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I TECHNICAL MANUAL I T W2007
AUGUST 19B9
HILLMAN-KELLEY MODEL 500 C
POWER TUBING & ROD TONG PAINTED IN USA
OPERATING AND MAINTENANCE INSTRUCTIONS

WITH ILLUSTRATED PARTS LIST
H-K 500 C POWER TONG
IMPORTANT SAFETY NOTICE
Proper seJVice and repair Is Important to the safe, reliable operation of all equipment. The
service procedures recommended by and described In the technical manuals are recom-
mended 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. . 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 "
must first satisfy himself thoroughly that neither his safety nor his equipment's safety will be jeopardized by the
method selected.
LIMITED PRODUCT WARRANTY

THE FOLLOWING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALLOTHER WARRANTIES, WHETHER EXPRESS,
IMPLIED OR STATUTORY, INCLUDING, BUT NOT BY WAY OF LIMITATION, ANY WARRANTY OF MERCHAN-
TABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
The Company warrants to Buyer ("PurchaSer") of new products manufactured or supplied by the Company that
such products are, at the time of delivery to the Purchaser, free of material and workmanship defects, subject
to the following exceptions:
A. Any product which has been repaired or altered in such a way, in the Company's judgment,
as to affect the product adversely, including any repairs, rebuilding, welding or heat treating
outside of a Company authorized facility.
B. Any product which has, In the Company's judgment, been subject to negligence, accident or
Improper storage.
C. Any product which has not been Installed, operated and maintained In accordance with
normal practice and within the recommendations of the Company.
D. For all Items of special order by Buyer which are not manufactured by the Company, Buyer
should submit warranty claims directly to the manufacturer thereof.
The Company's obligation under this warranty is limited to repairing or, at Its option, replacing any products
which In Its judgment proved not to be as warranted within the applicable warranty period. All costs of
transportation of products claimed not to be as warranted and of repaired or replacement products to or from
authorized Company seJVice facilities shall be borne by Buyer. Company may, at Its sole option, elect to refund
the purchase price of the products, and Company shall have no further obligation under the Sales Agreement.
The cost of labor for Installing a repaired or replacement part shall be borne by Buyer. Replacement parts
provided under the terms of this warranty are warranted for the remainder of the warranty period of the product
upon which Installed to the same extent as If such parts were original parts thereof.
The warranty periods for various products are:
A. Hydraulics and Mechanical Equipment: one (1) year from date of Installation or fifteen (15)
months from date of shipment from Company, whichever occurs first.
B. All Elastomer Diaphragms: six (6) months from date of shipment from Company.
C. Electronic Equipment: six (6) months from date of shipment from Company.
TW2007
MARTIN·DECKER
H·K SOD C POWER TONG
EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY,

THE REMEDIES PROVIDED FOR IN THIS AND THE PRECEDING SECTION SHALL CONSTITUTE THE SOLE
RECOURSE OF BUYER AGAINST COMPANY FOR BREACH OF ANY OF COMPANY'S OBLIGATIONS UNDER
THE SALES AGREEMENT WITH BUYER, WHETHER THE CLAIM IS MADE IN TORT OR IN CONTRACT,INCLUDING
CLAIMS BASED ON WARRANTY, NEGLIGENCE OR OTHERWISE.
IN NO EVENT SHALL COMPANY BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, REGARDLESS
OF THE FORM OF ACTION, WHETHER IN CONTRACT, STRICT LIABILITY OR IN TORT (INCLUDING NEG·
L1GENCE) NOR FOR LOST PROFITS.
CHANGES IN PRODUCT DESIGN

Company reserves the right to change, discontinue or modify the design and construction of any of Its products
without Incurring any obligation to furnish or Install such changes or modifications on products previously or
subsequently sold.
II TW2007
H-K 500 C POWER TONG
SAFE HANDLING PROCEDURE
Always lift the tong using the eye bolt of the Hanger Assembly with a safety hook
or wire line and shackle.
Never use wire rope slings, nylon straps or hooks attached to any other feature
on the tong (e.g. Hydraulic fittings, hoses, control handles or control linkages) to
lift or manipulate the tong.
Always remove the Back-up assembly from the tong when transporting. The leg
assembly under the tong is designed for the tool to be supported and free
standing when not in use.
Do not use forklift blades under the tong to lift the unit as they may damage the
brake band assembly on the underside of the tong.
Always use the safety sling when operating the tong.
Reference manual sections 3 and 4 for additional safety precautions and

warnings.
Operating noise levels are 85-90 DB. Personnel should take precaution when
running the tong by wearing appropriate hearing protection.
Operating vibration levels are below 2.5m/sec².
Safety labels have been installed at these locations.
iii
MARTIN·DECKER H·K 500 C POWER TONG
1. INTRODUCTION
This manual contains Important Instructions on the maintenance and safe operation of the Hillman·
KelleyTM Model 500 C Power Tubing and Sucker Rod Tong. A photographic presentation with
explanatory notes Is Included for assembly and disassembly of these tongs.
Full benefit of the long life and dependability of these units can only be realized by proper operation
and maintenance. The operator should familiarize himself thoroughly with the contents of this
manual before running, making adjustments, or carrying out maintenance procedures on the tong.
Information regarding a general subject, such as tong operating or storage Instructions, can best
be located by using the Table of Contents. An alphabetical Index at the back of the manual has been
provided as an additional aid for locating specific information. Throughout the manual the numbers
given In parentheses,l.e., (109), (59), etc., refer to Item numbers used in the illustrations and/orthe
parts list.
MARTIN·DECKER provides the Information, data, and recommendations contained In this manual
as a customer service. All are believed to be accurate. However, MARTIN·DECKER 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.
TABLE OF CONTENTS
SECTION TITLE PAGE

WARRANTY ....... . . · . I
1. INTRODUCTION ...... . · .1
2. GENERAL DESCRIPTION .. · .2
3. SAFETY PRECAUTIONS · .3
4. WARNINGS . . . . . . . · .. 3
5. TORQUE CURVE . . . . · .5
6. SPECIFICATIONS . . .. . . · .5
7. MODEL AND SERIAL NUMBERS · .7
8. NOMENCLATURE ......... . · .7
9. COMPONENT DESCRIPTIONS ..•. · .8
10. FIRST TIME START·UP PROCEDURE .. · .9
11 . OPERATING INSTRUCTIONS . . . . . • . · • 11
12. LINKAGE ADJUSTMENT PROCEDURES . . . • . • . . . · • 22
13. HYDRAULIC OIL SPECIFICATIONS . . . • • • . . •. • . . . 24
14. GREASE SPECIFICATIONS . . . • . . . . . . . . . • 24
15. LUBRICATION AND PREVENTIVE MAINTENANCE . 25
16. TROUBLESHOOTING ............. • ... 29
17. STORAGE INSTRUCTIONS .......•. . . • .. 36
18. OVERHAUL PROCEDURE . . • • . . . • . . . . . . • . . . . 37
PARTS LIST . . . . . . . 53
INDEX • . • • • . • . . . . . .. . . .. . . . • • • • . • .. • . • . . . . . . . . . . 61
TW2007 1
H-K SOD C POWER TONG MARTIN-DECKER
2. GENERAL DESCRIPTION
The Hlllman-KelleyTM MOdel 500 C Is a compact multl·purpose power
tong. It has been designed to run tubing or sucker rOds by just a
change 01 the power and back-up jaws. A low gear with ample power
provides enough power to break any tubing or sucker rod In the range
of sizes Included In Its specifications.
The 500 C dillers from ordinary power tongs In that lull torque Is
developed In either direction while the tong Is In an upright position.
It Is not necessary to turn the tong or jaw mechanism over for
"make-up" and "break-out".
The tong Is suspended In the derrick or mast by a wire line and swung
onto the tubing or sucker rods. The guard doors open and close as
the tong Is guided onto the tubing or sucker rods and the jaws are
activated as the throttle Is engaged. Operate the throttle In the forward
position and the joint Is automatically "made-up" to a pre-set torque.
Pull the throttle toward the operator and the jaws will release, the rotor
opening may be aligned wllh the housing opening, and the tong may
be retracted from the "string". Change the position of the directional
control bar and reverse shifter and the same procedure as above
breaks the joint quickly, eaSily, and safely.
The compact, lightweight design has proven It to be the best power
tong lor running multiple strings.
2 TW2007
MARTIN-DECKER H-K SOD C POWER TONG
3_ SAFETY PRECAUTIONS
Safety based on technical skill and years of experience, has been carefully built Into your HILLMAN-
KELLEY Tong. Time, money, and effort have been Invested In making your tong a safe product. The
dividend you realize from this Investment Is your own personal safety_
It should be remembered, however, t hat power-driven equipment Is only as safe as the person who
Is at the controls. You are urged, as the operator of this equipment, to observe the following rules:
1. Operate Ihe long from the back-up line or stiff ann side only. (Does not
apply to front COntrol tongs.)
2. Never change a jaw or put hands within the rotating parts of the tong
while the hydraulic system Is engaged. The hydraulic system should be
disengaged and locked out or shut down.
3. Never operate the tong without the guard doors In place and operallng
properly.
4. Do not exceed the maximum pressure for which this system Is rated.
S. Always use a back-up (snub) line or stiff arm for all tong operations.
6. Keep loose fltllng clothing away from the rotating parts of the tong.
4. WARNINGS
4.1 WARNINGS - PERSONAL INJURY
Failure to comply with the following warnings could result In serious bodily
harm or loss of life.
4.1 .1 Read and understand all operating and maintenance Instructions. Consult
the nearest MARTIN-DECKER representative If additional Instruction or
Information Is required.
4.1.2 Do not operate tong with the door open, toose, or missing.
4.1 .3 Keep hands, clothing, and foreign objects clear of rotallng parts.
4.1.4 Shut off power unit and disconnect supply hose to tong before changing
jaws, dies, or perfonnlng any type of maintenance or adjustments.
4.1.5 A stiff ann or Iwo snub lines must be Installed and used al all times when
operallng the tong. If using snub lines, one must be Installed In the make-up
direction and one In Ihe break-out direction.
4.1.6 The stiff ann ortwo snub lines must be kept level, tight, and at a right angle
(90°) to the tong when jaws are engaged.
4.1.7 Apply the load slowly against snub lines. DO NOT JERK SNUB LINES.
TW2007 3
H-K SOO C POWER TONG MARTIN-DECKER
4.1 WARNINGS - PERSONAL INJURY - Cont'd
4.1.8 The wol1<lng strength of the snub lines must be rated at 6800 pounds
minimum. Minimum 5/8 wire rope size made from Improved plow steel Is
recommended.
4.1.9 All hanging hardware, bolts, pins, back-up attaching bolts and snub lines
must be Inspected for tightness, wear and/or damage before each jOb o r
trip.
4.1.10 Read and comply with all warnings placed on t he tong and on other
manufacturers' parts on the tong.
4.2 WARNINGS - EQUIPMENT OR PROPERTY DAMAGE

Failure to comply with the following warnings could result In equipment or
property damage.
4.2.1 The tongs must be leveled and stiff arm or snub lines installed at right
angles to the centerline of the tong.
4.2.2 A spring hanger or means for free movement of the tong up or down must
be Installed in the hanging IIne_
4.2.3 The power unit must be the correct size for the tong. See "Specifications."
4.2.4 All relief valves must be checked and set as specified prior to running any
jOb.
4.2.5 A.P.I. or manufacturers' recommended torque values for the given tubing
or sucker rods must not be exceeded.
4.2.6 Do not operate tong with Incorrect or mismatched jaw sizes Installed.
4.2.7 Do not operate tong unless all parts are funCtioning properly and all safety
devices are Installed correctly.
4 TW2007
MARTIN-DECKER H-K 500 C POWER TONG
5. TORQUE CURVE
COMMERCIAL SHEARING 25 x 2 In. MOTOR
Oil TEMPERATURE AT 135 of
III
~ ~~+-~-+~--~+-~-+~~+-~-+~~~+-~-+~--+-~
Ii:
~ 25~~~~~~~~+-+-~~+-+-+-+-+-+-+-+-~~~~
I
w
:;,
~ ~~+-~-+~~+-+-~~~L-L--L-+~__+-+-~-+~~+-~~~~
~
HIGH GEAR
oL-~~~~~~~~~~~~~~~~~~~~~
o 2 4 6 8 10 1214 16 18 ~ 22 24
Oil PRESSURE -100 PSI
6. SPECIFICATIONS
These specifications comprise the Hillman-Kelley Model 500 C Power Tong:
TONG PERFORMANCE CHARACTERISTICS:
Running RPM (35 GPM, 132.6 lPM) at 800 PSi, 56.24 kg/cm2
High Gear . . • . . • • • . • • . • • • • • . . • . • • • . . . • 125 RPM
low Gear ••.•. • . . . ••. . . . . • • . • . • . • • • . . . 33 RPM
low Gear, 1000-2000 psi (70.3-140.6 kg/cm 2) • • • • • • • 17 RPM
Torque • . . . • . • . • • • • • • • • • • • • • • • . . • • • . . . ·4500 fI-lbs

(low Gear, 2000 psi, 140.6 kg/cm 2) . • • . • . . • • • • • 622.35 kg·m
'Higher torques are obtainable at 2000 to 2500 psi (140.6 -175.8 kg/cm 2).
Refer to ''Torque Curve" for torque In the higher pressure range.
TW2007 5
H-K 500 C POWER TONG MARTIN-DECKER
6. SPECIFICATIONS· Cont'd
TONG ECUIPMENT:
Four-Way Control Valve
Manual control for direction of tong rotation.
Hydraulic Motor
Gear type, flxed displacement, 2" (5.08 em) gears
2500 PSi (175.8 kg/em 2 ) maximum working pressure.
GearBox
Planetary reduction unit with 5.5 : I reduction ratio.
Dlverter (By-Pass) Valve
At Inlet side 01 Motor Valve
High Pressure Hydraulic Hose
3/4 In. (1.9 em) 1.0. x 50 It (15.2 m)
2250 psi (158.2 kg/em 2 ) working pressure
low Pressure Hydraulic Hose
lin. (2.54 em) 1.0. x 50 It (15.2 m)
200 psi (14.1 kg/em 2 ) working pressure
800 psi (56.2 kg/cm 2) burst pressure
Hydraulic Hose Couplings
Self-sealing quick-disconnect type wilh dust plugs
Torque Indicator (Optional)
Part Number 8500-5087 for 29 In. (56 em) handle
0 - 5000 It-Ib (0 - 691 .5 kg-m)
TONG WEIGHT:
Less Back-up . •. . . . • • . . . . . . . . . • . . . 469 Ibs (212.9 kg)
Wllh Back-up (mechanical) . . . • . . . . . • .•. 543 Ibs (246.5 kg)
Stili Arm . • . • • • . . . • . . . . • . . • . • . • . . • 35 Ibs (15.9 kg)
TONG DIMENSIONS:
Length • . • • • . • . • . . • • • . . . . . • . . • • • • 38 In. (88.9 em)
Width (over handles) • • . • • • • . • • • • . • •.•• 161n. (40.6 em)
Width (less handles) ••••••.•••• .• • . ••• 121n. (30.5 em)
Height . • • • • • . • . • •• ..• ••••••••.. • 40 In. (73.7 em)
HYDRAULIC REQUIREMENTS:
Maximum Pressure • . • . • • . . • • . . . . • . 2500 psi (170 kg/cm 2 )
Tandem Pump (1800 RPM) . • . • • • • • • . • . ' 35 GPM (132.6 LPM)
High Pressure Section •••• . . . . • . . • . . . 18 GPM (68.2 lPM)
Low Pressure Section • .• . ••.•••••• • • 17 GPM (64.4 LPM)
'800 -1000 psi (54.4 - 68.0 kg/cm 2 )
6 TW2007
MARTIN· DECKER H·K SOO C POWER TONG
7. MODEL AND SERIAL NUMBERS
FIG. 7·,: Tong Identlflcatlon Pial.
8. NOMENCLATURE
HANGER
(PIVOT T'tPE)
LO+HI
LO
+. ROD BACK·UP
FIG. 8.,: Tong In Tubing Conflgur.lIon FIG. 11-2: Tong In Rod Conflgur.tlon
TW2007 7
9. COMPONENT DESCRIPTIONS
Location of components described In this secllon can be found by referring to figures In the
"Nomenclature" section.
9.1 SAFETY BYPASS VALVE

This valve Is mounted between the Inlet to the four-way valve and the high pressure quick
disconnect coupling hall. Its function Is to cut all the flow of the hydraulic all from the hydraulic
motor and dlven the flow back to the hydraulic 011 reservoir. This diversion shuts the tong motor
down and provides added safety to making jaw changes, adjustments or servicing the tong.
9.2 FOUR-WAY CONTROL VALVE

A four-way control valve Is mounted on the tonI! for the purpose of controlling the dtrection of
tong rotation. It Is manually operated by the throttle lever.
9.3 HYDRAULIC MOTOR

The hydraulic motor Is mounted directly beneath the four-way valve on the tong. It converts the
hydraulic power Input to a rotary mechanical output and drives the tong's gear train.
9.4 HYDRAULIC HOSE COUPLINGS

The couplings on the tong are self-sealing and are provided with dust caps which must be used
when the hoses are disconnected In order to maintain clean hydraulic fluid and to protect the
threads on the brass coupling hall. The use of this type of coupling ensures the pressure and
return hoses, four-way valve, and fluid motor always being full of oil, and minimizes spillage.
9.5 TORQUE INDICATOR (Optional)

There Is a torque Indicator assembly available to mount on the tong. The gauge provides accurate
readings of torque (directly In FT-LBS) applied to the tubing. The unit Is completely Isolated from
Interference and uses lis own hydraulic sending unit which Is attached to the back-up line when
used.
9.6 BACK-UP ACCESSORIES

Back-ups are available for both tubing and sucker rods. The back-up prevents the tubing from
turning In the slips during make-up and assures that the joint breaks out at the top of the coupling.
II also ensures Ihal both threaded connections In the coupling are made-up.
9.7 ROCKER BAR-REVERSE SHIFTER

The SOOC dillers from some other longs In that 1\ operales In both dlrecllons while In Ihe upright
position. The In-out directional pins In the rocker bar controllhe jaw mechanism. The words "IN"
and "our' are cast In the top of the rocker bar and the operator selecls the proper side by
depressing the "IN" or "our' side of the rocker bar.
8 TW2007
9. COMPONENT DESCRIPTIONS - Cont'd
9.8 HANGER
The hanger on the tong serves a dual purpose. First, It provides a leveling adjustment. Second, It
allows venlcal travel between the tong and back-up during make-up and break-out operation. A
worn or non-functional hanger assembly will adversely affect tong and die life.
9.9 GEAR BOX

The planetary gear box provides a 5.5 : 1 reduction between the motor RPM and the gear train.
Torque Is transmitted from the motor output shaH through the planet gear frame to the pinion
shaft of the tong.
10. FIRST TIME START·UP PROCEDURE

The operator shOuld read and follow these Instrucllons and "Safety Precaullons" before attempting
to operate the tong for the first time. When preparing to operate a new or overhauled tong, or a tong
t hat has been in storage, perform all of the operations listed below. Before a roullne stan (at each
Shift), see Section 11.8 - Running Tong .
NOTE: If the tong Is used with 8 Hillman-Kelley Hydraulic Power

Unit. follow the St8rt-up sequence Included under "First Time
Start-Up Procedures" In the power unit manual BS well.
10.1 TONG RIG-UP

1. Remove any packIng materIal and clean tong.
2. Grease. (Section 15.4)
3. 011. (Secllon 15.3)
4. lubricate drag band. (Section 15.2)
5. Check for free operation of linkages and shift mechanism.
(SectIon 12)
6. Suspend In derrick. (Section 11.3)
10.2 HYDRAULIC HOSES

1. Clean couplings. (Section 11.2)
2. Connect hoses to tong and power unit. (Section 11.2)
TW2OD7 9
10.3 STARTING SEQUENCE

1. Back off hydraulic system pressure to 500 PSi or less.
2. Shift tong to neutral position.
3. Engage hydraulic system.
4. Push throttle lever toward tong.
5. Allow hydraulic fluid to circulate with tong safety valve In the
"off" position (handle down) and In the "on" position (handle
horizontal) for 10 to 15 minutes In each pOSition.
6. Set system pressure. Refer to "Operating Instrucllons" for the
power unit being used.
7. Check for leaks In system.
8. If operating In cold weather, put tong In high gear and rotate
2-3 minutes for wann-up. Check tong linkage adjustments.
Refer to Section 12.
10 TW2007
11_ OPERATING INSTRUCTIONS

Hillman-Kelley Power Tongs are assembled with parts carefully ma-
chined from selected materials. Each tong Is thoroughly tested and
Inspected and Is shipped from the factory with confidence that It will
efficiently perform any job for which Ir Is rated. The ensuing pages
have been prepared for your guidance. These procedures are neces-
sary and must be followed for proper operation and maximum life of
yourtong.
11 .1 FLUID REQUIREMENTS
The Hillman-Kelley Model 500 C Hydraulic Tubing Tong requires a
fluid volume for proper operation of approximately 35 to 40 gallons
per minute (132.5 LPM to 151.4 LPM) up to 1000 PSi (70.3 kg/cm 2)
and a minimum of 10 GPM (3.8 LPM) from 1000 to 2000 psi (70.3 to
140.6 kg/cm 2 ) for obtaining the proper torque In making up and
breaking out. Every effort should be made to keep the hydraulic
system clean. The couplings on the tong are self-sealing, and dust
caps are provided and should be used whenever the hoses are
disconnected. Use olthls type of coupling ensures the pressure and
return hoses, four-way valve, and fluid motor always being full of 011
and minimizes spillage.
Hydraulic oil specifications may be found In Section 13.
11 .2 HOSE AND HOSE CONNECTIONS

CAUTION: Before connecting the hoses, turn the safety valve handle
to the "Off" (handle down) position. Make sure there Is no pressure
In the system. Back off the relief valve handle before engagIng Ihe
prime mover. ALWAYS CONNECT THE 1" (2.54 em) RETURN HOSE
TO THE TONG FIRST, then connect the 314" (1.90 cm) pressure hose.
ALWAYS DISCONNECT THE 314" (1.90 cm) PRESSURE HOSE
FIRST. (Refer to Nomenclature.) ThIs prevents any pressure from
buildIng up In the fluId mOlar and seal. When attachIng the hoses to
'he tong, ALWA YS MAKE UP THE WING NUT COUPLINGS ALL THE
WA Y, but DO NOT HAMMER. If thIs /s not done, the restriction
formed by the self-sealing couplings not being fully opened will
cause Improper operation ofthe tong_ THE DUST CAPS AND PLUGS
PROVIDED SHOULD ALWA YS BE USED WHENEVER THE HOSES
ARE DISCONNECTED. Should the open end of the coupling be
allowed to come In contact with any dirt, It should be carefully
cleaned before putting on the dust cap or dust plug or beIng
connected. A very small amount of dIrt, sand, or foreIgn materIal can
cause serIous damage to the pump, fluId motor, and valves.
TW2007 11
11.3 SUSPENSION OF TONGS IN DERRICK

1. Hang the tong In the derrick with as long a line as possible at a
height to grip the tubing at least 6" (15 em) ABOVE THE UPSET.
For running rods, position the tong on the first rod by raising or
lowerlng It until the V's In the jaws match the squares on the
sucker rod.
The angle of the hanging line from vertical when tongs are on
tubing or rods must not be great enough to pull tong off pipe.
NOTE: For easiest handling of the tong during operations,

suspend with a counter-weight. 1
l[V(l
2. Attach the back· up line. A back-up line Is attached to the top FIG. 11-1: Stiff Arm aack·up
transmission cover (109). A stiff arm arrangement Is recom·
mended when running tubing (Fig. 11·1). It Is necessary to use
a cable when running rods because the rearolthetong must be
free to align with the backup jaw when removing tong from the
rods. II a cable Is used, the line must be properly secured and of
sufficient strength. A 1/2" cable (1.3 cm) Is minimum.
THE BACK-UP LINE MUST BE HORIZONTAL TO TONG: THAT
IS, IT MUST NOT PULL UP OR DOWN ON TONG WHILE IN
OPERATION. FOR CORRECT TORQUE READINGS, THE BACK·
UP LINE MUST BE ON A 90 DEGREE ANGLE WITH TONG.
NOTE: A back·up line must always be used, with or without

the tubing or rOd back·up assembly.
3. Level the long. The tong must be leveled on tubing or rods and
over the well bore.
II the tong Is equipped with a pivot type hanger (Fig. 11-2) use
adjusting boll (98) . Screwing It In will lower the fronl end of the
tong; backing off will raise II.
Spring hanger should not be completely compressed from we-
Ight of tong. Tong should have some bounce. II spring Is com·
pletely compressed trom weight of tong, II should be replaced.
Reterto Section 18.2.B.
FIG. 11·2: Lo ••1Adjustment

'or Pivot Type Hange,
12 TW2007
MARTIN-DECKER H-K SOO C POWER TONG
11.4 TUBING BACK-UP ASSEMBLY

Back-up accessory Is applied to the coupling when "coming-out" 01
the hole, as shown (Fig. 11-3), assuring that the pipe joint "breaks
out" at the top of the coupling. Note that proper position of back-up
Is on lower half 01 coupling.
When "going-Into" the hole the back-up may be applied to the body
ofthe pipe as shown (Fig. 11-4), thus preventing the pipe string from
turning In the slips and assuring that the make-up of both threaded
connections Is complete.
Install the tubing back-up assembly on socket (293) by Inserting pin
(273) through hole In socket and post (274).
How to use back-up assembly:
FIG. 11-3
1. Swing tong onto tubing.

2. Apply just enough throttle to set jaws.
3. Put on back-up.
4. Adjust crank (275) to grip tubing (Fig. 11-3), but keep slack
enough to stili come off pipe.
S. Break or make joint.
6. Release back-up.
7. Reverse tong to come off tubing.
NOTE: The back-up accessory cannot be used on critical

make-up joints, 8S the torque Indicator will not function
properly.
To change gripping direction lor "make-up" or "break-out", slide fixed

jaw (281) back In carrier (277) and rotate assembly.
NOTE: "IN" and "our'ls cast In the hook jaw (287). Inslall
assembly with corresponding notes facing up for going "IN"
hole or coming "our' of hole.
A second consideration for assuring proper Installation Is that when

tubing rotation Is to the right (clockwise), lever (286) Is on right, and
when rotation Is to the left (counter-clockwise), the lever Is on the
left. FIG. 11'"
The height of the baCk-Up may be adjusted by placing pin (273) In
the deSired hole of the post (274). After the back-up Is adjusted to
the proper height, hang the support ring on clip (299) In a position
which supports the baCk-Up jaw. There Is a clip (299) on either side
of the tong for make-up or break-out pOsitions.
TW2007
13
11.5 ROD BACK-UP ASSEMBLY

In$lall the Rod Back-Up Jaw Holder (260) beneath the tong by
Inserting the pin (265) through the ears on the lower transmission
cover (Flg _11-5). The back.up holder (260) should be left assembled
with the adju$llng screw (261), spring (263) and nut (264). After the
(265) pin Is In place, mate the (261) adju$llng screw with the (293)
clevis, which Is pinned to the (139) base plate.
How to use the rod back-up:
1. Select and In$lall the proper size back-up jaw with the pIn (267)
and keeper (266).
FIG. 11-5: Sucker Rod Blck-up
ROD SIZE BACK·UPJAW A... mbly
5/8" 8503-5369
3/4"-7/8" 8503-5370
1" 8503-5371
'·118" 8503·5372
2. Swing the tong onto the rod string and raise or lower It until the
V's In the tong jaws match the squares of the sucker rods_
3. Using the T-screw (261), raise or lower the back-up jaw until It
engages the mIddle 01 bottom squares.
4. Break or make connection.
5. The back-up jaw Is desIgned to pIvot If the rod squares are not
aligned after make-up. For easy removal olthe tong, simply shift
tong so back-up jaw Is lined up with the tong opening .
6. Release tong jaws and come off rods.
11.6 TORQUE INDICATOR

The Torque Indicator (Fig. , 1-6) Is In$lalled on the tong with the
cylinder as part 01 the back-up line. Mount the IndIcator In a con-
venient location lor the operator.
The damper Is used to control pressure fluctuations from the cyl-
Inder. Back the damper out until a smooth reading Is displayed by
the Indicating ann 01 the gauge. Do not back damper all the way out.
Too much damping will result In slow gauge reaction and Inaccurate CHARGING VAlVE
torque readings.
LOCK·HUT --'lJ~_.,J
I! the pl$lon 01 the cylinder Is lully extended when torque Is applied,
an all·purpose In$lrument 011 mu$l be added and the air bled from
the system. Proceed as follows: I_.,O..... ~. i
CYUN~':>~
~=~:CYUN'"
1. Fill reservoir and bleed air from pump.
2. Attach pump to cl)arglng valve.
"STON~.~~~~. .~
3. Back-out damper.
4. Crack cylinder port to bleed air from sy$lem. FIG. 11-': Torque l"dlcolOr Allombly
14 TW2007
MARTIN-DECKER H·K 500 C POWER TONG
11.6 TORQUE INDICATOR - Cont'd

5. Pump all Into system, taking care to keep reservoir lull.
6. Pump until no air passes cylinder port.
7. Tighten cylinder port and disconnect pump Irom charging valve.
IMPORTANT: Accurale lorque readings require correct tong

suspension and Inslallallon of Ihe back-up lIne. Refer 10
Section 11.3.
11.7 ADJUSTMENT FOR TUBING AND ROD SIZES

All jaws, whether for rods or tubing, should be handled carefully.
These are machined parts, not just castings, and the correct move-
ment In the tong Is dependent upon the care they receive. They
should be kept free 01 wax, dirt, sand, and above all else, free of nicks
or burrs on the edges.
To change jaws: FIG. 11-7: Changing Jaws
1. Rotate tong In either direction until jaws move toward center.
Turn salety valve handle to the "Off" position (handle down).
2. Place a screwdriver In the slot located on top of each jaw holder
(41) and pry out jaw holder (Fig. 11-7).
3. Push jaw all the way down until It seats.
4. Change opposite jaw per above Instructions.
5. Turn the salety valve handle to the "On" position
(handle horizontal).
All of the jaws, whether for rods or tUbing, have the same back and
will fit the jaw holders (41) on either side.
To change the dies In the jaws, remove the top die screw (247) and
slide die out, Fig. 11·8. Clean the die slots and Insert new dies.
Replace die screw. FIG. 11-8: Tubing J....
TABLE 11.1: JAW AND DIE SIZES FOR TUBING AND RODS
TUBING (Other Sizes on Request) RODS
NOM. 0 .0. JAW PART' DIE PART. SIZE DIEPARTI
3/." 1.050 1502-5064 1502-5071 5/8" 8502-5013
I" 1.315 8502-5064 8502-5071 314" 8502-5013
1..1/4- 1.660 8502-5062 8502-5085 7/8" 1502-5013
1-112" 1.900 8502-5P61 1502-5075 I" 850M014
1-314" 2.062 8502-5061 8502-5075 1·118" 8502-5056
2" 2.375 8502-5063 8502-5076
2-1/2" 2.875 8502-5065 1502-5158
2-112" 2.875 8502-5241'
3" 3.500 8502-5077'
,One pt..,. Jaw end die d..lgn.
TW2007 15
11 _8 RUNNING TONG
Before operating tong for the first time, refer to Section 10 - First
Time Start-Up Procedure_
Before a routine start-up, review the Safety Precautions and Warn-
Ings In Sections 3 and 4_
1. Grease and 011 the tong as described In Section 15- Preventive
Maintenance. Liberally grease t he cluster gear and Idler gear
bearings, Fig. 15-6.
2. Install the baCk-up and adjust for correct tubing or rod size.
NOTE: "the back-up Is not used, set the tubing as low as

possible In the Slips to prevent bendlng_
3. Select and Install the correct jaws and dies.

4. Connect the hydraulic hoses.
5. Make certain the tong Is level when on the tubing or rods and
over the hole_
6. Be sure the back-up line Is Installed and properly secured.
7. Determine and set the required hydraulic pressure as described
In "Making Up Rods" or "Making Up Tubing."
8. Grease the tong after every trip.
Controls are provided to operale the tong from ell her the front or the
side, see Section 8. When operating tong from the side, always stand
on the same side as the back-up line.
NOTE: This Is an open-throat tong designed to come 0"

the
pipe at each connection. Do not strip through tong, as this
may damage Internal parts.
To go In the hole, the directional bar (27) must be down on the right
side (IN) (Fig. 11-9). To come out of the hole, the directional bar (27)
must be down on the left side (OUT). This tong remains upright at
all times and operates In both directions without changing jaws or
dies. Only change the directional bar (27) when the rotor opening Is
stopped at the doors.
For IN operation, the throttle (19) (on the right hand side) Is pushed
to the rear and the jaws wilt close; the tong will rotate until the
desired pre-set torque Is encountered. Pull the throttle (19) forward,
and the jaws will retract or open. Position the opening at the door, FIG. 11·9: Directional Sar and Reve,..
and the tong Is ready to come off the tubing or rod. Levar
16 TW2007
11.8 RUNNING TONG· Conl'd
For OUT operation, the throttle (19) Is pulled forward, and the jaws
will grip and rotate. If low gear Is needed to break the JOint, shift to
low by pulling forward on the left hand gear shift lever (20). Afterthe
joint Is broken, shift back to high to spin out. Position the opening
at the door, and the tong Is ready to come off of the tubing or rod.
When Shifting gears, the tong rotor should be turning at a slow speed
In order for the HI·Lo gears to engage. If the tong Is stopped, the
position of the gear teeth may keep them from engaging. In normal
operation, Just slack off the throttle, and the tong will shift very
easily.
11.9 RUNNING MULTIPLE STRINGS

The SOO C tong was designed with the problems of running multiple
strings In mind. In as much as multiple strings must be run from the
back of the tong, the front controls must be taken off and back
controls put on. Remove the three handle bolls (87) and the clevis
pin (115) on the gear shift sIde. Remove the same handle bolts and
the shoulder bolt (85) on the throttle side. On the present throttle
side olthe tong there Isa back control gear shift handle. The present
throttle lever (214) can be used as the back control throttle. An
additional throttle handle can be attached to the opposite side of the
throttle shaft (21B) . A shift arm may be welded onto the shift lever
(lOB). Now the tong Is ready to attach the baCk-Up line and operate
the tong from either side. When ready to return the tong to front
controls just put the handles and pins back In place - no adjustment
Is necessary.
When operating the tong from the side, always stand on the same
side as the back-up line.
11 .10 BREAKING OUT TUBING AND RODS

Perform all operations described for a routine start up. When break·
Ing out rods or tubing, the relief valve setting on the hydraulic power
system Is not critical. Set It high enough to break the connections·
but not more than 2500 PSi (140.6 kg/cm 2 ).
Set the directional bar (27) In the correct position - OUT - by hitting
the left hand end down (marked OUT).
The right hand throttle (19) Is then pulled toward the operator, or
forward, and the rod Is broken out. If low gear Is needed, pull the
gear shift (20) forward, break the JOint, then shift to high by pushing
the shift lever to the rear. When the joint Is unscrewed, push the
throttle lever back away from the operator. The jaws will release.
Position the opening at the door, and the tong will then swing off the
rod.
If the throttle (19) Is actuated the wrong way for direction of rotallon,
merely push the throttle (19) In the other direction.
TW2007 17
11 .11 MAKING UP RODS

For opllmum performance, the sucker rod pin and coupling joint
must be made up to achieve the desired preload. Because of the
many variables Involved - machine asperilles, differences In ma-
terials, variations In lubricants employed, cleanliness of connec-
tions, and condillon of power tong equipment - torque does not
provide an accurate measurement of the repeatable desired preload
value In the sucker rod pin jOint.
Calculallons and test data show that a more accurate measurement
Is provided by the angular or clrcumferenllal displacement of a
coupling and pin after shouldering from a hand-light posillon. This
method Is preferred In the field to achieve the desired preload In a
sucker rod pin and coupling joint. It Is also a method of callbrallng
the tongs.
11.12 OIL TEMPERATURE

When using hydraulic powered rod tongs, It Is recommended that
the hydraulic 011 be circulated until a normal operating temperature
Is reached. This temperature should be maintained within a reason-
able level through tong calibration and Installation of rods.
11.13 JOINT CONDITION

To achieve sallsfactory preload results for sucker rod joints, the
joint must be perfeclly clean, undamaged, welliubticated and have
a free-running fit to shoulder contact. Applied displacement will then
efflclenlly preload the joint to prevent shoulder-face separation
during pumping.
11.14 CALIBRATION OF TONG

The tong must be calibrated to produce the recommended circum-
ferenllal displacement make-up values shown In Table 11.2. After
Inillal callbrallon, check the power tong calibration each 1,000 feet
and re-callbrate for each change In rod size.
Procedure:
1. Check condition of power tong. Circulate hydraulic 011 as dis-
cussed above. Scribed
Vertical
2. To avoid over-torquing a rod before the correct torque seiling Is Line
obtained, back off on the relief valve until the pressure Is low
enough to slowly turn the tong. Put tong In high gear.
3. Screw the box and pin together until they are In a shouldered
hand-light relationship. Scribe a fine venicaillne across the pin
and coupling shoulder to establish a hand-tight relationship, as
shown by Fig. 11-10. FIG. 11-10: Hand TIght Joint
4. Make up jOint with power tong operating and the tong throttle
depressed to the fully open position. Do not hit the throttle a
second time after jOint shoulder and tong have stalled.
18 lW2007
11.14 CALIBRATION OF TONG - Cont'd

5. Remove the tong and measure the circumferential displacement
of the scribed, hand-tlg ht vertical line. See Fig. 11·11.
6. Increase or decrease the tong operating pressure to achieve the
selected prescribed circumferential displacement, as shown In
Table 11.2.
7. Repeat Steps 4,5, and 6 until proper displacement Is achieved. Measured
Circumferential
Check calibration of tong for a minimum of 4 joints, for each Diwlacement
1,000 feet thereafter, and for each change In rod size.
8. For the Initial run of API Grade C and Grade K Rods, a constant
correction factor cannot be recommended because of Inherent
variables Involved. Therefore, It Is Imperative to make-up and
break the connection prior to calibration of power tongs If proper
preload Is to be assured.
FIG. 11-11: Made-up Jolnl
9. Once the joint Is made up and broken, follow the same procedure
as outlined In steps 1-7 above.
TABLE 11 .2: SUCKER ROD JOINT

CIRCUMFERENTIAL DISPLACEMENT VALUES
(All dimensions In Inches)
1 2 3
Running New Rerunning New
Grade 0 Grad .. C, 0, & K
DlspJacement Values Displacement V.'ues
RodSI.. Minimum MaxImum Minimum Maximum
1/2 6132 8/32 4/32 6/32
5/8 8132 9/32 6/32 8/32
3/4 9/32 11132 7/32 17132
7/8 11/32 12132 9/32 23132
1 14/32 16132 12132 14132
,.,/8 18/32 21/32 16132 19/32
If a pin Is crossed In the make-up, pull the throttle (19) forward and
stop at the door - then reverse the rotation by hitting the directional
bar (27) (OUT), pull the throttle (19) forward - this will unscrew the
joint - a matter of seconds Is required to do this. Then reverse the
procedure to start making up again. It Is not necessary to use low
gear for the rod make-up. Do not hit the throttle a second time after
jOint shoulder and tong have stalled.
TW2007 19
11.15 MAKING UP TUBING

Perform all operations described for a routine start-up. The relief
valve setting Is critical when making up tubing. Determine the tubing
manufacturer's recommended torque. Obtain required hydraulic
pressure for specific torque values from the torque curve, page 5.
Set the relief valve for proper pressure. On high pressure wells,
these stall pressures should be higher. High torque and critical
Joints should be made up using the tubing manufacturer's recom-
mended torques and taking direct readings from the torque In-
dicator. The pressure relief valve may be set at maximum, and low
gear should be used for correct torque readings. Accurate readings
are also dependent upon proper tong suspension, Section 11.3.
Refer to Section 11.6 for proper use of the torque Indicator.
To set the pressure for the tong, proceed as follows:
1. Adjust relief valve to less than 500 PSi (35.2 kglcm 2 ).
2. Swing tong on first joint of tubing.
3. Apply full forward throttle.
4. Adjust relief valve to required pressure.
5. Release throttle.
Set the directional bar (27) by hitting the right end down (IN), then
push the throttle (19), making It go away from the operator, for the
make-up. When the joint Is made up, pull the throttle forward and
the jaws will open. Rotate the jaws to the opening and remove tong
from the tubing.
11 .1 6 TONG SPEED
Tong speed Is purely a function of the amount of fluid delivered to
the tong. Rotor speed may be controlled by varying the position of
the throttle (19).
20 lW2007
12. LINKAGE ADJUSTMENT PROCEDURES

All tong linkage adjustments are Initially set at the factory, and the
tongs are checked for proper operation. Minor adjustments of the
throUle rods may become necessary to compensate for normal wear.
After an overhaul the linkages should be adjusted In the following
order:
1. Throttle rods.
2. Gear shift rod.
3. Gear shift tension.
NOTE: Make all linkage adjustments at a constant RPM of

the power source to simulate operating conditions.
12.1 THROTTLE RODS
12.1.1 Starting conditions

1. linkage Is assembled with set screws at all pivot points finger
tight.
2. Throttle rod (216) Is adjusted to setlhrottle (19) In the middle
position of grip (18) and throttle lever (214) In a vertical position
(Fig. 12-1).
3. Throttle rod (215) Is adjusted so that approximately 1/2" (13 mm)
of threads are exposed beyond the jam nut on the lower end 01
the rod. The upper clevis Is adjusted to sel throttle yoke handle
(198) In a horizontal, level position. Lock nut and capscrew (223,
225) are finger tight. FIG. 12·1: Throm. Rod Adjustment.
12.1.2 Adjustment sequence

1. Push throttle toward the tong.
2. Check lor full travel 01 throttle yoke handle (198) up from neutral:
a. Note position of handle (198) with throttle pushed all the way
toward tong.
b. Remove cap screw (225). Place a wrench on throttle yoke
handle and check lor additional travel 01 handle (198)
(Fig. 12-2).
3. Adjust rod end (228) to provide lull travel of handle (198). Install
cap screw (225).
4. Re-adjust throttle (19) to middle pOSition 01 grip (18).
FIG. 12-2: CI1ecklng Thronle Yoke
5. Pull throttle away from tong. H.ndl.T,....1
TW2007 21
12.1.2 Adjustment sequence - Conl'd

6. Check for full travel of handle (198) down from neutral as In
Step 2.
7. Adjust rod end (228) to give maximum possible travel of handle
(198) In both directions.
8. Re-adjust throllle (19) to middle pOSitiOn of grip (18).
12.2 GEAR SHIFT ROD

Adjust the rod end (92) to set the shifter (20) In the middle oflhe grip
(18) when the tong Is In neutral. Check for full engagement of high
and low gears.
12.3 GEAR SHIFT TENSION

To adjust the gear shift tension, turn set screw (52) In until the gears
will not shift (Fig. 12-3). Back out set screw for easy shifting.
FIG. 12-3: Gea, Shih Tension

Adjualment
22 TW2007
13. HYDRAULIC OIL SPECIFICATIONS

Performance and service life of all other components of a hydraulic
system are affected by the hydraulic system fluid. Some Of the factors
especially Important In the selection of 011 for use In a hydraulic
system are:
1. The 011 must contain the necessary additives to ensure high
antlwear characteristics. Not all hydraulic oils contain these In
sufficient amounts.
2. The 011 must have proper viscosity to maintain adequate sealing
and lubricating quality at the expected operating temperatures
of the hydrauliC system.
3. The 011 must have rust and oxidation Inhibition lor satisfactory
system operation.
Viscosity 01 fluid Is a measure of Its resistance to lIow as well as Its

ablilly to prevent metal·to-metal contact 01 moving parts. II Is recom-
mended that the lollowlng maximum and minimum viscosity ranges
of the 011 at start-up and during running be maintained:
Nominal: 150 - 300 SUS at 1DO OF (38°C)

Running: 70-250 SUS
At Start-Up 4000 SUS maximum
An antlweartype 01 heavy-duty Industrial hydraulic 011 comparable to

Sunoco Sunvls 754 Is recommended. A good grade 01 SAE 20 "MS"
automotive crankcase 011 can be substituted. Formost elflclent opera-
tion, the temperature 01 the 011 should not exceed 150 OF. (66°C.).
14. GREASE SPECIFICATIONS

Dueto the operating environment olthe tong, a water Insoluble grease
Is required. The grease should also have high pumpablllty to permit
appliCatiOn during very cold weather.
The grease recommended lor cold weather operation Is Shell 8&8,
Code 70919, which conlorms to Govemment Specifications MIL-G-
10924-C.
In milder climates, an all-purpose grease such as Shell Alvina 112 Is
recommended.
TW2D07 23
15_ LUBRICATION AND PREVENTIVE MAINTENANCE
IMPORTANT: The 500 C Is a compac/tong with many closely

machined parts_ To obtain the long life and best performance
from a tong, the operator must adhere to the following
Instructions on lubrication and preventive malntenance_
The dally Instructions pertain to roullne or dally sl artlng 01 a tong and

not to new equipment. For new tongs, carry out Instructions given
under "First Time Start-Up Procedures:'
The time Intervals given In the Instrucllons reler to actual operating
hours olthe tong_
15.1 CLEANI NG THE TONG

The most Important Item for trouble-free operallon Is cleaning the
tong. A buildup of wax and dirt will cause prematu re failure olthe
gripping mechanism and linkage assemblies.
For easy and thorough cleaning, submerge the entire head of the
tong In an approprlale commercial solvent. Connect tongs 10 hy-
draulics and rolale 2 - 3 minutes In both dlrecllons. Grease and 011
the long after cleaning.
15.2 DRAG BAND AND DRUM ASSEMBLY

The drag assembly Is localed on the bOllom of the long (Fig. 15-1)
and consists of the drag drum (1 18), drag band (121), mounting
brackets (122, 123), right hand and left hand, respectively, springs
(125), screws (127), washers (128), locknuts (129), drag band anchor
(126) and support brackets (124)_
Every elgh! hours, the drag band (121) should be lightly coated with FIG. 15-1
3OWoli for maximum IIIe_Too much all will cause Ihe drag assembly
to Slip, and the Jaws will not advance_
Adjust drag band by tightening nuts (129) evenly (Fig. 15-2) until
jaws grip and release. Tightening the nuts (129) beyond the point
where the Jaws move out and In (or grip and retract) will cause the
lining to overheat and accelerate the wear of the lining.
Inspect the drag band for wear. Replace when t here Is approximately
1/16 Inch (1.8 mm) lining on the steel band (121).
To replace drag band, proceed as follows:
1. Shut power unit down and tum safety valve to off (handle down).
2. Remove support brackets (124).
3. Remove nuts, washers, springs and bolts.

4. Slide band from drag drum. FIG. 15·2: Adlulling DrOll &.nd
S. Install new drag band with bolts, springs, washers and nuts.
24 TW2007
MARTIN·DECKER H·K SOD C POWER TONG
15.2 DRAG BAND AND DRUM ASSEMBL Y • Cont'd

6. Draw evenly on both sides and tap new drag band (121) around
drag drum to conform to drag drum (118). Check to see that
sloHed clip on back on drag band Is not binding on drag band
anchor pin.
7. tnstall suppa" brackets (124).
8. Adjust drag band.
CAUTION: After every trip, check the cap screws (120) for
tightness. Always shut the power unit down and turn the
safety valve to the off position (handle down) before per·
FIG. 15·3; Lubricating JIW Carr"'r
forming any of the steps from 2 through 8.
15.3 OIL
Every trip, lubricate the guard door springs and bushings, the rocker
bar pins (28) and two throttle rod clevises (126) with 30W 011 or
equivalent.
Every 8 hours, lubricate the jaw carrier (37) and jaw holders (41).
Four weep holes, two In the cover (36) and two In the rotor base (35),
are provided to all the jaw carrier (Fig . 15-3). Rotate the tong In both
directions to spread the 011 over the carrier. To all the jaw holders
(41), push the throttle to advance the jaws and 011 between holders
. and carrier. Retract jaws and 011 again.
15.4 GREASE
Grease the tong according to t he schedule In Table 15.1. When
greasing the tong, avoid getting grease on the drag band assembly.
One ortwo strokes with a hand gun Is sufticient forthe cam rollers
(70). Take care not to get grease on the drag assembly.
FIG. 15-4: Grel8lng Jaw Holder,
To grease the jaw holder rollers, use LO gear, put the tong Into IN IN Position
position - rotate the rotor to the right (In the hole) so the jaws are In
closed position. Rotate one full turn and stop opening of the rotor
at the opening of the housing (or at the doors). Open the doors and
you will see the grease fitting (43) between the two rollers (Fig. 15·4).
After greasing, reverse the tong rotor In the normal manner. Change
the rocker barto OUT. Again rolate the rotor one turn to the left (out
of the hole) and SlOP allhe door opening. This time you will see the
grease fitting on the right side of the tong (Fig . 15·5).
FIG. 15·5; Gr."'ng J.w Holder,

OUT Po.llion
TW20D7 25
15.4 GREASE - Cont'd
TABLE 15.1: GREASE SCHEDULE (DAYS)

ITEM (See Figs. 15-6 and 15-7) DAilY 8 40 180
Idler Gear. (5) X

Cluater Gear (10) X
Lower Transmlsalon Cover (17) X
Jaw Holdar Rolla,. (43) X
Directional Conlrol Assembly (K) X
Gea, BOI (203) X
Th,olll. Unkag. (l) X
Th,olli. and Gea, Shih Rod. (92) X
Cam Rollers (70) X
Spring Hango, (138) X
15.5 DUST CAPS

FIG. 15-6: Grease LocatIons (Bottom)
The dust caps and plugs provided must be used to protect the hose
couplings. upon removal of each dusl cap or plug from hose cou-
plings, Inspect each to see that openings are free of any dirt. Dip
coupling In bucket of solvent 10 clean. Do not submerge hose. If
wiping must be done, use a clean rag. Make certain that no dirt gets
Into the couplings both at assembly and disassembly. Hoses should
be wiped clean and stored In a warm place.
Forconnecling and disconnecting procedures, relerto Section 11 .2.
15.6 A WORD ON THE HYDRAUliC SYSTEM

Clean Is the word. When the tong Is powered by a MARTIN-DECKER
power un", the Instructions given In the "Lubrication and Preventive
Maintenance" section of the unit's manual must be followed . If you
are using your own hydraulic power source, care should be taken to
keep all filters In service. Use caution when adding oil to the reser-
voir to avoid Introducing contaminants.
The length of service which can be expected from the tong's hy-
draulic components Is directly related to proper maintenance of the
FIG.1S·7: Gr.ase location. (Top)
hydraulic system.
26 TW2007
MARTlN·DECKER H·K 500 C POWER TONG
16. TROUBLESHOOTING
The following notes on troubleshooting are general In nature and serve as a guide to analyze your
hydraulic and tong problems. Please refer any speCific equipment troubles to our engineering
department for Its consideration.
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
PUMP MAKES Plugged or restricted Intake line Clean Intake line and filter. Be sure
EXCESSIVE NOISE or Intake filter. filter Is of sulliclent capacity for
pump In use.
Plugged reservoir air vent. Clean or replace.
Oil of too high viscosity, too high Change oil, allow more warm·up
pour pOint, ortoo cold. time.
Air leaking Into system. Check to see that oil Intake Is well
below surface of oil In reservoir.
Check pump packing and line con·
nectlons on Intake side by pouring
011 over suspected leak. If noise
stops, the leak has been located.
Tighten jOints or change packing
or gaskets when necessary.
Loose or worn parts. Replace parts. 011 may be of 1m-

proper grade or quality.
Sticking vane (vane type pumps). One or more vanes sticking due to
solid contaminants (dirt, chips, lint)
or gummy deposit from oxidized
oil. Clean parts affected and
change oil If necessary. Check the
IIlter.
Pump drive speed too slow or Check manufacturer's recommen·

too fast. datlons.
Pump misaligned with motor. Check alignment.
HYDRAULIC SYSTEM Excess diSCharge pressure (relief Reset relief valve In accordance
OVERHEATING valve set too high). with maximum pressure required.
Check with manufacturer's recom·
mendatlons.
011 viscosity too hlg h or too low. Change 011. (Check pump and
motor manufacturer's recommenda·
tlon.)
TW2007 27
HYDRAULIC SYSTEM ExcessIve Internal leakage. RepaIr or replace worn pans, loose
OVERHEATING - Conrd packIng. Check all to see that vIs-
cosity Is not too low. Check for ex·
cesslve contamInation or wear.
ExcessIve frIctIon. Check pump for poorly fitted

movIng pans or for pumps as-
sembled too tightly.
Leaks In pump eheck valve or RepaIr or replace.

relief valve.
Oil reservoIr too small lor ade- Add larger reservoIr, or equIp with
quate cooling. heat exchanger.
Oil supply In reservoIr too low for MaIntaIn proper all level.
proper cooling.
Pump dIscharge beIng throttled Check open-center dIrectional val·

or unduly restrIcted. ves lor proper operation. Check
relief valve. Large pump volumes
shou Id not be allowed to remal n at
hIgh pressure for long perIods 01
time. Check all self-seal hose con·
nectlons lor proper engagement.
RestrIcted or undersIzed valves Clean valves and pIpIng. RedesIgn

or hydraulic lines. pIpIng system If under sIze.
EXCESSIVE WEAR OF AbrasIve contamInants In all. Replace filter element or Install

MOVING PARTS large filter. Change all more fre-
quently.
MIsalignment of movIng pans. Check and realign.
Operating at pressures above Check relief valve and reset.

manufacturer's recommenda-
tions.
VIscosity 01 all too low at work· Check and change to all of hIgher
Ing temperatures. vISCOSity or o f a better vIscosity
Index.
AIr In system. Bleed aIr and eheck for leaks. See

"AIr leakIng Into system" under
PUMP MAKES EXCESSIVE NOISE.
28 TW2007
MARTIN·DECKER H·K SOD C POWER TONG
EXCESSIVE WEAR OF Excessive wear of packing Check for misalignment of moving

MOVING PARTS· Cont'd glands. parts, vibration and excessive side
thrust on shafts.
Improper suspension of tong In Hang properly. (Section 11.3).

derrick. Hanger bottomed out.
TONG RUNNING TOO Pump Intake line plugged. Clean Intake line and filter.
SLOWLY
Reservoir 01/ level too low. Add 01/.
Air leak In pump Intake line. (01/ Repair the leak. See "Air leaking
In reservoir may be foamy.) Into system" under PUMP MAKES
EXCESSIVE NOISE.
Pump speed too slow. Check manufacturer's speed

recommendations and actual
speed of pump. Vane type pumps
will not prime If running too slowly.
Excessively worn or damaged Replace. Follow manufacturer's

pump or motor. recommendations.
WARNING: Refer to procedures NOTE: Follow this procedure to

"e" and "f". Do not pump de/ennlne which Is defective.
hydraulic pressure directly Into
one-half of a self sealing cou· a. Ollis at operating temperature.
pIIng. Couple the matIng half,
whIch should have B hIgh pres· b. Set relief valve at 2000 psi
sure pIpe plug screwed Into the (154. kg/cm 2 ) or at maximum,
open end, to the coupling half. whichever Is less.
Failure to follow thIs procedure
may result In failure of the self· c. Place a substantial wooden
sealing mechanism and loss of block In the tong opening to
hydraulic 011. prevent rOlatlon.
d. To avoid damaging Ihe housing,

the tong must be In high gear.
Apply full throttle and record
hydraulic pressure to the tong.
e. Disconnect high pressure hose

and set relief valve at less than
500 psi (35.2 kg/cm 2).
TW2007 29
TONG RUNNING TOO

SLOWLY - Cont'd I. Run pump and gradually In-
crease pressure with relief
valve. Record the maximum
pressure obtainable by the
pump.
g. The lesser of the two readings

will determine whether the
pump or motor Is at fault.
Pump control Improperly set Check position 01 control.

(variable delivery pumps).
Viscosity of 011 too high. Some pumps will not prime If the
ollis too heavy. Check
manulacturer's recommendations
and viscosity 01 011 used.
Viscosity too low:

a. Excessive heat. See HYDRAULIC SYSTEM OVER-
HEATING.
b. Presence of diesel, gaSOline, Change 011.

etc. In 011.
c. Improper grade of 011. Change to 011 01 a higher viscosity

or 01 a better viscosity Index.
Restriction In line between power This condition may be detected

unit and tong. when pump pressure Is not reach-
Ing the tong or when excessive
back pressure Is created In the
return line. The return line pressure
should be about 100·1 SO psi (7.03-
10.54 kg/cm2). Check sell·seal cou-
plings to make certain they are
properly engaged. Check cou·
pllngs lor rubber pieces lodged In
valves. If clear, check for collapsed
Inner layers of the return hose.
Improperly adjusted throttle rod. Rs-adjust, Section 12.1.
Hose connections not made up Check hose connections prote-

properly. dure In Section 11.2.
30 TW2007
MARTIN· DECKER H·K SOD C POWER TONG
TONG WILL NOT Relief valve on unit or valve on

DEVELOP SUFFICIENT tong not working:
TORQUE
a. Set too low. Increase seiling. To check, block

the oil line beyOnd the relief valve
and determine the pressure with a
pressure gauge.
b. Valve stuck. Check for dirty or gummy sludge.

Check for contamination of oil.
Check for broken valve spring.
c. Valve leaking. Check valve seat lor scouring.

Check oil seals. Check for particles
stuck under valve stem.
Stuck, worn or damaged pump Inspect and clean. Replace worn or

parts. broken parts. Check relief valve
(See "Relief valve on unit or valve
on tong not working".)
Pump speed too slow. Check prime mover speed.
Viscosity 01 oil too high. Some pumps will not prime If oil Is
too heavy. Check viscosity at work·
Ing temperature (alSO at Initial
temperature, If this Is considerably
lower).
Viscosity 01 oil too low. See "Oil viscosity too high or too
low" under HYDRAULIC SYSTEM
OVERHEATING.
Oil bypassed to reservoir. Check relief valve for proper opera·

tlon. Check directional valves:
open center neutral position
should return oil to the reservoir.
Tong motor worn or damaged al· Replace or repair worn or damaged

lowing excessive slippage. parts. See "Excessively worn or
damaged pump or motor" under
TONG RUNNING TOO SLOWLY.
Excessive drag In long due 10 Repair or replace damaged parts.

damaged bearings or gears.
TW2007 31
TONG WILL NOT Restriction In line between power This condition may be detected
DEVELOP SUFFICIENT unH and tong. when pump pressure Is not reach-
TORQUE - Cont'd Ing the tong or when excessive
back pressure Is created In the
return line. Check self-seal cou-
plings to make certain they are
properly engaged.
Defective torque gauge. Check torque gauge cylinder to as-

sure proper quantity of all. Make
sure dampening screw has been
loosened and that the gauge Is
calibrated for proper handle length.
FAILURE OF TONG Rotor Is not In proper position. Use throttle to re-posltlon rotor.
DOORS TO OPEN
Obstruction In door arms. Check pivot points and anns.
FAILURE OF JAWS TO Improper tong suspension. See Section 11.3.

GRIP CASING OR TUBING
Dull dies. Replace dies or clean with wire

brush.
Too much lubricant on drag band. See Section 15.2.
Improper jaw or die size. See Section 11.7.
FAILURE OF TONG TO The shifting handle Is either Replace or straighten If possible.

SHIFT OR DIFFICULTY IN broken or bent.
SHIFTING
TenSion not adjusted properly. Re-adjust. See Section 12.3.
Shift Is attempted at too high Shift at lower R.P.M. or after

R.P.M. momentary stop.
POOR DIE LIFE Improperly suspended tong ; tong Refer to Section 11.3.
hanger bottomed out.
Tong worn excessively. Repair tong as required.
Improperly reconditioned dies. Replace.
Ole slots are worn In jaws. Replace jaws. see Section 11.7.
32 TW2007
JAWS DO NOT CLOSE Check the directional bar (27) lor

correct pOSition.
Tong could be full 01 wax. Pour sol-

vent In tong while rotating. Grease
tong when clean.
Check drag assembly, Section 15.2.
Check jaw holders for nicks or

burrs on edges.
JAWS DO NOT RELEASE Check the directional bar (27) for

correct position.
Check for broken rocker bar pin

(28). See Step 15, Section 1B.2.1.
Worn jaw mechanism, Section

18.2.1. Dll1ln jaw mechanism.
Clean.
TONG ROTATES IN Check hose connections,

WRONG DIRECTION Section 11.2.
HYDRAULIC OIL IN TONG Indicates that the lower seal (160-1,

HOUSING -2, -3, -5) on the motor or the motor
shaft (172) Is worn. Replace as
necessary.
GENERAL 011 drain periods not frequent Check by regular sampling and
The following factors are enough. analysis of 011.
responsible lor most
complaints 01 Inefficient
hydrauliC operation:
Air leaks.
Failure to select proper hydraulic

oils.
Defective paCking and seals.
Inadequate understanding of the

components 01 the hydraulic sys-
tem.
TW2007 33
17_ STORAGE INSTRUCTIONS
17.1 PREPARING TONG FOR STORAGE

When a tong Is to be stored or removed from operation for a period
of time, special precautions should be taken to protect the Interior
and exterior of the tong from rust accumulation and corrosion. The
parts requiring allenllon and the recommended preparation Bre
given below.
It will be necessary to remove all rusl or corrosion completely from
any exposed part before applying II rust preventive compound.
Therefore, It Is recommended that the tong be processed for storage
as soon as possible after removal from operation. Storage should
be In a building which Is dry and can be heated during the winter
months. Moisture absorbing chemicals are available commercially
lor use when excessive dampness prevails in the storage area.
17.2 TEMPORARY STORAGE (30 days or less)

To proteC1 a tong lora temporary period oltime, proceed as follows:
1. Clean entire exterior of tong with fuel 011 and dry II with air.
Cieanlng Is especially Important if unit has been used around
salt water.
2. Grease and 011 the tong as recommended under "Lubrication
and Prevenllve Malntenance_"
3. 011 four-way valve spool (178) through the cover (182) op-
posite the directional control assembly_
4. Cover the entire unit with a good weather-resistant tarpaulin
or other cover If it must be stored outdoors. A clear plastic
cover Is recommended for indoor storage.
17.3 EXTENDED STORAGE (30 days or more)

When a unit Is to be removed from operation for an extended period
of time, prepare It as follows:
1. Perform Steps 1, 2, and 3 of "Temporary Storage."
2. Spray all exterior surfaces of the tong and power unit with a
suitable liquid automobile body wax, a synthetic resin var-
nish, or a rust preventive compound.
3. Cover the tong and power package with a good weather-resis-

tant tarpaulin or other cover If It must be stored outdoors. A
clear plastic cover Is recommended for Indoor storage.
The stored unit should be InspeC1ed periodically. If there are any

Indications of rust or corrOSion, corrective steps must be taken to
prevent damage to the parts. Perform a complete Inspection at the
end of one year and apply additional treatment as required.
For restoring the tong to service, refer to Section 10.
34 TW2007
MARTIN-DECKER H-K SOO C POWER TONG
1a. OVERHAUL PROCEDURE

The long life and dependability built Into these tong s can be realized
through proper operation and maintenance. Of equal Importance Is
the use of proper procedures during an overhaul.
Before any work Is done on these units, It Is suggested that all the
steps required for assembly and disassembly be reviewed by the
serviceman. Such a digest will familiarize him with the subassemblies
and any special considerations required for proper servicing 01 the
tong.
Sufficient illustrations are provided and referenced Inthe procedures.
The numbers used In the text (called out In parentheses) relerto items
as noted on the illustrations and In the parts list IPL 2007 which Is
Included as a supplement to this manual. Any welding on the tong
should be done with stainless steel rods.
1B.1 DISASSEMBLY
1. Steam clean or otherwise clean the exterior of the tong. After
each sub-assembly Is rem oved and disassembled, the In-
dividual parts should be cleaned.
2. Suspend tong on hanger (F) to remove guard doors (23, 24)

and springs (33, 34).
3. Remove leveling bracket (101).
4. Remove pin (232) from spring hanger bracket (231) and
remove hanger assembly.
5. Disconnect gear shift rod (21) at the front shift conlrol (20)
and rear shift link (108).
fiG. 18·1 : Throttle Rod lind
6. Disconnectlhrottle rod (216) at the throttle handle (19) and Dlrecllonal Assembfy
rear linkage (214).
7. Remove throttle (19) and shifter.
8. Remove the front control grip assemblies (18).
9. Disconnect throttle rod (215) Irom throttle yoke handle (198).
10. Remove nuts (174) and two studs (175) and remove directional
control assembly (l), Fig. 18-1.
11. Remove two nuts (191).
12. Remove bracket (102) and lock nuts (194).
13. Lift motor and valve assembly straight up to remove.
14. Check the throttle linkage sub-assembly for wear. The throttle
lever (214) should rotate easily with no up and down or side
movement, Fig. 18-2.
FIG. 18·2: Thronle Rod
TW2007 35
H·K 500 C POWER TONG MARTIN·DECKER
1B.1 DISASSEMBLY - Cont'd
15. Remove the grease IIttlng (56) from side of gear box to allow
clearance for removing throtlle linkage, Fig. 18-3.
16. Remove two cap screws (222) and remove linkage assembly. 56
17. Remove the two rear cap screws (116) from gear housing (203)
and 11ft housing straight up to remove.
lB. Remove four cap screws (190) and remove motor adapter (243)
and planet gear frame assembly, Fig. 18-3. Put motor adapter In 209
vice and drive out planet gear frame'. If bearing (211) comes out
with the planet gear frame, put assembly In vice and chisel off
bearing.
19. Turn gear frame assembly (207) over In vice and drive planet C~>rt--212
gear shafts (208) out. Shafts must be driven from bottom side,
Flg. 1B·4.
20. Remove pin (73) In shift rod lark (3) through access hole In the
side of top transmIssIon cover (109).
21. Remove roll pins In Inner shift lever (105) and remove shift link
(lOB) and outer shift lever (104).
22. Remove the spring hanger bracket (231 I, If applicable.

fiG. 18·3: Gear Box Assembly
23. Flip tong over.
24. Remove drag band support brackets (124) from housIng cover
(38), FIg. 18-5.
.h
FIG. 1B~: ptanll Go.. ShIh'
FIG. 18·5: Drag Band Support Bracket.

and Cover
36 TW2007
18_1 DISASSEMBLY - Cont'd
25. Remove locknuts (129), bolls (127), springs (125), and plain
washers (128) from drag band (121) and remove the drag band,
Flg_18-6.
26_ Check drag band for wear.
27. Remove cap screws (130) and lockwashers (131) from housing
cover (38) and remove right hand mounting bracket (122) and
left hand mounting bracket (123), Fig. 18-6.
28. Remove cap screws and lockwashers (120, 119) from jaw carrier
(37) and remove drag drum (118), Fig. 18-7.
29. Remove bulton head sockel screws (90) and lockwashers (93)
and free rear of springs (33, 34), Flg_ 18-8.
AG. 18oG: Remo~ng the Drag Band
30. Remove bullon head socket screws (72), spring cone discs (99)
and guard door bushings (22) from housing cover(38). Slip hook
of springs (33, 34) from arms of guard doors (23, 24), Fig. 18-8.
31. Remove bullon head sockel screws (71) and guard door bush-
Ings (22) from housing (39) and remove guard doors.
32. Remove three grease fittings (56), Fig . 18-9.
FIG. 18·7: Removing the Or'9 OrP.Jm
AG. 18-8: Removfng Spring.

ond GUlird 000,.
TW2007 37
H·K 500 C POWER TONG MARTIN-DECKER
18.1 DISASSEMBLY· Cont'd
33. Check the condition 01 the gear shaft bushings (4). There should
be a press fit belween bushing and shalt. II bushing Is worn or
the weld Is broken, the bushings must be replaced. Grind weld
from bushing to housing and remove old bushings. Do not
replace at this time, Fig. 18-9.
34. Remove lour bolts (146) and socket (145).

35. Remove gearshift tension assembly (52, 53, 54), Fig. 18-10.
NOTE: Magnet may be necessary to remove ball (54).
36. Remove clevis base plate (122).

37. Remove two bolts (55) and pry evenly to remove lowertransmls-
slon cover (17).
38. Remove bearing spacer (1), Fig. 18·32, page 45.
39. Remove six cap screws (75).

FIG. 18·9: GruN location.
40. To remove cover (38), pry evenly around perimeter. Be sure
shafts do not come up with cover.
41. Remove three thrust washers (6, 9), Fig. 18·31, page 45.
42. Remove the Idler gears (5), Fig. 18-31, page 45.
52-~
32
43. Remove rotor assembly. 53
54
44. Remove bearing sleeves (88) and lower thrust washer (6). If
these can not be removed, drive out the shaft.
45. Use gear puller to remove high speed pinion (16). Tapped holes
are provided In pinion lor this purpose. See Fig. 18-28, page 44.
17'--"'t:::::::::::::'
FIG. 18-10: LowefTranamlulon Cover
46. Remove low speed pinion (14), shift rod lork (3) pinion shalt
(103), and thrust washer (2). See Fig. 18-29, page 44.
47. Remove cluster gear assembly (A) and thrust washer (8), Figs.
18-29 and 18-26, pages 44 and 43, respectively.
48. Put rotor In vice and remove fifteen cap screws (81) In the rotor
cover (36). Tapcoverto remove, Fig. 18-11.
FIG. 1.·11: Rotor Auombly
38 TW2007
16.1 OISASSEMBLY - Conl'd

49. Pull out jaw carrier assembly (37).
SO. Remove jaw holder (41) and bow string (30).
51. Flip tong over.
52. Remove two bolts (114) from top transmission cover (109) and
pry cover evenly to remove. Note the four dowels (110, 117) In
cover, Fig. 18-12. FIG. 18·12: Top T,.n8ml .. lon Cover
16.2 ASSEMBLY
1. Completely flush the tong housing and all paMs with a com-
mercial heavy-duty solvent. Thorough cleaning of each paM Is
absolutely necessary before It can be satisfactorily Inspected.
2. Check for bent or stretched housing. Dimension "AU Is
measured between center lines 01 the cam roller shaft holes;
5.1 36 In. (130.5 mm) maximum, Fig. 16-13. Return to factory
for repair.
3. Inspect the cluster (7) and Idler gear shaft (13) holes In the FIG. 18·13: Checking lor
housing. There should be a press fit between shaft and hous- Streched Housing
Ing. Return to factory for rework If required.
4. Inspect the Idler and cluster gear shafts lor corrOSion, pitting,
or galling. Check for clear grease channels through center 01
shaft. Replace shafts as required.
NOTE: When Installing a new cluster gear shaft (7) always

use B new bushIng (4).
5. Check all cam rollers (70) In housing (39) and cover (36) for
any side movement, cracks, or tight spots. Rollers should turn
freely. Replace as required.
To replace a cam roller, Insert bearing shaft through housing.

Using a small punch In center of shaft only, Fig. 18-14. Lightly
tap roller until It seats. Failure to lollow these Instructions can
result In pre-mature failure of the cam roller.
Torque cam roller nut (26) to 30-40 It-Ibs (4.1-5.5 kg-mI. Check
for free rOfation. FIG. 18·14: So.Ung the CoIm Roller.
TW2007 39
18.2 ASSEMBLY - Cont'd

6. Check for excessive movement In any direction of the Inner
race of the pinion shaft bearing (64). Replace as necessary.
Install with the sealed facing out, Fig , 16-15,
7. Tap four pins (1 10, 117) flush with underside of t ransmission
cover (109), Fig. 16-15.
8. Set cover (109) on housing (39). Drive pins In place, and Install
two cap screws (114). See Fig. 18-12, page 39,
9, Check for free play of shift rod fork (3) In bushing (107), Rod FIG. 18-15: Pint and Be.rlng on
should work easily up and down, Replace bushing If required. Tranlmlaalon Cover
A new bushing may need to be reamed, Fig , 16-16,
10, Flip tong overto assemble geartraln.
18.2.1 INSPECT ROTOR ASSEMBLY
11, Check rotor (35) for worn or missing teeth. Badly worn teeth
Indicate that the rotor Is being pushed forward In the tong.
Check for a stretched housing (Step 2) and minimum dimen-
sions on the rotor and cover, Fig. 16-17.
1----- 7.855 MIN . - - - - - - l

Rotor CO". , (36)
~~~;.00;5~S~tlP
L
M inimum FIG. 18·16: Checklng Shift Rod Fork In
5.780" (REFJ Bushing
7.700" (REFJ - - -....
7,700" (REF .l
5.9" (REF.l
Rotor 135'
1 - - - - - 7.855 M I N . - - - - - - i
FIG. 18·17: Critical Dlmen.lonl on ROlor and Rolor Coy.,
40 TW2007
MARTIN·DECKER H·K SOO C POWER TONG
18.2.1 INSPECT ROTOR ASSEMBLY · Cont'd
12. Inspect four cams (40). Some grooving Is permissible, but the
wear should be even over the length of the pattern. If the wear
pattern Is brlnelled over the edge of the cam, It must be
replaced. See FIg . 111-18.
When checkIng or Installing cams (40), the leading edge
must be even with the rotor detent and bolts (68) must not
protrude beyond flush.
13. Check rotor cover (36) for mInimum dimension as

noled In Fig. 111-17. Replace II necessary.
14. Check lor broken or cracked rotor stop pins (25).
NEW USABLE
fiG. 18-18; Cam Wear and In.tallatlon
15. Check dlrectronal assembly for lightness 0 1 roll pIns, brackets,

and broken or cracked rocker bar pins (28), Fig. 111-'9.
16. The leadIng edges olthe rolor (35) and cover (36) openIng must
be tapered and free 01 burrs.
17. Set the jaw carrier In the rotor with the openings aligned. Check
for excessive side movement 01 the carrier In the rotor,
FIG. 18·19: Dlrectlonsl Aooombly
Fig. 111-20. If there Ismorethan .025-.030cleara nce (.64-.76 mm)
at the opening, the carrIer and/or rotor should be replaced. Too
much clearance In this area may cause the jaws to bind In the
carrIer under high torque.
18. Remove the carrier from the rotor and set It In the rotor cover.
Repeat the checks In Step 17.
19. All edges on the carrIer must be free 01 burrs. The leadIng
edgesolthe carrIer should be chamfered as noted In Fig. 18·20.
FIG. 11·20: CIIocklng Jaw Car.... and

Rotor Side Mov....ent
TW2007 41
18.2.1 INSPECT ROTOR ASSEMBLY - Cont'd
20. Inspect jaw holder rollers (43) for free movement, FIg. 18-21.
There should be no sIde play.
21 . Remove two set screws (42) and drIve out roller shaft (44),
FIg. 18-21.
FIG. 18-21 : J.w Hold., Auembly
22. Inspect shafts (44) l or groovIng, pilling, or cracks. Replace as
requIred. Be sure grease holes are clear.
23. Check the sIdes of the jaw holder (41) lor brinelling. The sIdes
must be parallel at all poInts. Replace as required.
24. Check the clearance between the jaw holders (41) and carrier
(37), FIg. 18-22. Note that the jaw beIng checked must be In the
advanced poslllon and the leeler gauge placed as shown. "
there Is more than .030 clearance (.76 mm), the jaw holder
and/or the carrIer should be replaced. Too much clearance In
thIs area will cause the jaws to bind In the carrIer under hlg h
torque.
NOTE: If the carrier Is equipped with wear plates In this

area, the plates are all thaI must be replaced. See Fig. 18-23 FIG. 18-22 : Checking Clearance of Jaw
and Table 18.1. Holder. and Carrier
,
TABLE 18.1 : CARRIER WITH WEAR PLATES
Part No_
Item Req'd Descrlpllon •
1 1 8502-5267 Jaw Carrier
2 2 8502-5268 Wee, pc.te, Front
3 2 8502-5269 We.r Plat., Rear
4 8 901538-9 Socket Hd. Shoulder Screw
5 8 902395-1 AI.loc Nut
FIG. 18·23: Carrier with Wea, pt.,"
25. Install rollers (43) with lip facIng center secllon 01 jaw holder,
FIg. 18-21_
26. Install shaft (44) and two set screws (42).
27. Install grease fitting (50) and grease assembly. Check lor free
movement 01 rollers In both dIrections.
28. Install new roll pIns (49) In lower positIon on jaw holders,
FIg. 18-21.
29. Check bow sprIng blocks (46) for tightness.
42 TW2007
MARTIN·DECKER H·K SOO C POWER TONG
18.2.2 ASSEMBLE ROTOR
30. Assemble jaw holders (41) bow spring (30), and Install holders
In jaw carrier (37). Check for free movement of holders In
carrier, Fig. 18-22. Pack Inside of rotor wIth grease.
31 . Install jaw carrier assembly In rotor with opening aligned.
32. Install rotor cover assembly; alternately and evenly torque

bolts (81) to 30·35 ft·lbs. Use new bolts on reassembly. See Fig.
18-11. ~ QII •
FIG. 18·24: Checking Moyemenl of Jaw
33. Check for free operation olthe jaw carrier, Fig. 18-24. Jaws and Carrier
carrier should travel easily In both directions.
18.2.3 ASSEMBLE GEAR TRAIN
34. Pinion shaft (103) should have a slight press fit Into bearing
(64) and splines should not be worn over half the flat on crest
of spline, Fig . 18·25. Replace If necessary.
35. Install bearing thrust washer (2) on shoulder of pinion shaft
(103) and Install shaft.
36. Install cluster gear thrust washer (8), Fig. 18-26.
37. Check cluster gear base (11), Fig 18·27, for excessive wear.
Replace when wear exceeds more than quarter of flat on crest
of teeth.
38. Replace bearing set (66) In cluster gear. The bearing set can·
slsts of three bearings. Two of these have a seal on one side. FIG. 18·25 : We.r Are. or Pinion Short
The third has no seals. Install seals to outside on each end of
set and the bearing with no seals In the center position.
39. Install cluster gear assembly, See Fig. 18-29.
FIG. ,8-26: Inatolllng PInion Shalt

FIG. 18·27: ClulI.r .nd Idl.r Geers
TW2007 43
H·K 500 C POWER TONG MARTlN·DECKER
18.2.3 ASSEMBLE GEAR mAIN· Conl'd

40. Check clutch surface on high and low
speed pinion 14 and 16. Replace II worn
on an angle, Fig. 18-28.
NOTE: Always replace high and lowspeed

pinions as a set.
41 . Inspect shift rod lork (3) lor fatigue cracks

at rod and fork joint and grooving between
notches on rod. A deep groove In this area
will allow tong to jump out 01 gear.
Inspect yoke on shift rod for wear. the lork
should be replaced II yoke Is worn more
t han one quarter ollis original thickness.
Check for free play of shift rod l ork In FIG. 18·28 : Low and High Speed Plnlona
housing before Installing pinions.
Rod should work easily up and down with
a minimum 01 lateral movement.
II, when Installing the low speed pinion on the pinion Shaft, the
pinion slides easily on the shaft and l alls to snap Into the
groove provided l or meshing wi t h high speed pinion, t he
retaining ring (15) may be at fault and should be replaced.
42. Fit shift rod lork (3) In groove 01 low speed pinion (14) and
Install assembly, with retainer ring (15) lacing up, on pinion
shaft, while aligning the pin end of shift rod with proper hole
In housing, Fig . 18·29.
43. Check lor excessive play In any direction 01 the high speed
pinion bearing (51), Fig . 18-32. To replace bearing, t he retainer
ring (60) must be removed, a new bearing pressed In, and the
retainer replaced. See Fig. 18·28, which shows the retainer ring
groove.
44. Install hl·speed pinion on pinion shaft with clutch area down.
FIG. 18·29: Inotalling Shift Rod Fork

a nd Pinion
44 TW2007
MARTlN·DECKER H·K 500 C POWER TONG
18.2.3 ASSEMBLE GEAR TRAIN· Conl'd

45. InSialithe Idler gear thrust washer (6) with cup side lacing up,
Fig. 111·30.
46. Install sleeves lrom bearing set (88) on Idler gear shafts, Fig.
18-30.
47. Align rotor opening with either Idler gear shaft, and InSiall rotor
assembly In housing, Fig. 18-30.
48. Inspect Idler gears (5) lor wear. Replace If teeth are worn more
than a quarter 01 flat on crest 01 teeth. FIG. 18-30: Idler Gea, Thrull w•• herI
endS'Mv..
49. Replace bearing set (88) In Idler gears. Press In bearings,
leaving a lip the height 01 the recess as In Fig. 18-27.
50. InSlalildler gears (5), Fig. 18·31.
51. Liberally pack the gear train with grease.
52. Inslalltwo Idler Ihrusl washers (6) with cup lacing down,
Fig. 18-31.
53. Inslall cluSier gearlhrusl washer(9) with chamlerlaclng down

on gear, Fig. 18-31.
54. Tap cover (38) Inlo place with 5011 mallet.
55. Install two hanger clips (296) (For Back·Up support only). FIG. 18.:)1 : Inol.lllng Th,u.1 W.sh ....
56. Alternalely lorque six bolts (75) and tighten cover (38) 10
housing evenly.
57. InSiall bearing spacer (1) and press bearing (32) on pinion shaft
(103), Fig. 18-32.
58. Check condition 01 shift rod bushing In lower transmissIon

cover (17). Replace If necessary.
59. Check lor play In pinIon shaft bearIng (32) and replace II
necessary.
FIG. 18-32: Inllllllng Beorlng SPIcer
TW2007 45
18.2.3 ASSEMBLE GEAR TRAIN - Cont'd
60. press transmission cover (17) onto bearing (32).
61. InSiall clevis base plate (122). See Fig. 18-33.
62. InSiall new ball (54), spring (53), and set screw (52). See
Flg.18-10.
63. If the gear shaH bushings (4) have been removed, Install new t-
bushings. Tack weld to cover (38) with stainless steel rod,
Fig. 18-33.
64. InSiall three grease fillings (56), Fig. 18-33. Note the longer
grease fitting for the cluster gear shaft.
FIG. 18-33: Lowe, TranemlNlon Cover

Asaembly
18.2.4 INSPECT AND REPAIR DRAG ASSEMBLY
65. Inspect drag drum (118) for wear, nicks, and surface defects.
Replace If drag band surface Is badly worn or damaged.
66. Install drag drum (118) using new cap screws and lockwashers
(120,119) to secure drag drum (118) to the jaw carrier (37),
Fig. 18-34. FIG. 18-34: Ins'olllng .h. or.g Drum
67. Attach right hand mounting bracket (122) and left hand mount-
Ing bracket (123) to housing cover (38) with cap screws (130)
and lockwashers (131), Fig. 18-35.
68. Inspect drag band (121) lor wear and condition. II the lining
thickness Is less than 118", replace the drag band.
FIG. 18-35: ......Olng th. Dr"" Bond
46 1W2007
MARTIN· DECKER H·K 500 C POWER TONG
18.2.4 INSPECT AND REPAIR DRAG ASSEMBLY· Cont'd
69. Fit the drag band (121) to the drag drum (118) and attach to
right and left hand mounting brackets (122, 123) with bolts
(127), springs (125), plain washers (128), and locknuts (129).
See Fig. 18-35. Tap drag band around drum to contou r drag
band to the drag drum and check to see that the slotted Clip at
t he back of the drag band Is not binding on the drag band
anchor post (126). See Fig . 18-36.
70. Install the drag band support brackets (124) to the housing
cover (38) with cap screws (75) and lockwashers (111). See
Fig. 18-5
71. LubrIcate drag drum frictional surface with only 30Woll to keep
the surface from rusting.
CAUTION: DO NOT USE PIPE DOPE.
72. Flip tong over.

73. If tong Is equipped with the pivoted base, eyebolt type hanger, FIG. 18·36; Drag Band Anchor Po,.
Install the hanger bracket (231), Fig. 18-45.
74. Check for up and down motion of shll1l1nk (lOB) and outer shift
lever (104) due to worn bushings (106).
75. Check for bent, broken, or loose levers and links (104, l OS,
l OB). Replace Items as required.
76. Use new roll pins (117) for reassembly.
NOTE: It Is possible fO Invert Inner shift lever (105) In

Installation and the gear shift mechanism will not have the
required travel. Refer to Fig. 1S·37 for proper InstallatIon.
Note direction on roll pins.
77. Align yoke of Inner shift lever (105) and hole In shift rod forlc
(3) and Install pin (73) with punch through access hole In side
of cover (109), Fig. 18-37.
AG. 18-37; lnatoll.llon of

In_ Shlll ...._
TW2007 47
H·K 500 C POWER TONG MARTlN·DECKER
18.2.5 INSPECT AND REPAIR GEAR BOX
78. Inspect bearing (211) for play In any direction and replace as 56
required, Fig 18-38.
79. Inspect planet gears (210). Replace as a set If worn more than 209
one quarter of flat on crest of teeth.
SO. Install new bearings (209) In planet gears. Pack gears with 209
grease.
81. Install planet gears (210) In cage (207) with new shafts (20B).
82. Inspect lower bearing (213) for play In any direction and replace
as required. The bearing must be pressed out Irom the bottom 19'--e
of the gear housing (203). 192----;j1
83. Inspect Internal gear (204) for wear. Replace If worn by more
than one quarter of flat on crest 01 teeth. Internal gear (204)
must be removed by a punch from bottom of gear housing (203)
or by an Internal gear puller.
84. Reassemble gearbox, noling placement olthrust washer (212).

85. Align pinion shalt splines (103) with splines 01 gear frame FIG. 18·38: Goar Box A•• embly
assembly (207) and set gear box In place on cover (109). Be
sure gear box Is fully seated on cover. Do not draw gear box
down with bolts (116, 222), Fig. 18-39.
lB.2.6 INSPECT AND REPAIR THROTTLE

LINKAGE SUB·ASSEMBL Y
B6. Setthrottle bracket (219) on gear housing (203) and torque four
bolls (116 and 222) with lock washers.
B7. Temporarily Install the throttle shaft (21 8), Fig. 18·39. Check for
free rotation of the throttle shalt (218). If bind Ing Is noticed, the
bracket (219) may have distorted on Installation. Ream holes
or tap on slde.s of bracket unlll shafts work freely.
FIG. 18-39: Chocking the ThrotU. Shah for
NOTE: Mating sul1aces between the bracket (219)and gear free Rotation
housing (203) may have to be ground flat before linkage
will worle freely. Bracket holes may have to be reamed.
88. Thread throttle shalt (218) through one arm of bracket, noting
posilion ot threaded end, Fig. 18-39.
89. InSlalithrottle link (217) with two roll pins (235). Thread throttle
shaft through other bracket arm, Fig. 18-40.
90. InSlall throttle lever (214) and roll pin (235), Fig 18-41.
FIG. 18-40: Inotolllnil Throtlle Unk
48 TW2007
18.2.6 INSPECT AND REPAIR THROTTLE

LINKAGE SUB-ASSEMBLY - Cont'd
91. Install one cone washer and nut (230). Tighten nut on throttle
shaft (218) until cone washer Is slightly compressed and there
Is a light drag on the linkage as It rotates.
92. Install throttle rod (215) with cap screw (225). Check for clear-
ance between the throttle link (217) and gear box (203), Fig.
18-41. Grind clearance If necessary.
93. Install grease fitting (56).

94. If dismantling of the hydraulic motor Is required, refer to the
manufacturer's manual (supplement). To order parts for the
motor, refer to exploded view In the Parts list section.
95. Align splines of motor shaft with splines In gear box and Install
motor. Motor should drop In place. DO NOT FORCE.
96. Install bracket (102) - pivot type hanger only - with two lock
nuts (194). AG.18-41: In."'lling ThroW. Rod
97. Install two lock nuts (191) and lock washers. Tighten motor on
gear box evenly.
98. Inspect directional control assembly (195-202) for wear. Throt-

tle yoke handle (198) should work freely, with no side play. If
repaIr Is needed, grind welds at yoke (197) and handle (19B), TACK ,
Fig. 18-42. Remove roll pin (202) and shoulder bolt (196). lACK
99. Replace bushings, part 90an5-206 and other parts as re- AG. 18-42: Dlroctlonal Conlrol
A...mbly
quired. On reassembly, tack weld yoke (197), and handle (198)
to shoulder bolt (196), Fig. 18-42.
100. "lour-way valve has been removed, set valve on motor cover
(165). Install shoulder bolt (200), Fig. 18-43.
AG. 18-43: In,""lIng Molor and V,I..
TW2oo7 49

LINKAGE SUB-ASSEMBLY - Conl'd
101. Inslall directional conlrol assembly, placing Ihrottle yoke (197)

on shoulder boll (200). Torque four nuls (174) evenly 10
200 fI-lbs (27.7 kg-m), Fig. 18-44.
102. Check for free opera lion of valve In bolh dlrecllons. Thelorque
on nuls (174) may be lowered sllghlly 10 permit free operallon
of the valve.
NOTE: It four-way valve has been disassembled, Install

housing (177) on motor and torque nuts (174) befOre as- FiG. 18-44: Thtottfe Rod and
sembling valve. Dlrecllonal.Membly
103. Install throttle rod (215) finger tight to throllle link (217) and
yoke handle (198), Fig. 18-44.
104. Check for worn bushings (89) In the grip assemblies (18).
Replace worn bushings (89) as required.
105. If grip assemblies have been removed, care must be laken

when Installing so thai bolts (87) do not protrude Inside hous-
Ing. Align rotor opening wllh bolts and check Inside housing.
Add washer and grind as required.
106. Tack weld grip assemblies In two places as shown In Fig. 18-45.
107. Inspecl Ihrottle (19) and shifter (20) for excessive wear. Re-
place as required, Figs. 18-45 and 46.
108. Inslalllhrottle (19) and Ihrottle rod (216). Nole position of shan
end, Fig. 18-45.
109. Inslall shlfler (20) and shift rod (21), Fig . 18-46.
NOTE: It shift rod (21) does not fit correctly, check for FIG. 18-45: Throttle and Grip Auembly
proper Installation of Inner shift lever (105), Fig. 18-46.
110. Replace all grease fittings.
111 . If pivot type hanger Is used,lnstall hanger assembly on bracket

(231) with pin (232), Fig. 18-45.
112. Install leveling bracket (101).
FIG. 18-46: Gaor Shift Rod
50 TW2007
MARTIN· DECKER H·K SOO C POWER TONG

LINKAGE SUB·ASSEMBL Y • Cont 'd
113. Install left and right hand guard doors (24, 23)wlth left and right
hand guard door springs (34, 33}, and four new bushings and
bolts (72) first, Fig. 18-47. Then posllfon rear 01 springs with
bolts (90).
114. Grease and 011 the tong, SectIons 15.3-15.4.
115. Adjust linkages, Seclfon 12.
FIG. 1&-47: In.talllng Spring.

and Guard Door.
18.2.7 INSPECT AND REPAIR ALL JAWS
116. Check all jaws for worn or cracked die slots, Fig . 18-48. There
should not be any side movement of dies In slots. Replace as
required.
117. Check the V's on all rod jaws for wear. Excessive wear will
probably be noticed when coming out olthe hole. The rods will
pull the jaw up /n the tong. This /s because the wear In the V
allows the jaw to come too far /n and ouf from under the rotor
cover (36). Replace jaws as required.
FIG. 18-48: Tubing JOWl
TW2007 51
H-K 500 C POWER TONG MARTIN·DECKER
18.2.8 INSPECT AND REPAIR HANGER ASSEMBLY
118. The hanger assembly must be repaIred II the cap (133) Is .,.
excessIvely worn, the eyeball (132) Is bent. II the hanger
bOttoms out from the weIght of the tong, the sprIng (135) must
be replaced, Fig. 18-49.
119. Remove hanger cap (133) and eyebOlt assembly (132).
120. Grind weld from lock nut (137) and remove. "'-~~
CAUTION: Spring (135) Is under compression. Failure to
use proper care In removing lock nut (137) may result In
'''_'-1g
serious bodily Injury.
,..,---@
"'...- -.....88
121. Reassemble with new parts as requlred_
122. Install new lock nut (137) and tack weld In place. g
18.2.9 INSPECT AND REPAIR TUBING AND ROD BACKUPS fiG. 1849: Hanger Assembly
123. Check the jaw for worn or cracked die slots, Fig. 18-50. There
should not be any side movement 01 the dies In slots. Return
to factory for repair.
124. Inspecl the crank (275) and screw (276) assembly for Iree
operation. Check the condition of the threads, the groove wear
on the crank, and the condition 01 the retaining bolt (279).
125. The slot In fixed jaw (281) should be Iree 01 burrs and allow full
travel of the hook jaw (287).
126. Check for excessive wear on all rod backup jaws. Replace as
required.
18.3 HOW TO ORDER PARTS

FIG. 18-50: Tubing a.cit-up Assembly
When ordering parts for your tong, refer to the Parts LIst section.
Use Isometric drawing to locate correct lIem number and then obtain
part number from list.
When ordering Include:
• Quantity required.
• Part Number (not Item No.).
• Part Name.
Tong Model Number.
• Tong Serial Number.
52 TW2007
PARTS LIST
ITEM NO. PART ITEM NO. PART

PART NAME PART NAME
NO. REQ'O NO. NO. REa'O NO.
1 1 8501).5246 Bearing Spacer C , 8502·5046 Jaw Carrier A.a·y (37 - 37-4)
2 1 8501).5247 Beering Thrust Washer 37 1 8502·5267 Jaw Carrier
3 1 8501).5136 Shift Rod Fork 37·1 2 8502·5268 Front WfMJr Plate
4 4 8501).5220 Gear Shaft Bushing 37·2 2 8502·5269 Back Wur Plate

5 1 8501).5249 kllerCea, 37-3 8 901538-9 Screw, Socket Head Shoulder
SA 1 8502·5202 4·Lobe Idler Gear (not shown) 37-4 8 902395-1 Nut, Flexloc
6 4 8501).5251 Thru •• Wa8her 38 1 8502·5159 Housing Cover

7 1 8501).5255 Cluster Gear Shaft 39 1 8502·5160 Housing
8 1 8501).5256 ThruB' Wash.r 40 4 8502·5161 C.m
9 1 8501).5257 Thrust Washer
D 2 8502·5378 Jaw Holder A.s 'y. (41- 50)

41 2 8502·5162 Jaw Holder
A 1 8502·5030 Cluster Gear Ass'y (10 - 12)
42 4 904685-120 Roll Pin, Plain
10 1 8502·5029 Cluater Gear Hub (20 teeth)
11 1 8502·5028 Cluster Gear Base (36 t8eth) 43 4 8502·5164 Jaw Holder Aoller
12 1 8500·5189 Key 44 2 8502·5167 Jaw Holder Roller Shaft
45 2
.- Set Screw {#8·32 UNC x 7/16"}
46 2 8502·5104 Bow Spring Block

13 1 8502·5147 Idler Geer Shah 47 2 904686-n Roll Pin
48 4 902238·25 Cap Screw
49 4 904686-197 Roll Pin
B 1 8501).5273 low Speed Pinion Ass'y 50 2 901261·15 Greue Filling
(14 - 15) 51 1 940048·5205 Bearing
,4
15 ,
1 8500·5643
8500·5305
Low Speed Pinion (14 teeth)
Retaining Ring 52
53
1
1
900509·63
8500·5304
Set Screw
Spring
54 1 900572· 5 Ball
55 2 900016-14 Cap Screw
16 1 8501).5272 High Speed Pinion (29 teeth)
56 4 901261·1 Grease Filling
17 1 8502·5094 lower Transmission Cover
57 10 900305-3 lockw8aher
18 2 8502·5103 Front Control Grip As.'y
58 3 900323-9 Flat Washer
19 1 8502·5101 Throttle Handle Ass'y 59 Gr...., Fitllng
2 901261-9
20 1 8502·5102 Front Shih Control 60 1 901691).205 Snap Ring
21 1 8502·5096 Gear Shllt Rod
&1 3 9001n-4 Nut
22 4 8502·5105 Guard Ooor Bushing
23 1 8502·520H)3 Guard Door, R.H.
n 3 903541).46 Nut
&3 3 900625-9 Pin, Cotler
24 1 8502·5208-03 Guard Door, LH.
64 1 940021·206 Bearing
25 2 8502· 5293 Stop Pin (Rotor)
4 900305-5
Guide Roller Nut 65 lockw88her
26 7 8502· 5095 8501).5301
&6 1 e ••rlng Set (3)
27 1 850201.090 Rocker Bar
67 22 901257·26 Grea" Fitting
28 2 8502·5091 Rocker Sar Pin
4 902224·38 CapSer_
PIvot Block
68
29 1 8502·5106
69 11 90537,.,2 Locknut
30 1 8502-5139 Bow Spring
70 22 8501).51n Cam Roller
31 4 8502·5169 Guide RoUer Nut
71 2 900388-16 Cap Screw, B.H.S.S.
32 1 940007·304 Searing
72 2 900388-38 Cop Scr_, B.H.5.5.
33 1 8502·5042 Guard Door Spring, R.H. (not.
shown) 73 5 904686-108 Pin
74 1 8501).5185 Bushing
34 1 8502·5043 Guard Door Spring, LH.
75 8 900012-34 CapSer_
35 1 8502·5156 Rotor
36 1 8502·5157 R01arCover 76 2 902238·751 CopS.row
78 8 902238-60 CapSerow
80 2 902238·818 CapSerew
TW2D07 53
"
t5"~
.'
TO IT[~ 102.
PAGE 55
N TOITEMS4,
PAGE 55
TOllEY 31,
PAGE 51
54 lW2007
,..-.Z26
214
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':::--220
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' ~78
TO ITEM u,
PAGE $7
TW2007 55
H-K SOO C POWER TONG MARTIN-DECKER
".
'''--~~
"'~ --."
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• ~
" .32
~
.
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s,
2> 1 •
56 TW2007
:r
TO ITE"" 103.
TO ITEM 1011,
",f,GE!.4
I
--- 18
'2< 27'-~ '~~

._""-..., _ :~ r ~ 293
~ f--294
A---295
-1<0
lW2007 57
H·K 500 C POWER TONG MARTIN·DECKER

PART NAME
PART NAME REO'O
NO. REO'O NO. NO. NO.
81 17 80223W2 Cap Screw F 1 8502-5178 Spring Hanger A..·y
82 2 8501).5428 Cap Serew, S.H.5 .S. (132 -138)
83 2 900307·5 Lockw•• her, HI·Colla , 132 1 8501).5223 Eye Boll
133 1 8500-5224 Hang.rCap
84 3 804885-202 Pin
85 2 90153~24 Shoulder Screw 134 1 8502·5037.03 Hangar Tube An'y
86 1 901538-25 Shoulder Screw 135 1 8500-5575 HangOf Spring
136 2 800321·7 FlatW••har
87 6 900016-401 Cap Screw
88 4 8500-5302 Bearing Sel (2) 137 1 902395-7 Flax-Lee Nut
89 2 903375-191 Bushing 138 1 901261·1 Grease Fining
90 4 8500-5427 Cap Screw, B.H.5.S .
92 3 90748H Rod End
139 1 8502-5027 Clavla aa .. Plale
93 6 900302·109 lockw•• her
96 4 900302·112 Lockwasher
97 3 900093-3 Nut G 1 8500-5085 Discharge & Return Piping
98 1 802224-71 Cap Screw (140 -154)
140 1 9950552·1 Dlvertar Valve wllh Handle
99 2 8500-5244 Spring Cone Disc 141 1 900012·21 Cap Screw
100 2 900012·23 Cap Screw
101 1 8502·5098 leveling Bracket 142 1 902392·1 Locknut
143 1 906058-1612 Adapler
102 1 8502·5100 Bracket 144 1 903888-10 Elbow
103 1 8500-5264 Pinion Shah
145 1 901098-5 Tee
146 1 8500-6010 Hose Assty
147 1 902983-12 Coupling
E 1 850H011 Top Trans. Cove, Sub-AII 'y
(104 -117) 148 1 903003-10 Dust Cap
104 1 8500-5211 Shift lever (Ou1ar) 149 1 902983-16 Coupling
105 1 8500-5199 Shift lever (Inner) 150 1 903003-16 DuatCap
106 2 8500-5181 Bushing 151 1 906310-16 Elbow
107 1 8500-5182 Bushing 152 2 901052·5 Elbow, Street
108 1 8500-5207 Shih Link 153 2 901178·51 Nipple
154 1 906058-16 Nipple, Hex
109 1 8502·5089 Top Transmission Cover
110 2 904584·52 Pin
111 6 900305-5 lockwasher
155 1 8500-6018 Torque Arm Ass' y
112 2 9Q0305-112 lockwasher
113 1 903678-3 Knob
114 2 90223~73 Cap Screw
H 1 8500·5116 Hydraulic Motor w/4-way
115 1 8oo44~ Clevl. Pin °t Valve & Spring Ret.
116 2 80223N25 CepScrew (156 -176 Plus J)
117 4 904584-44 Pin 156 1 8500-5590 Cover
156·1 4 8500-5467 Bushing
157 1 8501).5603 Bearing
118 1 8502·5281 Brlke Drum 160·1 1 8500-5613 Retainer
119 7 900308-27 locl<wOIher 160·2 1 902298-6 "O"-Rlng
120 7 902241-755 CopSe"".
160·3 1 9022n-23 "O"·Rlng
121 1 8502· 5287 Ollg Band Aaa'y 160 ... 1 8500-5614 Retafner Ring
122 1 8502·5290-03 MounlJng eracket, R.H. 160·5 1 8500-5652 Back·up Ring
123 1 8502·529H'3 Mounting Brackel, LH.
161 2 8501).5593 Check Valve
124 2 8502·529H3 SUPPOrl Bracket 162 4 8501).5594 Bearing
125 2 8501).5288 Spring 163 1 8501).5595 Spring
126 1 8500-8022.03 Drag Sand Anchor
164 1 8500-5596 Bushing
127 2 8500-5420 Boll 165 1 8500-5597 Cover
128 2 900322·9 Washer 1611 1 8500-5598 Plata (Not 'hown)
129 2 903540-19 Locknut
130 4 902224-49 Cap Screw tCAUTlON: Some older tongs have been convened to
131 4 900302-3 Lockw••her 2" motor. 8500-5116 Is a 2" motor w/4-way valve.
'NOTE: Serial No. up to 11317 with 1'k" motor.
58 TW2007
MARTIN.DECKER H·K 500 C POWER TONG

PART NAME PART NAME
NO. REQ'D NO. NO. REQ'O NO.
167 2 85011-5609 Screws (Not shown) 208 3 8521-5012 Planet Gear Shaft
168 1 85011-5587 Housing 209 6 8521-5014 Bearing
169 2 85011-5599 Plate 210 3 8521·5008 Plane. Gear
170 2 850().5600 Gasket 211 1 94001&-208 Bearing
171 12 85011-5601 Seal 212 1 8521-5010 Thrust Wa3her
172 1 85011-5602 Shah 213 1 903337-17 Bearing
173 1 85011-5589 Gear Set

174 4 85011-5604 Nul
175 4 85011-5820 Stud N 1 8502-5009 Throttle Unbge Sub-Ass'y
176 4 85011-5606 Washer (214 -230)
214 1 850().5194 Thronle Lever
J 1 85011-5607 Valve Ass 'y (1n -189)
215 1 850()'5111 Throttle Rod
In 1 85011-5608 Housing
178 1 85011-5483 Spool 216 1 8502-5097 Throttle Rod
217 1 8502-5108 ThrotUe Unk A.I'y
179 1 85011-5492 Ring
218 1 8502·5109 Throttle Shaft
180 1 85011-5485 Spring
181 1 8500·5489 Spacer 219 1 8502-5170 Throttle Bracket
220 4 903n5-180 Bushing
182 1 85011-5491 Cover 221 2 900305-5 lockwasher
183 1 85011-5487 Guide
184 1 85011-5490 Ring 222 1 902237-827 Cap Screw
223 3 S0354().18 Locknut
185 1 85011-5488 Seal 224 5 90468&-72 Pin
186 1 85011-5486 Washer
187 2 9022n·122 Gasket 225 2 SOOOl&-22 Cap Screw
226 1 901538·25 Shoulder Screw
188 2 9022n· 19 Seal 227 1 907485-6 Rod End
189 2 850()'5619 Closure (nol show n)
228 2 907485-5 Rod End
229 1 9OO1n·3 Nut, Jam
190 4 902239·82 Cap Screws 230 1 903S4().43 locknut
191 2 90354()'19 Locknut 231 1 8502-5034 Spring Hanger Bracket
192 2 900012·24 Cap Screws
232 1 915752·1018 Pin, Clevis
193 2 90030&-112 Loekwasher 233 1 900448-4 Clevis Pin
194 2 903540·43 locknut
234 1 90062&-17 Pin, Coller
235 1 9OO47().4 Rod End Clevis
236 1 8502·5358-03 Base Support Ass 'y
K 1 850()'5154 Dlrecllonal Control As.'y
Les. V,ive (195 - 202) 237 2 900012-45 Cap Screw
195 1 850()'S155 Valve Cover 238 2 900302·64 Lotkwasher
195·1 2 903n5-106 Bushing 239 2 900012-34 Cap Screw
196 1 85011-5192 ThrotUe Pin
240 2 i00302-4 Lockwaaher
197 1 850(),S193 ThrotUo Yoke 241 1 85011-5038 Plate, Serial Number
198 1 850()'5194 ThrotUe Yoke Handle 242 6 900257-9 Drive Screw
199 1 90354().46 Nut
243 1 850()'512i Motor Adapter
200 1 801538-26 Shoulder Bolt 244 2 8502-5188 Siud
201 1 90354().18 NUl
202 2 90468&-72 Pin
0 2 8502-5057 Jaw A... ·y -1 .315" 0.0.

(245,246,247)
L 1 8521-5007 Planetary Gear Box Ass'y 245 2 8502-5071 Ole
(M + 207 - 213) 246 2 8502-5084 Jew
247 4 8502-5085 Ole Screw
M 1 85011-5046 Gur Housing Au'y

(203 - 206) p
203 1 850()'5195 Gear Housing 2 8502-5053 Jaw AII'y -1.56" & 1.66" 0 .0.
204 1 8521-5009 Intemal Ge., (247, 249)
247 4 8502-5085 Ole Screw
205 2 904584-32 Dowel Pin 248 2 8502-5070 Die
206 2 902n3-123 Stud 249 2 8502-5062 Jaw
207 1 15011-5047 Gear Frame A••'y
TW2007 59
ITEM NO. PAI'IT ITEII NO_ PART

PART NAME PART NAME
NO. REQ'O NO. NO. REQ'O NO_
0 2 8502-5052 Jaw A•• 'y -1.9",2.0",

& ,,V,.
0 .0. (247, 250, 25')
287
288 ,,, 8500-6020
900323-13
HookJI.
FI.t W.,her
247 4 8502-5085 Ole Screw 289 9OO49o-n lockw•• her
250 2 8502-5075 01.
25' 2 8502-506' Jaw 290 4 800323-8 Fla. W••her
29, 4 90030&-27 Lockw •• her
292 4 90037-388 Cap Screw
R 2 8502-5059 Jaw A.a'y - 2%" 0.0. 293 , 8502-5165 Socket

(247,252, 253) 294 4 900305-5 Lockw.. her
247 4 8502-5085 Die Screw 295 4 902224-825 CapScr_
252 2 8502-5076 Ole
253 2 8502-5063 Jaw
S 2 8502-5058 Jaw A•• 'y - 27/8" 0 . 0.

(247, 254,255)
247 4 8502-5085 Oi.Screw
254 2 8502-5,58 Ole
255 2 8502-5065 Jaw
256 2 8502-50n Jaw Au'y - 3Vz" 0 ,0 .

257 2 8502-5013 Rod Jaw, %", ¥." ~~..
258 2 8502-5014 Rod Jaw, 1"
259 2 8502-5056 Rod Jaw. 1 'AI"
T , 8502-5008 Rod Back·up Jaw Holder Ass'y
260 , 8502-50'5-03
Le •• Back-up Jaw (260 - 268)
Back.up Jaw Holder Ass'y
261
262 ,
1 8502-5026-03 T·Screw Ass'y
900323-9 Washer
263 ,, 8502-5179 Spring
264 9oo,n-4 Nut
265 1 8502-5,49 Lock Pin (Ball)
266 1 904993-7 Keeper

267 1 9'5752·,012 Back-up Jaw Pin
268 1 900625-9 Cotter Pin
269 , 8502-5369 Saclt-up Jaw Ass'y . ¥e" Rod
,,
270 1 8502-5370 Back-up Jaw Ass')' - :V."_7/e" Rod
27, 8502-5371 Back-up Jaw Ass'y . ' " Rod
272 8502·5372 Back-up Jaw Ass'y • 1v." Rod
U 1 8502-6023 Complete Back-up Asa'y

(273 - 295)
273
274 ,
2 8502-5'43
8502·5'42
Pin, Ball Lock
POlt
,,
275 1 8500-5339 Crank & NUl
276 8500-602' Screw
2n 8502·5,34 Coupling Carrier
278 , 8500-5639 Compreaslon Spring

279
280
2
, 8502·5'36
90'252-9
Lock Screw
Gr.... Fll1lng
28, ,, 8500-&019-03 Axed Jaw

282 901531H17 Shoulder 80U
283 2 8500-5457 Spring
,,
284 2 8500-51,2 DI.
285 904686-111 1'1011 Pin
286 8502·5'73 lever
60 1W2007
INDEX
A R
Adjustment.: Releeslng Tong ....... .. ......... . . 17
Idler Gear. . . . • ......• . ....... .. 38, 45
BBCk-iJp, Rods ••• • •••••• . •.• . .•.• 14 Requiremenls. Hydraulic . . .. .... ..... 6
Indicator, Torque _..... .•. ..... . 6, 8, 14
Back·up, Tubing .• . ... . . , .... .. •.. 13 Rlg·up, Tong ..... .•.•..... . ..... 9, 12
Ge.r Shih Rod .. ...•.• .. • . .... . . . 22 Introducllon •.......•• , ... . .. • ..•.•• 1
Rocker Bar ........... _ .....• . 8, 19, 41
Gear ShUt TensIon • • .• •••. . ••••••• 22 Roller" Cam . .•..... .. . . ...•...... 39
leveling, Tong ..... . .•........... 12 Rotor .•.•.....• • .. . . ....... 3B, 40, 45
Rod Size .•.•. • • •..•.. • . • ... .•••. 14 J Rotor Covet .. . . .....•... • • . ... . 41,43
Throttle Rods .••••...• .• • •• • • .. . . 21 Jaw Carrier ....... . . 37, 39, 41 , 42, 43, 46 Running Tong . . . . .. .. ... .•.•.•. . .• 16
Tubing Size . . . . . .. ... .. •. • ... . .. . 15 Jaw Holder .. .......•.. ... ... 39, 42. 43
Assembly Instructions ... .• ••• . . , ... 39 Jaw.: S
Installing . . . •. ..... .... ...•. .•.. •15
B Overhaul •••..• • ••••••• • •• . • .•. .. 51 Safety Precautions . . .. . . . 3, Back Covet
Back-up line .• .• . ............... .. 12 Serial Number •...... . .......•....•. 7
Back-up, Rod ..... . ......... . . 8, 14,52 Shafts :
Back-up, Tubing .•.•... . . ... . . 8, 13,52 Cluster Gear ..•.. • ...•.. . ... . . 39, 46
L
Break-Oul •• • ••• • . . ..• .•.••. . •••..• 17 Idler Gear ..•.•.•. .... . , ..... . 39, 4S
leveling Tong .. . . . .. . ....... .... . . . 12 Pinion •. . . •. . . . .. . . ....... 38,43, 44
C Lever, Shift ............. 7, 17, 36, 47, 50 Shift Rod Fork . .. . . .... 36, 3B , 40, 44, 47
Cam, Rollers .. .... ...• . ........... 39 Lever, ThroUie . . .. . .•. . •... 7, 16, 35, 48 Shifter, Gear ..... ...•... ..... .. . 35, SO
Cams, Rotor •••• •.•• • .. . .... ...• ••. 41 Liability .... . . ... . ... .. . . .. ... ...... iI Snub Line - See Back-up Line
Cleaning, Tong .. ..... ...... ...... . 24 Unkage Adjuslments . . .... . ..... .... 21 Specifications:
Component Descriptions .•. .••.••.••. a Lubrication . ........•. . .. . . .. ...... 23 General .... •... ... . ..•... .. ...... 5
Couplings, Hose •• •• •• • •..• . . 6, 9,11,26 Grease ...•. . ...... , ..•..•... • ... 23
Cover: Hydraulic Oil ...... . . . .. .. ........ 23
Lower Transmission ... ... •. 39,45,46 M Speed, Tong ... ... ..•........ . ... 5,20
Rolor . . ..... . ... . ........ . 39, 41 , 43 Start-up:
Top Transmission .. . . , .• , .. 36,39, 40 Maintenance ... • . . . .• . ...• . .• ...•.. 24 Firsl Time ..•..... • ••..• . •.•• . • 9, 10
Make-up: Roullne ••• . •. . . . . • . • •.• .• ... .. .. 16
D Rode .. • ... . . .. ••.• •. ••• • . .... . . . 18 Stiff-arm .......••. • •. • ••.••....... 12
Damper, Torque Indlca1or • . , ....•. . . . 14 Tubing .......... . ••• • •• ... . .. . . . 20 SlOP Pins ... •.• . .•..•• .•.•. ... ... . 41
Description, Genersl . ... . .. .....•.... 2 Model Number •.... . .. .• ... ... ....•. 7 Storage .... •. • . •.. • .. . ..• •. .....•• 34
Dies .. . •. ...... . ........... .. ..... 15 Motor, Hydraulic ..... •••.•. . . . .. 6,8,35 SU8penslon, Tong . . ..... ........... 12
Dimensions, Tong ..... . • . ... . . • ...• . 6 Multiple Strings ..... .. . ... ......... 17
Directional Control Ass'y .... • . 34, 35, 49
Disassembly Instructions . .. . .. . •.... 35
T
Drag Assembly . .. . •. . , •.. ... 24, 37,46 N Throttle • ..•• • • . .••• . ••. .. , 7, 16, 35, 48
Oust Caps ... • ..... ..............• 26 Throltle Unkage .....•...• 21,35.36,48
Nomenclatufe ..•.•...• . •. .. ••.••. . •. 7 Tong Equipment . ...... ... . . ... . . . . . 6
F Torque Curve •... _. ... . .. ..••..... . _ 5
Fluid Requirements .. .. .. . .. . ....... 11 Torque Indlcelor .•......•...... 6,8,14
Four-way Control Valve ....•. 6,7,34,49 o Torque R.tinga • . . .. . . .• ..•.••.•.. . • 5
Oiling Tong •..... ••.. .. •....•.• . ••. 25 rranlmlsslon Cover •• ... . .. .••• . •• : 40
G Troubleshoollng . •..•• .. • .. .•.... . . 27
Operating Instruction• . . ••.• • • •• ..... 11
Gear Box .. . ...... _. . .• . .•. 6, 9, 36, 48 Overhaul Procedure ................. 35
Tubing Size ...••• . . . .. .. •.•.• ..• .. 15
Gear Train • •... • ..• • •...••....•... 43
Gre... Specifications . •• .. ... . .•. . . . 23 U
Greale Tong •.• .. . ..• •••.•.•. .. • .• 25 p Upset, Tubing ••.•• . . . • . • • • • , . ••.•• 12
Grip Assembly . •...•...• • .. .. .• . 35, 50
Guard Door•..• •• .....•... 7,35,37,51 Partl:
How to Order .. • ... .• •.• . .... ••.•. 52 V
H Part. U.t • ..•.. •...•. .. .....• . .•• 53 Varve, Four-way Control •• • • •. 6,7,34, 49
Hanger ............... 35,36,47,49,52 Performance Characlerlstlca . ...• . • •.• 5 VI.co"Iy, 011 . •.•...•....•..•..•••. 23
Hanging Tong . ................ ... . 12 Pinion Shaft ......••••..•. ••• 38, 43,44
High Pressure Wells ............. . . . 20 Pinion I :
Hose, Coupling • •. ••• •••. .•. 6, 9, 11,26 High Speed .••........ .. •...•. 38, 44 W
Hose, Hydraulic ... •••.... . •. ..•.. 6, 11 Low Speed .. .•. . • ..• • ••......• 38, 44 Warnings:
Houllng, Tong . •... . . .......•• .. . .. 39 Pre •• ure Settings: Equipment or Property Damage . •. , . . 4
Hydraulic all Specifications ... .• ....• 23 Rod •.. •• .•••• • •....• .•... . • ..• •• 17 Pereonallnlury •. •• •••..•.. . •.• .... 3
Hydraulic Requirements .. _....•••• ... 6 Tubing .... • • •.•••.•••• .. • .. ...•. 20 Warranty •. .. .... . . . ...•.... .. . ..... .1
Hydraulic System •• .•.. ...... . . • . . . 26 Preventive Maintenance ...........•. 24 Weight, Tong • • . .. ..• ..•.•... ..••..• 6
TW2007 61
SAFETY PRECAUTIONS
Safety based on technical skill and years of experi- 1. Operate the tong from the baCk-up line or stiff arm
ence, has been carefully lSull! Into your HlllMAN-KEl- side only . (Does not apply to front control tongs.)
lEY Tong. Time, money, and effort have been Invested
In making your tong a safe product. The dividend you 2. Never change a jaw or put hands within the rotating
realize from this Investment Is your own personal parts 01 the tong while the hydraulic system is
safety. engaged. The hydraulic system should be disen-
gaged and locked out or shut down.
It should be remembered, however, that power-driven
equipment Is only as safe as the person who Is at the 3. Never operate the tong without the guard doors in
controls. You are urged, as the operator of this equip- place and operating properly.
ment, to observe the lollowlng rules:
4. Do not exceed the maximum pressure lor which
.thls system Is rated.
5. Always use a back-up (snub) line or stiff arm for all
tong operations.
6. Keep loose fitting clothing away Irom the rotating

parts 01the tong.
7. Read and understand All WARNINGS In this man·

ual. Failure to comply with all warnings could result
In serious bodily harm or loss 01 tile.

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I TECHNICAL MANUAL I T W2007

OPERATING AND MAINTENANCE INSTRUCTIONS

IMPORTANT SAFETY NOTICE

LIMITED PRODUCT WARRANTY

EXCLUSIVITY OF REMEDY AND LIMITATION OF LIABILITY,

CHANGES IN PRODUCT DESIGN

SAFE HANDLING PROCEDURE

Always use the safety sling when operating the tong.

Reference manual sections 3 and 4 for additional safety precautions and

Operating vibration levels are below 2.5m/sec².

Safety labels have been installed at these locations.

SECTION TITLE PAGE

4.1 WARNINGS - PERSONAL INJURY - Cont'd

4.2 WARNINGS - EQUIPMENT OR PROPERTY DAMAGE

Torque • . . . • . • . • • • • • • • • • • • • • • • . . • • • . . . ·4500 fI-lbs

'800 -1000 psi (54.4 - 68.0 kg/cm 2 )

7. MODEL AND SERIAL NUMBERS

FIG. 7·,: Tong Identlflcatlon Pial.

9.1 SAFETY BYPASS VALVE

9.2 FOUR-WAY CONTROL VALVE

9.3 HYDRAULIC MOTOR

9.4 HYDRAULIC HOSE COUPLINGS

9.5 TORQUE INDICATOR (Optional)

9.6 BACK-UP ACCESSORIES

9.7 ROCKER BAR-REVERSE SHIFTER

9. COMPONENT DESCRIPTIONS - Cont'd

9.9 GEAR BOX

10. FIRST TIME START·UP PROCEDURE

NOTE: If the tong Is used with 8 Hillman-Kelley Hydraulic Power

10.1 TONG RIG-UP

10.2 HYDRAULIC HOSES

2. Connect hoses to tong and power unit. (Section 11.2)

10.3 STARTING SEQUENCE

11_ OPERATING INSTRUCTIONS

11 .2 HOSE AND HOSE CONNECTIONS

11.3 SUSPENSION OF TONGS IN DERRICK

NOTE: For easiest handling of the tong during operations,

NOTE: A back·up line must always be used, with or without

FIG. 11·2: Lo ••1Adjustment

11.4 TUBING BACK-UP ASSEMBLY

1. Swing tong onto tubing.

NOTE: The back-up accessory cannot be used on critical

To change gripping direction lor "make-up" or "break-out", slide fixed

A second consideration for assuring proper Installation Is that when

11.5 ROD BACK-UP ASSEMBLY

11.6 TORQUE INDICATOR

11.6 TORQUE INDICATOR - Cont'd

IMPORTANT: Accurale lorque readings require correct tong

11.7 ADJUSTMENT FOR TUBING AND ROD SIZES

NOTE: "the back-up Is not used, set the tubing as low as

3. Select and Install the correct jaws and dies.

NOTE: This Is an open-throat tong designed to come 0"

11.8 RUNNING TONG· Conl'd

11.9 RUNNING MULTIPLE STRINGS

11 .10 BREAKING OUT TUBING AND RODS

11 .11 MAKING UP RODS

11.12 OIL TEMPERATURE

11.13 JOINT CONDITION

11.14 CALIBRATION OF TONG

11.14 CALIBRATION OF TONG - Cont'd

TABLE 11 .2: SUCKER ROD JOINT

11.15 MAKING UP TUBING

12. LINKAGE ADJUSTMENT PROCEDURES