Eckel Manufacturing Co. Inc.

Hydraulic Power Tongs — "World Wide"

7-5/8 Standard Hydraulic

Power Casing Tong

OPERATION
and SERVICE
INSTRUCTIONS
Copyright

© Copyright 1990, Eckel Manufacturing Co., Inc. All rights reserved. No part of this manual may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language in any form by any means without the written
permission of Eckel Manufacturing Co., Inc.

Trademarks

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

Loctite is a registered trademark of Loctite Corporation
7-5/8 Standard Hydraulic Power Tubing Tong is covered by U.S. and Foreign Patents and Pending Patent Applications
Hydraulic Cam Backup is covered by U.S. and Foreign Patents and Pending Patent Applications

First Editon

March 1990
Printed in U. S. A.

Main Offices and Plant: International Sales Office:

8035 West County Road 480 N. Beltway 8 East, Suite 200
Box 1375, Odessa, Texas 79760 Houston, Texas 77060
Phone (432) 362-4336 Phone (281) 999-6680
Telex 74-5434 (ODS) Telex 77-4644 (HOU)
FAX 432-362-1827 FAX 281-999-8707
 Contents
Section 1 - General Description ................................................................................1
Introduction .........................................................................................................2
Functional Description ........................................................................................3
Specifications ......................................................................................................7
Options and Aceessories .....................................................................................7

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

General Considerations .......................................................................................12
Connecting Hydraulic Lines ...............................................................................14

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

General Operation ...............................................................................................18
Operating Controls and Gauges ..........................................................................18
Pre-Operating Checks .........................................................................................18
Typical Operating Sequence ...............................................................................20
Section 4 - Servicing ........................................................................................................ .23
Daily Inspection ..................................................................................................24
Maintenance After Each Job ...............................................................................24
Lubrication ..........................................................................................................25
Tests and Adjustments ........................................................................................26
Section 5 - Troubleshooting, Repair and Overhaul .................................. .29
Troubleshooting ..................................................................................................30
Repair ..................................................................................................................31
Tong Overhaul ....................................................................................................31
M4D Motor Overhaul .........................................................................................32
A35 Valve Overhaul ...........................................................................................35
Section 6 - Parts List ....................................................................................................... .37
Parts List, Eckel 7-5/8 Standard Tong ................................................................38
Parts List, Clutch Assembly ................................................................................42
Parts List, Pinion Assembly ................................................................................43
Parts List, Pinion Idler Assembly .......................................................................44
Parts List, Rotary Idler Assembly .......................................................................45
Parts List, M4D Motor Assembly .......................................................................46
Parts List, A35 Valve Assembly .........................................................................48
Parts List, Tong Suspension ................................................................................50
Parts List, Manual Backup ..................................................................................51
Parts List, Hydraulic Cam Backup ......................................................................53
Parts List, Door Interlock Assembly ...................................................................59
Parts List, Microswitch Assembly ......................................................................62

iii
 Section 1
General Description

1
 INTRODUCTION
This manual describes the function, operation and maintenance of the Eckel 7-5/8
Standard Hydraulic Power Tong. This section provides a functional description, system
specifications, and a description of options and accessories available. Section 2 through
5 present the operating and maintenance aspects of the tong and Section 6 provides a
fully illustrated parts list with spare recommendations.
The 7-5/8 Standard Tong, Figure 1-1, handles tubulars in sizes as small as 2-1/16 inch
and as large as 7-5/8 inches diameter. The open-throat design, combined with high-
speed operation, assures both ease and speed in tubular handling. A safety door on the
open throat helps insure against accidents. The following paragraphs describes the
functions of the tong during tubular make-up or break-out operations.

HYDRAULIC
DRIVE SYSTEM

CAGE PLATE
WITH HEADS

SAFETY
DOOR

E L GEAR TRAIN,

E CK CLUTCH AND
SPEED SHIFT
(INSIDE HOUSING)

Figure 1-1
Functional Elements of the 7-5/8 Standard Tong
7-5/8 Standard is covered by U.S. and
Foreign Patents and Pending Patent Applications

2
FUNCTIONAL DESCRIPTION
Operating from a hydraulic power unit, the power tubing tong provides torque of 15,000
ft-lbs. The heart of the unit is a head-closing system which forces the heads together
and rotates them by means of a cam-type rotary gear. The rotary gear is driven by a
two-speed gear train powered from a vane-type hydraulic motor.
In operation, the tong is suspended over the well bore on a chain bridle. A snub line
restrains the tong from moving around the pipe as torque is applied.
HYDRAULIC DRIVE SYSTEM. Figure 1-2 is a hydraulic schematic of the drive
system. Hydraulic pressure from a separate power unit is applied through screw-type
hose couplings having built-in check valves. To prevent cross-connection of the hoses,
the pressure hose from the power unit is designed to mate with a 1-inch coupling and
the return hose mates with a 1-1/4 inch coupling. Connection of the hoses opens the
check valves to provide hydraulic pressure to the tong.

1-1/4" COUPLING REVERSIBLE

RETURN MOTOR

PRESSURE
RELIEF
VALVE

PRESSURE
M

1"
COUPLING MAKE-UP
BREAK-OUT

CONTROL VALVE

Figure 1-2
Hydraulic Drive System Schematic Diagram for 5-1/2 UHT

The tong control levers acts as a throttle valve for the unit. Pushing the lever applies
pressure to drive the motor in a forward direction (for make-up operation) and pulling
the lever applies pressure in a reverse direction (for break-out operation). While the
lever is in a neutral position, fluid circulates freely through the valve and back to the
return line. Refer to Section 3 for tong control lever positions.
An adjustable relief valve permits adjustment of the operating pressure at the tong if
desired, and a built-in pressure gauge indicates the operating pressure at all times. The
maximum pressure available, of course, depends upon the power unit. Eckel Manufac-
turing Co., Inc. recommends a power unit that will deliver 3,000 PSI pressure and 65
GPM to achieve maximum torque and speed.
The hydraulic motor and control valve, along with other plumbing components, are
located on the top tong plate.
GEAR TRAIN AND CLUTCH FUNCTION. Closure and rotation of the pipe-
gripping heads are accomplished by means of a large rotary gear having its inner
diameter formed into a double cam surface. This topic explains how mechanical power
is transmitted from the hydraulic motor to turn the rotary gear in either direction.

3
 ROTARY
IDLER SHIFT
PINION LEVER
IDLER PINION CLUTCH
CLUTCH ASSEMBLY ASSEMBLY
ASSEMBLY SHIFTING
YOKE

ADJUSTABLE
DETENT
MOTOR
GEAR
PINION HIGH
SHIFTING
DUMBBELL LOW COLLAR
ASSEMBLY SPEED SPEED
ROLLER

NOTE

SHIFT ASSEMBLY IN NEUTRAL POSITION. CUTAWAYS

SHOW HIGH-SPEED AND LOW-SPEED POSITIONS.

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

PIPE

HEADS OPEN
HEADS CLOSED

Figure 1-4
Head Biting Action, Makeup

Rotary Gear and Head Cage Rotation. Figure 1-5 illustrates the cam follower
rollers that permit the semi-independent rotation of the cage plates and rotary gear. The
figure illustrates how the top cage plate is free to rotate on a ring of cam follower rollers
attached to the cage plate and following a groove in the rotary gear. The rotary gear is
turned independently within a circle of dumbbell rollers. The bottom cage plate rotates
on a ring of cam follower rollers identically with the top cage plate. This plate is bolted
to the top cage plate to enclose the heads. The heads are forced in to bite the tubular as
brought about by the cam action of the rotary gear on the head rollers (Figure 1-4).
Brake Band Function. Consider again the actions of the rotary gear cam and heads
in view of the freedom that the cage plates have to rotate. It becomes evident that, if the
cage plates have unrestricted freedom to rotate, the heads will simply move with the
rotary gear and will not cam up on the rotary cams to force the biting action. Figure 1-6
illustrates how brake bands are placed around the cage top and bottom plates to exert
continuous friction on these plates and to restrict their freedom to move.

RETAINER SCREW
AND WASHER BACKING PIN
RETAINER BACKING PIN
BACKING PIN HOLE (BREAK-OUT POSITION)
(MAKE-UP POSITION)
CAM FOLLOWER ROLLER

CAM FOLLOWER CAM FOLLOWER

BACK CAGE NUT AND WASHER
PLATE BOLT
TOP
TOP TONG PLATE
CAGE PLATE

BOTTOM
CAGE PLATE
BACKING
LUG

DUMBBELL
CAM FOLLOWER ROLLER
NUT AND WASHER
ROTARY
GEAR
BOTTOM
TONG PLATE

Figure 1-5
Head Cage Plate and Rotary Gear Details

5
 BACKING PIN ROTARY
HEADS GEAR CAM
SURFACE

HEAD PIVOT
BOLT HEAD
ROLLERS

BRAKE
BAND
ADJUSTMENT
BRAKE
BAND
ADJUSTMENT THROAT
PIPE
SAFETY
DOORS

Figure 1-6
Brake Bands and Safety Door

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

6
 SPECIFICATIONS
The specifications for an operating tong must consider the hydraulic power unit as well
as the tong itself.
HYDRAULIC POWER UNIT SPECIFICATIONS. The power tong is designed to be
powered by a hydraulic power unit capable of delivering at least 3000 pounds per square
inch (PSI) for maximum operating torque.
At least 65 gallons of hydraulic oil per minute, depending upon the power unit used, are
recommended to operate the tong at maximum RPM.
TONG SPECIFICATIONS. Table 1-1 list the specifications for the Eckel 7-5/8
Standard.
HYDRAULIC CAM BACKUP SPECIFICATIONS. Table 1-2 list the specifications
for the Eckel 7-5/8 Hydraulic Backup.

OPTIONS AND ACCESSORIES

Options for the 7-5/8 Hydraulic Power Tong include lift cylinder with lift cylinder
control, spring hanger, torque gauge, manual or cam type backup and door interlock.
The optional items are described in the following paragraphs.
LIFT CYLINDER AND CONTROLS. A lift cylinder as illustrated in Figure 2-3 is
optionally supplied with the 7-5/8 UHT tong. This cylinder provides a means for raising
and lowering the tong during operations.
Lift Cylinder. The lift cylinder is a hydraulic cylinder attached to the tong suspension
and used for positioning the tong vertically on the pipe thus eliminating the need for a
counter-balance weight. The lift cylinder is controlled from the tong valve stack utilizing
Table 1-1
Specifications Eckel 7-5/8 Standard Tong

Torque:
High Gear .................. 3,000 ft/lbs (4,066 nm)
Low Gear .............. 15,000 ft/lbs (20,340 nm)
Torque Handle Lengths:
Tong Only ................................ 36" (914 mm)
Tong and Cam Backup ............ 37" (940 mm)
RPM:
High ................... 132 at 65 GPM (246 L/min)
Low ...................... 26 at 65 GPM (246 L/min)
Hydraulic Requirements:*
65 G.P.M. (250 L/min) at 1,000 P.S.I. (68 bar)
30 G.P.M. (113 L/min) at 3,000 P.S.I. (170 bar)
Hyd. Pump Operating Temperature:
Normal .................................. 130° F. (54° C)
Maximum .............................. 180° F. (82° C)
Dimensions:
Length .................. 57.5 inches (1460.5 mm)
Overall Width ................. 30 inches (762 mm)
Pipe Space Required7.375 inches (187.32 mm)
Max. Elevator Diameter ............... (Unlimited-
Tong comes off Pipe)
Weight:
Approximately ......... 1,100 Pounds (499 Kg.)
Heads Available:
For Tubing Size O.D.: . 2-1/16", 2-3/8", 2-7/8"
3-1/2",4", 4-1/8",4-1/2", 4-3/4", 5", 5-1/2"
6-5/8", 7" 7-5/8"
NOTE: Any size head between 2-1/16" and 7-5/8" may
be specified as needed.

7
 the tong system pressure. Maximum pressure for the cylinder is 3000 psi. Maximum vertical
travel is 6 foot.
Lift Cylinder Controls. When a lift cylinder is ordered with a tong, the tong contains
an additional control lever for controlling the lift cylinder movement. The lever-
operated control valve is identical to the tong operating control lever. This lever is
illustrated in Figure 3-1 and its operation is shown in Figure 3-2 and Table 3-1. Pulling
the control lever outward provides hydraulic pressure from the hydraulic power unit to
operate the lift cylinder upward, and thus raise the tong. While pushing the control lever
forward operates the cylinder downward to lower the tong. The center lever position is
the neutral position and does not operate the cylinder in either direction.
SPRING HANGER. The optional spring hanger (Figure 2-3) is designed to permit the
tong to move up or down to allow for thread length in make-up and break-out opera-
tions. When used, the spring hanger should be attached directly to the tong bridle ring
and used as a hanger for the tong.
TORQUE GAUGE ASSEMBLY. The optional torque gauge assembly (Figure 2-2) is
used to measure the torque exerted in make-up or break-out operations. Consisting of a
hydraulic cylinder and torque gauge connected together by a pressure hose, the torque
gauge assembly senses and indicates the torque developed during an operation. For
operation, the hydraulic cylinder is connected by a shackle to the rear of the tong and a
snub line is connected to the cylinder. The snub line is tied off to a solid part of the rig
structure to form an angle of 90° in order to measure accurate torque readings.
MANUAL BACKUP. The manual backup, mounts directly beneath the tong on the
centerline of the pipe, permitting the tong and the backup unit to remain in a level,
balanced position. For make-up and break-out the manual backup can be reversed by
simply pulling one pin and inverting the jaw assembly.
HYDRAULIC CAM BACKUP AND CONTROLS. A hydraulic backup tool as
illustrated in Figure 1-8 is optionally supplied with the 7-5/8 Standard. In operation
this tool provides a back-up when in break-out or make-up situations. The specifica-
tions for the hydraulic back-up are supplied in Table 1-2.
Hydraulic Cam Backup. The hydraulically operated backup tool, which utilizes the
same biting principal as the power tong, uses a cam and sliding head arrangement to
insure slip-free operation.

Table 1-2
Distance Points from Midpoint
Tong Dies Midpoint Backup Dies

Hole Set Distance

Top (First) 13"
Second 16.5"
Third 20"
Fourth 23.5"
Bottom (Fifth) 27"

The stinger part of the backup, extending from the rear of the unit, is inserted into the
torque bracket mounted on the underside of the tong. This method of hook up prevents
movement of the back-up about the pipe during torquing operation of the tong. Between
the stinger and bracket is located the torque gauge compression load cell. During make-
up or break-out operations, the tong unit rotates slightly causing the stinger to compress
the load cell. The compression force is translated to torque which is indicated on the
torque gauge connected to the load cell. Torque readings are available in make-up or

8
Table 1-3
Specifications Eckel
7-5/8 Standard Hydraulic Cam Backup

Capacity (PIPE O.D.) ............. 2-1/16 thru 8-1/2"

Max. Holding Torque ... 15,000 ft-lbs (20340 nm)
Maximum Pressure ........... 3000 P.S.I. (204 Bar)
Handle Length ........................ 37 inch (940 mm)

Dimensions:
Length (Tong & Backup) . 58.5 inches (1486mm)
Height (Tong & Backup) .. 61" inches ( 1549 mm)
Pipe Space Required
(Backup Only) .......... 12.187 inches (309.55 mm)

Weight:
Approximately
(Tong and Backup) .............. 2900 lbs (1315 kgs)

Heads Available:
For Tubing Size O.D ........... 2-1/16",2-3/8",2-7/8"
3-1/2",4,"4-1/2",5",5-1/2",6", 7" 7-5/8",8-1/2"

NOTE: Any size between 2-1/16" and 8-1/2" may

be specified as needed.

Make-up Break-out

Tong Dies
Tong Dies Tong Dies

Non Upset & External Upset Integral Joint Connections

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

Make-up and Break-out

Cam-Type
Backup Dies Cam-Type Backup Dies

Figure 1-7
Make-up and Break-out Biting Locations

9
 break-out, depending on position of load cell in the bracket. The load cell should be on
the operator side of the backup stinger for make-up and for break-out the load cell
would be inserted on the opposite side of the backup stinger to register the torque. The
hydraulic cam type backup requires a 37 inch torque gauge handle which offers direct
reading of torque between the back-up and the tong.
The hydraulic backup is suspended at an adjustable level below the power tong by
means of hanger legs and springs. This setup allows the backup to remain stationary
while the power tong moves vertically to compensate for thread travel of the connection.
Hydraulic Backup Controls. When a hydraulic backup is ordered with a tong, the
tong contains an additional control lever for controlling the backup and a directional
valve for controlling the rotation of the back-up. These levers are illustrated in Figure 3-
1 and its operation is shown in Figure 3-2 and Table 3-1. Pushing the control lever
inward provides hydraulic pressure from the hydraulic power unit to rotate the back-up
cage plates clockwise for make-up or counter-clockwise for break-out and engages the
heads on the pipe. Pulling the control lever disengages the back-up heads from the pipe.
The backup cage plates are always rotated in the direction that the tong will turn and by
using the directional control lever the operator controls which direction the back-up
rotates.
Adjusting Backup Spacing. The vertical spacing between the backup and tong is
adjustable in steps using different sets of holes in the hanger legs for the bolts which
hold the back-up hanger springs in position. There are five sets of holes located at
various distances below the tong. The distance of these holes from the midpoint of the
tong dies to midpoint of back-up dies is described in Table 1-3.
Close spacing between the back-up and tong is desirable from the standpoint of insuring
the closest possible length of contact between the dies and pipe. This is particular
important with drill pipe where short upsets may be encountered. Also, close spacing is
beneficial in reducing twisting forces in the tong and back-up structures. On the other
hand, the design provides spacing when it is necessary to straddle extra long couplings
or upsets as is required in make-up operations.
DOOR INTERLOCK. The door interlock device is an optional added safety feature
that Eckel Manufacturing Co., Inc. offers with its tongs. The door interlock device
impedes hydraulic fluid from reaching the motor when the tongs door is open thus
preventing tong operation.

10
 Section 2
Installation

11
 GENERAL CONSIDERATIONS
Installation of the power tong requires consideration of the tong itself, the hydraulic
power unit to be used, and the accessories that will be required.
TONG CONSIDERATIONS. The 7-5/8 Standard Tong is capable of handling pipe
sizes from 2-1/16 inch to 7-5/8 inch in outside diameter. The heads to be used with the
tongs, of course, depend upon the size pipe being used. Refer to Table 1-1, Specifica-
tions for the various heads provided with the tong.
Head Installation. Install the correct size heads according to the following proce-
dure.
! Warning WARNING: Do not attempt to change heads with power unit in operation. Failure to
observe proper precautions could be extremely hazardous and result in loss of a hand
or arm.
1. Put backing pin in make-up or break-out position, bringing backing pin against
backing lug. This will allow heads to drop into neutral cam by aligning the
cage plates with the rotary gear openings.
2. Remove to head pivot bolts (Figure 1-6).
3. Swing in and lift out the heads.
4. Select the proper heads for pipe to be worked and install in head cage in
reverse order of steps 2 and 3.
Tong Space Requirements. You should consider the space requirements of the
tong, both in storage and in operation. Figure 2-1 gives the tong dimensions.
POWER CONSIDERATIONS. Before installing the tong for field operations, you
must be sure that an appropriate power unit is available and that the power unit is
adjusted for use with the tong. To operate the tong within its full capability, the relief
valve on the hydraulic power unit should be adjusted to 3,000 pounds per square inch.
Refer to power unit manual for the procedure on power unit valve adjustments.
Accessory Considerations. Tong installation requires that the necessary accesso-
ries be available for the type of operation to be performed.
Installation of Torque Gauge Assembly. Measurement of the applied torque
requires a torque gauge assembly installed on the equipment. Once installed, the torque
gauge assembly becomes an integral part of the unit. To install the torque gauge on the
tong, proceed as follows:
1. Using three mounting screws, mount torque gauge into position on torque
gauge plate, Figure 2-2.

23.25 IN
590.55 MM 30 IN 8.25 IN
762 MM 209.55 MM

30 IN
762 MM

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

Figure 2-1
Tong Dimensions

12
 TORQUE
GAUGE

HYDRAULIC
CYLINDER

KEL SNUB LINE

Figure 2-2
Torque Gauge Installation

2. Route hose to avoid interference with tong operation.

! Warning WARNING: The tong should be snubbed for both make-up and break-out operation at
all times, by utilizing the snub line. If this is not done, the tong may be thrown against
operator causing physical harm.
LIFT
3. Secure one side of hydraulic cylinder to snub line eye on rear of tong.
CYLINDER
4. Securely attach other side of torque gauge cylinder to snub line.
5. Attach the other end of the snub line to a part of the rig structure that is rigid
enough to with stand the line-pull. Please note that an angle of 90° must be
maintained between tong and snub line for the gauge to indicate accurate
SPRING torque readings.
HANGER
Lift Cylinder Considerations. If the tong suspension line is not counter balanced, a
lift cylinder should be used. Also, if an Eckel lift cylinder is to be used, the tong must
be equipped with an additional control valve and lever. The lift cylinder should be
TURN
BUCKLES
suspended from the line that will hang the tong as shown in Figure 2-3.
(3)
Spring Hanger Consideration. A typical spring hanger installation is shown in
Figure 2-3. For a counter-balanced support line, the spring hanger is suspended from the
line. When a lift cylinder is used, the spring hanger may be installed above or below the
TONG
lift cylinder as described.
HYDRAULIC BACKUP CONSIDERATIONS. The hydraulic backup is capable of
handling pipe sizes from 2-1/16 inch to 8-1/2 inch in outside diameter. Any significant
Figure 2-3 difference between actual pipe diameter and design diameter may result in failure of the
Tong Installation heads to take an initial bite, slipping under torque, and other problems.
HEAD INSTALLATION. Heads are installed into the backup similar to the tong.
Throat openings are aligned by operating the backup control lever to the release
position.
WARNING: Do not attempt to change heads with power unit in operation. Failure to
! Warning observe proper precautions could be extremely hazardous and result in loss of a hand or
arm.
1. Align cage plate opening with cam ring and plate..
2. Detach head springs from head spring bolts.
3. Push the head opposite the cut-out in the top cage plate all the way back
against the neutral cam. Then slide the other head toward the center until the
head roller clears the cage plate opening and it can be lifted from the tong.
There is then room to remove the first head by sliding it toward the center into
the cage plate opening.
13
 4. Select replacement heads of the proper size and install them in the tong using
steps 2 and 3 in reverse order.
HANGING THE TONG. The tong is transported to the well site and hung into position
as illustrated in Figure 2-3 and as follows:
CAUTION: Do not hook lift-line on turnbuckles. Be sure bridle chains are clear of
Caution valves and controls.
1. Connect bridle to tong
2. Using the cat line on drilling rig, or a specially rigged line, lift tong to desired
height in the work area and secure. Be sure the lift cylinder or counter-balance
system is properly in place and functioning.
3. Adjust the turnbuckles as necessary to level the tong to ensure an even bite on
the pipe. This is done by first placing tong on pipe, and running heads out to
where they are just touching the pipe to see where adjustment on turnbuckles is
necessary.
4. Connect snub line to hydraulic cylinder of torque gauge assembly to restrain
tong rotation and to provide torque readings for make-up or break-out opera-
tions.
5. Secure other end of snub line to a solid part of rig at a 90-degree angle from the
tongs center line. Verify tong is snubbed for both make-up and break-out
operations.

CONNECTING HYDRAULIC LINES

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

14
 CONNECT HYDRAULIC
PRESSURE LINE
FROM POWER UNIT

CONNECT HYDRAULIC
RETURN LINE FROM
POWER UNIT

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

15
16
 Section 3
Operation

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

OPERATING CONTROLS AND GAUGES

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

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

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

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

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

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

Backing Pin
In Make-up Hole
In Break-out Hole
Shifting Lever
Up Position
Center Position
Down Position
Tong Control Levers
Forward Position
Back Position
Manual Relief Valve
Pressure Gauge
Torque Gauge
Lift Control Lever*
Forward Position
Back Position
Hydraulic Backup
Control Lever*
Forward Position
Back Position
Hydraulic Backup*
Directional Valve
Allows tong to bite when operated clockwise for makeup.
Allows tong to bite when operated counter-clockwise for break-out.
Shifts tong gear train into high-speed position.
Neutral position-motor and clutch shaft turn but rotary gear does not rotate.
Shift tong gear train to low speed.
Operates rotary gear and cage plates clockwise. For make-up, heads bite and for
break-out heads release.
Operates rotary gear and cage plates counter-clockwise. For break-out, heads bite
and for make-up, heads release.
Permits operator to set hydraulic pressure to desired setting.
Measures pressure applied to hydraulic motor.
Measures torque exerted in make-up or break-out operations.
Operates lift cylinder to lower tong.
Operates lift cylinder to raise tong.
Sets the backup heads (bite). Spring return neutral.
Releases the backup heads. Spring return neutral.
Selector valve for make-up and break-out. Move handle to right for
make-up, move to left for break-out. Handle operation is detented.

* Not shown in Illustration

PRESSURE
BREAK-OUT TORQUE
GAUGE
GAUGE

BACKING
SHIFTING
PIN LEVER
MAKE-UP

TONG CONTROL
LEVER

L
KE
EC MANUAL RELIEF
VALVE

Figure 3-2
7-5/8 Standard. Operating Controls and Gauges

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

TYPICAL OPERATING SEQUENCE

Typical operation of the tong is described in the following procedures.
INITIAL OPERATIONS. After the tong is transported to job site, hoisted into operat-
ing position, snubbed, leveled, and connected with power unit as described in Installa-
tion Section, proceed as follows.

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

21
 (A). When the openings are aligned, release the control lever.
12. Disengage the cam backup by pulling out on the backup control lever (B).
13. Unlatch and open the safety door. Remove the tong from the made-up joint and
close the safety door.
14. Reposition the pipe and repeat the operation.
Break-out Operation: Refer to Figure 3-1 for control lever locations.
1. Verify tong is snubbed for both make-up and break-out operations.
2. Place the backing pin in break-out (right hole) position (Figure 3-2).
3. Shift the hydraulic cam backup tool (if used) into the break-out mode by
pulling back on the backup directional control lever (D).
4. Begin the operation with the power tong in the low speed mode. In break-out
operation, the low speed mode is required due to the high torque associated
with this mode.
5. Position the tong on the pipe. The tong unit may be raised or lowered by
operating the lift cylinder control (C). Pushing in on the lever lowers the tong
while pulling out on the lever raises the tong. After positioning, close and latch
the safety door.
6. Engage the cam backup heads by pushing forward on the backup control lever
(B).
7. Grip the pipe with the power tong heads and begin rotation by pulling back on
the tong control lever (A).
8. After breaking the connection and when torque requirements have fallen off,
shift the tong into high speed, by pulling up on the speed shift lever (E).
9. When the joint has been fully broken apart, release the tong control lever (A) to
stop the tong. The control lever is spring return to center neutral position.
10. To release the pipe and align the door openings, push forward on the tong
control lever (A). When the openings are aligned, release the control lever.
11. Disengage the cam backup by pulling out on the backup control lever (B).
12. Unlatch and open the safety door. Remove the tong from the broken-apart joint
and close the safety door.
13. Reposition the pipe and repeat the operation.
CROSS THREADED PIPE. The backing pin may be left out of its hole during make-
up operation to allow for quick tong reversal due to cross-threaded joints. It must be
replaced, however, after each joint completion in order to align the door openings so the
tong can be removed from the pipe.

22
 Section 4
Servicing

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

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

Rig Dies

CAGE PLATE
BOLT

CLUTCH
DOOR
L
KE
EC
BRAKE
BANDS

Figure 4-1
Tong Inspection Points

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

MAINTENANCE AFTER EACH JOB

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

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

* Specifications are listed for average conditions. For applications involving

extreme heat and cold, consult Eckel for recommendations.

6 10 2 5 2

9
7
8
4
1
1
5

TOP BOTTOM

Figure 4-2
Tong Grease Points

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

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

LUBRICATION
Proper lubrication is important to the operation and long life of the tong. This topic
describes both the lubricating grease and the hydraulic fluid requirements for the tong.
HYDRAULIC FLUID. Under normal operation the tong should remain charged with
hydraulic fluid even when the hydraulic hoses are disconnected. This is because check
valves at the disconnect points retain the hydraulic fluid within the tong when the
connection is separated. However, should hydraulic fluid be lost from the tong due to
leaks or during maintenance, you should recharge the tong by connecting the hoses from
the hydraulic power unit and operating the tong for a short period.
GREASE ZERTS. At the beginning of each job and daily thereafter while job is in
progress, you should use a grease gun to grease the various grease zerts. Over greasing
will do no harm, while under greasing can result in excessive wear. Figure 4-2 shows
the lubrication points and Table 4-1 gives information on the type of grease to be used.
Numbers enclosed in parenthesis refer to grease points identified in Figure 4-2.
1. Grease dumbbell roller bearings (1) top and bottom of tong. A special grease
gun adapter (Eckel part number 103877) is required when greasing dumbbells.
2. Grease Cam Follower Bearings (2) top and bottom of tong.
3. Grease door latch (3).

25
 4. Grease rotary idler bearings (4) top of tong.
5. Grease pinion idler bearing (5) bottom of tong.
6. Grease shifting shaft (6) top of tong.
7. Grease motor gear (7) top of tong.
8. Grease clutch bearings (8) bottom of tong.
NOTE: You must rotate cam and cage plates as necessary to obtain access to cam
followers. At the same time you should grease outside of cam followers as described on the
Important following page.
CAM FOLLOWERS. When greasing cam follower, lubricate outside of cam follower
rollers as listed below.
1. Use gear grease as described in Table 4-1.
2. Apply grease liberally to outside of each roller.
HEAD ROLLERS. Lubricate head rollers as follows.
1. Knock out head roller pins and grease with gear grease, then replace rollers on
heads. Be sure rollers turn freely.
2. Apply gear grease liberally to outside of head rollers.
HYDRAULIC BACK-UP LUBRICATION. The above lubrication points for the cam
followers and head rollers apply also to the hydraulic back-up.
GEAR GREASE. To pack the tong with grease refer to Figure 4-2 and Table 4-1, and
proceed as follows.
! Warning WARNING: Packing the gears while power unit is operating is extremely dangerous.
Failure to observe proper precautions in maintaining this unit could result in extreme
personnel hazard.
1. With power unit connected and operating, rotate rotary gear so that opening is
turned to back of tong, Figure 4-2 (9).
2. Disable tong by both of the following methods.
! Warning WARNING: Keep hands out of the head area while the power unit is operating.
a. Disconnect power from the power units electrical motor or turn off diesel
engine as applicable.
b. Disconnect hydraulic pressure line (1-inch line) from tong at hose connec-
tor.
3. Remove cover from inspection door (10).
4. Pack the unit with specified gear grease (see Table 4-1) as follows:
a. Apply grease liberally through opening at back of cage plates, Figure
4-2 (9).
b. Apply grease liberally through inspection door to gear, Figure 4-2 (10).
! Warning WARNING: Failure to disable hydraulic system after operating tong could result in
serious personnel injury.
c. Operate tong to distribute grease, then disable hydraulic power unit and
repeat steps a and b.
5. Replace cover on inspection door.

26
 RELIEF
VALVE
BRAKE BAND
ADJUSTING NUTS
(UPPER)

L
KE SHIFTING
EC DETENT

BRAKE BAND
ADJUSTING NUTS
(TWO UNDERNEATH)

Figure 4-3
Tong Adjustment Points

TESTS AND ADJUSTMENTS

The following test should be made and the adjustments performed as indicated.
BRAKE BANDS. At the beginning of a job and at the start of each shift thereafter,
perform the brake band test and brake band adjustment as required.
Brake Band Test. Check each brake band adjustment according to the following
steps.
1. Place backing pin in Make-up position.
2. Operate the tong several times and verify that the heads bite at each operation.
3. Place backing pin in Break-out position.
4. Operate tong several times and verify that heads rotate out of neutral cam.
5. If heads fail to bite in either Make-up or Break-out position of backing pin,
adjust brake bands.
Brake Band Adjustment. When inspection or test indicates the brake bands require
adjustment, then adjust the brake bands according to the steps given below. Refer to
Figure 4-3 for the adjustment points.
1. Turn each of four brake band adjusting nuts one-fourth turn.
2. Check brake operation as in preceding topic.
3. Repeat steps 1 and 2 as necessary until heads extend from cage plate smoothly.
Important NOTE: A total of one-half to one turn should normally be sufficient.
SHIFTING DETENT. The shifting detent that holds the shifting mechanism in the
selected speed is adjustable. This adjustment should be checked at the beginning of a
job and at the start of each shift thereafter, and the detent should be adjusted if required.

27
 Detent Operation Check. Check the operation of the shifting detent as follows.
1. Raise shifting handle to High Speed position and verify that the control snaps
into position.
2. Exert force on shifting lever and verify that lever remains in High Speed
position until considerable force is exerted, then gives way to slide freely to
next position.
3. Repeat steps 1 and 2 for Low Speed position.
4. Repeat steps 1 and 2 for Neutral position.
5. If above steps indicate need for adjustment, adjust detent.
Detent Adjustment. When an operation check indicates the need to adjust the
shifting detent, refer to Figure 4-3 and adjust the detent as outlined below.
1. Loosen the jam nut on adjusting bolt.
2. Tighten bolt one-half turn.
3. Repeat Detent Operation Check.
4. If mechanism operates properly, tighten jam nut while holding adjusting bolt at
setting obtained in step 2.
5. If additional adjustment is indicated, repeat steps 1 and 3 until proper operation
is achieved.
TORQUE CHECK ADJUSTMENT. The relief valve for the tong may be set to
achieve the maximum torque desired. The following procedures describe the method
for checking and adjusting the relief valve to obtain the torque desired (up to the
maximum torque of the tong). Refer to Figure 4-3 for the adjustment point.
Important NOTE: Refer to the manual on the power unit and be sure unit is adjusted to provide the
required operating pressure.
Maximum Torque Adjustment. Adjust the maximum torque to the desired value
according to the following steps.
1. Set up tong on tong test stand with tubing coupled or installed so that it can not
turn and verify tong is snubbed for both make-up and break-out operations.
2. Be sure the torque gauge is correctly installed and is in proper operation.
3. Back off relief valve to minimum torque setting.
Important NOTE: Adjustment is extremely difficult to turn when pressure is applied.
4. Incrementally adjust relief valve, then apply pressure and read torque value.
Continue until desired maximum torque value is obtained.

28
 Section 5
Troubleshooting, Repair
and Overhaul

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

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

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

M4D MOTOR OVERHAUL

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

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

MATERIAL 4140 OR EQUIVALENT

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

Figure 5-1
M4D Special Tools

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

33
 c. Inspect bearings for wear or flat spots. If the bearings are rough or loose
they must be replaced.
d. Inspect the cam ring for excessive wear (ripples or washboard marks on the
contour). Replace a badly worn or defective cam ring.
e. Inspect the rotor for scored, marred or scratched (faces and vane slots)
surfaces. Replace a defective rotor.
f. Inspect the vanes for excessive wear marks (burrs, nicks and scoring).
Replace defective vanes.
g. Inspect the wear surfaces of the port plate and end cap for deep scratches.
Replace if defective.
h. Inspect the body and end cap for cracks or other casting damage. Replace
all damaged castings.
i. Inspect the shaft for excessive wear (internal spline, bearing surface and
drive end). Replace if defective.
CAUTION: Dirt is a major cause of wear and motor failure. Cover all parts after
cleaning to prevent dust and dirt from settling on them. All surfaces should be coated
Caution with a film of hydraulic lubricating oil after they have been cleaned.
LUBRICATION. No external lubrication is required. The hydraulic fluid which
operates the motor provides adequate internal lubrication.
REASSEMBLY. Immerse the seals and bearings in clean hydraulic fluid to make the
reassembly easier and to provide initial lubrication.
Shaft End:
1. Position the body (18) on a clean flat surface with the small open end facing up.
Press the felt wiper (17) in the 2-1/16" hole. The wiper must be flush with the
bottom of the counterbore. Turn the body (18) over with the large open end
facing up. Use the shaft seal drive (Figure 5-x) and drive the shaft seal (16)
into the body (18) until it seats in the counterbore. Make certain that the open
side of the seal is toward the inside of the body. The shaft seal driver will
prevent damage to the seal during installation.
2. Press bearing (13) on the shaft (14) to the shoulder and install external snap
ring (12). Be certain that the ring is seated in the snap ring groove.
3. Apply lubricating fluid to the inside of seal (16) and wiper (17). Press the shaft
and bearing assembly (12, 13 and 14) into the body (18).
4. Install snap ring (11) in the body (18) and against bearing (13) to hold the shaft
assembly in place. Make certain snap ring (11) is fully seated in the groove.
Port Plate Sub-Assembly:
The special screws and the port plate including the internal threads must be degreased.
Apply a very small amount of Loctite #242 to the special screws only. An excessive
amount of Loctite on the screws would be forced into the shuttle spool bore when the
screws are installed. Allow the Loctite to cure for one hour after installing the screws.
1. Install one of the special screws in the shuttle spool bore of the port plate.
Torque screw to three to five ft. lbs. maximum. Insert the shuttle spool in the
shuttle bore and install the other special screw and torque. Tilt the port plate
sub-assembly back and forth to be certain that the spool travels the full length
of the bore.
2. Lubricate seals (9) and (10) and install on back of port plate.
3. Insert dowel pin (7) in hole in face of port plate assembly.
4. Thread two #10-24 screws in the tapped holes in face of the port plate assembly
(8) and install in the body.
34
 Cam Ring Sub-Assembly:
1. Place the cam ring (6a), rotor (6b), vanes (6c) and vane springs (6d) on a clean
flat surface. Arrange the vanes side by side with the three spring holes up.
Insert the vane springs in the vanes. Install the vanes with the springs in the
slots in the rotor.
WARNING: Be certain that the springs are started in the holes in each rotor slot.
! Warning a. Place a ring compressor around the vanes and tighten the compressor
gradually until the springs and vanes are in the position they will occupy
while in the cam ring. Place a back up plate, slightly smaller than the
outside diameter of the rotor in the ring compressor and push the rotor,
springs and vanes into the cam ring. The back up plate will prevent the
vanes from sliding end wise in the rotor slots and damaging the slots and
springs.
WARNING: Be certain that the rotor and vane assembly is inserted far enough in the
! Warning cam ring to prevent the vanes from flying out of position when the ring compressor is
removed.
2. Thread two #10-24 screws into the cam ring assembly on the same side of the
ring that indicates the cam size. Insert the dowel pin (5) in the cam ring and
position the complete assembly in the body over the dowel pin (7).
End Cap Sub-Assembly:
1. Lubricate the rubber seal (3) and install on the cap (2)
2. Press the needle bearing (4) into the end cap (2) with markings on the bearing
1/16" below the face of the cap.
3. Position the end cap (2) over the dowel pin (5). Hole the end cap firmly
against the cam ring assembly and rotate to line up the bolt holes.
4. Insert screws (1) and tighten evenly to 130 ft. lbs. torque.

A35 VALVE OVERHAUL

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

35
 CAUTION: For detented spool models, be careful not to remove the detent poppet
Caution sleeve (9) unless it is to be serviced. Without the sleeve, the spring-loaded steel balls (8)
can pop free and be lost.
5. Remove and discard rubber spool seals.
6. These parts should not be removed from the spool unless they are to be
replaced. Once the spool is free of the housing, it must be carefully handled to
avoid damage. If it is necessary to remove the spring, place the spool in a soft-
jawed vise and remove the stripper bolt with a wrench.
NOTE: Cautious applications of heat may be required to free the stripper bolt or detent
Important retainer as an anaerobic thread adhesive is used in their assembly.
7. Remove items (8,9,15) by placing a rag around the sleeve to keep the parts
from springing loose, and pulling firmly to free them from the poppet retainer.
Cleaning, Inspection Repair:
1. Inspect the spool bores and spools for deep scratches, gouges or excessive
wear. If any of these conditions exist, replace the section. Minor surface
damage on the spool may be polished away with very fine crocus cloth.
2. Examine the machined surfaces of the valve housings for nicks or burrs that
could cause leakage between sections. Lightly stone these surfaces to remove
any rough spots.
CAUTION: A shallow, machined relief band extends across the "O" ring face of the
valve housing and should not be stoned or ground off.
Caution
3. Wash all parts thoroughly in clean solvent and blow dry before beginning
reassemble.
Assembly:
1. Clamp the spool in a soft-jawed vise. Apply a small amount of Loctite™ 262 or
equivalent anaerobic adhesive to the stripper bolt (16) before assembly.
NOTE: Follow the adhesive manufacturer's instructions for proper curing. Assemble
the spring (15), spring guide (14) and stripper bolt (16) on the spool. The detent poppet
Important retainer (6) is assembled in similar fashion.
2. Apply a light coating of clean hydraulic oil to the valve spool. Place the
retaining plate (5), back up ring (4) and spool seal (3) over the spool. These
items rest against the spring guide or poppet retainer in the order illustrated in
Figure 6-9. Install the spool seal (3) into the groove at the clevis end of the
valve body. Carefully insert the spool guides should be lightly coated with a
high temperature grease to prevent rusting. The detent mechanism should be
packed with a high temperature, extreme pressure grease for lubrication and
ease of operation. Place Loctite™ 262 or its equivalent on the valve cap screws
prior to attaching the cap to the valve body.
3. Coat the section seals (1 and 2) with grease to help keep them in place during
assembly. Place the valve sections on the tie bolts in their numbered sequence.
Torque the tie bolts nuts to 33 ft. lbs.

36
 Section 6
Parts List

37
 This section contains a complete illustrated parts list for the Eckel 7-5/8 Standard Tubing
Tong. Figure 6-1 is the top assembly drawing and Table 6-1 is the top assembly parts list.
Figure 6-2 through 6-8 illustrate the subassemblies not broken down in the top assembly
illustrated, and Table 6-2 through 6-8 list the parts for the subassemblies. Figures 6-9 through
6-16 illustrate the accessories available, and Table 6-9 - 6-12 list the parts for these accessories.
Table 6-1
Parts List, Eckel 7-5/8 Standard Tong – Figure 6-1
INDEX PART NO. DESCRIPTION QUANTITY
REF 108998 7-5/8 Tubing Tong 1
1 103475 Top Tong Plage 1
2 101539 Tong Plate Bolt - 3/8" N.C. x 1-1/4" Hex Head 54
3 101643 Tong Plate Bolt - 3/8" N.C. x 1-1/4" Flat Socket Head 4
4 108994 Brake band 2
5 101543 Brake Band Adjustment Screw - 3/8" N.F. x 1-3/4" Hex Head 4
6 101741 Nut for Adjustment Screw - 3/8" N.F. Full Lock Nut 4
7 100437 Brake Band Lug 4
8 100439 Brake Band Retainer 4
9 101764 Roller Shaft Nut - 7/8" N.F. Thin Lock Nut 18
10 101183 Roller Shaft Grease Zert - 1/4-28 Thd. 18
11 108996 Top Cage Plate 1
12 108997 Bottom Cage Plate 1
13 101570 Cage Plate Bolt - 1/2" N.C. x 6" Hex Head 2
14 100445 Cage Plate Spacer 3
15 100432 Head Pivot Bolt 2
16 101537 Retainer Screw - 3/8" NC x 3/4" Hex Head 1
17 101699 Retainer Washer - 3/8" Lock Washer 1
18 101698 Retainer Washer - 3/8" Flat Washer 1
19 100450 Backing Pin Retainer 1
20 100089 Backing Pin 1
21 100088 Back Cage Plate Bolt 1
22 100563 Door Spring Plunger 1
23 101095 Overcenter Spring 1
24 100545 Door Spring Sleeve 1
25 101538 3/8" x 1" NC Hex Head 2
26 100566 Door Spring Bushing 2
27 101789 Cam Follower - Torrington CF 1-1/2" SB 22
28 101714 Cam Follower Washer - 5/8" Lock Washer 22
29 101753 Cam Follower Nut - 5/8" N.F. Jam Nut 22
30 101186 Cam Follower Grease Zert - Drive Zert 22
31 100399 Head Roller Pin 2
32 100931 Head Roller 2
33 100507 Dumbbell Roller Shaft 9
34 100561 Dumbbell Roller 10
35 100513 Dumbbell Door Roller Shaft 1
36 100550 Dumbbell Roller Bushing 20
37 100404 Rotary Gear 1
38 100410 Backing Lug 1
39 101640 Backing Lug Screw - 3/8" N.C. x 1" Socket Head 1

38
 100,101

80
55
25
84
22,23 82 60
26
16 85 64
62
83 63
17 66
81
24 18 19
65
15
96
13 99 61
21 98 67
97
11 90 68

2 20 88
14 92
1 69
70
41 87
27 89
93 86 79
91

41 94,95

28 3 8
9,10 78
4
5
6 7
31
29
30
36
102 71
32

74
33 35 39 75 77

37 72
57
52
56 73
34
50
53
38
51 40
75

42 12 76

54

48 59
43 47 58
47
44
45,46
Figure 6-1
Eckel 7-5/8 Standard Tong, Exploded View

39
Table 6-1
Parts List, Eckel 7-5/8 Standard Tong - Figure 6-1 (Cont.)
INDEX PART NO. DESCRIPTION QUANTITY
40 100538 Tong Door 1
41 101944 A35 Control Valve Handle 1
42 102404 Door Ear 2
43 101809 Door Bearing 1-Z99R14 2
44 100543 Door Washer 2
45 101764 Door Shaft Nut - 7/8" N.F. Think Lock Nut 2
46 101183 Door Shaft Grease Zert - 1/4-28 Thd. 2
47 100542 Door Bearing Spacer 4
48 102796 Latch Spring 1
49 103067 3/16" x 2-1/2" Spring Pin 1
50 103068 5/32" x 1" Spring Pin 1
51 103361 Door Latch Arm 1
52 100626 Door Latch Pin 1
53 100526 Tong Body 1
54 100529 Side Hanger 2
55 100531 Back Hanger 1
56 100536 Clutch Door 1
57 101621 Clutch Door Bolts - 1/4" N.C. x 1" Socket Head 2
58 103476 Bottom Tong Plate 1
59 100533 Tong Leg 3
60 100476 Shifting Handle 1
61 100478 Pivot Arm 1
62 101172 Shifting Shaft Connecting Link #80 Chain Link 2
63 101534 Connecting Link Bolts 5/16" N.F. x 1-1/4" Hex Head 3
64 101734 Connecting Link Nuts 5/16" N.F. Lock Nuts 3
65 100473 Shifting Shaft 1
66 101185 1/8 N.P.T. Grease Zert 2
67 101091 Shifting Ball 1
68 101090 Shifting Spring 1
69 101744 7/16" NF Jam Nut 1
70 101551 Shifting Ball Screw - 7/16" x 1-1/4" NF 1
71 100472 Shifting Yoke 1
72 101714 Shifting Shaft Washer - 5/8" Lock Washer 1
73 101753 Shifting Shaft Nut - 5/8" N.F. Jam Nut 1
74 101756 5/8" N.F. Full Lock Nut 1
75 105589 Rotary Idler Assembly (See Figure 6-5 for Breakdown) 2
76 105590 Pinion Idler Assembly (See Figure 6-4 for Breakdown) 1
77 105591 Pinion Assembly (See Figure 6-3 for Breakdown) 1
78 105592 Clutch Assembly (See Figure 6-2 for Breakdown) 1
79 105071 Motor Gear 1
80 Tong Suspension (See Figure 6-8 for Breakdown) 1
81 100525 Motor Box 1
82 101661 Motor Box Bolts - 1/2" N.C. x 2" Socket Head 4
83 101709 1/2" High Collar Lock Washer 4
84 101946 Denison Motor Flange 1-1/4" x 1-1/4" 2
85 107893 Hydraulic Motor - Denison M4D 1
(See Figure 6-6 for Breakdown)

40
Table 6-1
Parts List, Eckel 7-5/8 Standard Tong - Figure, 6-1 (Cont)
INDEX PART NO. DESCRIPTION QUANTITY
86 100547 Torque Gauge Stand 1
87 100564 Torque Gauge Plate 1
88 101555 Gauge Plate Mount Bolt 1/2" NC x 3/4" Hex Head 1
89 101200 Torque Gauge 36" Handle 1
90 101524 1/4" x 3/4" N.C. Hex Head 3
91 100548 Valve Stand 2
92 101876 Control Valve - Standard
Commercial A35-AA4-MA53-Z16
(See Figure 6-7 for Breakdown) 1
101878 Control Valve - W/Lift Cylinder
Commercial A35-AA4-MA53-MA53-Z16 1
93 101568 Valve Mount Bolts - 1/2" N.C. x 4" Hex Head 2
94 100551 Microswitch Base 1
95 7625-CT-1025 Microswitch Assembly (See Figure 6-16 for Breakdown) 1
96 101041 1-1/4" Male Coupling - Aeroquip 5100-S2-20 1
97 101076 Dust Cap - Aeroquip 5100-32-20S 1
98 101038 1" Male Coupling - Aeroquip 5100-S2-16 1
99 101075 Dust Cap - Aeroquip 5100-32-16S 1
100 102369 3/8" Hose x 18" O.A.L. M.P. Ends 1
101 102370 3/8" Hose x 22" O.A.L. M.P. Ends 1
102 100823 J 2-1/16" Die Head 2
100824 J 2-3/8" Die Head 2
100825 J 2-7/8" Die Head 2
100827 J 3-1/2" Die Head 2
100828 J 4" Die Head 2
100830 J 4-1/2" Die Head 2
100832 J 5" Die Head 2
100833 J 5-1/2" Die Head 2
102733 J 6" Die Head 2
100834 J 6-5/8" Die Head 2
100835 J 7" Die Head 2
100836 J 7-5/8" Die Head 2
103 101243 2-1/16 Contour Die 2/HD
101245 2-3/8 Contour Die 2/HD
101247 2-7/8 Contour Die 2/HD
101249 3-1/2 Contour Die 2/HD
101251 Rig Die, 1/2" 2/HD
104 101109 Snap Ring, MTR F/M77 (Not Illustrated in Figure 6-1) 1

41
Table 6-2
Parts List, Clutch Assembly – Figure 6-2
INDEX PART NO. DESCRIPTION QUANTITY
REF 105592 Clutch Assembly 1
1 100468 Clutch Shaft Drive Gear 1
2 100466 Top Clutch Bearing Bushing 1
3 101799 Top Clutch Bearing 1
4 100464 Top Clutch Bearing Retainer 1
5 100460 Low Clutch Gear 1
6 101792 Clutch Gear Needle Bearing 4
7 100454 Clutch Shaft 1
8 100470 Shifting Collar 1
9 100458 High Clutch Gear 1
10 101796 Bottom Clutch Shaft Bearing 1
11 100461 Bottom Clutch Bearing Cap 1
12 101699 Bearing Cap Lock Washer 3/8" Lock Washer 4
13 101539 Bearing Cap Bolt 3/8" N.C. x 1-1/4" Hex Head 4
14 101061 Bearing Cap Pipe Plug - 1/8 N.P.T. 3

8
2
6
3

9
4
TOP TONG
PLATE

5 10 BOTTOM TONG
PLATE

6 11

7 12

14 13
14

Figure 6-2
Clutch Assembly, Exploded View

42
Table 6-3
Parts List, Pinion Assembly – Figure 6-3
INDEX PART NO. DESCRIPTION QUANTITY
REF 105591 Pinion Assembly 1
1 101558 Bearing Cap Bolt 1/2" NC x 1-1/4" in. HH 8
2 101708 Bearing Cap Lock Washer 1/2 in. Lock Washer 8
3 101061 Bearing Cap Pipe Plug 1/8 in. NPT 4
4 100488 Pinion Bearing Cap 2
5 101801 Pinion Bearing 2
6 100487 Low Pinion Gear 1
7 100482 Pinion Gear 1
8 100486 High Pinion Gear 1

3
1
2
4
5
TOP TONG
PLATE

BOTTOM TONG
PLATE

5
4
3
2
1

Figure 6-3
Pinion Assembly, Exploded View

43
Table 6-4
Parts List, Pinion Idler Assembly – Figure 6-4
INDEX PART NO. DESCRIPTION QUANTITY
REF 105590 Pinion Idler Assembly 1
1 101103 Idler Shaft Snap Ring 1
2 101145 Bearing Seal 2
3 101099 Bearing Retainer Ring 2
4 101805 Idler Gear Bearing 1
5 100492 Pinion Idler Gear 1
6 100495 Pinion Idler Shaft 1
7 101185 Pinion Idler Grease Zert 1/8" N.P.T. 1
8 100594 Pinion Idler Pad 1
9 101714 Idler Pad Lock Washer 5/8" Lock Washer 3
10 101583 Idler Pad Bolt 5/8" NC x 2" Hex Head 3
11 101726 Idler Shaft Lock Washer 1-1/2" Lock Washer 1
12 101772 Pinion Idler Shaft Nut 1-1/2" NF Hex Nut 1

2
1

2
6
3

7
BOTTOM TONG
4 PLATE

5 8

9
11
10

12
3

Figure 6-4
Pinion Idler Assembly, Exploded View

44
Table 6-5
Parts List, Rotary Idler Assembly – Figure 6-5
INDEX PART NO. DESCRIPTION QUANTITY
REF 105589 Rotary Idler Assembly 2
1 101772 Rotary Idler Nut 1-1/2" NF Hex Nut 2
2 101726 Rotary Idler Lock Washer - 1-1/2" Lock Washer 2
3 100505 Rotary Idler Pad 2
4 100504 Rotary Idler Gear Spacer 2
5 101145 Bearing Seal Nilos 6212 AV 2
6 101099 Bearing Retainer Ring - RR 433 2
7 101805 Idler Gear Bearing 1
8 100492 Rotary Idler Gear 1
9 101185 Rotary Idler Grease Zert - 1/8 N.P.T 1
10 100498 Rotary Idler Shaft 1
11 100501 Rotary Idler Gear with Micro Cam 1

9
1

2
3 10
TOP TONG
PLATE

4 6

5 5

6
4

7 BOTTOM TONG
PLATE

3
8,11
2

Figure 6-5
Rotary Idler Assembly, Exploded View

45
Table 6-6
Parts List, M4D Motor Assembly – Figure 6-6
INDEX PART NO. DESCRIPTION QUANTITY
REF 107893 Hydraulic Motor - Denison M4D 1
1 358-24260 Socket head cap screw 5/8-11 x 2-1/4" lg. 4
2 034-49753 End cap with SAE-20 threaded ports 1
3 691-10250 Square section seal #250 1
4 230-82002 Needle bearing BH-1212 1
5 324-21612 Dowel pin 1/4" x 3/4" 1
6 S14-26712 Cam Ring Assembly 1
6a 034-49750 Cam Ring M4D-113 1
6b 034-49747 Rotor 1
6c 034-49746 Vanes 10
6d 034-49743 Vane Springs 30
7 324-21612 Dowel pin 1/4" x 3/4" 1
8 S14-26066 Front port plate assembly 1
034-49754 Front port plate 1
034-70341 Shuttle spool 1
311-45020 Set screw 5/16-18 x 1/2" flat point w/spotlok 2
9 691-00246 "O"-ring #246 1
10 691-10232 Square section seal #232 1
11 356-32283 Internal snap ring 5008-283 1
12 356-31137 External snap ring 5100-137 1
13 230-00207 Shaft ball bearing ND#3207 1
14 034-49744 Shaft with 5/16" key way 1
15 034-49676 Shaft key 1
16 637-00003 Shaft seal 1
17 605-10020 Felt wiper 1
18 034-49756 Body 1

46
Figure 6-6
M4D Motor Assembly, Exploded View

47
Table 6-7
Parts List, Typical A35 Valve Assembly – Figure 6-7
INDEX PART NO. DESCRIPTION QUANTITY
REF 101876 Control Valve - Standard
(Comm. A35-AA4-MA53-Z16) 1
1 391-2881-403 Section Seal 1
2 391-2881-200 Section Seal 3
3 391-2881-101 Spool Seal 2
4 391-2681-001 Back-up Ring 1
5 391-2183-005 Retaining Plate 1
6 391-2583-006 Detent Popper Retainer 1
7 391-3581-015 Poppet Spring 1
8 391-0282-009 Steel Ball 2
9 391-3283-008 Detent Poppet Sleeve 1
10 342-6000-100 End Cap 1
11 391-1433-009 Fillister Head Screw 2
12 391-2881-095 O-Ring Seal 1
14 391-1642-013 Spring Guide 2
15 391-3581-124 Spring 1
16 311-1432-021 Stripper Bolt 1
17 391-2481-003 Check Valve Poppet 1
18 391-3581-114 Check Valve Spring 1
19 391-0581-004 Check Valve Cap 1
20 101950 Main Relief Valve Assembly - BL6625K 2
21 391-1583-012 Gasket Washer 1
22 391-2681-165 Back-up Ring 1
23 391-2881-137 O-Ring 1
24 391-2881-260 O-Ring 2

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

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

Figure 6-7
Typical A35 Valve Assembly

49
Table 6-8
Parts List, Tong Suspension – Figure 6-8
INDEX PART NO. DESCRIPTION QUANTITY
REF Tong Suspension 1
1 101985 Lift Cylinder 1
2 100721 Spring Hanger Assembly 1
3 102373 Lift Cylinder Hose Assembly 1
4 101885 Pilot Operated Check Valve 1
5 100674 Bridle Assembly 1
6 101241 3/4" Clevis 2
7 101168 5/16" Clevis 3
8 101042 1/2" Male Quick Disconnect 1
9 101878 Control Valve Comm. A35-AA4-MA53-MA53-Z16 1

6
3

5 4
9

Figure 6-8
Tong Suspension

50
Table 6-9
Parts List, Manual Backup Assembly – Figure 6-9
INDEX PART NO. DESCRIPTION QUANTITY
REF 103859 7-5/8 Manual Backup 1
1 103786 Hinge Pin 6
2 103783 Long Jaw Assembly 1
3 103780 Fail Type Swivel Arm 1
4 103784 Short Jaw Assembly 1
5 103782 Latch Spring 1
6 103789 Latch Lug Jaw 4-3/4" - 6-1/4" 1
7 103788 Latch Lug Jaw 3-1/2" - 5" 1
8 103787 Latch Lug Jaw 2-3/8" - 3-1/2" 1
9 104149 Bracket 1
10 104220 Swivel & Extension Link Assembly 1
11 101183 1/4 Grease Zert 3
12 101760 3/4 Lock Nut NC 1
13 101729 1/4 Lock Nut NC 1
14 106034 3/4 NC x 6 Hex Head Bolt 1
15 103769 Bracket Pin Spring 1
16 103765 Bracket Pin 1
17 101529 1/4 NC x 2 Hex Head Bolt 1
18 101251 Dies 3
19 104252 Die Retaining Pins 6
20 103420 1/8 x 2 Cotter Pins 12
21 103864 Latch Spring Plunger 1
22 103865 Latch Spring Plunger Pin 1
23 104253 Latch Arm 1
24 103856 Latch Lug Jaw 5-3/4" - 7-1/4" 1
25 103858 Latch Lug Jaw 7-1/4" - 8" 1
26 112220 Latch Lug Jaw 8" - 8-5/8" 1
27 103920 Short Link 2

51
 22
2
19,20

22 5 1,20
2
19,20 21
5 1,20 3
21

3 23
18

24
23
18

8
PIPE RANGE
5-3/4 - 7-1/4
4

PIPE RANGE
2-3/8 - 3-1/2
11 9
22 12 10
2
19,20
5 1,20
21

23
18
15
7 14
13 17
4

PIPE RANGE
16
3-1/2 - 5

22 22 22
2 2 2
19,20 19,20 19,20
5 1,20 5 5
1,20 1,20
21 21
21

3 3 3

23 23
23 18 18
18

4 4
27 27 27
4

25 26

PIPE RANGE PIPE RANGE PIPE RANGE

4-3/4 - 6-1/4 7-1/4 - 8 8 - 8-5/8
Figure 6-9
Manual Backup Assembly, Exploded View

52
Table 6-10
Parts List, Hydraulic Cam Backup – Figures 6-10 through 6-13
INDEX PART NO. DESCRIPTION QUANTITY
REF 107180 7-5/8 Hydraulic Cam Backup 1
1 107164 Cam Ring 1
2 107170 Backup Plate 1
3 107196 Bolt, Socket Head, 3/4" N.C. x 2-1/2" 17
4 101719 Lockwasher, 3/4" Hi-Collar 17
5 107169 Top Cage Plate 1
6 104260 Cage Plate Key 1
7 103374 Bolt, Socket Head, 3/4" N.C. x 1-1/4" 1
8 107168 Bottom Cage Plate 1
9 108062 Bolt, Hex Head, 7/8" N.C. x 5-1/2" 6
10 101788 Cam Follower 30
11 101718 Lockwasher, 3/4" 30
12 101759 Jam Nut, 3/4" N.F. 30
13 101186 Grease Zert, 3/16" Drive 30
14 101183 Grease Zert, 1/4" - 28 N.F. 8
15 101646 Bolt, Socket Head, 3/8" N.C. x 2 2
16 103614 Spring, Head Return 2
17 103383 Bolt, Socket Head, 3/8" N.C. x 3-1/2 2
18 107174 Torque Link Assembly 1
19 103374 Bolt, Socket Head, 3/4" N.C. x 1-1/4" 2
20 107196 Bolt, Socket Head, 3/4" N.C. x2-1/2" 2
21 101719 Lockwasher, 3/4" Hi-Collar 4
22 107183 Washer, Torque Link/Cylinder Anchor 2
23 101699 Lockwasher, 3/8" 2
24 101538 Bolt, Hex Head, 3/8" N.C. x 1" 2
25 107119 Anchor Post 1
26 101684 Bolt, Socket Head, 3/4" N.C. x 2" 3
27 101719 Lockwasher, 3/4" Hi-Collar 3
28 107165 Cylinder Rod Extender 1
29 107120 Pivot Post 1
30 101684 Bolt, Socket Head, 3/4" N.C. x 2" 4
31 101719 Lockwasher, 3/4" Hi-Collar 4
32 107167 Pivot Arm 1
33 106669 Pivot Arm Washer 1
34 101538 Bolt, Hex Head, 3/8" x N.C. x 1" 1
35 101699 Lockwasher, 3/8" 1
36 107122 Stinger 1
37 107123 Load Cell Retainer 1
38 101557 Bolt, Hex Head, 1/2" N.C. x 1" 1
39 107178 Mounting Plate, Load Cell Bracket 1
40 107209 Bolt, Socket Head, 3/8" N.C. x 2-1/2" 7
41 101700 Lockwasher, 3/8" Hi-Collar 7
42 101684 Bolt, Socket Head, 3/4" N.C. x 2" 8
43 101719 Lockwasher, 3/4" Hi-Collar 8
44 107172 Load Cell Bracket 2
45 107910 Bracket Cap 1
46 101714 Lockwasher, 5/8" 4

53
Table 6-10
Parts List, Hydraulic Cam Backup – Figures 6-10 through 6-13 (Cont.)
INDEX PART NO. DESCRIPTION QUANTITY
47 101583 Bolt, Hex Head, 5/8" N.C. x 2" 4
48 107808 Bolt, Hex Head, 5/8" N.C. x 12" 2
49 101757 Locknut, 5/8" N.C. Full Height 2
50 107920 Rear Spring Retainer Plate 2
51 104188 Spring Assembly 3
52 107171 Front Hanger Leg 2
53 101606 Bolt, Hex Head, 3/4" N.C. x 7" 2
54 101760 Locknut, 3/4" N.C. Full Height 2
55 107177 Mounting Bracket, Hanger Leg 2
56 101601 Bolt, Head 3/4" N.C. x 4" 2
57 101760 Locknut, 3/4" N.C. Full Height 2
58 107194 Hydraulic Cylinder, 2" x 8" 1
59 107192 Hydraulic Cylinder, 2" x 7" 1
60 106317 Shuttle Valve, 1/4" 2
61 101890 Valve Section, 1" - Commercial, A35-MA53 1
62 104173 Control Valve, 1/4" Rexroth RWMM 1
63 101963 Subplate and Bolt Kit for 1/4" Valve 1
64 101058 1/4" Quick Disconnect Coupling, Male Half 2
65 101059 1/4" Quick Disconnect Coupling, Female Half 2
66 103823 3/8" Quick Disconnect Coupling, Male Half 1
67 103820 3/8" Quick Disconnect Coupling, Female Half 1
N/S Body Guard, Left Side 1
N/S Body Guard, Right Side 1
N/S 101538 Bolt, Hex Head, 3/8" N.C. x 1" 8
68 107210 Torque Gauge Assembly 1
69 112551 Z Slide Head, 2-1/16" -4" W.A. Die 2
70 112552 Z Slide Head, 4-1/16" - 5-9/16" W.A. Die 2
71 112553 Z Slide Head, 5-5/8" - 7-5/8" W.A. Die 2
72 112554 Z Slide Head, 7-3/4" - 8-5/8" W.A. Die 2
73 107569 Z - 2-1/16" Wrap Around Die 2
74 107570 Z - 2-7/8" Wrap Around Die 2
75 107571 Z - 2-3/8" Wrap Around Die 2
76 107572 Z - 3-1/2" Wrap Around Die 2
77 107573 Z - 4" Wrap Around Die 2
78 107574 Z - 4-1/8" Wrap Around Die 2
79 106936 Z - 4-1/2" Wrap Around Die 2
80 107575 Z - 4-3/4" Wrap Around Die 2
81 107580 Z - 5" Wrap Around Die 2
82 106935 Z - 5-1/2" Wrap Around Die 2
83 107577 Z - 6-5/8" Wrap Around Die 2
84 107581 Z - 7" Wrap Around Die 2
85 107578 Z - 7-5/8" Wrap Around Die 2
86 Z - 8-1/2" Wrap Around Die 2
87 107579 Z - 8-5/8" Wrap Around Die 2
88 112159 Die Retaining Screws (2 per head) 4
89 100946 Head Roller, 2-1/2" 1/HD
90 104259 Head Roller, 2" 1/HD
81 100402 Head Roller Pin 1/HD

54
 55 56,57 40,41,42,43

39

5
1
37
2 50
6 51 (Not Shown)
3,4 44
51 36

53 46,47
54 50

52 48,49
45

5
1
36 37
2

6 38
3,4

29
34,35 33

Figure 6-10
Hydraulic Cam Backup, Side View

55
 37

3,4

7,8
89,90,91

15

10,11,12,13
16,17
88
73-87 69-72 9

Figure 6-11
Hydraulic Cam Backup, Top View

56
 37 38

33

34,35

32 29
30,31

59
58
24 26,27
25
19,21

8
22,23 22,23

24 14

18 10,11,12,13

20,21
3,4

Figure 6-12
Hydraulic Cam Backup, Bottom View

57
 58

60

60

66,67

23
64,65
64,65
a b

t p

44,45

61

t p

Figure 6-13
Hydraulic Cam Backup Drive System Schematic

58
Table 6-10
Parts List, Door Interlock Assembly – Figure 6-14 and 6-15.
INDEX PART NO. DESCRIPTION QUANTITY
REF 107258 Door Interlock Device (Single Door Tongs) 1
1 106882 1" Relief valve R4V-06-513 1
2 101472 1" Ell 2
3 101495 Straight Swivel M/F 2
4 101342 1" x 2-1/2" Nipple XH 1
5 101437 1" 90° ELL 2
6 101284 1" Tee Steel 3
7 101343 1" x 3" Nipple XH 1
8 101344 1" x 3-1/2" Nipple XH 1
9 104313 0-5000 PSI Pressure Gauge 1
10 106716 1-1/4 x #65 Check Valve 1
11 101340 1" Nipple AT XH 6
12 100968 1-1/4" X 1" Bushing 1
13 100963 1" x 1/4" Bushing 1
14 101273 1/4" Tee Steel 1
15 101300 1/4 Nipple AT 1
16 101409 1/4" 90° Swivel 2
17 101352 1" x 6-1/2" Nipple XH 1
18 101039 1-1/4" Coupling 1
19 101040 1" Coupling 1
20 102395 1/4" NPT Hose Ends 4
21 101485 1/4" Straight Swivel M/F 2
22 101409 1/4" x 90° Swivel M/F 2
23 104378 1/4" Deltrol Plunger Valve CH V MOC20 1
26 107256 Door Cam 1
28 107257 Valve Bracket 1
29 102366 1/4" x 60" Hose Assembly 2

59
 2 6 11
7

10 9
13
12 11

6
8

11

7
RETURN LINE

PRESSURE LINE

Rear View Front View

2
5
5 4 3

11
26
1
28
12 11 16
23
RETURN LINE
13 15
5
19

18
26 28 23
A
PRESSURE LINE
B

6 17 14 16
5

Side View

21 22
20 23
A

Figure 6-14
Door Interlock Assembly and Hydraulic Components

60
 DOOR INTERLOCK
RELIEF VALVE
PRESSURE

RETURN

TONG
MOTOR

DOOR INTERLOCK
PLUNGER VALVE

TONG CONTROL
VALVE

Figure 6-15
Door Interlocking Schematic

61
Table 6-12
Parts List, Door Interlock Assembly – Figure 6-16.
INDEX PART NO. DESCRIPTION QUANTITY
REF 7625-CT-1025 Microswitch Assembly 1
1 101192 Micro Switch BZ-2RN 702 1
2 100553 Micro Bushing Housing 1
3 100565 Micro Switch Push Rod 1
4 101811 Micro Bushing Consolidated A4812 3
5 103689 1/4" x 3/4" NF HH 2

Figure 6-16.
Microswitch Assembly

62