79 101041 1-1/4” Male Coupling – Aeroquip 5100-S2-20 1
80 101076 1-1/4” Dust Cap – Aeroquip 5100-32-20S 1
81 101038 1” Male Coupling – Aeroquip 5100-S2-16 1
82 101075 1” Dust Cap – Aeroquip 5100-32-16S 1
83 100529 Side Hanger 2
84 100526 Tong Body 1
85 114298 Clutch Door 1
86 101621 1/4” NC x 1” Socket Head Bolt 2
87 100533 Tong Leg 3
88 100823 “J” 2-1/16” Pivot Heads 2
100824 “J” 2-3/8” Pivot Heads 2
100825 “J” 2-7/8” Pivot Heads 2
100827 “J” 3-1/2” Pivot Heads 2
100828 “J” 4” Pivot Heads 2
100830 “J” 4-1/2” Pivot Heads 2
100832 “J” 5” Pivot Heads 2
100833 “J” 5-1/2” Pivot Heads 2
102733 “J” 6” Pivot Heads 2
100834 “J” 6-5/8” Pivot Heads 2
100835 “J” 7” Pivot Heads 2
100836 “J” 7-5/8” Pivot Heads 2
89 100931 Head Roller 1/Head
90 100399 Head Roller Pin 1/Head
91 101251 Rig Dies 2/Head
101243 2-1/16 Contour Die 2/Head
101245 2-3/8 Contour Die 2/Head
101247 2-7/8 Contour Die 2/Head
101249 3-1/2 Contour Die 2/Head
92 103350 Spring Pin 2/Head
93 106851 3/4” Pipe Plug 2
94 101185 1/8 NPT Grease Zert 1

37
Table 6-2
Dumbbell Roller Assembly, Figure 6-2
REF Dumbbell Roller Assembly 10
1 112150 Dumbbell Roller 1
2 100550 Bronze Bushing 2
3 100507 Shaft, Dumbbell Roller 1
1005113 Shaft, Dumbbell Door Roller 1
4 101764 Lock Nut, Thin Height, 7/8” NF 2
5 101183 Grease Zert, 1/4” – 28NF 2

2
4
5
Figure 6-2
Dumbbell Roller Assembly

38
Table 6-3
Parts List, Rotary Idler Assembly – Figure 6-3
REF Rotary Idler Assembly 2
1 101772 Rotary Idler Nut 2
2 101726 Rotary Idler Lock Washer 2
3 100505 Rotary Idler Pad 2
4 100504 Rotary Idler Gear Spacer 2
5 101145 Bearing Seal 2
6 101099 Bearing Retainer Ring 2
7 101805 Idler Gear Bearing 1
8 100492 Rotary Idler Gear 1
9 101185 Rotary Idler Grease Zert 1
10 100498 Rotary Idler Shaft 1

1
2
10
3
TOP TONG
PLATE
6

4 5
5
4
6 BOTTOM TONG
PLATE
7 3
2
8
1

Figure 6-3
Rotary Idler Assembly, Exploded View

39
Table 6-4
Pinion Idler Assembly, Figure 6-4
REF Pinion Idler Assembly 1
1 101185 Pinion Idler Grease Zert 1
2 101772 Pinion Idler Shaft Nut 1
3 101726 Idler Shaft Lock Washer 1
4 101583 Idler Pad Bolt 3
5 101714 Idler Pad 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 Idler Gear 1
12 101103 Idler Shaft Snap Ring 1

12

11

10

Bottom Tong Plate

3
5
2
4
Figure 6-4
Pinion Idler Assembly 1

40
Table 6-5
Pinion Assembly, Figure 6-5
REF Pinion Assembly 1
1 101588 Bearing Cap Bolt 8
2 101708 Bearing Cap Lock Washer 8
3 101061 Bearing Cap Pipe Plug 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
9 109819 Pipe Plug, 3/8 NPT 2

1 9
2 3

5
TOP TONG
PLATE

BOTTOM TONG
PLATE

4
Figure 6-5
Pinion Assembly

41
Table 6-6
Clutch Assembly, Figure 6-6
REF Clutch Assembly 1
1 100468 Clutch Drive Gear 1
2 100466 Top Clutch Bearing Bushing 1
3 101799 Top Clutch Shaft Bearing 1
4 100464 Top Cluch Shaft Bearing Retainer 1
5 100460 Low Clutch Gear 1
6 101792 Clutch Gear Needle Bearing 4
7 100454 Clutch Shaft 1
8 100470 Shifting Collar 1
9 100458 High 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" 4
13 101539 Bearing Cap Bolt, 3/8" NC x 1-1/4" HH 4
14 101061 Bearing Cap Pipe Plug, 1/8" NPT 2
15 101185 Bearing Cap Grease Zert, 1/8" NPT 1

8
2
6
3

9
4
TOP TONG
PLATE

5 10 BOTTOM TONG
PLATE

6 11

7 12

14 13

15

Figure 6-6
Clutch Assembly

42
Table 6-7
Shifting Shaft Assembly, Figure 6-7
REF Shifting Assembly 1
1 100473 Shifting Shaft 1
2 100478 Pivot Arm 1
3 101534 5/16 NF x 1-1/4 Hex Head Bolt 3
4 101734 5/16 NF Locknut 3
5 101172 Shifting Shaft Connecting Link 2
6 100476 Shifting Handle 1
7 101091 Shifting Ball 1
8 101090 Shifting Spring 1
9 101744 7/16 NF Jam Nut 1
10 101551 7/16 NF x 1-1/4 Hex Head Bolt 1
11 100472 Shifting Yoke 1
12 101753 5/8 NF Jam Nut 1
13 101714 5/8 Lockwasher 1
14 101756 5/8 NF Locknut 1
15 101185 Grease Zert 1/8 NPT 2

2
3 4
5
6 4
1

15

7
12 8
13 9

10

11

Figure 6-7 14
Shifting Shaft Assembly

43
Table 6-8
Tong Hanger: Chain Bridle Assembly, Figure 6-8
REF Tong Hanger: Chain Bridle Assembly 1
1 116953 Bridle Assembly 1
2 100530 Side Hanger 2
3 111836 Back Hanger 1
4 111173 Back Hanger Support 1

The following Items are included in 116764 Bridle Assembly

5 100421 Bridle Ring 1
6 116608 Connecting Link, 3/8” 6
7 116620 Turnbuckle 3
8 116607 Connecting Link, 1/4” 6
9 101215 Chain, 1/4”, 9 Links 1
10 101215 Chain, 1/4”, 11 Links 2
11 101168 Clevis 3

6
1 3
7
4
6
2
8
9
10
10
8
8
8
11

11 11 2

Figure 6-8
Tong Hanger: Chain Bridle Assembly

44
Table 6-9
Tong Hanger: Solic Hanger Assembly, Figure 6-9
REF Tong Hanger: Solid Hanger Assembly 1
1 113766 Solid Hanger 1
2 108503 Pivot Base 2
3 101682 Bolt, Socket Head, 5/8” NC x 4-1/2” 8
4 101715 Lockwasher, 5/8” Hi-Collar 8
5 111987 Bolt, Hex Head, 5/8” NC x 2-1/4” 4
6 101754 Jam Nut, 5/8” NC 4
7 108515 Base Pin 2
8 109252 Balance Screw 1
9 108516 Balance Screw Pin 1
10 109292 Master Link 1
11 109287 Hitch Pin Clip 6

8 10

1 9

11

11
6 3
5

11
2

Figure 6-9
Tong Hanger: Solid Hanger Assembly

45
Table 6-10
Parts List, Tong Suspension – Figure 6-10
REF Tong Suspension 1
1 100721 Spring Hanger Assembly, Single (Tong Only) 1
100722 Spring Hanger Assembly, Double (Tong with Backup) 1
2 105655 Valve, Pilot Operated Check 1
3 101042 Coupling Half, 1/2” Male 1
4 101947 Valve Section, Lift Cylinder Control 1

The following Items are included in 103201 Lift Cylinder Assembly

5 101985 Cylinder, Hydraulic, 3-1/4” x 72” 1

6 116951 Vent Plug 1
7 107072 Orifice 1
8 102373 Hose Assembly, Lift Cylinder 1
9 101241 Anchor Shackle 2
10 101043 Coupling Half, 1/2” Female 2
11 101042 Coupling Half, 1/2” Male 1
12 112222 Rod Clevis, Hydraulic Cylinder 1
13 112221 Clevis Pin, Hydraulic Cylinder 1

13 12
7
11

10
5

8
2,3

Figure 6-10
Tong Suspension

46
Table 6-11
Door Interlock System, Figure 6-11.1 and 11.2
1 115568 Cam Valve 1
2 112675 Mounting Plate, Cam Valve 1
3 112696 Bolt, Hex Head, 1/4” NC x 2-1/2” 4
4 101693 Flat Washer, 1/4” 8
5 101729 Locknut, 1/4” NC 4
6 113014 Angle Bracket, Right Hand 2
7 101539 Bolt, Hex Head, 3/8” NC x 1-1/4” 2
8 101698 Flat Washer, 3/8” 2
9 101699 Lockwasher, 3/8” 2
10 101735 Hex Nut, 3/8” NC 2
11 115795 Mount, Door Cam 1
12 115619 Door Cam, Sleeve Type 1
13 110137 Set Screw, Socket Head, 1/4” NF x 1/4” 4
14 115620 Door Washer 1
15 106882 Relief Valve 1
16 114638 Check Valve 1

16

17

Figure 6-11.1
Door Interlock Schematic

47
 13
11

12
14
9

7
8
10

1
6

3
5
4

16
15

Figure 6-11.2
Door Interlock System

48
Table 6-12
Parts List, Series 15 Motor Assembly – Figure 6-12
REF Hydraulic Motor - Splined Shaft 1
1 015-0111 Seal Plate Snap Ring 1
2 015-0112 Dust Seal 1
3 015-0113 Seal Plate Quad Ring 1
4 015-0110 Seal Plate 1
5 015-0114 Seal Plate O-Ring 1
6 015-0730 Snap Ring, Bearing 1
7 015-0779 Ball Bearing, HD 1
8 015-0780 Shaft, Splined 1
015-1719 Shaft, Keyed 1
9 015-0901 Bolt, Main 4
10 015-0102 Front Housing, Internal 1
11 015-0428 Dowel Pins, Front 2
12 015-0610 O-Ring, Main 4
13 015-0902 Ball Check 4
14 015-0600 Plate Screw 4
15 015-0402 Plate Timing 2
16 015-0403 Stator, GA 9.5 1
17 015-0300 Rotor 1
18 015-0313 Rotor Vane 10
19 015-0320 Rotor Vane Spring, Outer 20
20 015-0321 Rotor Vane Spring, Inner 20
21 015-0410 Stator Vane 4
22 015-0420 Stator Vane Spring 8
23 015-0429 Dowel Pin, Rear 2
24 015-0720 Needle Bearing 1
25 015-0800 Rear Housing 1

49
Figure 6-12
Series 15 Motor Assembly, Exploded View

50
Table 6-13
Parts List, A35 Valve Assembly – Figure 6-13
REF 101876 A35 Control Valve
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
6 391-2583-006 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
17 391-2481-003 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

51
 tral
Neu
n to
e tur roup 11
R G
r i ng ap
p C
a l S End 14
pi c
Ty
on 10
e cti ) 16
S 8
n l et A12 15
I (C 1 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 e
alv 53)
o
V
y MA 3 17
wb ing ( 18
o 2
L us 12 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 6-13
A35 Valve Assembly

52
Table 6-14
A35 Control Valve Handle, Figure 6-14
REF A35 Control Valve Handle 1
1 101944 Handle, A35 Control Valve 1

The following items are included with Control Valve Handle 101944
2 101953 Knob, Valve Handle 1
3 101945 Link, Valve Handle 1

Figure 6-14
A35 Control Valve Handle

53
Table 6-15
Parts List, 7-5/8 Standard Hydraulic Tri-Grip Backup – Figure 6-15.1 through 6-15.3
1 113262 Backup Plate Assembly 1
2 113292 Pivot Arm Assembly 2
3 112544 Pivot Pin 2
4 112570 Head Pivot Pin 3
5 103760 Cotter Pin, 5/32” x 2” 5
6 115628 Clevis Pin, 1” 2
7 112794 Cylinder, Hydraulic, 3-1/4” Bore x 4-1/2” Stroke w/ Clevis Pin 2
8 112515 Rod Eye, Cylinder 2
9 113295 Mounting Plate, Load Cell Bracket 1
10 101684 Bolt, Socket Head, 3/4” NC x 2” 8
11 101719 Lockwasher, 3/4” Hi-collar 8
12 113268 Load Cell Bracket 2
13 107910 Load Cell Bracket Cap 1
14 101583 Bolt, Hex Head, 5/8” NC x 2” 4
15 101714 Lockwasher, 5/8” 4
16 113301 Front Hanger Leg Assembly, Left Hand 1
17 113302 Front Hanger Leg Assembly, Right Hand 1
18 101601 Bolt, Hex Head, 3/4” NC x 4” 8
19 101719 Lockwasher, 3/4” 8
20 112221 Clevis Pin 2
21 113398 Rear Spring Assembly 3
22 101606 Bolt, Hex Head, 3/4” NC x 7” 2
23 101760 Locknut, 3/4” NC Full Height 2
24 101090 Compression Spring 2
25 104375 Flow Divider, 1/2” 1
26 105655 Pilot Operated Check Valve, 1/2” 1
27 113054 “ZTB” Head For Wrap-Around Die 2-1/16” Thru 4” 3
28 113055 “ZTB” Head For Wrap-Around Die 4-1/16” Thru 5-9/16” 3
29 113056 “ZTB” Head For Wrap-Around Die 5-5/8” Thru 7-5/8” 3
30 113057 “ZTB” Head For Wrap-Around Die 7-3/4” Thru 8-5/8” 3
31 112159 Die Retainer Screw 2/Head
32 113239 “ZTB” 2-3/8” Wrap-Around Die Coarse Tooth 3
33 113240 “ZTB” 2-7/8” Wrap-Around Die Coarse Tooth 3
34 113241 “ZTB” 3-1/2” Wrap-Around Die Coarse Tooth 3
35 113306 “ZTB” 3-3/4” Wrap-Around Die Coarse Tooth 3
36 113242 “ZTB” 4” Wrap-Around Die Coarse Tooth 3
37 113243 “ZTB” 4-1/2” Wrap-Around Die Coarse Tooth 3
38 113244 “ZTB” 5” Wrap-Around Die Coarse Tooth 3
39 113245 “ZTB” 5-1/2” Wrap-Around Die Coarse Tooth 3
40 107577 “Z” 6-5/8” Wrap-Around Die Coarse Tooth 3
41 107581 “Z” 7” Wrap-Around Die Coarse Tooth 3
42 107578 “Z” 7-5/8” Wrap-Around Die Coarse Tooth 3
43 107579 “Z” 8-5/8” Wrap-Around Die Coarse Tooth 3
44 101947 Valve Section, Commercial DVA35-DA4 1
45 107920 Rear Spring Retainer Plate 2
46 107808 Bolt, Hex Head, 5/8” NC x 12” 2
47 101757 Locknut, 5/8” NC Full Height 2
48 108706 Two Position Load Cell Retainer 1
49 101555 Bolt, Hex Head, 1/2” NC x 3/4” 2
50 101708 Lockwasher, 1/2” 2
51 101042 Quick Disconnect Coupling, Male Half, 1/2” 2
52 101043 Quick Disconnect Coupling, Female Half, 1/2” 2
53 114578A Torque Gauge, US Scale, 0-20,000 ft-lbs 1
54 113257A Torque Gauge, US/Metric Scale, 0-20,000 ft-lbs 1
55 116437 Flow Divider Tie Down Plate 1
56 116635 Tie Down Plate Spacer 1

54
Table 6-15
Parts List, 7-5/8 Standard Hydraulic Tri-Grip Backup – Figure 6-15.1 through 6-15.3

57 101701 5/16" Flat Washer 1

58 101702 5/16" Lock Washer 1
59 101730 5/16" NC Full Hex Nut 1
60 101161 Grab Hook 2
61 113004 1/2" x 29" Hose Assembly 2
62 113003 1/2" x 25" Hose Assembly 2
63 113002 1/2" x 22" Hose Assembly 4
64 101417 1/2" 90 Degree Swivel Adapter 2
65 106523 1/2" x 2-1/2" Nipple 2
66 100962 3/4" MPT x 1/2" FTP Bushing 4
67 101416 1/2" 90 Degree Swivel Adapter 4
68 101463 1/2" 90 Degree Street Elbow 9
69 101277 1/2" FPT Tee 2
70 101042 1/2" Male Coupling 2
71 101043 1/2" Female Coupling 2
72 101315 1/2" Nipple, All Thread 3
73 107433 1/2" MPT x 1/2" FPT 45 Degree Swivel Adapter 1
74 100960 1/2" MPT x 1/4" Bushing 1
75 101301 1/4" Nipple, All Thread 1
76 113581 Lift Hook Bracket 2

55
 16,17
9

19

20 11
3
18 10
5
4 48

49
8 7 50
5

24
2
31
60
45
27-30
76
32-43 21
1
4
45
31 47 12
5
31

27-30 21
46
32-43
23 22

15
14
13

Figure 6-15.1
7-5/8 Standard Tri-Grip Backup: Exploded View

56
 57,
25 58,59

47 47
48 48
51

24

Figure 6-15.2
7-5/8 Standard Tri-Grip Backup: Hydraulic Components

57
 7 25

7 26

51,52 51,52

51

Figure 6-15.3
7-5/8 Standard Tri-Grip Backup: Hydraulic Schematic

58
 68
62
69

59 72 68
68 58 69 62
57
64 68
74 73
63 65 75 63
71
55 70
64 63 61
68 65 71
68 70
68 61
63

67 67
67 67
67
66 66
67

Figure 6-15.4
7-5/8 Standard Tri-Grip Backup: Hydraulic Components - Exploded View

59