GILL SERVICES, INC. TECHNICAL MANUAL GILL MODEL 500 POWER TUBING TONG OPERATING AND MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS LIST
Model 500 Serial No.________________________ Customer Reference No._____________________ Gill Services, Inc. 650 Aldine Bender, Houston, TX 77060 Phone: 281-820-5400 Fax: 281-820-0034 Website: www.gillservicesinc.com
IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation of all GILL SERVICES equipment. The service procedures recommended by GILL SERVICES and described in the technical manuals are recommended methods of performing service operations. Some of these service operations require the use of tools especially designed for the purpose. The special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods that can damage the equipment or render it unsafe are stated in the manuals. It is also important to understand that these warnings are not exclusive. GILL SERVICES could not possibly know, evaluate, and advise the service people of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Accordingly, anyone who uses service procedures or tools which are not recommended by GILL SERVICES must first satisfy himself thoroughly that neither his safety nor his equipment’s safety will be jeopardized by the method selected.
WARRANTY AND GUARANTEE GILL SERVICES, INC. warrants and guarantees that all equipment furnished hereunder and manufactured or reconditioned by GILL SERVICES, INC. (hereinafter called “Vendor”) is warranted to be free from defects in workmanship and material for a warranty period of six (6) months from date of receipt of the the original retail purchaser. If, under normal use and service, any failure of any parts by reason of a defect in workmanship or material shall appear within such warranty period, Purchaser shall notify Vendor thereof immediately, and if so requested by Vendor, shall return the defective part to Vendor, transportation charges prepaid, and Vendor shall, upon verifying that the cause of the failure is within the terms hereof, correct any such defects by repairing the defective part at its works or by supplying a replacement thereof F.O.B. Vendor’s works or warehouse. This guarantee does not apply to any parts or items items thereof which shall have been repaired or altered by other than Vendor in any way so as, in Vendor’s judgment, to affect same or which has been subjected to negligence, accident or other than normal use and service. The liability of of Vendor arising out of the supplying supplying of any material hereunder or or its use, whether on warranties or otherwise, shall not exceed the cost of correcting defects as herein provided, and shall not include transportation charges, Purchasers’ labor or materials (except as authorized in wiring in advance), loss of use or revenue, or any indirect or consequential damages. Upon expiration expiration of said warranty period, all such liability liability shall terminate. Vendor shall have no liability, other than as specifically herein provided, upon warranties, expressed or implied, of any nature whatsoever, (exclusive, however, of its warranty of title) including, but without limitation, warranties with respect to workmanship, material performance and fitness for use. Upon the expiration of said six six (6) month period after the original original receipt to retail purchaser of the machinery, all liability hereunder with respect to the machinery or any part or parts thereof repaired or replaced by reason of this this guarantee shall terminate. Any parts or material material not of Vendor’s manufacture is covered only to the extent of any guarantee given to the Vendor by the seller of said material and enforceable by the Vendor against said seller.
IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation of all GILL SERVICES equipment. The service procedures recommended by GILL SERVICES and described in the technical manuals are recommended methods of performing service operations. Some of these service operations require the use of tools especially designed for the purpose. The special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods that can damage the equipment or render it unsafe are stated in the manuals. It is also important to understand that these warnings are not exclusive. GILL SERVICES could not possibly know, evaluate, and advise the service people of all conceivable ways in which service might be done or of the possible hazardous consequences of each way. Accordingly, anyone who uses service procedures or tools which are not recommended by GILL SERVICES must first satisfy himself thoroughly that neither his safety nor his equipment’s safety will be jeopardized by the method selected.
WARRANTY AND GUARANTEE GILL SERVICES, INC. warrants and guarantees that all equipment furnished hereunder and manufactured or reconditioned by GILL SERVICES, INC. (hereinafter called “Vendor”) is warranted to be free from defects in workmanship and material for a warranty period of six (6) months from date of receipt of the the original retail purchaser. If, under normal use and service, any failure of any parts by reason of a defect in workmanship or material shall appear within such warranty period, Purchaser shall notify Vendor thereof immediately, and if so requested by Vendor, shall return the defective part to Vendor, transportation charges prepaid, and Vendor shall, upon verifying that the cause of the failure is within the terms hereof, correct any such defects by repairing the defective part at its works or by supplying a replacement thereof F.O.B. Vendor’s works or warehouse. This guarantee does not apply to any parts or items items thereof which shall have been repaired or altered by other than Vendor in any way so as, in Vendor’s judgment, to affect same or which has been subjected to negligence, accident or other than normal use and service. The liability of of Vendor arising out of the supplying supplying of any material hereunder or or its use, whether on warranties or otherwise, shall not exceed the cost of correcting defects as herein provided, and shall not include transportation charges, Purchasers’ labor or materials (except as authorized in wiring in advance), loss of use or revenue, or any indirect or consequential damages. Upon expiration expiration of said warranty period, all such liability liability shall terminate. Vendor shall have no liability, other than as specifically herein provided, upon warranties, expressed or implied, of any nature whatsoever, (exclusive, however, of its warranty of title) including, but without limitation, warranties with respect to workmanship, material performance and fitness for use. Upon the expiration of said six six (6) month period after the original original receipt to retail purchaser of the machinery, all liability hereunder with respect to the machinery or any part or parts thereof repaired or replaced by reason of this this guarantee shall terminate. Any parts or material material not of Vendor’s manufacture is covered only to the extent of any guarantee given to the Vendor by the seller of said material and enforceable by the Vendor against said seller.
WARNING DO NOT OPERATE, ADJUST, OR REPAIR THIS TONG WITHOUT PROPER TRAINING. READ AND UNDERSTAND ALL OPERATING AND MAINTENANCE INSTRUCTIONS AND ALL OTHER WARNINGS CONCERNING SAFETY BEFORE USING THIS TONG. DO NOT REMOVE OR PAINT OVER WARNING LABELS.
1. DO NOT OPERATE TONG UNTIL ANCHOR ANCHOR ARM IS ATTACHED TO THE TONG AND ANCHOR POST. 2. DO NOT CRAWL OR STAND UNDER TONG. 3. CAUTION: KEEP HANDS CLEAR OF TONG HEAD WHILE TONG IS IN OPERATION, AS PARTS INSIDE TONG HEAD ROTATE. KEEP ALL PARTS OF THE BODY AND CLOTHING AWAY FROM MOVING PARTS. 4. SHUT OFF POWER SUPPLY TO THIS UNIT UNIT BEFORE PERFORMING ANY WORK, (i.e., CHANGING TONG DIES OR JAWS, ADJUSTMENTS, MAINTENANCE, OR LUBRICATION). 5. FAILURE TO COMPY WITH WARNINGS COULD RESULT IN EQUIPMENT DAMAGE AND PERSONAL INJURY.
1. INTRODUCTION This manual contains information regarding the GILL Model 500 Power Tong. Full benefit of long life and dependability of this unit can only be realized by proper operation and maintenance. The operator should familiarize himself thoroughly with information contained in this manual before operating this tong. GILL SERVICES, INC. provides the information, data, and recommendations contained in this manual as a customer service. All are believed accurate. However, GILL SERVICES, INC. assumes no responsibility, implied or otherwise, for errors in or for the application of the Information, data, and recommendations presented herein. The right is reserved to make changes in this manual at any time, without obligation.
SECTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
TITLE
PAGE
WARRANTY……………………………………………….. WARNING ………………………………………………… INTRODUCTION …………………………………………. GENERAL DESCRIPTION ……………………………… TORQUE CURVE ………………………………………... SPECIFICATIONS ……………………………………….. INSTALLATION AND OPERATION INSTRUCTIONS .. VICKERS HYDRAULIC FLUID RECOMMENDATIONS LUBRICATION AND MAINTENANCE …………………. FINAL DRIVE ASSEMBLY ……………………………… TRANSMISSION ASSEMBLY ………………………….. JAW SETS LISTS ………………………………………... TONG DRAG RING ASSEMBLY ………………………. CLUTCH ASSEMBLY ……………………………………. HYDRAULIC LIFT ASSEMBLY …………….……………. COMMERCIAL HYDRAULICS ………………………….. HYDRAULIC TORQUE GAUGE ASSEMBLY ……..…… BACKUP TOOL ……………………………………..……. AIR CONTROLS FOR BACKUP TOOL ……………….... MAINTENANCE LOG……………………………………..
l ll 1 1 2 3 4 6 7 9 11 13 16 17 20 23 26 27 30 31
2. GENERAL DESCRIPTION GILL MODEL 500 Power Tong is a safe and accurate unit for the makeup and breakout of tubing and casing 1-5/16 in O.D. through 7 in O.D. These power tong features include: closed head design, allowing tong to remain in position during the entire trip, reducing makeup and break-out time; pressure oil bath lubrication; positive case seal; direct motor drive; roller chain final drive; two speed operation; controlled torque; and stiff torque arm for safety.
4. SPECIFICATIONS Cont’d Torque Range: 300 to 6,000 ft lb torque High Gear……………………………………………………………………...300 to 1,300ft lb Low Gear………………………………………………………………………………6,000 ft lb -
RPM High Gear……………………………………………………………………….……………*126 Low Gear……………………………………………………………………………..….……*27 Hydraulic Requirement………………………………………….……….33 GPM at 2,000 psi Tong Length…………………………………………………………………………….………51” Space Required on Pipe Tong…………………………………………………………………………………….…9-1/2 in With backup……………………………………………………………………...……..16-1/2 in Maximum Elevator Diameter Clearance…………………………………………………...30” Approximate Weight Tong……………………………………………………………………………………...1,000 lb (RPM based on published requirements of motor manufacturer: 33.5 GPM to tong motor *
5. INSTALLATION AND OPERATION INSTRUCTIONS 5.1 INSTALLING WITH SPRING CUSHIONED HYDRAULIC LIFT
1. Move tong to convenient position near well. 2. Lift hydraulic cylinder, set in position on tong, attach with pins, and connect hydraulic line from control valve to cylinder. 3. Lift tong with line approximately 3 feet above well head. (Cylinder has 6 foot travel.) The hydraulic lift is ready to operate by means of controls. The line supporting the tong should be located so the tong head will hang over the center of the well. 4. Weld anchor bracket on right rear corner of rig approximately 4 feet above ground. Additional anchor brackets can be purchased for use of this tong on more than one rig. See Figure 5-1. 5. Connect torque arm to rear of tong and to anchor bracket on rig. The torque arm Is adjustable, so adjust the torque arm so that the tong will be at a right angle to torque arm. See Figure 5-2. Tong should then have about 4 feet of free vertical travel. Lower tong over tubing. 6. Attach hoses from hydraulic power source. Be sure all self-sealing hose couplings are tight before starting engine. Tighten firmly by hand. Failure to do this will cause engine to run at full speed when tong is not in use. 7. To level tong, use the leveling screws and compression spring nuts. If tong is not level, it will cause excessive wear to tong jaws and Inserts. See Figure 5-3.
Fig. 5-1. Hydraulic Lift
5.2 JAW ARRANGEMENT
1. For breaking out and/or making up joints, place jaws on pins with long side of jaw against gear teeth. 2. Inserts are reversible and should be turned around when they become worn or replaced if reversing fails to bring sharp teeth In contact with pipe. 5.3 SETTING HYDRAULICS FOR PROPER OPERATION
1. Check all hose connections before engaging hydraulic power source. 2.
Engage hydraulic power source.
3.
Adjust tong relief valve. The relief valve on the tong operates in makeup direction only. a. Turn relief valve adjusting screw to left to reduce pressure until tong reduces speed. b. Place tong on tubing to be made up and gradually increase the pressure to reach make up required. Check manufacturers’ recommended makeup torque for type of joint being made up. c. Lock relief valve adjusting screw and make up second joint checking torque where tong stalls. d. Make minor corrections as necessary until torque readings are satisfactory. e. If tong grips and slips, increase pressure on drag plugs by screwing in drag screws in drag ring. Adjust screws evenly. See Figure 5-4. NOTE: It
is not necessary to change makeup torque to break-out. Tong operates at system pressure for breakout. System pressure is controlled by a relief valve set at 2200 PSI in power unit tank. PSI should not exceed 2500 PSL 4. If pump fails to pick up oil after hoses have been connected or if tong runs in surges, screw out relief valve all the way and let pressure back to tank. Circulate to remove air. Screw In pressure screw until tong operates. Repeat if necessary. 5. In operating tong, stop operating lever in center position one second before reversing motor. This reduces fluid shock In motor.
Fig. 5-2. Tong at Right Angle to Torque Arm
5.4 STEPS TO DISMANTLE
1. Raise tong to top of hydraulic lift travel. 2. Use a line to lower tong and hydraulic lift to ground. 3. Shut off hydraulic source to tong. Engage lever on control valve for lift hose. 4. Disconnect hoses and prepare unit for transporting.
to release pressure off lift
6. VICKERS HYDRAULIC FLUID RECOMMENDATIONS 6.1 OIL-TYPE
Oils used in hydraulic systems perform the dual function of lubrication and transmission of power. Oil must be selected with care and with the assistance of a reputable supplier. Crankcase oils meeting or exceeding the “Five Engine Test Sequence” for evaluating oils for API (American Petroleum Institute) service MS (Maximum Severity) best serve the needs of mobile hydraulic systems. These engine sequence tests were adopted by the Society of Automotive Engineers, American Society for Testing Materials, and automotive engine builders. The MS classification is the key to selection of oils containing the type of compounding that will extend the operating life of the hydraulic system. Oils meeting Diesel engine requirements, DG through DS classifications, may or may not have the type of compounding desired for high performance hydraulic systems.
HYDRAULIC SYSTEM OPERATING RANGE (Mm. to Max.) 0°F to 180°F 15°F to 210°F 32°F to 230°F 0°F to 210°F
SAE VISCOSITY
10W 20-20W 30W 10-30W
API SERVICE CLASSIFICATION
MS MS MS MS
Automatic Transmission Fluid, Type “A,” is usually satisfactory for power steering systems or those systems operating under moderate hydraulic service. 6.2 OPERATING TEMPERATURES
These temperature ranges for each grade of oil are satisfactory If suitable procedures are followed for low temperature start-up conditions and if sustained operation is avoided at the upper temperature limits. Operation in excess of these temperatures results in increased wear of the system components and causes more rapid deterioration of the oil. For optimum operation, a maximum oil viscosity of 4,000 SSU at the low temperature start-up condition and a minimum oil viscosity of 60 SSU for the sustained high temperature operating condition are recommended. Good oils are the most economical. Specifications can be set up which will indicate, to a limited degree, the characteristics essential in a good hydraulic oil. These are listed herein and should be checked with the oil manufacturer prior to the use of their product.
6.3
VISCOSITY Viscosity is the measure of fluidity. The oil must have sufficient body to provide adequate sealing effect between working parts of pumps, valving, cylinders, etc., but not enough to cause pump intake cavitation or sluggish valve action. Viscosity recommendations must at best be a compromise, which takes Into consideration the working temperature range, the type of hydraulic equipment used, and class of service. Refer to table of oil viscosity recommendations.
6.4
VISCOSITY INDEX The viscosity Index Is a measure of the rate at which temperature changes cause a change in oil viscosity. It is very desirable that the oil viscosity remain as nearly constant as possible under the wide range of temperature conditions en countered in operating mobile construction machinery. The viscosity Index (Vi.) of hydraulic oil should not be less than 90 for this type of service.
6.5
ADDITIVES Research has developed a number of additive agents which materially improve various characteristic of oils for hydraulic systems. They may be selected for compounding with a view toward reducing wear, Increasing chemical stability, inhibiting corrosion, depressing pour point and improving the anti-foam characteristics. Proper use of additive agents requires specialized knowledge, and they should be Incorporated by the oil manufacturer only, as serious trouble may otherwise result. Most oil companies have several brands of crankcase oils of somewhat varying formulation that will meet the API service classification of MS. The more desirable of these oils for hydraulic service will contain higher amounts of the type of compounding that avoids scuffing and wear of cam lobes and valve lifters. These oils will also be formulated to be stable under oxidative conditions and when in contact with small amounts of moisture. There should also be reasonable protection against rust to any ferrous materials submerged in the oil or covered by the oil’s film.
6.6
CLEANLINESS Thorough precautions should be taken to filter the oil in the entire hydraulic system prior to its initial use to remove paint, metal chips, welding shot, lint, etc. If this is not done, damage to the hydraulic system will probably result. In addition, continuing filtration is required to remove sludge and products of wear and corrosion, throughout the life of the system. Precautions should be taken in the design of hydraulic circuits to assure that a means is provided to keep the oil clean. This can best be accomplished by the use of a 25-micron full-flow filter or a 10-micron bypass filter plus a micronic filter type air breather or sealed reservoir.
6.7
MISCELLANEOUS The performance of hydraulic valves and cylinders is less affected by the lubricating quality of the oil and, therefore, selection of the oil is less critical than for pumps and motors. It is always good practice, however, to use the best quality oil available for all components.
7.
LUBRICATION AND MAINTENANCE LUBRICATION REQUIREMENTS TRANSMISSION: Oil meeting API classification MS: Temperature above 32°F SAE 30W Temperatures below 32°F SAE low TRANSMISSION CAPACITY…...10 quarts GREASE FITTINGS…………..Any soft gun lubricant
Lube Fitting in Drag Ring, remove Guide Bell
_______Lube Fittings___________
Oil Level
Fig. 7-1. Tong Lube Fittings & Oil Level
7.2 OPERATIONAL MAINTENANCE
1. Grease lube fittings weekly, (Fig. 7-1). 2. Check the transmission after every trip. If water or dirt is found in transmission, change oil. Under normal conditions, oil should be changed every 100 work-hours. 3. Clean and grease tong head and backup tool after every trip. Use kerosene or solvent and a wire brush for cleaning. After cleaning, apply cup grease to jaws, pins, ring gear, and top seal. 4. Do not steam clean tong head. Steam cleaning tong head will force water by the top seal Into the transmission, removing all of the lubricants from top seal and causing It to harden. If steam cleaning is used, guide bell should be pinned in place. After cleaning, check the transmission for the presence of water. 7.3 SAFETY POINTS AND WARNINGS
CAUTION: Keep hands clear of Tong Head while Tongs are in operation. Caution should be taken whi!e operating this equipment, as parts inside the Tong Head rotate.
1. Do not crawl or stand under Tongs as hydraulic line could be cut or broken, and Tongs will fall. 2. Do not operate Power Tongs until the Anchor Arm is attached to the Tong and Anchor Post. 3. Power should be OFF before any size equipment change, maintenance, or any work Is done to this equipment.
R509-1P R501-15
Gill Model 500 Final Drive Assembly
y l b m e s s A n o i s s i m s n a r T 0 0 5 l e d o M
9. TRANSMISSION ASSEMBLY
PARTS LIST PART NO.
DESCRIPTION / (Foster Ref. No)
QTY.
A501
RING GEAR COVER (93-18)
1
A502
TRANSMISSION END PLATE (58-17-3)
1
SIDE PLATE ASSY 6-1/2”x9-1/2” (58-295)
2
A504
SIDE PLATE FOR CHAIN (93-295-1)
1
A508
GUARD COVER (93-122)
1
B501
TIMKEN BEARING (50-32-1)
3
B502
BEARING (93-32)
1
A503-A
B503
TIMKEN BEARIING (93-183)
PART NO.
DESCRIPTION
QTY.
G503
RING & PINION GEAR (50-20)
1
G504
HIGH DRIVE GEAR (58-10)
1
G505-A
HIGH CLUTCH GEAR ASSY (50-9-1)
1
G506-A
LOW CLUTCH GEAR ASSY (50-12-2)
1
G507-A
OIL PUMP GEAR (58-143-1)
1
K500-3
HYPRO KEY #18 (11-1760
3
L517
LEVELING PIN (123-27)
2
M500
MOTOR M25X (1-1/2) (77-90)
1
O500-4
O-RING 1/8” x 1” x 1-1/4” (11-349)
1
P501-A
OIL PUMP ASSY (119-202)
1
P510
5/16” OIL PUMP LINE (93-114)
1
P511
1/4” OIL PUMP LINE (93-115)
1
R503-1
SPIROLOX RING (11-900)
3
1
B504
BALL BEARING (58-25)
4
B505
TIMKEN BEARING (92-183)
1
B509
BEARING CAP, TOP (58-23-1)
1
BEARING CAP, BOTTOM (58-23)
1
B510
BEARING CAP, BACK (58-29-1)
1
B511
BEARING CAP MOTOR MOUNT (93-37-2)
1
S500
RING GEAR & HUB SPROCKET (93-19)
1
B512
SPACER—PINION (58-137-1)
1
S501
DRIVE SHAFT (93-11)
1
B512-1
PINION SHIM (NOT PICTURED) (58-83)
3
W500-5
WAHSER, 3/4” FLAT (11-255)
2
B512-2
BEARING SPACER (50-45-1)
2
W501-5
WASHER, 1/2” LOCK (11-87)
2
C500
CLUTCH ASSY (50-13-1)
1
W501-11
WASHER, 1” INT LOCK (N/A)
1
C501
CLUTCH SHIFTIING YOKE (50-193)
1
X500-6
CAPSCREW (5/16”x1/2” HEX) (11-662)
20
C502
CLUTCH SHIFTIING FORK (50-28-3)
1
X500-11
CAPSCREW (3/8”x3/4” HEX) (11-604)
8
C503
CLUTCH SHAFT (58-14-2)
1
X500-12
CAPSCREW (3/8”x1” HEX) (11-603)
30
C503-1
CLUTCH SHAFT NUT, 1” (58-363-1)
1
X500-31
CAPSCREW _1/2”x2-1/4” HEX) (11-1492)
2
C503-2
CLUTCH SHAFT PINION KEY, ( NO PICTURE)
1
X501-13
SCREW 3/8”x1” SKT HD (11-113)
4
C518
CLUTCH LEVER WITH SHAFT (58-27-10)
1
X503-7
SCREW, 5/16”x5/16” SKT SET (11-595)
2
E500
OIL SIGHT GAUGE (56-81)
1
X503-13
SCREW, 3/8”x2” SQ. HD SET (11-1578)
2
E500-1
PET COCK (1/8” PIPE) (11-299)
1
Y500-5
NUT, 3/4” HEX (11-76)
2
F501-2
ELL 1/4” STD. BLK STREET (11-321)
1
Y500-22
NUT, 1” SAE JAM (11-1137)
1
F502-5
STR. 1/4” OD x 1/4” PIPE (11-59)
1
Z506-7
SAFETY PIN (11-920)
2
F505-6
PLUG, 1/2” SKT PIPE (11-601)
1
F505-10
PLUG, 1-1/4” XQ. HD. PIPE (11-324)
2
B509-3
10. JAW SETS LISTS
SINGLE-ACTING JAWS—TUBING ITEM NO
O.D. TUBULAR
1
1-5/16” - 1.9”
1A
2
2A
2B
2C
3
3A
3B
3C
1-5/16” - 1.9”
1-7/8” - 3-1/2”
1-7/8” - 3-1/2”
2-3/8” - 2-7/8”
2-7/8” - 3-1/2”
3-1/2” - 5”
3-1/2” - 4-1/2”
4” - 5”
5” - 6-1/16”
DESCRIPTION Drag Ring Assembly Consists of: Drag Ring Cover Plate Split Guide Bell Jaw Assembly Consists of: Jaw Insert Insert Screw Drag Ring Assembly Consists of: Drag Ring Cover Plate Split Guide Bell
PART NO
D500-2-A R501-15 R509-1-A
J501 N501 N507
D500-2-A R501-15 R509-1-A
NO. REQUIRED/ TONG OR ASSY.
1/Assy. 1/Assy. 1/Assy
5 10 10
1/Assy 1/Assy 1/Assy
Jaw Assembly Consists of: Jaw Insert Insert Screw
J502 N502 N507
5 10 10
Jaw Assembly Consists of: Jaw Insert Insert Screw
J503 N503 N507
5 10 10
Jaw Assembly Consists of: Jaw Insert Insert Screw Drag Ring Assembly Consists of: Drag Ring Cover Plate Split Guide Bell
5/Tong J505-2 N505-4 N507
1/Assy 1/Assy 1/Assy
D501-A R501-2 R506-1-A
5 5 5
Jaw Assembly Consists of: Jaw Insert Insert Screw
J505-2 N505 N507
5 5 5
Jaw Assembly Consists of: Jaw Insert Insert Screw
J505-2 N505-1 N507
5 5 5
Jaw (solid)
J507
5/Tong
SINGLE-ACTING JAWS—CASING ITEM NO
O.D. TUBULAR
1
4” - 5-1/2”
1A
1B
2
DESCRIPTION
Drag Ring Assembly Consists of: Drag Ring Cover Plate Split Guide Bell
4” - 4-1/2”
5” - 5-1/2”
6-5/8” - 7”
PART NO
NO. REQUIRED/ TONG OR ASSY. 1/Tong
D502-1-A R501-3-1 R507-1-A
1/Assy. 1/Assy. 1/Assy/
Jaw Assembly Consists of: Jaw Insert Insert Screw
J506 N505-2 N507
5 5 5
Jaw Assembly Consists of: Jaw Insert Insert Screw
J506 N505-3 N507
5 5 5
Drag Ring Assembly Consists of: Drag Ring Cover Plate Split Guide Bell
D503-A R501-4 R508-1-A
1/Assy 1/Assy 1/Assy
2A
6-5/8”
Jaw (solid)
J508
10/Tong
2B
7”
Jaw (solid)
J509
10/Tong
DOUBLE ACTING JAWS—TUBING 1
1A
1B
2-3/8” - 3-11/16”
2-3/8” - 3-1/16”
2-7/8” - 3-1/2” 3-1/2” Only
Drag Ring Assembly Consists of: Drag Ring Cover Plate Split Guide Bell Jaw Assembly Consists of: Jaw Insert Insert Screw Insert Insert
D500-2-A R501-15 R509-1-A
1/Assy 1/Assy 1/Assy 5/Tong
J510 N504 N507
5 5 5
N504-3 N504-1
5 5
JAW LIST—BACKUP TOOL ITEM NO. 1
2
3
O.D. TUBULAR
1-5/16” - 2-1/16”
2-3/8” - 3-3/4”
3-1/16” - 4-1/2”
DESCRIPTION
Jaw Assembly Consists of: Jaw Insert Insert Screw Jaw Assembly Consists of: Jaw Insert Insert Screw
PART NO.
NO. REQUIRED/ TONG OR ASSY 5/Backup
BU501 N501 N506
1/Assy 1/Assy 1/Assy 5/Tong
BU502 N503 N506
1/Assy 1/Assy 1/Assy
Jaw Assembly Consists of: Jaw Insert Insert Screw
5/Tong BU503 N503 N506
1/Assy 1/Assy 1/Assy
4
4-1/2” - 5-9/16”
Jaw (solid)
BU504
5/Backup
5
5” - 6-1/16”
Jaw (solid)
BU505
5/Backup
When more than one drag ring assembly is required, do not duplicate the same items included in other drag ring assemblies. Example: Running tubing 1-5/16” through 1.9” O.D. requires a D500-2-A Drag Ring, an R501-15 Cover Plate, and an R509-1-A Split Guide Bell. To change over to run 3-1/2”” through 5” O.D., you would need to change to P/N D501-A Drag Ring; P/N R501-2 Cover Plate; and P/N R506-1-A Split Guide Bell. The Backup Tool must have a 6-1/4” bore through the head to use the 4-1/2” through 6-1/16” O.D. Jaw Sets. The BU509-2 Housing Adapter is used on the other equipment size to reduce the bore from 6-1/4” O.D. to 5” O.D. The sizes listed are the actual O.D. size for tubing, upset, or collar that the jaws will catch.
11. TONG DRAG RING ASSEMBLY PARTS LIST D500-2- A
DRAG RING ASSEMBLY 1-5/16” - 3-1/2” O.D. (5-1/2” BORE) PART NO. Jaw Pin—1”
5
D507
Drag Plug
5
D506
Drag Spring
5
D505
Set Screw
5
Grease Fitting
1
DRAG RING ASSEMBLY 4” - 5-1/2” O.D. (7-1/4” BORE) PART NO.
D501-A
DESCRIPTION
QTY.
D508-1
Jaw Pin—3/4”
5
D507-1
Drag Plug
5
D506-1
Drag Spring
5
D505-1
Set Screw
5
Z503-1
Grease Fitting
1
DRAG RING ASSEMBLY 3-1/2” - 6-1/16” O.D. (6-1/4” BORE) PART NO. D508
DESCRIPTION
QTY.
Jaw Pin—1”
5
Drag Plug
5
Drag Spring
5
D505-1
Set Screw
5
Z503-1
Grease Fitting
1
D507-2 D506
D503-A
QTY.
D508
Z503-1
D502-1-A
DESCRIPTION
DRAG RING ASSEMBLY 6-5/8” - 7” O.D. (7-7/8” BORE) PART NO. D104
DESCRIPTION
QTY.
Jaw Pin—1”
10
D507-1
Drag Plug
5
D506-1
Drag Spring
5
D505-1
Set Screw
5
Z503-1
Grease Fitting
1
Clutch Assembly C516 C513
C511 C517
C512
C509
C508 C515
C505-A
C510
C507 C514 C506-A
C507 C508
C510
C517
C511
C509
C512 C513 C516
13. CLUTCH 13.1 Adjustment For Clutch 1. Remove side panel from operator’s side of tong. 2. Be sure tong is in neutral position. 3. Rotate clutch with hand until slot in adjusting collar is facing toward the opening in tong. 4. Insert screwdriver or similar object in slot in the adjusting collar. 5. Pry the adjusting collar away from pressure plate so that the teeth are free from each other. 6. Rotate adjusting collar in the direction shown to adjust clutch. 7. Follow the above procedure for both ends of the clutch. 8. Adjust left end of clutch for high gear. 9. Adjust right end of clutch for low gear. 10. If the clutch slips or the disc stack heats up, adjustment is required.
PARTS LIST PART NO. (Foster Ref. No.)
DESCRIPTION
REO’D.
C504 (819-1 )
Anchor Pin
1
C516 (819-5)
Split Ring
4
C508 (819-9 )
Pressure Plate
2
C509 (819-10 )
Inner Disc
12
C510 (819-11 )
Outer Disc
14
C511 (819-12 )
Thrust Plate
2
C507 (819-13 )
Adjustment Collar
2
C513 (819-14)
Spring Pin
6
C512 (819-16 )
Separating Spring
6
C514 (819-17 )
Dog
6
C515 (819-18 )
Dog Pivot
6
C505-A (819-20 )
Body
1
C506-A (819-21)
ShIpper Sleeve
1
C517 (11-1186)
No.CHyProKey
6
(Foster Ref. No. 123-3-1) (Foster Ref. No. 123-1-1) (Foster Ref. No. 123-23) (Foster Ref. No. 123-2-1) (Foster Ref. No. 126-7
(Foster Ref. No. 136-8-1) (Foster Ref. No. 123-13-7) (Foster Ref. No. 58-91-1) (Foster Ref. No. 58-71) (Foster Ref. No. 74-73 & 58-72)
(Foster Ref. No. 123-4) (Foster Ref. No. 123-4-1) (Foster Ref. No. 123-5-1) (Foster Ref. No. 123-9) (Foster Ref. No. 123-10) (Foster Ref. No. 11-1076 & 123-6) (Foster Ref. No. 11-148) (Foster Ref. No. 123-20) (Foster Ref. No. 11-1563) (Foster Ref. No. 11-317) (Foster Ref. No. 12-130) (Foster Ref. 11-361) (Foster Ref. 11-356) (Foster Ref. 11-355) (Foster Ref. No. 11-353) (Foster Ref. No. 11-1367) (Foster Ref. No. 123-26)
Foster Ref. No. 11-946) (Foster Ref. No. 11-947) (Foster Ref. No. 11-849) (Foster Ref. No. 11-850) (Foster Ref. No. 11-816) (Foster Ref. No. 181-24-1)
(Foster Ref. No. 11-1293) (Foster Ref. No. 11-145) (Foster Rerf. No. 11-803) (Foster Ref. No. 11-1153)
(Foster Ref. No. 11-18)
-
-
-
-
-
-
-
-
-
3 1 0 0 5 X
2 1 0 0 5 T
5 1 1 0 5 F
6 0 5 T
-
-
-
6 1 5 V
15. COMMERCIAL HYDRAULICS
PARTS LIST PART NO. (Foster Ref. No)
DESCRIPTION
QTY. REQ’D.
T500-A (10-606)
Steel Tubing
1
T501-A (10-607)
Steel Tubing
1
T502-A (10-608)
Steel Tubing
1
Y500-5 (11-76)
Hex Nut, 3/8” (not pictured)
3
W501-5 (11-87)
Lock Washer, 1/2” (not pictured)
5
F502-7 (11-90)
Str. Fitting, 3/8” Flare to 3/8” Pipe (not pictured)
1
F501-15 (11-165)
Ell, 1” x 90 Degree,s,H.P.
1
F503-10 (11-254)
Nipple, 1” Close H.P.
1
F507-5 (11-265)
Collar, 1” H.P.
1
F503-12 (11-333)
Nipple, 1” x 2-1/2” H.P.
1
F503-17 (11-337)
Nipple, 1” x 6” H.P.
1
F500-5 (11-427)
Ell, 1/4” Flare to 1/4” Pipe, 45-Degrees
1
Q500-18 (11-560)
Dust Cap, 1”
1
Q500-23 (11-566)
Dust Cap, 1-1/4”
1
F505-9 (11-606)
Pipe Plug, 1” Socket (not pictured)
2
X500-26 (11-641)
Capscrew 1/2” X 1” Hex (not pictured)
3
Q500-4 (11-850)
Dust Plug (not pictured)
1
Q500-1 (11-946)
Coupling Half, 1/2” (not pictured)
1
Q500-17 (11-953)
Coupling Half, 1”
1
Q500-21 (11-955)
Coupling Half, 1-1/4”
1
(Continued on Page 2)
15. COMMERCIAL HYDRAULICS
PARTS LIST (cont.) PART NO. (Foster Ref. No)
DESCRIPTION
QTY. REQ’D.
T500-12 (11-963)
Ell, 1” Pipes 1” Tube, 90-Degrees
4
T500-4 (11-966)
Straight Fitting
1
X500-20 (11-1286)
Capscrew, 3/8” x 4” Hex
3
Z501-2 (11-1401)
Yoke Pin, 3/8” x 1”
4
X500-32 (11-1363)
Capscrew, 1/2” x 2-1/4” Hex
2
F500-9 (11-1563)
Ell, 3/8” Flare to 3/8” Pipe, 45-Degrees (not pictured)
1
T506 (11-1572)
Tee, 3/4” x 3/4” x 1” Bax w/1/4” NPT
1
H502 (12-130)
Hose Assy
1
V500 (58-240-5)
Commercial Valve
1
T512 (76-166)
Tee
1
M500 (77-90)
Hydraulic Motor
1
V519-1 (93-117-6)
Linkage
4
A507 (93-125)
Counterbalance
1
A506 (93-126)
Valve Plate
1
V514 (181-24-1)
Check Valve Assy (not pictured)
1
V507-NSP
Cartridge Style Relief Valve
1
V508 (183-9)
Knob
1
V516 (867-22)
Handle
2
X500-13 (11-1043)
Capscrew, 3/8” x 1-1/4” Hex Hd
16
I501
I500-1
F500-5
I502
Y500-1
H500 X502-4 F507-1 F500-6
F500-6 F507-1 F500-5 X502-4 Y500-1 H500 I500-1 I501 I502
(Foster Ref. No. 11-162) (Foster Ref. No. 11-323) (Foster Ref. No11-427) (Foster #11-1580) (Foster Ref. No. 11-1581) (Foster Ref. No. 12-249) (Foster Ref. No. 236-2) (Foster Ref. No. 236-4) (Foster Ref. No. 236-8)
BU50O-A BACKUP TOOL
INSTRUCTIONS FOR BU500-A BACKUP TOOL
(Foster Ref. No. 147-7) (Foster Ref. No. 147-6) (Foster Ref. No. 147-1-1) (Foster Ref. No. 147-2-10) (Foster Ref. No. 147-19) (Foster Ref. No. 147-20)
(Foster Ref. No. 147-5-80) (Foster Ref. No. 121-10) (Foster Ref. No. 11-1335) (Foster Ref. No. 147-43) (Foster Ref. No. 147-40) (Foster Ref. No. 147-41)
(Foster Ref. No. 50-48-1) (Foster Ref. No. 50-49-2) (Foster Ref. No. 11-196) (Foster Ref. No. 11-87) (Foster Ref. No. 11-806)
(Foster Ref. No. 11-603) (Foster Ref. No. 11-1575) (Foster Ref. No. 11-878) (Foster Ref. No. 11-188)
(Foster Ref. No. 11-145) (Foster Ref. No. 11-131) (Foster Ref. No. 11-920)
AIR CONTROLS FOR BU500-A BACKUP TOOL
F502-4 F500-6 Q500-27 F500-5 F505-3 Z502-4
(Foster Ref. No. 11-161) (Foster Ref. No. 11-162) (Foster Ref. No. 11-296) (Foster Ref. No. 11-427) (Foster Ref. No. 11-574)
Cotter Pin, 1/2” x 1-1/2” (Foster Ref. No. 11-796)
Z500-2
Foster Ref. No. 11-1300)
H519-2
(Foster Ref. No. 12-11)
H519-1
(Foster Rerf. No. 12-91)
H504-4 BU521-A V523
(Foster Ref. No. 12-126) (Foster Ref. No. 105) (Foster Ref. No. 195-6)
GILL SERVICES, INC. MODEL 500 MAINTENANCE LOG MODEL 500 SERIAL NO.______________________________ DATE
TYPE OF MAINTENANCE PERFORMED
INITIALS
