WFT 5.5 - 15

REVISION 08 2001
ALL EARLIER REVISIONS OBSOLETE
Hydraulic
Tubing Tong
Model TT 5.5-15
This Operating Manual is valid for the following serial numbers:

Tubing Tong 5.5 Serial Numbers: Free Floating Backup 5.5 Serial Numbers:
WL 5-455 till WL 5-523 WL 5-594 till WL 5-654 5-391 till 5-729
WL 5-525 till WL 5-539 WL 5-656 till WL 5-736
WL 5-542 WL 5-738 till WL 5-824
WL 5-544 till WL 5-592
OPERATING
MANUAL
Hydraulic Tubing Tong
Model TT 5.5-15
with Free-Floating Back-Up
Keep this manual for future reference!

Issue/Rev. Date: 08 2001
Publisher:
Weatherford Oil Tool GmbH
Hainhäuser Weg 150
D -30855 Langenhagen
TEL +49 (0)511-7702-0
FAX +49 (0)511-7702-187
This operating manual may not, in whole or in part, be copied or converted to any
mechanical, electronic or machine readable form. This manual contains company
confidential, property information which may not be disclosed to any unauthorized
parties.
All rights reserved.
p/n: 9110032 5.5-15 Tubing Tong with Backup/Commercial Motor Version

9110033 5.5-15 Tubing Tong with Backup/Commercial Motor Version, IS Dump Valve
9110035 5.5-15 Tubing Tong with Backup/Danfoss Motor Version, A-Q-TORK
9110037 5.5-15 Tubing Tong with Backup/Radial Piston Motor
9110011 5.5-15 Tubing Tong without Backup/Commercial Motor Version
© 23 July 2008 BL
SUMMARY OF CONTENTS
CONTENTS PAGE
PREFACE
1 SAFETY
1.1 RISKS INVOLVED WHEN OPERATING THE TUBING TONG..................... 1-1
1.2 SAFETY INSTRUCTIONS AND HINTS ........................................................ 1-2
1.3 DESIGNATED USE ...................................................................................... 1-2
1.4 SOURCES OF DANGER .............................................................................. 1-3
1.5 USE IN POTENTIALLY EXPLOSIVE ATMOSPHERE ................................. 1-4
1.6 OPERATOR´S POSITION ............................................................................ 1-5
1.7 DANGER ZONES ......................................................................................... 1-6
1.7.1 Used Warning Sings ..................................................................................... 1-7
1.7.2 Security Layout ............................................................................................. 1-7
1.8 QUALIFICATION OF PERSONNEL ............................................................. 1-8
1.9 PROTECTIVE CLOTHING ............................................................................ 1-8
1.10 SAFETY MEASURES FOR INSTALLATION ............................................... 1-9
1.11 PROTECTIVE DEVICES ............................................................................. 1-11
2 TRANSPORTATION AND INSTALLATION

2.1 TRANSPORTATION DEVICES .................................................................... 2-1
2.1.1 Hanging the Tong .......................................................................................... 2-2
2.2 INSTALLATION OF THE HYDRAULIC TUBING TONG .............................. 2-3
2.2.1 Installation Procedure ................................................................................... 2-3
2.2.2 Hydraulic Supply for the 5.5 – 15 Tubing Tong .............................................. 2-4
2.2.3 Backup Line Installation ................................................................................ 2-7
2.2.4 Installation Summary ..................................................................................... 2-8
SUMMARY OF CONTENTS
CONTENTS PAGE
2.3 JAW INSTALLATION ................................................................................. 2-10

2.3.1 Standard Jaws ............................................................................................ 2-11
2.3.2 Micro-Grip™ Jaws ........................................................................................ 2-14
2.3.3 Tong Jaws ................................................................................................... 2-16
2.3.4 Backup Jaws ............................................................................................... 2-18
3 GENERAL DESCRIPTION
3.1 POWER TONG ............................................................................................. 3-1
3.2 DESCRIPTION OF THE MAIN COMPONENTS ........................................... 3-2
3.3 FUNCTIONAL DESCRIPTION ...................................................................... 3-4
3.3.1 Hydraulic Drive System ................................................................................. 3-4
3.3.2 Gear Train ..................................................................................................... 3-4
3.3.3 Tong Jaw System .......................................................................................... 3-6
3.3.4 Description of the Pressure Indicators ........................................................... 3-8
3.4 OPTIONS AND ACCESSORIES .................................................................. 3-9
3.4.1 Free-Floating Backup .................................................................................... 3-9
3.4.2 Load Cell / Torque Gauge Application ......................................................... 3-10
3.4.3 A-Q-TORK™ Model C-12 Tong Speed Control System .............................. 3-11
3.4.4 IS Dump Valve Final Torque Control System .............................................. 3-13
3.5 TECHNICAL DATA ..................................................................................... 3-14
3.5.1 Technical Specification ................................................................................ 3-14
3.5.2 Technical Details ......................................................................................... 3-16
3.5.3 Hydraulic Oil Specification ........................................................................... 3-17
SUMMARY OF CONTENTS
CONTENTS PAGE
4 OPERATION
4.1 SAFETY CONSIDERATIONS ....................................................................... 4-1
4.2 DESCRIPTION OF THE TONG CONTROLS ............................................... 4-2
4.2.1 Control Handles for Commercial and Dinamic Motor Version ....................... 4-2
4.2.2 Control Handles for A-Q-TORK Version ........................................................ 4-3
4.2.3 Make-Break Catch on all 5.5-15 Tong Versions ............................................ 4-4
4.3 PRE-OPERATING ADJUSTMENTS ............................................................. 4-5
4.3.1 General Hydraulic Adjustments ..................................................................... 4-5
4.3.2 Specific Hydraulic Adjustments for A-Q-TORK ............................................. 4-6
4.4 SEQUENCE OF OPERATION ...................................................................... 4-8
4.4.1 Preparation...................................................................................................... 4-8
4.4.1.1 Lift Cylinder Setting ....................................................................................... 4-8
4.4.1.2 Setting the backup height .............................................................................. 4-9
4.4.1.3 Functional check ........................................................................................... 4-9
4.4.2 Make-up Operation ..................................................................................... 4-11
4.4.3 Break-out Operation .................................................................................... 4-12
4.4.4 Changing the Rotation Direction in between ............................................... 4-12
4.4.5 Special Functions with the A-Q-TORK System ........................................... 4-13
4.5 COMMISSIONING CHECKLIST ................................................................. 4-14
5 PLACING OUT OF OPERATION

SUMMARY OF CONTENTS
CONTENTS PAGE
6 TROUBLESHOOTING
6.1 GENERAL REMARKS .................................................................................. 6-1
6.2 GENERAL TROUBLESHOOTING ............................................................... 6-2
6.2.1 Excessive Pump Noise .................................................................................. 6-2
6.2.2 Hydraulic System Overheating ...................................................................... 6-3
6.2.3 Excessive Wear of moving Parts ................................................................... 6-3
6.2.4 Tong running too slowly ................................................................................ 6-4
6.2.5 Tong does not grip ........................................................................................ 6-4
6.2.6 Tong does not generate sufficient Torque ..................................................... 6-5
6.2.7 Motor runs but Tong does not rotate ............................................................. 6-6
6.2.8 Motor leaks .................................................................................................... 6-6
6.2.9 Backup does not grip ..................................................................................... 6-6
6.3 TROUBLESHOOTING THE A-Q-TORK SYSTEM ....................................... 6-7
6.3.1 No Pressure Build-up in the System .............................................................. 6-7
6.3.2 Constant Pressure Build-up .......................................................................... 6-7
6.3.3 Tong does not slow down automatically in low Gear ..................................... 6-7
6.3.4 Motor is stalled .............................................................................................. 6-7
6.3.5 No Dump Valve Operation (general) ............................................................. 6-7
6.3.6 No MOOG IS Dump Valve Operation ............................................................ 6-8
SUMMARY OF CONTENTS
CONTENTS PAGE
7 SERVICE AND MAINTENANCE

7.1 CLEANING ................................................................................................... 7-2
7.2 RECOMMENDED LUBRICANTS ................................................................. 7-4
7.3 POINTS OF LUBRICATION ......................................................................... 7-5
7.3.1 Rotary Drag Brake Band ............................................................................... 7-7
7.3.2 Oil Change of Gear Shift Box ........................................................................ 7-8
7.4 HYDRAULIC PIPING .................................................................................... 7-9
7.5 HYDRAULIC ADJUSTMENTS ................................................................... 7-10
7.5.1 Servicing the MOOG IS Dump Valve .......................................................... 7-11
7.6 JAW DIE EXCHANGING ............................................................................ 7-19
7.7 PRE-OPERATION TEST ............................................................................ 7-20
7.7.1 Free Run Test ............................................................................................. 7-20
7.7.2 Torque-Up Test ........................................................................................... 7-20
7.8 TORQUE MEASURING SYSTEM .............................................................. 7-21
7.9 MAINTENANCE PLAN AND INTERVALS ................................................. 7-24
SUMMARY OF CONTENTS
CONTENTS PAGE
8 APPENDIX
8.1 OVERVIEW – PARTS LISTS ........................................................................ 8-2
8.1.1 Clamping Elements, Tong and Backup ......................................................... 8-4
8.2 Tong TT 5.5 – 15 ........................................................................................ 8-12
8.2.1 Body Assembly ........................................................................................... 8-12
8.2.2 Door Assembly ............................................................................................ 8-18
8.2.3 Hanger Assembly ........................................................................................ 8-20
8.2.4 Catch Assembly .......................................................................................... 8-22
8.2.5 Drive Assembly ........................................................................................... 8-24
8.2.6 Bearing Assembly ....................................................................................... 8-30
8.2.7 Pinion Gear Assembly ................................................................................. 8-32
8.2.8 Cluster Gear Assembly ............................................................................... 8-34
8.2.9 Tong Manifold Assembly (without Backup) ................................................. 8-36
8.2.10 Tong Manifold Assembly (with Backup) ...................................................... 8-38
8.2.11 Hydraulic Safety Interlock System ............................................................... 8-40
8.3 Free-Floating Backup ................................................................................ 8-46
8.3.1 FF-BU Connection Parts ............................................................................. 8-46
8.3.2 Cylinder Assembly ....................................................................................... 8-50
8.3.3 Backup Manifold Assembly ......................................................................... 8-52
8.4 Accessories ............................................................................................... 8-54
8.4.1 Lift Cylinder Manifold ................................................................................... 8-54
8.4.2 A-Q-TORK System (optional) ...................................................................... 8-58
8.5 Hydraulic Parts .......................................................................................... 8-62
8.5.1 Hydraulic Plan ............................................................................................. 8-62
8.5.2 Cartridge Block Assembly ........................................................................... 8-64
8.5.3 Hydraulic Plan (A-Q-TORK with 12V Dump Valve) ...................................... 8-66
8.5.4 12V Dump Valve .......................................................................................... 8-68
8.5.5 Hydraulic Plan (A-Q-TORK with MOOG IS Dump Valve)............................. 8-70
8.5.6 MOOG IS Dump Valve ( for A-Q-TORK / Danfoss motor only) .................... 8-72
8.5.7 MOOG IS Dump Valve Assembly (for Commercial motor only) ................... 8-76
PREFACE
PREFACE
With your new WEATHERFORD “Hydraulic Tubing Tong - Model TT 5.5-15” you have purchased
a piece of equipment leading the field in performance and dependability.
This operating manual applies to the WEATHERFORD “Hydraulic Tubing Tong - Model TT 5.5-
15”. If there are any further questions about areas which are not explained in this manual or in cases
of doubt it is imperative to consult our technical department for specialist assistance!
Each device, prior to leaving our facility, has been tested under simulated field conditions to ensure
its performance according to the specifications.
This operating manual is designed to provide the necessary information on operating liability, safety
measures, operation and maintenance for the WEATHERFORD “Hydraulic Tubing Tong - Model
TT 5.5-15”.
In the interest of continued development WEATHERFORD reserve the right to incorporate modifica-
tions without updating the operating manual at the same time. These modifications to improve the
product do not, however, affect the essential features of the type described.
Not all options and variations described within this manual necessarily form part of your “Hydraulic
Tubing Tong - Model TT 5.5-15”. For the exact scope of delivery see your purchasing contract.
All persons involved in operation or maintenance of this device must read and understand this oper-
ating manual thoroughly before starting operation. The contents of this manual have to be complied
with at all times. This operating manual is component of the unit, it is therefore imperative to keep it
in a safe place for later use and to submit it at resale!
In addition to serving as a ready reference for those already familiar with the WEATHERFORD
“Hydraulic Tubing Tong - Model TT 5.5-15”, this manual also provides step-by-step procedures for
the less experienced user.
No liability will be carried in the event of disregarding the safety notes, improper handling, contrary
use to the designated use of the unit and unauthorized conversions. For safety reasons, unauthor-
ized conversions and modifications to the unit are expressly forbidden.
PREFACE
NOTES
SAFETY
1 SAFETY
1.1 RISK INVOLVED WHEN OPERATING THE HYDRAULIC TUBING TONG
The Hydraulic Tubing Tong is equipped with protective devices and has undergone a safety
check and certification before shipment. Incorrect operation or misuse threaten ...
the life and limb of the operator and the surrounding personnel
this device and other material assets of the operating authority
the efficient performance of this device.
The operating authority of this unit must ensure, that all persons having to do with installation,
commissioning, operation, cleaning, maintenance, repair and servicing of the unit must …
be qualified according to the requirements and authorized by the op-

erating authority.
follow this operating manual thoroughly. It is recommended to the

operating authority, that all persons having read the operating man-
ual confirm the knowledge with their signature.
Safety first, don’t risk anything!
Remember: If you are not part of the SOLUTION,
you are part of the PROBLEM!
Operating Manual Rev.08 2001 Page 1-1 of 12

SAFETY
1.2 SAFETY INSTRUCTIONS AND HINTS

The following symbols are used in this manual:
describes a possibly dangerous situation.

Disregard can lead to death or severe injury.
describes a possibly dangerous situation.

Disregard can lead to minor injury.
describes a possibly harmful situation. Disregard can damage this device or

other material assets in its working range.
This sign also marks useful operating hints.
1.3 DESIGNATED USE
The WEATHERFORD Hydraulic Tubing Tong - Model TT 5.5-15 is designed exclusively for mak-
ing up and breaking out joints of tubing ranging from 1.66 till 5 1/2 inches in diameter. It is capa-
ble to generating torque up to 15 000 ft-lbs in either make-up or break-out mode. The tubing tong
can be used either with or without free-floating backup. Secure the tong always with a backup line
(refer to Section 2.2.3).
Using the Hydraulic Tubing Tong for purposes other than expressly mentioned above (such as for
running drill pipes, casing or eccentric tools) is considered contrary to its designated use and is
therefore prohibited. The manufacturer cannot be held liable for any damage resulting from such
use. The risk of such misuse lies entirely with the user.
Never make any modifications, additions, or conversions without the manufacturer’s written ap-
proval. This also applies to the installation and adjustment of safety devices.
Operating the machine within the limits of its designated use also involves observing the instruc-
tions set out in the operating manual and complying with the inspection and maintenance direc-
tives.
Due to extremely high gripping forces tubing can be deformed!
Page 1-2 of 12 Rev. 08 2001 Operating Manual

SAFETY
1.4 USE IN POTENTIALLY EXPLOSIVE ATMOSPHERE

This equipment is certified for use in potentially explosive atmospheres described in the European
Directive 94/9 EC (ATEX) - Zone 1.
When used in a potentially explosive atmosphere the user has to ensure the following:
The equipment must be earthed.
Observe all national and international regulations.
Tarpaulins may not be handled where an explosive atmosphere may be present.
Use this product in its original configuration without undertaking any modifications. The ex-
plosion proof certificates will become invalid, if modifications are made by the user.
NEVER undertake any repair or maintenance work where a potentially explosive atmos-
phere is present.
Impacts involving rust and light metals (e.g. aluminum) can form sparks. Prevent aluminum
parts of the power unit from objects falling onto or hitting it.

SAFETY
1.5 SOURCES OF DANGER

The Hydraulic Tubing Tong - Model TT 5.5-15 is a powerful hydro-mechanical tool. Insufficient or
improper maintenance of the hydraulic system can result in damages or malfunctions of the Tub-
ing Tong. The clamping elements are driven both mechanically and hydraulically. Disregarding
the safety instructions can lead to severe injury.
The operating authority must ensure to operate the unit only in unobjectionable state. Consider
the above and follow these directives:
The operator of the unit is responsible for all tong operations at the rig site.
Leaks in the hydraulic system may cause injuries. If a leak occurs, suspend operation and
repair immediately.
Prior to service, maintenance, repair or conversion work, the sources of hydraulic and elec-
tric power must be disabled and disconnected from the Hydraulic Tubing Tong. Even if the
unit is de-energized, the hydraulic system may still be under pressure. Decompress the
pipes before any service and maintenance work in these areas.
Never make any modifications, additions, or conversions which may affect the protective
devices.
Damaged or missing warning information or labeling on the unit must be replaced immedi-
ately.
Use only original spare parts.

SAFETY
1.6 OPERATOR´S POSITION
The position of the operator should be on the right side of the tong in front of the valve handles.
The shaded area in Fig. 1.1 shows the permitted working positions for the operator.
Under no circumstances may anybody stay underneath the suspended tong.
Guide the tong at the provided green handles only.
All other personnel must stay clear of the working range of the Hydraulic Tub-
ing Tong.
Failure to observe this safety precaution can cause severe injury or death.
Fig.1.1 Operator’s Position

SAFETY
1.7 DANGER ZONES
Every area of the unit or in its proximity where the risk of injury or health damage exists has to be
declared as danger zone.
Danger zones must clearly be declared and protected by barriers and/or labeled with warn-
ing signs to prevent unauthorized entering.
Missing or unreadable warning labels at the unit or its surrounding area must be replaced
immediately.
During remote controlled operation no person must enter a danger zone.
Only objects which are absolutely required for the operation of the unit are allowed to be
placed inside a danger zone.
1.7.1 Used Warning Signs

The following warning signs are used at the Hydraulic Tubing Tong - Model TT 5.5-15:
Warning Sign No.: 1
Warning Sign No.: 2
Fig.1.2 Warning Signs at Hydraulic Tubing Tong

SAFETY
1.7.2 Security Layout
Danger zone = Tong and backup rotating and clamping movements
2 1
Fig.1.3 Security Layout of Hydraulic Tubing Tong
o = No. of used warning sign according to Section 1.6.1

SAFETY
1.8 QUALIFICATION OF PERSONNEL
Only trained and properly instructed personnel may operate the Hydraulic Tubing Tong. The indi-
vidual responsibilities of the personnel who operate, set-up, maintain and repair this tool must be
stated clearly. Remember, during operation the operator is responsible for third parties.
Unclear responsibilities are a safety hazard.
The operating authority must ensure that ...
the operating manual is available to all involved personnel
all involved personnel have read and understand the contents of this manual, in particular
the chapter on safety, before beginning work.
1.9 PROTECTIVE CLOTHING
The protective clothing required for using the Hydraulic Tubing Tong Model TT 5.5-15 is the same
as that typically used on drilling rigs:
Hard hat to protect the head against falling parts and overhead
equipment.
Eye protection glasses must be worn to protect against flying parti-

cles.
Safety boots to protect against erroneous rest of the equipment.
Safety gloves to protect the hands against aggressive grease, lubri-

cants and mud.

SAFETY
1.10 SAFETY MEASURES FOR INSTALLATION
Do not transport or operate the Tubing Tong outside the specified tempera-
ture range (refer to Section 3.5.1). Components can break at lower tempera-
tures.
Disregard can lead to death or severe injury.
The Hydraulic Tubing Tong - Model TT 5.5-15 must hang from a WEATHERFORD Lift Cyl-
inder during operation (see Fig. 1.4).
Fig.1.4 Suspension of the Tong System
Installation or dismantling of this unit may only be carried out under supervision of a
WEATHERFORD employee or by WEATHERFORD trained staff, as otherwise there is a
risk of injury and permanent damage to the unit. The consequence would be expensive re-
pairs, replacement of components or expiration of warranty claims.

SAFETY
The unit must only be used if it has been set up in accordance with regulations and in con-
formity with the manual.
Do not work on or tamper with hydraulic connections when the unit is in operation. Even if
the unit is de-energized, the hydraulic system is under pressure. Before starting such work
decompress the pipes and tubes and take appropriate measures to secure all electrical
switches and drive mechanisms against unintentional activation.
All lifting equipment for the installation must have a minimum lifting capacity of 1 500 kg.
Ensure that no other rig equipment is rested in the operating area of the tong.

SAFETY
1.11 PROTECTIVE DEVICES
The tong is equipped with a Safety Interlock System at the tong door. Opening the tong
door blocks the tong motor function immediately. Thus the Safety Interlock System pre-
vents tong operation while the tong door is open (see Fig.1.5).
Warning - Danger to life and limb!

If the safety interlock is not working properly, stop operation immediately.
While the tong door is open, any rotation of the rotor must be inhibited by the
safety interlock. Do not operate the tong with defective safety interlock func-
tion.
If the tong is prepared to operate with a positioning device (e.g. PowerScope,

PushMaster or PowerMaster) this disabling function does not effect the posi-
tioning device.
Fig. 1.5 Safety Interlock System at the Tong Door

SAFETY
The door is equipped with a safety catch to prevent clamping of fingers while opening the
door (see Fig.1.6).
Fig. 1.6 Safety Catch at the Tong Door
During make-up or break-out operation, the clamping pressure of the backup is always
monitored by a pressure control valve (see Fig. 1.7). If the clamping pressure of the backup
should drop below a certain set value, the operation sequence will be terminated to protect
personnel and prevent pipe damage. In such cases a visual control of the backup pressure
is required. Suspend operation and evaluate the cause of backup pressure loss (see Sec-
tion 6 for troubleshooting).
Fig. 1.7 Pressure Control Valve

TRANSPORTATION AND INSTALLATION
2 TRANSPORTATION AND INSTALLATION
The WEATHERFORD Hydraulic Tubing Tong - Model TT 5.5-15 has been designed to provide quick
and accurate operation under field conditions. It has been fully serviced prior to shipment and is
ready for use after rig up.
No unusual regulations need to be followed for transporting the tong. All tong components must be
lifted to the rig floor by crane or equivalent device by attaching to the provided lifting points (see Fig.
2.1). All lifting equipment must have a minimum lifting capacity of 1 500 kg.
Ensure that all lifting equipment is in proper condition.
2.1 TRANSPORTATION DEVICES
For transportation and lifting, the housing of the Hydraulic Tubing Tong is equipped with a hanger
to ensure problem-free lifting and lowering during the installation (see Fig. 2.1).
It is strongly recommended to secure the tong in a transport cradle for the transfer to the rig site.
Transport cradles are available from WEATHERFORD on request.
Tighten the securing nuts on both torque tubes and install the rear support leg and the two front
support legs for transportation. For operation the two securing nuts must be loosened two turns
and the support legs must be removed.
Fig. 2.1 Transportation Safety Devices

2.1.1 Hanging the Tong
Fig. 2.2 Tong suspended by Lift Cylinder
The suspension line for the tong must be at least a 5/8" diameter steel cable.
Always use the WEATHERFORD lift cylinder for tong suspension (see Fig. 2.2).
Select the suspension point high enough in the derrick to ensure easy handling and as close
as feasible to the center of the rotary gear. Allow for the hanger offset from the center of the
tong opening. The line must be securely anchored at the rig frame.
Hang the tong at approx. the same height as the average joint.

2.2 INSTALLATION OF THE HYDRAULIC TUBING TONG
2.2.1 Installation Procedure
Place all tong equipment on the rig floor.
The Hydraulic Tubing Tong - Model TT 5.5-15 must hang from a WEATHERFORD Lift Cylin-
der during operation (refer to Section 2.1.1).
All lifting gear must have a minimum lifting capacity of 1 500 kg.
Ensure that all lifting equipment is in proper working condition.
Check the horizontal balance of the tong system while at the well center. For proper operation
the tong must be as horizontal as possible when gripping the tubing. The balance can be re-
adjusted with two adjustment screws at each side of the base points of the hanger (see Fig.
2.3).
Fig. 2.3 Horizontal Balancing
Make sure the correct jaws are installed (refer to Section 2.3) and the tong door is closed.
Loosen the screws and adjust tong position horizontally. Then tighten the screws. Make sure
both screws are in contact with the hanger strut.
For side-to-side leveling, move the clevis in the notched insert at the top of the hanger to the
required position.

2.2.2 Hydraulic Supply for the 5.5 – 15 Tubing Tong
The tong can be operated with a variable or fixed displacement hydraulic power unit. Depending
on the used hydraulic motor version the tong’s hydraulic system requires the following (see Fig. 2.4):
Pressure line (1“ quick-disconnect coupling, female)
Return line (1 1/4“ quick-disconnect coupling, female)
Leakage oil (quick-disconnect coupling

only ‘DINAMIC / Piston’ motor version)
Lift cylinder up / make-up thread compensation (1/2“ quick-disconnect coupling, male)
Lift cylinder down (1/2“ quick-disconnect coupling, female)
Backup grip (1/2“ quick-disconnect coupling, female)
Backup release (1/2“ quick-disconnect coupling, male)
All hoses are equipped with quick-disconnect couplings. Due to different coupling types (different
diameters, male or female), mixing up of the hose connections is impossible.
Lift Cylinder
(connector posi-
tions depend on
used motor version)
Backup
Power Unit
Fig 2.4 Hydraulic Supply, Connection Points (shown motor version: Commercial)
Hydraulic oil is under pressure! Splashing hydraulic oil can result in injuries.
Switch off the power unit and decompress the lines before connecting or
disconnecting the hydraulic lines!

Use petroleum-based hydraulic oil to ensure proper function of the tubing tong. Depending on the
used hydraulic motor version the power unit / hydraulic fluid must comply with the following values
to operate the tong:
1. COMMERCIAL – Hydraulic motor version

Max. hydraulic flow 300 liter / minute 80 gpm
Hydraulic pressure 175 bar 2 500 psi
2. DINAMIC/PISTON – Hydraulic motor version
General characteristics for the above
Viscosity / 40° C ISO – 32
Operating oil temperature 20 – 70° C 68 – 158° F
External filtration at the
20 μm; SAE class 5 (17/14 – ISO 4406)
power unit
3. DANFOSS – Hydraulic motor version with A-Q-TORK

Max. starting viscosity at min. oil temperature 1,600 mm 2/s at –15° C / 5° F
Min. oil viscosity at max. oil temperature 11 mm 2/s at 70° C / 158° F
Aniline point 80° C min. 176° F min.
Internal filtration at the tong
10 μm in supply line
motor
Recommended additives Foam depressant, rust and oxidation inhibitors
Oil specification for normal BP Energol HLP 32, Texaco Rando HD A 32, Shell Tellus 32,
temperatures Esso Nuto H 32, Mobil DTE 32 or other suitable fluids
At other operating oil temperatures use oil of the appropriate viscosity range
to ensure the needed viscosity of 32 centistokes (ISO-32), i.e. during winter-
time use winter oil with lower viscosity range.
In case of doubt contact the WEATHERFORD technical support.

Connect the two lift cylinder hoses to the tong valve.
Connect the two backup hoses to the tong valve (only if backup is used otherwise install the
backup line according to Section 2.3).
Connect the two main hydraulic hoses from power unit to the power tong.
Be sure connections are completely tight. Failure to tighten connections cor-

rectly will damage hydraulic equipment and cause loss of performance.
The operator must be familiar with all applicable environmental regulations in
the event of leakage or spillage and prepare to take appropriate steps for con-
trol and removal.
Start the hydraulic power unit. The Hydraulic Tubing Tong is now ready for operation.

2.2.3 Backup Line Installation
If no free-floating backup is used, the backup line must be equipped with a

torque cylinder. But attention, tong arm length in this case is 25” / 635 mm.
Use correct type of torque cylinder for accurate torque measurements.
If a free-floating backup with load cell / torque gauge application (refer to Sec-
tion 3.4.2) is used, a backup line without torque cylinder must be installed to
secure the tong against slip through of the backup (tong arm length in this
case 30” / 762 mm).
Fig. 2.5 Backup Line
Use a steel cable of at least 5/8" diameter as back-up line (see Fig. 2.5).
Connect back-up line to a torque gauge to restrain tong rotation and to provide torque read-
ings for operation (tong arm length = 25” / 635mm).
If no torque gauge is used or if a backup with load cell / torque gauge application is installed,
connect the backup line directly to the backup line bracket.
Secure the other end of the backup line to a solid part of the rig structure at a 90° angle with
the tong center line (see Fig. 2.5). Deviation from the 90° angle introduces torque measure-
ment errors.
Fig. 2.5 shows backup line configuration for make-up. For break-out, swing the backup line
by 180° and secure it to a solid part on the opposite side of the rig structure in the same way
as for make-up.

2.2.4 Installation Summary

If you need support or additional information, please contact the WEATHERFORD technical de-
partment.
For subsequent installation, proceed as follows:
Place all tong equipment on the rig floor.
Fix the lifting equipment to the lifting points of the tong for installation (see Section 2.1).
All lifting gear must have a minimum lifting capacity of 1 500 kg.
Ensure that all lifting equipment is in proper working condition.
Keep all other personnel away from the control valves of the positioning de-
vice to prevent accidental movements.
Fix the tong with the backup (if backup is used) to the lift cylinder (see Section 1.9).
Ensure that the correct jaws are installed (see also Section 2.3 Jaw Installation)
Hydraulic system under pressure!

Never attempt to tighten connections containing hydraulic pressure. To do so
may cause injury to personnel and damage equipment.
Before hook up hydraulic hoses, ensure that hoses are bled.
Connect the main hydraulic hoses from power unit to the power tong (see Section 2.2.2).
Connect the lift cylinder hoses to the tong valve (see Section 2.2.2).
Connect the backup hoses to the tong valve (see Section 2.2.2).
Be sure connections are completely tight. Failure to tighten connections cor-

rectly will damage hydraulic equipment and cause loss of performance.
Avoid any sharp bending of hoses.
Operator should be familiar with all applicable environmental regulations in
the event of leakage or spillage and prepare to take appropriate steps for con-
trol and removal.

Loosen the nut at the torque post on each side of the backup (if backup is used).
Check the horizontal balance of the tong system at the well center. If necessary, adjust the
position according to Section 2.2.1.
Remove the three support legs.
Start the hydraulic power unit.
The 5.5 – 15 tubing tong is now ready for operation. Proceed as described in Section 4.

2.3 JAW INSTALLATION

Jaw size requirements vary according to the size of pipe or tool joint to be gripped. Prior to any job
the tong and the backup have to be dressed with the correct size of jaws and dies.
Rotating clamping system!

Can cause severe injuries by squeezing; can kill you !
Disable the hydraulic power unit after extending the clamping cylinders and
before performing jaw installation or jaw removal!
To adapt the clamping elements according to the different pipe diameter it is necessary to combine
the clamping elements in the correct way.
Two kinds of jaws are available:
• Standard jaws for normal tubing. Combination possibilities of these clamping elements are listed
in table 2.1.
• Micro-Grip™ jaws for adverse conditions like premium connections with chrome tubing. Combi-
nation possibilities of these clamping elements are listed in table 2.2. This type of jaws eliminate
the use of the previous delivered ‘non-marking jaws’ which are obsolete and not available any
longer. Non-marking jaws are listed in Section 8.1.1.3 for reference purposes only for costumers
who still own them.
The installation procedure is described in Section 2.3.3 (for tong installation) and Section 2.3.4 (for
backup installation).

2.3.1 Standard Jaws

The jaws of a particular size can be used in the tong as well in the backup. Attention must be paid for
the right and left side markings (e.g. L 4 ½“ = left side, 4 ½“ pipe diameter). Sides are determined by
looking at the tong/backup from the front opening. Do not mix up right and left side jaws and jaws for
different diameters.
Jaw size requirements vary according to the size of pipe to be gripped. Jaw sizes available are listed
in Table 2.1.
Fig. 2.6 Standard Jaw Set consisting of left and right Jaw

Table 2.1 Standard Jaw Parts List for Tong and Backup Jaws
REQ'D NO.
PIPE SIZE
ITEM* DESCRIPTION PER JAW PART NO
(INCHES)
SET
1 JAW SET (incl. left and right jaw, dies, pins) 1 541 0120
1.66“ 2 DIE 3/8" STANDARD 6 541 0180
3 SPRING STRAIGHT PIN 6 521 0156
1.9“ 2 DIE 3/8" STANDARD 6 541 0180
2 1/16“ 2 DIE 3/8" STANDARD 6 541 0180
2 3/8“ 2 DIE 3/8" STANDARD 6 541 0180
2 7/8“ 2 DIE 3/8" STANDARD 8 541 0180
3 1/2“ 2 DIE 3/8" STANDARD 8 541 0180
4“ 2 DIE 3/8" STANDARD 8 541 0180
3
4 1/2“ 2 DIE /8" STANDARD 8 541 0180
5“ 2 DIE 3/8" STANDARD 8 541 0180
5 1/2“ 2 DIE 3/8" STANDARD 8 541 0180
* refer to Fig. 2.6.

Table 2.1.1 Jaw Parts List for specific Backup Jaws (for backup use only)
PIPE SIZE
ITEM* DESCRIPTION PART NO
(INCHES)
1.315“ 1 JAW SET (incl. left and right jaw, dies, pins) 541 0134
2 11/64“ 1 JAW SET (incl. left and right jaw, dies, pins) 541 0142
3
3 /4“ 1 JAW SET (incl. left and right jaw, dies, pins) 541 0148
1
3
* refer to Fig. 2.6.

2.3.2 Micro-Grip™ Jaws

The jaws of a particular size can be used in the tong as well in the backup. Attention must be paid for
the right / left side and the make-up / break-out markings (e.g. BL 4 ½“ = for break-out mode, left
side, 4 ½“ pipe diameter).
Sides are determined by looking at the tong/backup from the front opening. All Micro-Grip jaws can
be used for make-up or break-out by turning them upside down and using them on the opposite side
(refer to jaw markings on top and bottom). Do not mix up right and left side, make-up and break-out
as well as diameters.
Jaw size requirements vary according to the size of pipe to be gripped. Jaw sizes available are listed
in Table 2.2.
Fig. 2.7 Micro-Grip Jaw Set consisting of left and right Jaw (for pipe diameter 2 3/8” till 4”)
Fig. 2.8 Micro-Grip Jaw Set consisting of left and right Jaw (for pipe diameter 4 1/2” till 5”)

Table 2.2 Micro-Grip Jaw Parts List for Tong and Backup Jaws
REQ'D NO.
PIPE SIZE
ITEM DESCRIPTION PER JAW PART NO
(INCHES)
SET
1.66“ Not available

1* MICRO-GRIP ASSEMBLY (incl. inserts) 1 541 1903
2 3/8“
2* INSERT 2 541 1853
2 7/8“
2* INSERT 2 541 1854
3 1/2“
2* INSERT 2 541 1855
4“
2* INSERT 2 541 1856
1** MICRO-GRIP ASSEMBLY (incl. inserts) 1 541 1907
4 1/2“
2** INSERT 2 541 1857
1** MICRO-GRIP ASSEMBLY (incl. inserts) 1 541 1908
5“
2** INSERT 2 541 1858
5 1/2“ Not available
* refer to Fig. 2.7
** refer to Fig. 2.8
Further details can be seen in Section 8.1.1.2.
Do not use the 5” Micro-Grip jaw in the tong, it is for backup use only.

2.3.3 Tong Jaws

Jaw size requirements vary according to the size of pipe to be gripped. Tong jaw sizes available
are listed in Table 2.1 (standard jaws) and table 2.2 (Micro-Grip jaws).
Turn tong to the starting position, that means the opening of the tong body has to corre-
spond with the opening of the rotary. The tension levers are now in back-position and allow
easy access for installation. For parts identification refer to Fig. 2.9.
Fig. 2.9 Parts Identification
Switch off the hydraulic system.
Rotating clamping system! Can cause severe injuries by squeezing; can kill
you!
Disable the hydraulic power unit before performing jaw installation or jaw re-
moval!
Remove the cotter pin from the lower end of the jaw pin.
Pull the jaw pin and remove the jaw. Lubricate the jaw pin with a thin oil film.
Insert the new jaw set depending on the pipe size to be gripped. Do not mix up the left and
right jaws.
If the 4 ½“ Micro-Grip jaws are used, take care that they are vertical centered and use only
the specific jaw pins delivered with the Micro-Grip assembly.
Do not use the 5” Micro-Grip jaw in the tong, it is for backup use only.

Push the jaw spring and insert the jaw pin.
Fig. 2.10 Installation of Tong Jaws
Secure the jaw pin with the cotter pin.
Repeat the above mentioned steps with the other jaw set.
Check that the jaws are turned towards the body opening to ensure a good integration of the
pipe.
Fig. 2.11 Jaws turned towards the Body Opening

2.3.4 Backup Jaws

Jaw size requirements vary according to the size of pipe or tool joint to be gripped. Backup jaw sizes
available are listed in Table 2.1 (standard jaws) and table 2.2 (Micro-Grip jaws).
Ensure that the clamping cylinders of the backup are retracted.
Switch off the hydraulic system.
Hydraulic clamping system! Can cause severe injuries by squeezing; can kill
you!
Disable the hydraulic power unit before performing jaw installation or jaw re-
moval!
Remove the cotter pin from the lower end of the jaw pin. Pull the jaw pin and remove the
jaw. Lubricate the jaw pin with a thin oil film.
Insert the new jaw set depending on the pipe size to be gripped. Do not mix up the left and
right jaw set.
Insert the jaw pin and secure the jaw pin with the cotter pin.
If Micro-Grip jaws for a diameter ³ 4 ½“ are used, take care that they are vertical centered
and use only the specific jaw pins delivered with the Micro-Grip assembly.
Micro-Grip jaws need to set backup in lower position (refer to Section 4.4.1.2).
Repeat the above mentioned steps with the other jaw set.
Check that the jaws are turned towards the body opening to ensure a good integration of the
pipe.
Fig. 2.12 Installation of Backup Jaws

GENERAL DESCRIPTION
3 GENERAL DESCRIPTION
3.1 POWER TONG
The WEATHERFORD Hydraulic Tubing Tong - Model TT 5.5-15 is a hydraulic motor-driven tong
capable of running tubing from 1.66 till 5 1/2 inches in diameter. The tong can produce up to 15000
ft-lbs in low gear, forward or reverse operation. Optional the 5.5 free-floating backup can be
adapted.
The tong design includes a clamping system inside the rotor unit to provide secure tubing grip
with maximum gripping forces and protection for the operator under high load conditions. This
unique gripping concept also uses a load-bearing hook-type segment to absorb radial forces de-
veloped during make-up and break-out operations. The case body and rollers provide axial and
radial support for the rotary, which guides the cage plates around the circumference using cam
followers.
The system is driven by a hydraulic motor located on the tong casing. Three different hydraulic
motor versions are available on request:
Commercial – Gear Wheel Motor (with or without optional IS Dump Valve Assembly for fi-
nal torque adjustment)
Danfoss – Gear Wheel Motor (only available in conjunction with A-Q-TORKTM Model
C-12 M Tong Speed Control System, refer to Section 3.4.3)
Dinamic – Piston Motor
The optional backup underneath the tong restrains the tong from moving around the tubing when
torque is applied. The torque reaction between the tong and the backup is achieved via two verti-
cal torque tubes, reacting the torque as a couple. Torque load is then initiated into the load cell /
torque gauge application located on the operator’s side of the tong. This type of reaction system
eliminates shear and bending loads across the tool joint, thereby subjecting the joint only to tor-
sion loads.
During operation the tong is secured with a backup line to compensate the torque and to restrain
tong rotation. If the tong is operated without backup, the backup line must include a torque cylin-
der (refer to Section 2.2.3) must to provide torque readings.
The tong with backup (if used) is suspended through the hanger by the lift cylinder, controlled by
the operator, to give accurate vertical positional control on the tool joint.
Legs beneath the tong allow the whole system to be set down on the floor.
Operating Manual Rev. 08 2001 Page 3-1 of 20

GENERAL DESCRIPTION
3.2 DESCRIPTION OF THE MAIN COMPONENTS
Fig. 3.1 TT 5.5 – 15 Tubing Tong, Front View (shown without motor and valve section)
Fig. 3.2 TT 5.5 – 15 Tubing Tong, Side View, Right (shown with Commercial motor)

GENERAL DESCRIPTION
Item Parts description Explanation
1 Hydraulic motor Powerful main hydraulic motor with gear to drive the rotor clockwise or
with gear counterclockwise in two different speeds. Motor version depending on
costumer request. Motor block not shown in Fig. 3.1.
2 Tong case body Houses the rotary gear and guides the rotor with its mechanical
clamping system.
3 Load cell with com- Optional application if used with backup, not included if used with A-
pression link Q-TORK System or without backup. Tension type load cell to measure
the torque reaction between the tong and the backup during make-up
(if the load cell is mounted on the right side) or during break-out (if the
load cell is mounted on the left side). The compression link must al-
ways be installed on the opposite side of the load cell. Take care of
the different tong arm lengths (25” without backup, 30” with backup).
4 Backup Optional free-floating backup attached to the Tubing Tong. Contains

two clamping cylinders to restrain the tong from moving around the
pipe when torque is applied.
5 Manual valve handles Arrangement depends on used motor version. All functions can be
executed by using this manual handles at the valve block. Valve sec-
tion not shown in Fig. 3.1.
6 Tong door Manually activated tong door with safety interlock valve which detects
whether the tong door is properly closed during operation. If the tong
door is open, it prevents further operation.
7 Tong hand grip Totally three (3) green colored hand grips for easy positioning of the
tong while hanging. Do not grip elsewhere.
8 Backup hand grip Totally three (3) green colored hand grips for easy positioning of the
tong and backup while hanging. Do not grip elsewhere.
9 Support legs Totally three support legs (two front, one rear) for secure resting of the
tong with backup during transport and with adjustment holes for differ-
ent backup mounting heights.
10 Hanger The tong housing is provided with a hanger to ensure problem-free

lifting and lowering during transport and installation.
11 Make-Break catch Handle to select between make-up and break-out operation.

GENERAL DESCRIPTION
3.3 FUNCTIONAL DESCRIPTION
3.3.1 Hydraulic Drive System

The tong incorporates a two-stage gear-type, hydraulic motor providing drive power through a
power train. Three different motor versions are available on request. The heart of the tong is a
jaw-closing system, which moves the jaws towards the drill pipe/the tubing and rotates them by
means of a cam-type rotary gear. The rotary gear is driven by a cluster of gears, two idlers and
one driver housed in the main body of the tong. These gears in turn are driven through a gear box
located under the hydraulic motor.
To prevent cross-connection of the hoses, the pressure hose is designed to mate with a 1 inch
connector and the return with a 1 1/4 inch connector. If the hydraulic motor type ‘DINAMIC / Piston’
is used an additional 3/4 inch hose must be connected to drain the leakage oil.
3.3.2 Gear Train

Closure and rotation of the pipe-gripping jaws is accomplished by a large rotary gear. Mechanical
power is transmitted from the hydraulic motor to turn the rotary gear in either direction.
A schematic sketch of the complete tong gear train is shown in Figure 3.3. The gear train con-
sists of a hydraulic motor mounted on a shiftable two stage gear box in a separate housing
mounted on the tong top plate. The hydraulic motor drives a pinion directly through the high (1:1)
or low (1:4,6) ratio of the gear box. Through a cluster and an intermediate gear the input pinion
drives a pair of rotary idlers which in turn drive the rotary gear.

GENERAL DESCRIPTION
Fig. 3.3 Gear Train in high and low Gear

GENERAL DESCRIPTION
3.3.3 Tong Jaw System
The Model TT 5.5-15 tong uses a two-jaw system. Each jaw is pivotally attached to a jaw lever.
The jaw lever in turn is itself pivotally attached to the end of a C-shaped hook section. An exten-
sion of the jaw lever carries a cam roller. In this system the hook jaw and the jaw lever are struc-
turally mounted independent of the rotary.
Chucking wedges (cams) are attached to the inner surface of the rotary. These cams are offset,
i.e. installed at different elevations, thus permitting operation without interference between the jaw
rollers.
During operation, a braking action retards the movement of this hook jaw system. The resulting
relative movement brings a shallow-angle cam surface in contact with a tension lever jaw roller,
positioning one of the jaws. This jaw is moved into a fixed position against the hook. With no fur-
ther movement possible, this jaw becomes the reactive jaw. A slight additional rotation cams the
second jaw (power jaw) into engagement with the pipe.
During this process, the hook has not rotated. The jaws have been brought into contact with the
pipe only with minimal rotation, thus preventing scarring of the pipe. With both jaws engaged, the
systems becomes self-centering. The hook serves 2 purposes. On the one hand, the rotation has
moved the hook to close the rotary opening, thus preventing “pipe kick-off”. On the other hand,
the hook bears the normal component of the chordal vectors (which would otherwise attempt to
spread the rotary).

GENERAL DESCRIPTION
Fig. 3.4 Tong Jaw System

GENERAL DESCRIPTION
3.3.4 Description of the Pressure Indicators

The standard 5.5 – 15 Tubing Tong contains the following pressure gauges:
Fig. 3.5 Pressure Indicators at the Tubing Tong
The torque gauge is part of the load cell application and not included in spe-
cific configurations.

GENERAL DESCRIPTION
3.4 OPTIONS AND ACCESSORIES

3.4.1 Free-Floating Backup
The (optional) hydraulic free-floating backup is designed to oppose the output torque of the tong.
It is mechanically and hydraulically (via hoses) linked to the 5.5-15 tong and is self-compensating
for connection thread travel in make-up direction. An optional load cell (torque cylinder) can be fit-
ted between tong and backup and, by selection, can be used to record make-up or break-out
torque. Two jaws provide the gripping means. A flow divider ensures a centric clamping action of
the hydraulic clamping cylinder. The backup tong is designed to accommodate all collar diame-
ters within 1.66" to 5 1/2", refer to Table 2.1.
A pressure control valve is used to provide a means of adjusting pressure in the backup cylinders
so that jaw gripping loads can be varied to suit all combinations of tubular diameter and torque
requirements. A pressure booster increases the pressure set by the control valve (100 bar) by a
factor of four (400 bar) before it reaches the clamping cylinder.
Pressure booster Flow divider
Jaw Clamping cylinder Torque tube
Fig. 3.6 Free-Floating Backup, Top View

GENERAL DESCRIPTION
3.4.2 Load Cell / Torque Gauge Application
Hydraulically driven Power Tong!

Never attempt to make-up or break-out connections without compression link!
Always have a compression link fitted on the opposite side of the hydraulic
load cell!
The optional load cell / torque gauge assembly (see Fig. 3.7, shown in make-up configuration)
measures the torque applied while the tong is used in make-up or break-out operations. Consisting
of a hydraulic load cell and torque indicator connected by a pressure hose, the torque gauge as-
sembly senses and indicates the torque developed during an operation. The torque detected can
also be recorded on a chart recorder. In order to transduce the hydraulic pressure to electrical cur-
rent, the pressure transducer has to be connected via a quick-disconnect coupling and a pressure
hose.
For make-up operation, install the hydraulic load cell on the right side of the tong (as seen from the
tong door) between the torsion bar and torque tube.
If torque measurement is required during break-out operation, install the hydraulic load cell on the
left side of the tong (as seen from the tong door) between the torsion bar and torque tube.
If the optional backup is not used, the hydraulic load cell is connected to the rear of the tong and to
the backup line. The backup line is the tie-up to a solid part of the rig structure and must form an an-
gle of 90° to yield accurate torque readings (refer to Section 2.2.3). Take care of the different tong
arm lengths and the correct type of torque cylinder.
Fig. 3.7 Torque Measuring System – Make-up Configuration

GENERAL DESCRIPTION
3.4.3 A-Q-TORKTM Model C-12 M Tong Speed Control System

The optional A-Q-TORK control system has been developed specifically to provide controlled make-
up for special requirements to thread and material. This applies e.g. to premium connections includ-
ing corrosion resistant alloy (CRA) materials and specialty premium threads. Pipe manufacturers are
now specifying extremely low make-up speeds and this system will enable us to meet this require-
ments. A low torque spin-in feature is provided along with a controlled low speed high torque make-
up capability.
If the Hydraulic Tubing Tong Model TT 5.5-15 is ordered with this A-Q-TORK System the tong is fit-
ted with the A-Q-TORK drive module consisting of a Danfoss hydraulic motor, a computerized con-
nection monitoring / display system, JAM and a pressure relieving dump valve.
Fig. 3.8 Tong with A-Q-TORK System
3.4.3.1 A-Q-TORK Drive Module

This is an adjustable pressure and flow control module designed to give full control of the tong speed
during both make-up and break-out operations. Included into the module is an automatic change-
over valve which is operated simultaneously with the gear shift handle (see Fig. 4.2, lever V5) to al-
low the operator to shift from high gear (spin-in) to low gear (final torque) mode. During high gear
(spin-in) only the max. pressure is limited. During low gear (make-up) the A-Q-TORK mode is acti-
vated to provide speed and pressure limitation.

GENERAL DESCRIPTION
There is an electronic solenoid valve that is activated by a signal from the JAM system MCU. The
signal is generated by the logic of the JAM system. A ‘bad signal’ if the connection fails to reach or
exceeds the pre-set parameters or a ‘good signal’ if the information from the connection is between
the min. and max. pre-set parameters.
The module provides:
Sensitive initial spin-in speeds (5 – 25 rpm) at 20 gpm max.
Final make-up speed (5 – 0.3 rpm) at 20 gpm max.
Controlled break-out operation
A separate valve section bypasses the flow control block and provides:
Spin-in speed 40 rpm at 30 gpm max.
Final make-up 9 rpm at 30 gpm max.
3.4.3.2 JAM Systems

The A-Q-TORK System is compatible with the WEATHERFORD JAM 1000 IS system. To adapt the
IS Dump Valve with existing JAM Systems an electrical interface is needed (refer to Section 8.5.6.1).
The polarity of JAM dump signal is compensated and the voltage is limited electronically to a value
needed for the dump valve.
Never connect the IS dump valve directly to a JAM system. Even the 1000 IS
signal causes destruction of the valve solenoid.
Except when the JAM system is equipped for direct connection (refer to JAM
System documentation).
JAM units with 12V dump signal are also available (refer to Section 8.5.4).

GENERAL DESCRIPTION
3.4.4 IS Dump Valve Final Torque Control System (for Commercial motor only)
The optional IS Dump Valve has been developed specifically for tongs with Commercial motor to
limit the final torque applied to the pipe. If the torque exceeds the adjusted value this valve shuts off
the hydraulic motor.
The discharge valve (see Fig. 3.9) should be set to a value of 10% above the needed final torque.
Fig. 3.9 Tong with optional IS Dump Valve (Final Torque Limiter)

GENERAL DESCRIPTION
3.5 TECHNICAL DATA

3.5.1 Technical Specification
General Temperature Range Comments
Min. Design Temperature °F -4
°C - 20
Operational Temperature °F +32 till +158
°C 0 till +70
5.5 – 15 Tubing Tong System Comments

1
Pipe size range inch 1.66 – 5 /2
mm 42 – 140
Max. make-up/break-out torque ft-lbs 15 000
Nm 20 340
Max. rotor speed Commercial rpm
88 high gear
Upm
Dinamic / Piston rpm high gear
60
Upm
Danfoss rpm
40 high gear
Upm
Tong arm length inch 30 / 25
with/without backup
mm 762 / 635
Weight lbs 1 843 / 1 080
with/without backup
kg 840 / 490
Dimensions Length inch 37.9
with backup
mm 962
Width inch 41.3 with backup
mm 1 050
Height inch 65.5
with backup
mm 1 665
Environmental temperature °F 22 - 122
°C -10 to +50
Backup only
Weight lbs 763
kg 350
Dimensions Length inch 20.5
mm 520
Width inch 37.9
mm 962
Height inch 43.3
mm 1 100
Max. clamping pressure at backup psi 5 875
bar 400
Pressure booster on backup 1:4 input / output ratio

GENERAL DESCRIPTION
Technical specifications are subject to change without prior notice.
Fig. 3.10 5.5 – 15 Tubing Tong, Dimensions All dimensions in mm [inches]

GENERAL DESCRIPTION
3.5.2 Technical Details
5.5 – 15 Tubing Tong System Comments

Jaw Assemblies Available jaw assemblies from 1.66 – 5 1/2 “ pipe diame-
ter. Same jaw assemblies for tong and backup.
Hydraulic Motor Versions Three hydraulic motor versions available:
• Commercial (standard gear wheel motor with or
without optional IS Dump Valve for torque limiting)
• Danfoss (for A-Q-TORK tong speed control system)
• Dinamic (piston motor)
Torque Measurement Alternative hydraulic / electrical / electro-hydraulic
Make-up Thread Compensation Floating thread compensation during make-up mode.
Control System Hydraulic / electro-hydraulic / open center
Optional A-Q-TORK tong speed control system
Connections Hydraulic pressure line, return line, bleeding oil line (only
with Dinamic / piston motor), lift cylinder up/down, backup
grip/release.
Technical specifications are subject to change without prior notice.

GENERAL DESCRIPTION
3.5.3 Hydraulic Oil Specification

Use petroleum-based hydraulic oil to ensure proper function of the tubing tong. Depending on the
used hydraulic motor version the power unit / hydraulic fluid must comply with the following values
to operate the tong:
1. COMMERCIAL – Hydraulic motor version

2. DINAMIC/PISTON – Hydraulic motor version
General characteristics for the above
External filtration at the
20 μm; SAE class 5 (17/14 – ISO 4406)
power unit
3. DANFOSS – Hydraulic motor version with A-Q-TORK

Max. starting viscosity at min. oil temperature 1,600 mm 2/s at –15° C / 5° F
Min. oil viscosity at max. oil temperature 11 mm 2/s at 70° C / 158° F
Aniline point 80° C min. 176° F min.
Internal filtration at the tong
10 μm in supply line
motor
Recommended additives Foam depressant, rust and oxidation inhibitors
Oil specification for normal BP Energol HLP 32, Texaco Rando HD A 32, Shell Tellus 32,
temperatures Esso Nuto H 32, Mobil DTE 32 or other suitable fluids
Other desirable characteristics:
• Stability of physical and chemical characteristics.

• High demulsibility (low amulsibility) for separation of water, air and contaminants.
• Resistant to the formation of gums, sludges, acids, tars and varnishes.
• High lubricity and film strength.
At other operating oil temperatures use oil of the appropriate viscosity range
to ensure the needed viscosity of 32 centistokes (ISO-32), i.e. during winter-
time use winter oil with lower viscosity range.

GENERAL DESCRIPTION
Fig. 3.11 Commercial - Tong Motor Performance Diagram

GENERAL DESCRIPTION
Fig. 3.12 Danfoss - Tong Motor Performance Diagram

GENERAL DESCRIPTION
Fig. 3.13 Dinamic / Piston - Tong Motor Performance Diagram

OPERATION
4 OPERATION
4.1 SAFETY CONSIDERATIONS
Do not operate the Tubing Tong unless the commissioning check has been
carried out. This is certified on the commissioning checklist in Section 4.5.
Failure to observe this safety precaution can cause severe injury or death.
Before hanging the tong, inspect all cables, shackles, pulleys, etc. used to
hang or secure the tong to the rig. Parts should be of correct size and should
be inspected to detect wear or damage, inadequate lubrication and any miss-
ing parts such as retaining pins.
Failure to maintain lifting and restraining gear in operating order can result
in serious injury to personnel and damage to rig equipment.
NEVER disconnect any hose while it is under pressure. Disconnecting quick

connectors must be possible without applying excessive force. Stuck con-
nectors can indicate that the hose is still under pressure. Before continuing,
check again the pressures on the respective gauges.
Failure to comply with these rules may result in death, bodily harm or
equipment malfunction.
Be sure connections are completely tight. Failure to tighten connections

completely will damage hydraulic equipment and cause loss of performance.
Improper maintenance or operation may cause hydraulic lines to leak. leak-
age caused by failure to properly maintain or operate the tong may result in
spillage in violation of environmental laws.
Operator should be familiar with all applicable environmental regulations in
the event of leakage or spillage and prepare to take appropriate steps for
control and removal.
Be sure no part of the body or clothing is in the tong rotary area and no ca-
bles or equipment other than casing are enclosed in the tong. Operator and
all other objects must be clear of backup line and traveling path of tong while
in operation.
Failure to observe these procedures will cause severe injury to personnel and
damage rig equipment.

OPERATION
4.2 DESCRIPTION OF THE TONG CONTROLS

The arrangement of the manual control handles depends on the used motor version and/or if the
optional A-Q-TORK System is equipped. The following description explains the functions of the
controls, the shown pictorial representation can vary.
4.2.1 Control Handles for Commercial and Dinamic Motor Version
Fig 4.1 Manual Tong Controls
Always operate the manual valve handles one by one. Never activate more
than one valve handle at a time.
Failure to comply with these note may result in damage of parts.
Lever Settings Description

Push lever forward to select lift cylinder operation
V 1 – Switch Lever Backup – Lift Cylinder for the operating lever; pull lever backward to se-
lect backup operation for the operating lever.
Depends on setting of switch lever (V1), if …
Backup open – close V1 = Backup, push lever forward to open backup
V 2 – Operating Lever Lift cylinder up – jaws or pull lever backward to close them
down V1 = Lift cylinder, push lever forward to lower lift
cylinder or pull lever backward to lift it
Push lever forward for clockwise rotation of rotary
(make-up); pull lever backward for counterclock-
V 3 – Make / Break* Make-up – Break-out
wise rotation of rotary (break-out). Center position
is neutral.
Selects the speed of the hydraulic drive. Turn han-
V 4 – Gear Shift Low – High dle upward for high gear and downward for low
gear. Center position is neutral.
Turn counterclockwise to move lift cylinder down,
V 5 – Lift Cyl. down Open – Close
turn back clockwise to stop movement.
* Depends on position of make-break catch (refer to Section 4.2.3)

OPERATION
4.2.2 Control Handles for A-Q-TORK Version (Danfoss Motor Version)
Fig 4.2 Manual Tong Controls
Always operate the manual valve handles one by one. Never activate more
than one valve handle at a time.
Lever Settings Description

Push lever forward to lower lift cylinder or pull lever
V 1 – Lift Cylinder Up – Down
backward to lift it
Push lever forward to open backup jaws or pull
V 2 – Backup Open – Close
lever backward to close them
Motor speed control, no A-Q-TORK speed control.
V 3 – Make / Break* Make-up – Break-out (make-up); pull lever backward for counterclock-
wise rotation of rotary (break-out). Center position
is neutral.
V 4 – A-Q-TORK (make-up); pull lever backward for counterclock-
Make-up – Break-out
Speed Control* wise rotation of rotary (break-out). Center position
is neutral.
Selects the speed of the hydraulic drive. Turn han-
V 5 - Gear Shift Low – High dle upward for high gear and downward for low
gear. Center position is neutral.
* Depends on position of make-break catch (refer to Section 4.2.3)

OPERATION
4.2.3 Make-Break Catch on all 5.5 –15 Tong Versions

The make-break catch assembly allows the tong to bite when operating in the corresponding
mode.
Fig 4.3 Make-Break Catch Assembly
Before operating the make-break lever always push the make-break catch
into the corresponding position.
Push make-break catch left for break-out operation; push it right for make-up operation.

OPERATION
4.3 PRE-OPERATING ADJUSTMENTS
4.3.1 General Hydraulic Adjustments

It is assumed that installation and preparations have been carried out according to Section 2.
Visually inspect all connections. Check unit for correct clamping elements (see Section 2).
Switch on hydraulic power unit.
All functions are set hydraulically before shipment. Only the function “Backup Clamping” is
to be checked prior to each job. A clamping pressure of about 400 bar / 5 800 psi (shown
on the clamping pressure indicator, see Fig. 4.4) is sufficient for almost all torque and pipe
conditions. Do not exceed this pressure!
How to set the correct clamping pressure:
Loosen the lock nut at the clamping pressure control valve.
Turn the adjustment nut counter-clockwise to its end.
Push the valve handle of the backup section (backup clamp). Turn the adjustment nut
clockwise until the desired clamping pressure is shown on the pressure gauge.
Release the valve handle of the backup section and tighten the lock nut.Pull the valve han-
dle until the clamping cylinders (backup jaws are completely retracted; push the handle and
verify the adjustment.
Clamping Pressure Indicator
Clamping Pressure Control Valve
Fig. 4.4 Clamping Pressure Adjustment

OPERATION
4.3.2 Specific Hydraulic Adjustments for A-Q-TORK

Visually inspect all connections. Check unit for correct clamping elements (see Section 2).
Disconnect the power unit throttle either hydraulically or mechanically. Connect the hydrau-
lic power supply to the tong. The dump valve cable should be run to the dump valve from
the JAM system. Before making any adjustments allow the power unit to run 10 – 15 min-
utes to reach operation temperature in the hydraulics 86° F / 30° C as minimum. Optimum
temperature is 122° F / 50° C.
How to set the correct spin-in torque:
Ensure tong is in high gear.
Adjust spin-in torque valve (item 1, Fig. 4.5 depending on used dump valve version) with
the tong on a blank piece of pipe to stop at a torque just below the JAM reference torque.
Remove the tong from the pipe.
How to set the correct make-up torque:
Change to low gear.
Back-out the following valves: make-up torque (item 2, Fig. 4.5) and bypass valve (item 3).
The valves for make-up speed (item 4) and break-out speed (item 5) are pre-set to stan-
dard operation and can be adjusted at the job to an optimum. Ensure that the dump valve
connector is plugged in. Put the tong to the pipe and adjust the bypass valve (item 3) to a
suitable torque value.
A JAM torque time graph (see Fig. 4.6) will show a slower increase of torque
(not a steep rising line) by this function.
Disable the JAM dump valve and adjust the make-up torque valve (item 2) to just above the
required optimum make-up torque.
This completes the setup for dump only operation.

OPERATION
Fig. 4.5 A-Q-TORK with 12V Dump Valve Version (Item 7) A-Q-TORK with IS Dump Valve Version (Item 7)
1 Spin-in torque 5 Brake-out final speed

2 Make-up torque 6 Torque selector valve
3 Bypass valve 7 Dump valve
4 Make-up final speed
Fig. 4.6 A-Q-TORK Torque Graph of a Premium Connection

OPERATION
4.4 SEQUENCE OF OPERATIONS

Make sure no part of your body or your clothing is within range of the rotary.
Operator, other personnel, lines, hoses and any other objects must be kept
clear of the jaws, the backup line and the working area of the tong.
Drawing in of limbs or clothing can cause serious injuries or death!
Do not operate the tong with the tong door open! In its shipped configuration,
the interlock system prevents this.
Do not tamper with this safety device!
Operating the tong with deactivated interlock system and open tong door can
lead to serious injury!
Rotating threads! Can squeeze and shear off fingers and hands.
Do not grip pipe thread with your hands!
Always grip pipes above their thread.
4.4.1 Preparation
Make sure the hydraulic power unit is adjusted properly and switched on. See power unit
operating manual.
Make sure the correct clamping elements are installed and that the three support legs are
removed.
4.4.1.1 Lift cylinder setting
Set switch to lift cylinder operation.
Pull backup/lift cylinder lever back to lift the tong to the top final position.
Adjust pressure relief valve of lift cylinder in such a way that the tong just starts to drop slowly.
Then turn the valve back a little, so that the tong stops dropping.
Pull backup/lift cylinder lever to lower the tong to the appropriate height.

OPERATION
4.4.1.2 Setting the backup height
Depending on the used tool joint and jaw type the distance between tong and backup can be set in
two positions:
• upper backup position (short distance between tong and backup) for standard jaws according
table 2.1 and normal tool joints (with installed bushings (items 106, Section 8.3.1) at the two
torque tubes).
• lower backup position (bigger distance between tong and backup) for Micro-Grip/non-marking
jaws and specific tool joints (without bushings (items 106, Section 8.3.1) at the two torque
tubes).
Position tong around pipe and close door.
Close the backup and clamp it on the pipe. Tong must be unclamped.
To increase the distance between tong and backup, lower tong and remove the bushings of
the two torque tubes.
To decrease the distance between tong and backup, lower tong and reinstall the bushings of
the two torque tubes.
Unhook the chain suspension between tong and backup, lift tong and hang the chain sus-
pension into the correct chain link. Open the backup and check the horizontal balance of the
backup. If necessary, readjust the balance by hanging the chain suspension one chain link
higher or deeper.
4.4.1.3 Functional check
Position tong around pipe that the tool joint is between tong and backup and close door.
Make sure the make/break catch is set to “MAKE”.
Move gear shift handle up to select high gear.
Push tong lever forward and check that the jaws bite and that the rotary rotates in clockwise
direction at high speed.
Return tong lever to neutral position and move gear shift lever down to select low gear.
Push tong lever forward and check that the jaws bite and that the rotary rotates in clockwise
direction at low speed.

OPERATION
Return tong lever to neutral position.
Carefully operate the tong lever to align the rotary gear with cage plate and tong body open-
ing.
Shift make/break catch to “BREAK”.
Gear shift handle is still in low gear position.
Pull tong lever back and check that the jaws bite and that the rotary rotates in counterclock-
wise direction at low speed.
Return tong lever to neutral position and move gear shift lever to select high gear.
Pull tong lever back and check that the jaws bite and that the rotary rotates in counterclock-
wise direction at high speed.
Return tong lever and gear shift handle to neutral position.

OPERATION
4.4.2 Make-up Operation
Operate tong lever to rotate tong into starting position. In this process, all openings cover
themselves.
Pull the make/break catch to “MAKE”.
Open tong door and place tong around pipe. Direct the tool joint manually to a position be-
tween the jaws of the tong and backup. The jaws must turn backward until the pipe hits the
guide plate.
If Micro-Grip or non-marking jaws are used it is strongly recommended to keep

the gripping areas and jaw inserts clean at all times.
Oil or paraffin in these areas must be removed with a steam or water jet imme-
diately.
Close the tong door.
Move gear shift handle up to select high gear.
Push tong lever carefully forward to rotate the rotary by approx. 90°. One tension lever turns
forward and adjusts the tong to the pipe. Continue until the pipe is in the right position for
make-up with respect to the coupling.
Push tong lever slightly forward until the thread starts to make up.
Then push tong lever forward fully to make up the thread until the tong begins to stall.
Return tong lever to neutral position and move gear shift lever down to select low gear.
Push tong lever forward until you reach the required torque.
Pull tong lever back to disengage the jaws until the rotary opening corresponds to the open-
ings of the cage plates and the tong reaches its starting position.
Open door and remove tong from pipe.

OPERATION
4.4.3 Break-out Operation
Operate tong lever to rotate tong into starting position. In this process, all openings cover
themselves.
Pull the Make/break catch to “BREAK”.
Open tong door and place tong around pipe. Direct the tool joint manually to a position be-
tween the jaws of the tong and backup. The jaws must turn backward until the pipe hits the
guide plate.
If Micro-Grip or non-marking jaws are used it is strongly recommended to keep

the gripping areas and jaw inserts clean at all times.
Oil or paraffin in these areas must be removed with a steam or water jet imme-
diately.
Close the tong door.
Move transmission shift handle down to select low gear.
Pull tong lever carefully back to rotate the rotary by approx. 90°. One tension lever turns for-
ward and adjusts the tong to the pipe.
Pull tong lever slightly back until the connection has been broken out.
Return tong lever to neutral position and move gear shift lever up to select high gear.
Then pull tong lever back fully to unscrew the pipe completely.
Push tong lever forward to disengage the jaws until the rotary opening corresponds to the
openings of the cage plates and the tong reaches its starting position.
Open door and remove tong from pipe.
4.4.4 Changing the Rotating Direction in between
Set tong lever to the opposite direction to reverse the rotary movement until the jaws have
disengaged and tong reaches its starting position.
Shift the Make/break catch to the desired setting.
Recommence the first step until the jaws have re-engaged.

OPERATION
4.4.5 Special Functions with the A-Q-TORK System

The A-Q-TORK System performs several functions which are required when running high chrome
contents and/or shouldered tubing. These functions are:
Very low speed at high torque: RPM is variable from 1/3 to 10 at full torque output.
Very low stall torque: On initial thread engagement during spin-in this will prevent joint
damage due to cross-threading or foreign matter. Initial spin-in
torque value can be set as low as 200 ft-lbs.
Adjustable spin-in speed: Speeds from 5 to 45 rpm are attainable.
Accurate end point torque: On shouldered connections accurate end point torques are
achieved using the A-Q-TORK System. This is due to the slow
make-up speed which will eliminate the torque overshoot.
Controlled break-out: Prevents galling normally associated with this operation. There
is no high speed rotation of the connection after the connection
has broken, as there is with the conventional tongs.
Make-up in high gear:
The only valve that effects high gear operation is the spin-in torque control (item 1, Fig.
4.5). The tong will stop when the torque is reached. All other valves are disabled.
Make-up in low gear:
The tong will continue to run at up to full speed until the bypass setting of the bypass valve
(item 3, Fig. 4.5) is reached. Make-up will then proceed at the pre-set final make-up speed
(set with valve item 4, Fig. 4.5) until the JAM system dumps at optimum torque.
Break-out:
The break-out speed is controlled by the setting of valve 5 (see Fig. 4.5) and will increase
once the torque drops below the bypass valve setting (item 3, Fig. 4.5).

OPERATION
4.5 COMMISSIONING CHECKLIST
Passed
Step Test description
Tubing Tong
1 Tagging of the equipment
2 Documentation of the equipment
3 Painting and corrosion protection according to QS 06-02-21-00
4 Check function "make-up/break-out" (incl. "gear shifting")
5 Check function "backup clamping"
6 Check function "tong rotor clamping"
7 Check safety device "tong door safety interlock"
8 Torque performance of the tong (maximum ft-lbs)
9 Speed performance of the tong (maximum rpm)

PLACING OUT OF OPERATION
5 PLACING OUT OF OPERATION
NEVER disconnect any hose while it is under pressure. Disconnecting

quick connectors must be possible without applying excessive force. Stuck
connectors can indicate that the hose is still under pressure. Before con-
tinuing, check again the pressures on the respective gauges.
Failure to comply with these rules may result in death, bodily harm or
equipment malfunction.
After the job, proceed as follows:

When the tong is not needed for operation it must be properly secured.
Switch off the hydraulic power unit.
Disconnect lift cylinder hydraulic hoses from the tong.
Disconnect main hydraulic hoses from the tong.
Make sure to bleed the hoses. Keep the connectors clean.
Ensure that tong door is closed.
Tighten the nut at the torque post on each side of the Backup (see Fig. 5.1)
Remove the lift cylinder from the tong.
Fasten lifting equipment to the tong hanger and remove the tong from the rig floor
(see Fig. 2.1).
All lifting gear must have a minimum lifting capacity of 1500 kg.
Ensure that all lifting equipment is in proper condition.
Remove tong from the operation area.
Clean the tong, see Section 7 Service and Maintenance.
Visually inspect the complete tong system for damage. Replace or repair broken parts (see
Section 8 Appendix for part numbers).

PLACING OUT OF OPERATION
Lubricate the tong, see Section 7 Service and Maintenance.
If the tong with backup is to be used or stored, fix the rear and two front support legs to the
backup by attaching the locking bolt (see Fig. 5.1) and secure it with the cotter pin.
Fig 5.1 Rigging down the 5.5 Tong

TROUBLESHOOTING
6 TROUBLESHOOTING
The Hydraulic Tubing Tong - Model TT 5.5-15 is designed for operation under rig conditions.
Whenever it should be necessary to replace a worn or broken part, refer to Section 8 “Appendix”
and see the drawings and part lists.
After any major repair, the Hydraulic Tubing Tong - Model TT 5.5-15 must be serviced as de-
scribed in Section 7 “SERVICE AND MAINTENANCE”.
If you are unable to solve a technical problem concerning this product, con-
tact WEATHERFORD technical support as follows:
> + 49 (0)511-7702-0 Technical Department
Fax: + 49 (0)511-7702-187
e-mail: techsupport-germany@weatherford.com
Do not attempt to perform any adjustments, repair, disassembly, or grease

while the tong is connected to a power source. Ineffective and uncontrolled
operation of the tong while repair or maintenance work is in progress may
cause serious injury to personnel and damage equipment!
6.1 GENERAL REMARKS
When going about troubleshooting, keep in mind that the following factors are responsible for
most of the problems:
The oil is not changed at the required intervals. Observe maintenance intervals.
Oil is contaminated by cuttings and/or grinding fluids.
Air leaks within the hydraulic circuit.
The wrong hydraulic oil is used. Select the proper oil.
Defective packing or seals.
The operator(s) have insufficient knowledge about the components of the hydraulic sys-
tem.
Most of the troubles could have been prevented by proper selection of hydraulic oils and proper
maintenance of both equipment and oil.
Locating trouble in a hydraulic system is a job for a well trained maintenance man. He should be
familiar with the equipment used, its construction and operation. He should know enough about
hydraulic circuits and components to localize the troubles.

TROUBLESHOOTING
6.2 GENERAL TROUBLESHOOTING

6.2.1 Excessive Pump Noise
Probable cause Corrective action
Intake line clogged or restricted. Check and clean intake line.
Intake filter clogged. Clean intake filter.
Intake filter insufficient. Replace with filter of sufficient size.
Reservoir air vent clogged. Clean air vent; replace if necessary.
Oil viscosity too high. Replace with oil of correct viscosity.
Oil pour point too high. Replace with oil of correct pour point.
Air leaking into system. Check that oil intake is well below reservoir oil
level.
Check pump packing and line connection on the
intake side by pouring some oil over suspected
leak. If the noise stops, the leak has been lo-
cated.
Tighten joints; replace packing/gasket.
Loose or worn parts. Replace parts.
Check grade and quality of oil.
1 or more vanes sticking, due to solid contami- Clean contaminated parts.
nants such as dirt, chips, lint, or gummy deposits
Change oil if necessary.
from oxidized oil.
(for vane-type pumps only). Check filter.
Pump running in excess of rated speed. Check manufacturer's recommended speed.
Check pulleys, gears, power take-off, and drive
motor.
Pump misaligned with motor. Check alignment.

TROUBLESHOOTING
6.2.2 Hydraulic System Overheating

Excess discharge pressure Adjust relief valve according to max. pressure
(relief valve set too high). required (see manufacturer's recommendation).
Improper oil viscosity. Change oil according to pump and motor manu-
facturers' recommendations.
Excessive internal leakage. Repair/replace worn parts, loose packing.
Make sure the oil viscosity is not too low.
Check for excessive contamination and wear.
Excessive friction. Check pump for poorly fitted moving parts.
Check for too tightly assembled pump.
Leak in pump check valve or in relief valve. Repair/replace valve
Oil cooler inadequate or defective. Check for clogged oil passages and coolant flow
obstacles. If necessary, increase capacity by
using larger or additional equipment.
Oil reservoir too small. Use larger reservoir.
Oil supply in reservoir too low. Replenish to maintain the proper oil level.
Pump discharge is throttled or unduly restricted. Check open-center directional valves for proper
function. Check relief valve. Check all self-seal
hose connections.
Large pump volumes must not remain under
high pressure for long.
Valves or hydraulic lines blocked. Clean valves/hydraulic lines.
6.2.3 Excessive Wear of moving Parts

Abrasive contaminants within the oil. Replace filter element. If necessary, install larger
filter. Change oil more often.
Moving parts misaligned. Check and re-align moving parts.
Operating pressure above manufacturer's rec- Check relief valve; re-adjust valve if necessary.
ommendation.
Viscosity of oil is too low at working temperature. Replace with oil of higher viscosity or more ade-
quate viscosity index.
Oil leak within the system. Bleed air from hydraulic lines.
Check for leaks.
Excess wear of packing glands. Check for misalignment of moving parts, for vi-
bration and excessive lateral thrust on shafts.

TROUBLESHOOTING
6.2.4 Tong running too slowly

Pump line clogged. Clean intake line and filter.
Oil level in reservoir too low. Add oil to reservoir.
Oil leak in pump intake line. Repair leak.
Pump turning in the wrong direction. Check belts, gears and the electrical connec-
tions of the motor.
Pump speed too low. Check speed recommended by manufacturer
and actual speed.
To determine which component is defective, dis-
connect hydraulic pump from tong motor. Then
test pump pressure and volume output.
Vane type pumps do not prime if running too
slowly.
Pump control de-adjusted Check control setting.
(variable delivery pump).
Viscosity of oil too high. Check oil; replace with oil of proper viscosity.
Viscosity of oil too low. Excessive heat: See 6.2.2
Oil contaminated with diesel, gasoline, etc;
change oil.
Improper grade of oil; change to oil of higher
viscosity or better viscosity index.
Restrictions in the line between power unit and Check self-seal couplings for secure fit.
tong. The pump pressure does not reach the
tong and thus causes excessive back-pressure
within the return line.
6.2.5 Tong does not grip

Wrong jaw assembly size. Install correct jaws as described in Section 2.3.
Brake does not function. Tighten or replace brake bands, see Section
7.3.1.
Dull or worn out dies. Clean or replace dies, see Section 2.3.
Undersized pipe. Change to larger dies.
Oversized pipe. Change to a smaller dies.

TROUBLESHOOTING
6.2.6 Tong does not generate sufficient Torque

Relief valve on power unit or tong valve set too Increase setting. For measurement, block the oil
low. line beyond the relief valve and determine pres-
sure using a pressure gauge.
Relief valve on power unit or tong valve stuck. Check for dirty or gummy sludge.
Check for oil contamination.
Check valve and change oil. Check for broken
valve spring.
Relief valve on power unit or tong valve leaking. Check valve seat for scoring.
Check oil seals.
Check for particles stuck under valve stem.
Pump parts stuck, worn or damaged. Inspect and clean pump parts.
Replace or repair worn or broken parts.
Check relief valve (see above).
Pump control set too low Check control setting.
(variable delivery pumps).
Pump speed too low. Check motor speed, gear and belt ratios.
Viscosity of oil too high. Some pumps do not prime if the oil is too heavy.
Check viscosity at working temperature (and at
initial temperature if the difference is significant).
Change to oil with proper viscosity.
Viscosity of oil too low. See 6.2.2
Oil is by-passed to the reservoir. Check relief valve. Check directional valves.
Open center neutral position must return the oil
directly to the reservoir.
Tong motor wear or damage due to excessive Repair/replace worn and damaged parts.
slippage.
Excessive drag in tong due to damaged bear- Repair/replace damaged parts.
ings or gears.
Restrictions in the line between power unit and Check self-seal couplings for secure fit.
tong. The pump pressure does not reach the
tong and thus causes excessive back-pressure
within the return line.
Defective torque gauge. Check torque gauge cylinder to ensure proper
quantity of oil.
Make sure the dampening screw has been loos-
ened and the gauge is calibrated for a 25" (with-
out backup) or 30" handle (with backup).

TROUBLESHOOTING
6.2.7 Motor runs but tong does not rotate

Broken gear or gear shaft. Check for broken gear or gear shaft and replace
as necessary.
6.2.8 Motor leaks

Faulty shaft seal. Replace motor seal.
6.2.9 Backup does not grip

Backup clamping pressure is not properly ad- Adjust pressure control valve according to Sec-
justed. tion 4.3.1.
Adjust pressure switch, (Allen key, d = 5 mm).
Clean the filter element of the pressure booster
according to Section 7.1.
Wrong jaw size. Install correct jaws and check adjustment as
described in Section 2.3.
Wrong adjustment of the backup jaws. Check adjustment as described in Section 2.3.2.
Worn dies. Clean or replace dies, see Section 2.3.
Faulty cylinder. Replace seals, for part numbers refer to the
parts list and drawings in the appendix.

TROUBLESHOOTING
6.3 TROUBLESHOOTING THE A-Q-TORK SYSTEM

6.3.1 No Pressure Build-up in the System
Wrong adjustment of the torque setting. Check the setting of the torque adjustment
valves.
Tong door not closed properly. Check the door interlock valve is completely
closed.
Faulty unloading valve. Check the piston in the unloading valve is mov-
ing freely.
Filter clogged. Check the filter in front of the dump valve (re-
washable filter cartridge).
6.3.2 Constant Pressure Build-up

Quick-disconnect coupling not fully set. Check for high back pressure due to quick-
disconnects not fully made-up.
6.3.3 Tong does not slow down automatically in low Gear

Faulty bypass valve. Check the bypass valve (item 3, Fig. 4.5) for
correct operation. Screw out the valve and clean
it. Check the piston moves freely.
Faulty selection valve. Check the selection valve (item 6, Fig. 4.5) on
the gear shift handle. Watch the spool moving,
the actuator does not necessarily indicate cor-
rect operation.
6.3.4 Motor is stalled

Valve piston blocked. Fully release both flow regulators (items 4 and 5,
Fig. 4.5). Check the main piston in both valves
for free operation.
Tong door not closed properly. Check the three shuttle valves for correct opera-
tion.
Brake band tension too high. Release the tong brake band tension to a mini-
mum.
6.3.5 No Dump Valve Operation (general)

No electrical signal. Check the electrical signal to the dump valve.
Broken fuse. Check the fuse.
Filter clogged. Check the dump valve filter.
Defective dump valve. Replace the dump valve.

TROUBLESHOOTING
6.3.6 No MOOG IS Dump Valve Operation

Thorough cleanliness must be observed when checking the proportional control valve!
Valve does not respond even though the system pressure and control signal are applied.
1. Disconnect the mating connector. Check for moisture (possible short circuit).
2. Try to operate the valve with the MOOG Valve Checker D 129-008-A001 or with the manual override
lever. Does the valve respond?
NO
Check system for proper pilot stage supply (external / inter-

nal).
Is the system appropriately designed (see Section 7.5.1) ?
YES YES
Using an ohmmeter, measure the valve coil resistance of the Check the wiring to the Pro-
Proportional Control Valve (28 Ohm or 300 Ohm resistance per portional Control Valve.
coil). Are the coils O.K.?
NO YES
Return the Proportional Control Valve to Is there a connection between the

the works. coils and ground?
YES
Return the Proportional Control

NO Valve to the works.
The valve is probably contaminated.
Replace the filter element (see Section 7.5.1). Clean or replace the inlet orifices (see Section 7.5.1).
BEFORE mounting the valve and starting up, always check the filter system and flush the system (see Sec-
tion 7.5.1).
If the valve is still inoperative, return it to the works for repair.

SERVICE AND MAINTENANCE
7 SERVICE AND MAINTENANCE
Cleaning and maintenance intervals are decisive for the operational safety of
the unit and must therefore be kept strictly. Disregarding this caution will
cause a potentially hazardous situation which can result in personal injury
and/or material damage.
Always disable the hydraulic power unit before starting service or mainte-
nance work!
7.1 DAILY INSPECTION
Overall Equipment
Inspect 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.
Jaw Dies
Inspect jaw dies to be sure that the biting edge is not worn excessively and is capable of bit-
ing effectively. Change dies, if necessary.
Rotary Gear
Inspect gear teeth for excessive wear, damage or breakage. If excessive wear or breakage
is found, inspect all internal gears and grease packing for metal particles and damage.
7.2 MONTHLY MAINTENANCE

Once each month make the following checks and take appropriate corrective action:
Check rotary gear guide rollers for wear or breakage, and replace if necessary.
Check jaw rollers for wear or breakage, and replace if necessary.
Check shifting operation, shifting shaft nuts and shifting shaft detent operation as described
in Section 7.9.1.
Inspect rotary gear.
Check oil level in gear box (refer to Section 7.5.2).
Check torque gauge cylinder for low fluid volume. Fluid level is low if ½” or more of the cylin-
der rod is exposed when under tension.
Check all fasteners for tightness.

7.3 CLEANING
Attention:
Vapor beam must not be pointed directly to any electrical connectors, espe-
cially not to the electrical sensors.
Vapor beam must not be pointed directly to any lubrication points.
All exposed surfaces of the tong system should be cleaned with a steam jet or other suit-
able cleaning agents after each job.
Clean all tong and backup jaw dies with a steel brush after a job is finished or when filthy.
The filter element inside the pressure booster is to be cleaned once a week or when con-
taminated. Use 22-mm Allen key to unscrew plug and wash the filter element with petro-
leum or diesel. (see Fig. 7.1)
Fig. 7.1 Pressure Booster on the Backup Housing

Replace oil filter element (only A-Q-TORK Version) when the contamination indicator on
the oil filter housing is visible, (see Fig 7.2).
Fig. 7.2 Oil Filter Housing with Contamination Indicator

7.4 RECOMMENDED LUBRICANTS
Observe the product-related safety regulations when handling oil and grease
products.
The relevant lubrication points are described in Section 7.5.
Pos. Lubrication Points Recommended Lubricants Classification Quantity

1 Grease fittings 1 - 12 Texaco Multifak Grease BP 2 K 2 E-20 As required
Roller grease fittings BP Multi-Purpose L 21 M DIN 51502,
Brake band DEA Caron CG 2 51825
Jaw pins ESSO Multi-Purpose(Moly)
Mobil Mobilgrease Special
Shell Retimax AM
2 Rotor gearing DEA (TEXACO) Caron CG 3 K 2 E-30 As required
DIN 51502,
51825
3 Gear box DEA Deagear EP-A SAE 85W- Mil - L - 2105 1.4 liter
90 API GL - 4
Take care of the following cau-
tion note!
At different operating temperatures use gear box oil of the appropriate vis-
cosity range to ensure the needed viscosity of 90 centistokes.

7.5 POINTS OF LUBRICATION

Proper lubrication is important to operation and long life of the tong.
At the beginning of each job and once every operating day thereafter, apply grease through the
grease fittings. Use a grease gun with a flexible delivery pipe.
The rotary gearing was filled with grease during assembly. Refilling is only necessary after repair
work.
In general, be liberal with grease. Over-greasing will do no harm, whereas greasing to little can re-
sult in excessive wear or in a system breakdown.
Shut down the hydraulic system before starting lubrication service. Unex-
pected operation of the system from a third side can kill you!
Attach a warning sign to the main switch at the control cabinet.
Observe the product-related safety regulations when handling oil and grease
products.
Item Lubrication Point Method Number of

lubrication points
1 Door lock brush 1
2 Drag brake bands brush 2
3 Catch assembly nipples 2
4 Transmission shift handle brush 1
5 Operating levers brush 2
6 Torsion bar for backup nipple 1
7 Tension lever/jaw bolts and tension lever bolts nipples/brush 2 each
8 Rotary and top and bottom cage plate bearing nipples 2 each
9 Fixed gear nipples 2
10 Gear box, oil change 1.4 liter

Fig. 7.3 Lubrication Points

7.5.1 Rotary Drag Brake Band

The brake bands have to be disassembled for maintenance :
Remove the upper and the lower brake band from the rotary housing.
Wash the brake bands surfaces with petrol based cleaner.
Check brake band for thickness, t min = 11 mm (across the entire band)
Roughen the surfaces with abrasive paper.
Grease the brake bands surfaces with a brush.
Fix the brake bands back to the rotary housing. Tighten the adjustment nuts handtight.
Start the hydraulic power unit and operate the tong without having inserted a pipe.
Push the handle of valve section "Make-up" and check, whether the cage plate stops turn-
ing and the tension levers starts clamping action. If the cage plate is still turning, stop the
power unit and tighten up the adjustment nuts 180° more. Start the power unit and check
again. Repeat this procedure until the cage plate remains in its position and the torsion lev-
ers starts clamping from the beginning of rotation on.
Keep in mind that the smaller the pipe size the higher the brake effect must be.
Nominal thickness 14 mm
Brake band coating 8 mm
Adjustment nut Limit of wear 11 mm
Brake band
Carrier
t
Fig. 7.4 Drag Brake Band

7.5.2 Oil Change of the Gear Shift Box
The oil of the gear box has to be changed every 6 month :
Remove the upper plug from the gear box, see Fig. 7.5.
Remove the lower plug from the gear box and catch the oil in a collecting tank.
Tighten the lower plug and refill the gear box with gear oil (SAE 85W-90)
When oil is coming out the upper plug, the correct level is reached. Close the housing.
Ensure that all consumables are disposed of safely and with minimum envi-
ronmental impact.
Fig. 7.5 Oil Change – Gear Box

7.6 HYDRAULIC PIPING
For repair works at the hydraulic piping, seamless precision steel pipes with dimensions according
to DIN 2391, part 1 material St35.4 must be used. The wall thickness of the hydraulic pipes de-
pends on the working pressure and pipe diameter.
Hydraulic hoses should be replaced within appropriate intervals, even if no safety-relevant defects
have been detected. All hydraulic hoses should be ordered at WEATHERFORD. Use only original
spare parts. Find the part number for reference in the parts list.
Use only original WEATHERFORD spare parts. Part numbers can be found in
the parts list in Section 8. Work on hydraulic equipment may be carried out
only by persons having special knowledge and experience in hydraulic sys-
tems.
Remove hydraulic pressure before performing any repair work!

7.7 HYDRAULIC ADJUSTMENTS
The hydraulic system of the Model TT 5.5-15 is pre-adjusted in the factory and checked before
shipment. The maximum working pressure on all used motor versions is set to 175 bar / 2 540 psi
and is sufficient to achieve a maximum make-up torque of 20 000 Nm / 15 000 ft-lbs.
The oil flow depends on the used motor version (refer to Section 3.5.3). The other functions are
hydraulically set; see hydraulic diagram in Section 8. Usual working conditions do not require a
readjustment of these settings.
In case of replacement or repair work it could be necessary to readjust the pressure and flow set-
ting.
The pressure booster at the backup is protected by a pressure relief valve.

7.7.1 Servicing the MOOG IS Dump Valve

(only for A-Q-TORK Version with MOOG Valve)
Servicing of these valves is restricted to null adjustment, replacing the filter element and cleaning
the inlet orifices. All other servicing work must be carried out by trained personnel with a servo-
valve test stand, only available at a MOOG works.
The listed item numbers in this Section refer to the following Figure:
Fig. 7.6 Exploded View – MOOG IS Dump Valve
Needed tools and material:

5 mm screwdriver 2.5, 3 and 5 mm Allen wrench
7
3 Nm and 10 Nm torque wrenches /16” offset box wrench
Extractor tool 66356-002 (thread 4-40 UNC) Solvent, e.g. Freon
Hydraulic oil Oil resistant adhesive tape
Lint-free paper

Adjustment procedure – Null adjustment:
The valve null (hydraulic null = electrical null) has been properly adjusted at the factory by preload-
ing the flapper centering springs. It may be desirable to readjust this valve null.
Clean the valve externally. Use clean tools!
Disconnect the electrical mating connector.
Remove the pan head screw (item 33, Fig. 7.6).
Fig. 7.7 Turning the Adapter on the MOOG IS Dump Valve
Using a 3 mm Allen wrench, turn the adapter (item 93, Fig. 7.6) in a clockwise or counter-
clockwise direction to locate null.
NORMAL ADJUSTMENT SHOULD REQUIRE LESS THAN ± 1 TURN. (20° corresponds

approximately to 10% null adjustment).
Screw in the pan head screw (item 33, Fig. 7.6).
Connect the mating connector.
When adjusting valve null, it must be distinguished between axis cut and
overlapped valve spools.
Valves with axis cut spool:

Correct null setting has been found when equal pressures (cylinder pressure) are obtained
in the blocked load ports. If it is not possible to measure the pressure, search for the position
of the adapter (item 93, Fig. 7.6) at which the motor or cylinder does not move.

Valves with overlapped spool:

Observe increasing pressure in one of the blocked load ports by turning the null adjust
screw in one direction. Then turn the screw in the other direction and observe the increase
in pressure in the other load port. Note the two wrench positions. Hydraulic null is set by
turning to mid position.
Since it is normally not possible to measure the pressure when the valve is installed, the
null adjustment must be carried out by observing the cylinder or motor movement (loop
opened). The mid setting must also be used in this case. CAUTION - uncontrolled move-
ments may occur.
It is advisable to use the MOOG Valve Checker D129-008-A001 for checking the proper
null adjustment. This checker can be used to determine the relevant input current at which
pressure starts to rise in the load ports.

Dismounting the MOOG IS Dump Valve
All maintenance operations mentioned below require dismounting of the valve from the machine
on which it is used.
Basic rule:
Keep tools and work environment as clean as possible.
Cut off the pressure supply and relieve the accumulator.
Clean the valve externally.
Disconnect the mating connector and dismount the valve.
IMMEDIATELY PROTECT THE VALVE PORTS WITH THE SUPPLIED SHIPPING PLATE
(item 92, Fig. 7.6) AND PROTECT THE CONNECTING FLANGE WITH THE FLUSHING
PLATE or mask with oil-resistant adhesive tape.
Clean the valve with clean solvent, containing no acids or residues, and dry it off with
lint-free paper cloth.
Carry out all the maintenance work in a clean room.
Fig. 7.8 Dismounting the MOOG IS Dump Valve

Filter Element Replacement
The built-in filter protects the inlet orifices and nozzles against coarse dirt particles. If the filter is
heavily soiled, the valve will respond more slowly, operate unidirectionally or will be completely in-
operative. In this case, replace the filter element, do not clean it!
Remove the four socket head cap screws and lock washers (items 29 and 34, Fig. 7.6).
Remove the filter retainer (item 9, Fig. 7.6).
Remove the filter disk (item 10, Fig. 7.6, Part No. 5280553).
Remove the 0-ring (item 53, Fig. 7.6) in the filter retainer and the 0-ring (item 97, Fig. 7.6)
behind the filter.
Clean the filter bore in the valve body carefully and thoroughly with lint-free paper cloth.
Clean the filter retainer. On certain valve models, the filter retainer contains a 0.5 mm diame-
ter orifice bore. This must be cleaned carefully and not damaged.
Insert a new 0-ring (item 97, Fig. 7.6) in the valve body (item 1, Fig. 7.6) and a new 0-ring
(item 53, Fig. 7.6) on the filter retainer (item 9, Fig. 7.6).
Insert a NEW filter disk (item 10, Fig. 7.6, Part No. 5280553).
Fit the filter retainer (item 9, Fig. 7.6).
Fit the lock washers (items 34, Fig. 7.6) and socket head cap screws (items 29, Fig. 7.6).
Torque the screws uniformly to 3 Nm.
Fig. 7.9 Filter Element in the MOOG IS Dump Valve

Inlet Orifices, Cleaning or Replacement
Fine dirt particles may have plugged the inlet orifices. If they cannot be cleaned or are damaged
(visual check), the inlet orifices must be replaced. Replace orifices in pairs only.
The following procedures apply to both ends of the valve.
Remove the 3 hexagon head screws and the lock washers (items 28 and 35, Fig. 7.6).
Remove the end plate, seal plate and 0-ring (item 6, 7 and 49, Fig. 7.6).
Fig. 7.10 Inlet Orifices in the MOOG IS Dump Valve
Carefully remove the inlet orifice (item 11, Fig. 7.6) using the extractor tool 66356-002
(thread 4-40 UNC).
Remove the 0-ring (item 51, Fig. 7.6).
The spool which is now visible MUST NOT be rotated. The spool may be
moved carefully to-and-fro BY AT MOST ± 1 mm.
Larger spool displacement may damage the feedback wire. Repair in this
case, can be conducted only at the works.
Clean all disassembled parts carefully.
Clean the orifice bore (item 11, Fig. 7.6) with solvent and blow through with clean com-
pressed air. DO NOT use wire or similar means.
Fit a new 0-ring (item 51, Fig. 7.6) to the inlet orifice (item 11, Fig. 7.6) and lubricate the
0-ring.
Insert the inlet orifice (item 11, Fig. 7.6) using the extractor tool 66356-002, carefully moving
it to-and-fro. Do not damage the 0-ring (item 11, Fig. 7.6).

Fit the 0-ring (item 49, Fig. 7.6) into the seal plate (item 7, Fig. 7.6). Replace the 0-ring if re-
quired.
Fit the seal plate (item 7, Fig. 7.6) CORRECTLY so that oil can flow from the inlet orifice (item
11, Fig. 7.6) across the spool end to the feed bore on top of the valve body.
Fit the end plates (items 6, Fig. 7.6) with lock washers (items 35, Fig. 7.6) and secure them
with hexagon head screws (items 28, Fig. 7.6).
Torque the screws uniformly to 10 Nm.
Pilot Connection - Conversion from internal to external Supply and vice versa
The setting of the pilot connection as shipped can be seen from the last letter
of the type code on the name plate.
I = Internal pilot connection
E = External pilot connection
The socket head cap screw (item 15, Fig. 7.6) M 4 x 6 with Usit-ring (item 16, Fig. 7.6) (or the set-
screw M 5 x 6 on valves manufactured prior to August 1985) MUST be fitted:
In the case of internal pilot oil supply (I): in In case of external pilot oil supply (E): in
port X for the external pilot supply line to the bore for the internal pilot oil connection
block this line off. (inside port P of the valve bore so as to
block this line off).
When changing the pilot connection from internal to external or vice versa, fit the screw plug
into the other threaded bore.

In case of version with setscrew, this screw is fitted with Loctite and must
be secured again with Loctite when refitting.
Mounting the Valve
Since most valve failures are due to contamination, it is necessary to check all system filters and
flush the system in accordance with our start-up procedure D7, Para. 5.2, before mounting the
valve. Do not mount the valve until this has been done.
Clean the mounting manifold.
Remove the flushing plate.
Clean the mounting pad with lint-free paper cloth.
Remove the shipping plate (item 92, Fig. 7.6) from the valve base.
Clean the valve base with lint-free paper cloth.
Install new 0-rings (items 47 and 48, Fig. 7.6) if required.
Torque the mounting screws uniformly to 10 Nm.

7.8 JAW DIE EXCHANGING
Inspect jaw dies to ensure that the biting edges are not worn excessively and are capable of bit-
ing effectively. If wear of the dies is excessive, the dies must be replaced. The dies cannot be re-
worked.
Replacement procedure for tong and backup :
Push back the retaining pin.
Pull out the worn die and put in a new die.
Move retaining pin back to initial position.
Repeat with all dies of a jaw set.
Fig. 7.11 Die Replacement at Tong and Backup

7.9 PRE-OPERATION TEST
7.9.1 Free Run Test
Test Recommendations
A pre-operation test of the WEATHERFORD Hydraulic Tubing Tong - Model TT 5.5-15 is recom-
mended subsequent to motor replacement or repair, control valve replacement or repair, and ma-
jor parts replacement.
With the tong off the string, check all tong and backup functions once (in both directions).
Make sure to test tong rotation for 2 minutes, both in high gear and in low gear.
During these tests, listen for any unusual noises or grinding and watch for any misalign-
ment or erratic operation.
While observing tong rotation, listen for any unusual noise and watch for excessive move-
ment at door hinges and door facing which may indicate damage or wear.
Repeat the test procedure with the tong switched to break-out mode.
If a problem is detected during the free run test, correct the problem (see Section 6 “Trouble-
shooting”) and repeat the test to ensure that the corrective action was effective.
7.9.1 Torque-Up Test

Performing the torque test (with jaws installed) normally requires access to a mandrel or test fix-
ture. When a mandrel or test fixture is not available, a test should be run at the first opportunity on
“in-hole” pipe.
Close tong door and clamp the lower pipe end with the back-up.
Set „Make-up/Break-out“ to “Make-up”.
Set gear shift handle to low-gear position.
Slowly push the valve handle forward to „Make-up”.
As the tong jaws begin to grip the pipe, observe both output torque on the torque gauge and input
hydraulic pressure to the tong. Output torque should be a direct ratio to input hydraulic pressure
according to the ratios shown in the lower diagrams of Figures 3.10 – 3.12. Observe only the
black graph which corresponds to low gear.

7.10 TORQUE MEASURING SYSTEM

Check the torque measuring system for leakage after each job.
Leakage can be detected …
at the piston rod of the hydraulic load cell
at the vent hole of the hydraulic load cell
at the hose connectors between the load cell and the torque indicator
at the hose connectors between torque indicator and pressure transducer
When a hose connector is leaking, the connector is to be unscrewed, sealed with teflon tape and
tightened again.
When oil is leaking at the piston rod or vent hole, the load cell has to be disassembled and the
piston o-rings have to be replaced, see Fig. 7.12.
Fig. 7.12 Load Cell

Repair the load cell:
Ensure that the torque gauge is pressureless before disassembling!

Open the vent screw carefully!
Remove the lock screw and the hose connector.
Disassemble the load cell housing by unscrewing.
Remove the locking screw from the piston bottom and then the piston bottom from the pis-
ton by unscrewing. Remove both parts from the load cell housing.
Replace the o-rings on the piston, rod and vent screw.

O-Ring : 0.25“ x 0.375“ x 0.063“
O-Ring : 2.35“ x 2.750 “ x 0.210“
O-Ring : 1.50“ x 1.750“ x 0.125“ (all o-rings are included in the REPAIR KIT)
Reassemble the load cell and fix the lock screw and the hose with connector.
Check the vent hole with a needle for being open.
Bleed the load cell:
Fix the load cell in a vice, (vent screw to the top), see Fig. 7.13.
Put the torque indicator to a lower level (floor).
Attach the hand pump to the check valve at the torque indicator, see Fig 7.14.
Open the torque indication stabilizer valve.
Pump a couple of strokes until the torque indicator displays approximately 500 ft-lbs.
Open the vent screw carefully and pump until the fluid streams clearly.
Close the vent screw and check the calibration of the torque measuring system.
During hot weather it may be necessary to release excess fluid at the vent
screw, if the indicator shows pressure when not under tension.

Fig 7.13 Bleeding the torque measuring system
Stabilizer valve
Check valve
Torque indicator
Hand pump
Fig. 7.14 Hand pump
Use Martin-Decker W 15 fluid only !

7.11 MAINTENANCE PLAN AND INTERVALS
Cleaning and maintenance intervals are decisive for the operational safety of
the unit and must kept therefore strictly. Disregarding this caution will cause a
potentially hazardous situation which can result in personal injury and/or ma-
terial damage.
Meaning of the abbreviations in the column „Intervals“.

a = inspection or execution after each job
d = inspection or execution every day
w = inspection or execution every week
m = inspection or execution every month
3y = inspection or execution every 3 years
o = inspection or execution only after service work

Hydraulic Tubing Tong -

Maintenance Plan List no.: 1
Model TT 5.5-15
Execution
Pos. Intervals Remarks
(Inspection)
1 Hydraulic Tubing Tong
(Mechanical Structure and Main Components)
1.1 Cleaning a Clean all exposed surfaces with a steam jet
after each job
1.1.1 Remove undesired material a Visual inspect after each job
1.2 Check fastenings (mountings) w
Screws tighten? Visual inspection
1.2.1 Hanger a
1.3 Inadmissible vibration w
1.4 Check glide segments d replace, if necessary Visual inspection
1.5 Labeling (warning signs) m replace, if necessary Visual inspection
1.6 Lead sealing, type plates, security
d replace, if necessary Visual inspection
covers
1.7 Lubricate according to Section 7.5 a Type of lubricant: see Section 7.4
2 Hydraulic Drive
2.1 Fastening, alignment m Inspect under operating temperature and
pressure
2.2 Connections w
2.3 Locking of setting devices w Visual inspection
2.4 Bearing temperature m
2.5 Noise w
2.6 Oil change according to Section First oil change after 60 operating hours; afterwards
7.5.6 every 500 – 1500 operating hours
3 Rotor Drag Brake Band

3.1 Clean brake band surface a
3.2 Check thickness w T min = 11 mm Visual inspection
3.3 Grease brake band d Visual inspection


Model TT 5.5-15
Execution
(Inspection)
4 Valves
4.1 Fastenings w Visual inspection
4.2 Connections w replace, if necessary Visual inspection
4.3 Setting devices d Visual inspection
4.4 Temperature d
4.5 Noise w
4.6 Tightness d Visual inspection
5 Backup Clamping Cylinders

5.1 Fastenings w Visual inspection
5.2 Connections w replace, if necessary Visual inspection
5.3 Outer condition and tightness d Visual inspection
5.3.1 Surface condition of the piston rod d Visual inspection
5.4 Piston movement, attenuation (tol- m Visual inspection
erances)
5.5 Slide lubrication d Lubricate, if neces- Visual inspection
sary
6 Tong Door
6.1 Fastenings m Visual inspection
6.2 Connections m replace, if necessary Visual inspection
6.3 Bearing lubrication d Lubricate, if neces- Visual inspection
sary
7 Gripping System
7.1 Fastenings m Visual inspection
7.2 Connections m replace, if necessary Visual inspection
7.3 Outer condition and tightness d Visual inspection


Model TT 5.5-15
Execution
(Inspection)
8 Pipes, Tubes and Hoses
8.1 Check tubes d Visual inspection
8.1.1 Check tube connections d Tightness Visual inspection
8.1.2 Visual inspect outer damages d replace, if necessary
8.1.3 Replace hoses 3y Use only original spare parts
8.2 Fastenings (mountings) w Visual inspection
8.3 Tightness (pipe connections) w replace, if necessary Visual inspection
8.4 Inadmissible vibration d
9 Hydraulic System (Settings)

9.1 Check working pressure d 175 bar under every condition
9.2 Max. hydraulic flow o
9.2.1a Hydraulic motor – Commercial o 300 l/m / 80 gpm
9.2.1b Hydraulic motor – Danfoss o 120 l/m / 32 gpm
9.2.1c Hydraulic motor – Dinamic o 100 l/m / 27 gpm
9.3 Optimum oil temperature d 50°C / 122°F
9.4 Adjusted values o Visual inspection
9.5 Condition of the oil circulation sys- w
tem

NOTES

APPENDIX
8 APPENDIX
Section Content Page
8.1 Overview - Parts Lists ............................................................................. 8-2
8.1.1 Clamping Elements, Tong and Backup ..................................................... 8-2
8.1.1.1 Standard Jaws .......................................................................................... 8-4
8.1.1.2 Micro-Grip Jaws ........................................................................................ 8-6
8.1.1.3 Non-Marking Jaws (obsolete, for reference only) ..................................... 8-8
8.2 Tong TT 5.5 – 15 .................................................................................... 8-12
8.2.1 Body Assembly ....................................................................................... 8-12
8.2.2 Door Assembly ........................................................................................ 8-18
8.2.3 Hanger Assembly .................................................................................... 8-20
8.2.4 Catch Assembly ...................................................................................... 8-22
8.2.5 Drive Assembly ....................................................................................... 8-24
8.2.5.1 Accessories for Renold Motor ................................................................. 8-28
8.2.6 Bearing Assembly ................................................................................... 8-30
8.2.7 Pinion Gear Assembly ............................................................................. 8-32
8.2.8 Cluster Gear Assembly ........................................................................... 8-34
8.2.9 Tong Manifold Assembly (without Backup) ............................................. 8-36
8.2.10 Tong Manifold Assembly (with Backup) .................................................. 8-38
8.2.10.1 A35 4-Way Valve, Tong Section, modified .............................................. 8-40
8.2.10.2 A35 4-Way Valve, Backup Section, modified .......................................... 8-42
8.2.11 Hydraulic Safety Interlock System .......................................................... 8-44
8.3 Free-Floating Backup ........................................................................... 8-46
8.3.1 FF-BU Connection Parts ......................................................................... 8-46
8.3.2 Cylinder Assembly .................................................................................. 8-50
8.3.3 Backup Manifold Assembly ..................................................................... 8-52
8.4 Accessories ........................................................................................... 8-54
8.4.1 Lift Cylinder Manifold ............................................................................... 8-54
8.4.1.1 Lift Cylinder ............................................................................................. 8-56
8.4.2 A-Q-TORK System (optional) .................................................................. 8-58
8.5 Hydraulic Parts ...................................................................................... 8-62
8.5.1 Hydraulic Plan ......................................................................................... 8-62
8.5.2 Cartridge Block Assembly ....................................................................... 8-64
8.5.3 Hydraulic Plan (A-Q-TORK with 12V Dump Valve).................................. 8-66
8.5.4 12V Dump Valve ...................................................................................... 8-68
8.5.5 Hydraulic Plan (A-Q-TORK with MOOG IS Dump Valve) ........................ 8-70
8.5.6 MOOG IS Dump Valve (for A-Q-TORK / Danfoss motor only)................. 8-72
8.5.6.1 Electrical Interface for IS Dump Valve ..................................................... 8-74
8.5.7 MOOG IS Dump Valve Assy. (for Commercial motor only)...................... 8-76
8.5.7.1 MOOG IS Dump Valve (for Commercial motor only) ............................... 8-78

APPENDIX
8.1 OVERVIEW
Tubing Tong 5.5 - 15 with Free-Floating Backup
Shown without hydraulic motor and valve section

APPENDIX
Parts list - Drawing no. 1.09.5210 – Tubing Tong and Backup
Item Description Qty. Drawing No.

1 BODY ASSEMBLY (refer to Section 8.2.1) 1 0.09.557 Part A
2 DOOR ASSEMBLY (refer to Section 8.2.2) 1 0.09.557 Part B
3 HANGER ASSEMBLY (refer to Section 8.2.3) 1 0.09.557 Part C
4 CATCH ASSEMBLY (refer to Section 8.2.4) 1 0.09.557 Part D
5* GEAR BOX ASSEMBLY (refer to Section 8.2.5) 1 0.09.557 Part E
6 BEARING ASSEMBLY (refer to Section 8.2.6) 1 0.09.557 Part F
7 PINION GEAR ASSEMBLY (refer to Section 8.2.7) 2 0.09.557 Part G
8 CLUSTER GEAR ASSEMBLY (refer to Section 8.2.8) 1 0.09.557 Part H
9a* TONG MANIFOLD ASSEMBLY (w/o BU) (refer to Section 8.2.9) 1 0.09.557 Part I
9b* TONG MANIFOLD ASSEMBLY (w BU) (refer to Section 8.2.10) 1 1.09.4270
10* HYDRAULIC SAFETY INTERLOCK SYS. (refer to Section 8.2.11) 1 1.09.556
11 FF-BU CONNECTION PARTS (refer to Section 8.3.1) 1 3.09.4203
12 CYLINDER ASSEMBLY (refer to Section 8.3.2) 2 2.09.4224
13* BACKUP MANIFOLD ASSEMBLY (refer to Section 8.3.3) 1 1.09.4202
14* LIFT CYLINDER MANIFOLD ASSY (refer to Section 8.4.1) 1 2.09.0669
15* CARTRIDGE BLOCK ASSEMBLY (refer to Section 8.5.3) 1 2.09.4230
* not shown

APPENDIX
8.1.1 Clamping Elements, Tong and Backup

8.1.1.1 Standard Jaws
Tong and Backup Jaw Sets are identical and must be exchanged
simultaneously depending on the pipe / tool joint diameter to be gripped.

APPENDIX
Parts list – Standard Jaws, Tong and Backup
Pipe Size
Item Description Qty. * Part No.
(inches)
JAW SET 1,66"
1,66"
2 DIE 3/8" STANDARD 6 541 0180
JAW SET 1,9"
1,9" 3
2 DIE /8" STANDARD 6 541 0180
JAW SET 2 1/16"
2 1/16"
2 DIE 3/8" STANDARD 6 541 0180
3
JAW SET 2 /8"
2 3/8" 3
2 DIE /8" STANDARD 6 541 0180
JAW SET 2 7/8"
2 7/8"
2 DIE 3/8" STANDARD 8 541 0180
JAW SET 3 1/2"
3 1/2" 3
2 DIE /8" STANDARD 8 541 0180
JAW SET 4"
4" 3
2 DIE /8" STANDARD 8 541 0180
JAW SET 4 1/2"
4 1/2"
2 DIE 3/8" STANDARD 8 541 0180
JAW SET 5"
5" 3
2 DIE /8" STANDARD 8 541 0180
JAW SET 5 1/2"
5 1/2"
2 DIE 3/8" STANDARD 8 541 0180
* Quantity per Jaw Set (left and right). Other jaw sizes are available on request.

APPENDIX
8.1.1.2 Micro-Grip Jaws
Micro-Grip Jaw Set consisting of left and right Jaw (for Pipe Diameter 2 3/8” till 4”)
Micro-Grip Jaw Set consisting of left and right Jaw (for Pipe Diameter 4 1/2” till 5”)
Tong and Backup Micro-Grip Assemblies are identical and must be

exchanged simultaneously depending on the pipe / tool joint diameter to be
gripped.

APPENDIX
Parts list – Micro-Grip Jaws, Tong and Backup
Pipe Size
(inches)
MICRO-GRIP JAW ASSEMBLY 2 3/8" (incl. items 1 – 5) 1 541 1903
1 MICRO-GRIP JAW SET (same as NON-MARKING JAW SET) 1 541 1453
2 MICRO-GRIP INSERT (= 2 pcs) 2 541 1853
2 3/8"
3 LOCK RING SET (= 2 pcs) 2 541 1253
4 CAP SCREW 16 541 0520
5 LOCK WASHER (not shown) 16 521 0089
7
MICRO-GRIP JAW ASSEMBLY 2 /8" (incl. items 1 – 5) 1 541 1904
2 7/8"
3 LOCK RING SET (= 2 pcs) 2 541 1554
4 CAP SCREW 20 541 0520
1
3 1/2"
3 LOCK RING SET (= 2 pcs) 2 541 1555
4 CAP SCREW 20 541 0520
MICRO-GRIP JAW ASSEMBLY 4" (incl. items 1 – 5) 1 541 1906
4"
3 LOCK RING SET (= 2 pcs) 2 541 1256
4 CAP SCREW 16 541 0520
1
4 1/2" 3 LOCK RING SET (= 2 pcs) 2 541 1557
4 CAP SCREW 16 541 0520
6 JAW PIN 2 521 1471
MICRO-GRIP JAW ASSEMBLY 5" (incl. items 1 – 6) 1 541 1908
5" 3 LOCK RING SET (= 2 pcs) 2 541 1558
4 CAP SCREW 16 541 0520
6 JAW PIN 2 521 1471
* Quantity per Micro-Grip Assembly (left and right).
Do not use the 5” Micro-Grip Jaw Set in the tong, it is for backup use only.

APPENDIX
8.1.1.3 Non-Marking Jaws (obsolete, for reference only)
Chucking Wedges Mark II for use with Non-Marking Jaws
The use of non-marking jaws requires the installation of these specific

chucking wedges into the tong.

APPENDIX
Parts list – Chucking Wedges for Non-Marking Jaws, Tong

1 CHUCKING WEDGE MARK II 3 541 0897
2 CAP SCREW 3 541 0040
3 CAP SCREW 3 541 0269
4 CAP SCREW 3 541 0039
* Quantity per tong.
When changing back to standard jaws or Micro-Grip jaws the chucking wedges
Mark II must be also changed back to standard.
Otherwise exists the risk of crimping the pipe being run.

APPENDIX
8.1.1.3 Non-Marking Jaws (obsolete, for reference only) (continued)
Non-Marking Jaws consisting of left and right Jaw (for Pipe Diameter 4 1/2” till 5”, shown in Make-Up Configuration)
Tong and Backup Non-Marking Jaws are identical and must be exchanged
simultaneously depending on the pipe / tool joint diameter to be gripped.
Backup Non-Marking Jaws must be installed opposite to tong installation!

APPENDIX
Parts list – Non-Marking Jaws, Tong and Backup
Pipe Size
(inches)
NON-MARKING JAW SET ASSEMBLY 2 3/8" (incl. items 1 – 5) 1 0541 1503
1 NON-MARKING JAW SET 1 0541 1453
2 INSERT SET (left and right) 1 0541 1603
2 3/8"
3 LOCK RING SET (= 2 pcs, not shown) 2 0541 1253
4 CAP SCREW (not shown) 16 0541 0520
7
NON-MARKING JAW SET ASSEMBLY 2 /8" (incl. items 1 – 5) 1 0541 1504
2 7/8"
1
3 1/2"
NON-MARKING JAW SET ASSEMBLY 4" (incl. items 1 – 5) 1 0541 1506
4"
1
4 1/2" 3 LOCK RING SET (= 2 pcs, not shown) 2 0541 1557
6 JAW PIN (not shown) 2 0521 1471
NON-MARKING JAW SET ASSEMBLY 5" (incl. items 1 – 6) 1 0541 1508
5" 3 LOCK RING SET (= 2 pcs, not shown) 2 0541 1558
6 JAW PIN (not shown) 2 0521 1471
* Quantity per Non-Marking Jaw Set Assembly (left and right).
Do not use the 5” Non-Marking Jaw Set in the tong, it is for backup use only.

APPENDIX
8.2 TONG TT 5.5 - 15

8.2.1 Body Assembly - Drawing No.: 0.09.557 Part A

APPENDIX
Parts list - Drawing no. 0.09.557 Part A – Body Assembly
Item Description Qty. Part No.

1 CASE BODY 1
2 PLATE, BODY-TOP 1 541 0198 *
3 PLATE, BODY-BOTTOM 1
4 HANDLE, TONG 3 541 0116
5 CAP SCREW, M 10 X 20 28 541 0005
6 CAP SCREW, M 10 X 25 6 533 0616
7 PIN, 10M6X20 12 541 0004
8 LOCK WASHER S 10 28 521 0005
11 BEARING ASSEMBLY (refer to Section 8.2.6) 1 -
19 CLUSTER GEAR ASSEMBLY (refer to Section 8.2.8) 1 -
39 PINION GEAR ASSEMBLY (refer to Section 8.2.7) 2 -
54 ROTARY GEAR 1 541 0037
55 CHUCKING WEDGE, CAM 3 541 0170
56 PIN, CHUCKING WEDGE, 20H8 X 22 3 521 0044
57 CAP SCREW, M 12 X 60 3 541 0039
58 CAP SCREW, M 12 X 50 3 541 0269
59 CAP SCREW, M 8 X 35 3 541 0040
60 LOCK WASHER S 12 6 541 0048
61 LOCK WASHER S 8 3 521 0089
67 SHAFT, CAM FOLLOWER 36 541 0095
68 CAM FOLLOWER, NUTR 17 72 541 0089
69 WASHER 17 36 541 0097
70 HEXAGON NUT, M 16 36 541 0096
71 GREASE NIPPLE NIP A 2 36 541 0098
72 BEARING BLOCK 16 541 0260
73 NUT, KM 6, M 30 X 1,5 16 541 0261
74 GROOVED PIN 4 X 16 16 541 0263
75 SHAFT, CAM FOLLOWER 16 541 0264
76 CAM FOLLOWER NATV 15 PPX BEARING BLOCK 16 541 0094
77 PIN 12 M 6 X 28 16 541 0262
78 CAM FOLLOWER RNA 22/8.2RS 16 541 0076
84 CAGE PLATE 2 541 0049
85 HOOK 1 541 0045
86 CAP SCREW, M 12 X 30 8 521 0067
87 GROOVED PIN, 12 X 40 4 541 0046
* only available as set, complete with items 5, 7, 8

APPENDIX
8.2.1 Body Assembly - Drawing No.: 0.09.557 Part A (continued)

APPENDIX
Parts list - Drawing no. 0.09.557 Part A – Body Assembly (continued)

88 LOCK WASHER S 12 8 541 0048
89 TENSION LEVER PIN 2 541 0083
90 TENSION LEVER - LEFT 1 541 0171
91 SHAFT, JAW ROLLER 1 521 0074
92 JAW ROLLER 1 521 0076
93 TENSION LEVER - RIGHT 1 541 0172
94 SHAFT, JAW ROLLER 2 521 0070
95 JAW ROLLER 2 521 0072
96 PIN, SPRING STEEL, 5 X 40 3 521 0159
97 GREASE NIPPLE HLA 5 521 0065
98 JAW SPRING, LEFT 1 541 0085
99 JAW SPRING, RIGHT 1 541 0086
100 CAP SCREW M10 X 25 2 521 0109
101 WASHER, B 10,5 2 521 0091
102 JAW PIN 2 541 0084
103 COTTER PIN 4 523 0481
106 ARRESTING DEVICE ASSEMBLY (incl. item 107 - 111) 1 541 0267
107 OPERATING LEVER, HOOK 1 541 0268
108 TENSION BOLT, HOOK INSIDE 2 541 0053
109 STOP LEVER, HOOK INSIDE 2 541 0054
110 SPIROL PIN, 6 X 35 2 541 0055
111 CHAIN COUPLER LINK 2 541 0056
116 CATCH ASSEMBLY (refer to Section 8.2.4) 1 -
126 BRAKE BAND ASSEMBLY (incl. item 126.1 - 126.4) 2 541 0278
126.1 BRAKE BAND LINING 2 521 0102
126.2 WELDING PART, BRAKE BAND 2 541 0279
126.4 RIVET B6 X 12 30 521 0103
127 HEXAGON NUT, M10 4 521 0097
129 BUSHING 4 541 0109
130 LASHING, BRAKE BAND 4 541 0108
131 HEXAGON SCREW, M 8 X 45 4 541 0110
132 WASHER B 8,4 4 521 0062
141 DOOR ASSEMBLY (refer to Section 8.2.2) 1 -
142 BUSHING G22 X 16 2 541 0271
146 STOP DOG, UPPER 1 541 0195
147 BOLT 16 H 11 X 40 X 33, STOP DOG 2 541 0276
148 SPLIT PIN, 4 X 25 2 541 0078

APPENDIX
8.2.1 Body Assembly - Drawing No.: 0.09.557 Part A (continued)

APPENDIX
Parts list - Drawing no. 0.09.557 Part A – Body Assembly (continued)

149 CAP SCREW M 10 X 30 2 521 0007
150 LOCK WASHER S 10 4 521 0005
153 STOP DOG, BOTTOM 1 541 0196
154 CAP SCREW M 10 X 35 2 541 0197
199 BASE, FRONT 2 541 0106
199 BASE, FRONT (only when using a backup) 2 541 0601
200 BASE, BACK 1 541 0277
200 BASE, BACK (only when using a backup) 1 541 0656
201 HEXAGON SCREW, M 16 X 35 4 541 0107
202 HEXAGON SCREW, M 10 X 35 2 521 1181
203 SPRING WASHER A16 4 541 0175
205 HEXAGON SCREW M 16 X 12 (only used without backup) 8 541 0629
206 PIPE STOP 1 541 0117
207 HEXAGON SCREW, M 16 X 35 2 541 0107
208 WASHER B 17 2 541 0625
209 SHACKLE NO. 4 1 541 0114
210 NOMENCLATURE PLATE, TONG 1 522 0400
240 GEAR BOX ASSEMBLY (refer to Section 8.2.5) 1 -

APPENDIX
8.2.2 Door Assembly - Drawing No.: 0.09.557 Part B

APPENDIX
Parts list - Drawing no. 0.09.557 Part B – Door Assembly

141 DOOR 1 541 0270
143 SHAFT, DOOR 1 541 0272
144 WASHER B 23 1 541 0273
145 SPLIT PIN, 5 X 35 1 541 0274
155 SNAP ON, DOOR 1 541 0352
156 BOLT, SNAP ON, DOOR 1 541 0353
157 WASHER B 10,5 2 521 0091
158 HEXAGON NUT, SELF LOCKING M 10 2 521 0097
159 DOOR SPRING ASSY (incl. item 160 - 162) 2 541 0354
160 SPRING HOUSING TUBE, DOOR CYLINDER 2 541 0355
161 PLUNGER, DOOR CYLINDER 2 541 0356
162 SPRING 2 522 0225
163 HEXAGON SCREW M 6 X 25 2 562 2207
164 WASHER B 6,4 12 541 0212
165 HEXAGON NUT, SELF LOCKING M 6 4 562 2208
166 HEXAGON SCREW M 6 X 35 2 562 2247

APPENDIX
8.2.3 Hanger Assembly - Drawing No.: 0.09.557 Part C

APPENDIX
Parts list - Drawing no. 0.09.557 Part C – Hanger Assembly

185 FITTING PLATE RIGHT, HANGER 1 541 0093
186 FITTING PLATE, HANGER 1 541 0100
187 HEXAGON SCREW, M 16 X 35 4 541 0107
189 HEXAGON SCREW, M 12 X 50 4 541 0113
190 HEXAGON NUT, M 12 4 541 0177
191 HANGER 1 541 0115
191 HANGER (for A-Q-TORK only) 1 541 0370
192 HEXAGON BOLT, M 20 X 75 2 541 0111
193 HEXAGON NUT, M 20 4 521 0094

APPENDIX
8.2.4 Catch Assembly - Drawing No.: 0.09.557 Part D

APPENDIX
Parts list - Drawing no. 0.09.557 Part D – Catch Assembly

116 CATCH ASSEMBLY (incl. item 117 - 120) 1 541 0265
117 WELDING PART, CATCH 1 541 0266
117.4 THREADED PIN, CATCH 1 521 0054
117.5 THRUST PIECE, M 16 X 24 1 521 0056
117.6 BALL HEAD 1 521 0055
118 SEALING V 20 A 1 541 0059
119 WASHER 10,5 1 541 0058
120 HEXAGON NUT, M 10 1 521 0097

APPENDIX
8.2.5 Drive Assembly - Drawing No.: 0.09.557 Part E

APPENDIX
Parts list - Drawing no. 0.09.557 Part E – Drive Assembly

240 GEAR BOX ASSEMBLY, COMMERCIAL (incl. item 240.1 - 240.32) 1 541 0281
240 GEAR BOX ASSEMBLY, DANFOSS (incl. item 240.1 - 240.32) 1 541 9065
240 GEAR BOX ASSEMBLY, RENOLD (incl. item 240.1 - 240.32) 1 541 9036
240.1/2 GEAR BOX, STEEL ASSEMBLY (BOX + COVER) 1 522 0167
240.3 GEAR AND PINION SHAFT 1 522 0175
240.4 GEAR, CLUTCH 1 522 0182
240.4 GEAR, CLUTCH (for Danfoss version only) 1 541 2015
240.5 BEARING U 1207-TM 1 522 0169
240.6 SNAP RING 172 X 2,5 1 521 0024
240.7 SEAL 45 X 72 X 10 1 522 0317
5 3
240.8 BOLTS GEAR BOX EXTENSION RING /16" - 18 UNC X /4" 4 522 0172
240.9 SNAP RING A 32 X 1,5 1 522 0190
240.10 BUSHING, PINION SHAFT 1 522 0318
240.11 GEAR, HI-LO CLUSTER 1 522 0177
240.12 SHAFT, HI-LO CLUSTER GEAR 1 522 0181
240.13 BEARING GR 14N, HI-LO CLUSTER NARROW 1 522 0179
240.14 BEARING, SIZE 14, HI-LO CLUSTER GEAR 2 522 0178
240.15 BUSHING, CLUSTER GEAR 1 522 0176
240.16 O-RING, 28,2 X 3,53, CLUSTER GEAR THRUST 1 522 0242
240.17 THRUST WASHER, CLUSTER GEAR, UPPER 1 522 0180
(3/8" thick x 29/32" ID x 2 15/16OD)
240.18 LOCK, CLUSTER GEAR SHAFT 1 522 0193
240.19 BOLT 1 522 0650
240.21 BREATHER, GEAR BOX 1 522 0186
240.22 SHIFTING FORK ASSEMBLY 1 522 0183
1
240.23 LOCATOR PIN, /2" UNC 1 522 0184
240.24 O-RING, SHIFTING FORK, 15,5 X 2,6 1 522 0234
240.25 PLUG, MAGNETIC, GEAR BOX 1 522 0188
1
240.26 PLUG, R /2" 1 533 0630
240.27 GASKET, GEAR BOX 1 522 0233
240.28 GASKET, GEAR BOX TO TONG 1 522 0236
240.29 GASKET, GEAR BOX EXTENSION RING TO GEAR BOX 1 522 0237
1
240.30 NUT, /2 - 13 UNC 4 522 0194
240.30 HEXAGON NUT (for Danfoss version only) 6 536 5005
240.31 LOCK WASHER, 1/2" 4 522 0195
3
240.32 LOCK WASHER, /8" 1 522 0192

APPENDIX
8.2.5 Drive Assembly - Drawing No.: 0.09.557 Part E (continued)

APPENDIX
Parts list - Drawing no. 0.09.557 Part E – Drive Assembly

240.60 PLUG, GEAR BOX (for Danfoss version only, not shown) 2 522 0232
241 RING, GEAR BOX EXTENSION 1 541 0252
242 GEAR, PINION 1 541 0256
1 1
243 STUDS, GEAR BOX AND MOTOR (all thread /2" - 13 UNC x 7 /4") 2 522 0164
243 STUDS, GEAR BOX AND MOTOR (for Danfoss version only) 2 541 2033
1
244 STUDS, GEAR BOX (all thread /2" - 13 UNC x 6") 2 522 0165
248 MOTOR, HYDRAULIC M 76 X 878 (Commercial motor) 1 529 0550
250 GASKET, MOTOR TO GEAR BOX 1 522 0235
1
251 CAP SCREW /2" - 13 UNC (for Commercial version only) 2 522 0197
1
251 HEXAGON BOLT /2" - 13 UNC (for Renold version only) 2 536 1663
1
251 STUD /2" – 13 UNC (for Danfoss version only) 2 541 0373
252 BRACKET, SHIFT HANDLE 1 521 0113
253 BLOCK SHIFTING FORK 1 521 0114
1
254 LOCK WASHER /2 2 522 0195
255 CAP SCREW, BRACKET 1 521 0115
256 HANDLE, SHIFT 1 522 0201
257 PIN, BLOCK 1 522 0200
308 MOTOR FLANGE 2 522 0214
7
309 CAP SCREW /16"-14 UNC, MOTOR FLANGE 8 522 0250

APPENDIX
8.2.5.1 Accessories for Renold Motor - Drawing No.: 1.09.2506

APPENDIX
Parts list - Drawing no. 1.09.2506 – Accessories for Renold Motor

1 ADAPTER, RENOLD MOTOR 1 541 2201
2 SPLINE SHAFT FOR RENOLD MOTOR 1 541 2200
5 HEXAGON SCREW 5 521 1181
6 WASHER 5 521 0091
7 BEARING, BALL 1 541 2202
8 COUPLING BUSHING 1 528 2001
9 RADIAL PISTON MOTOR, RENOLD 1 528 2000

APPENDIX
8.2.6 Bearing Assembly - Drawing No.: 0.09.557 Part F

APPENDIX
Parts list - Drawing no. 0.09.557 Part F – Bearing Assembly

11 BEARING FLANGE 1 541 0254
12 CAP SCREW, M 8 X 16 6 541 0520
13 LOCK WASHER S 8 6 521 0089
14 GREASE NIPPLE, H1A 1 521 0065
15 BEARING, HK 2518-RS 1 541 0253

APPENDIX
8.2.7 Pinion Gear Assembly - Drawing No.: 0.09.557 Part G

APPENDIX
Parts list - Drawing no. 0.09.557 Part G – Pinion Gear Assembly

39 SHAFT, ROTARY DRIVE PINION 2 541 0019
40 GEAR, ROTARY DRIVE PINION 2 541 0025
41 BEARING NUP 207 4 521 0023
42 RETAINING RING, I 72 X 2,5 4 521 0024
43 BUSHING, ROTARY DRIVE PINION 2 521 0029
44 BEARING SEAL NUP 207 AV 4 521 0026
45 BUSHING, ROTARY DRIVE PINION 2 541 0026
46 WASHER B 25 4 521 0020
47 HEXAGON NUT, M 24 X 2 4 521 0018
48 GREASE NIPPLE H2A 1 521 0019
50 GREASE NIPPLE H3A 1 541 0234

APPENDIX
8.2.8 Cluster Gear Assembly - Drawing No.: 0.09.557 Part H

APPENDIX
Parts list - Drawing no. 0.09.557 Part H – Cluster Gear Assembly

19 SHAFT, CLUSTER GEAR 1 541 0237
20 GEAR CLUSTER 1 541 0255
21 BEARING 6007 1 521 0013
22 BUSHING LR 35 X 40 X 12,5 1 521 0014
23 RETAINING RING, I 62 X 2 1 521 0009
24 BEARING SEAL, A 40 X 62 X 7 1 521 0015
25 BEARING SCE 2620 1 541 0028
26 BUSHING PI 222 620 1 521 0012
27 RETAINING RING, I 51 X 2 2 541 0041
28 BUSHING 1 541 0043
29 BEARING SEAL 160 07 AV 1 521 0011
30 BUSHING 1 541 0044
31 WASHER B 25 2 521 0020
32 HEXAGON NUT, M 24 X 2 2 521 0018
33 GREASE NIPPLE, H3A 1 541 0234

APPENDIX
8.2.9 Manifold Assembly (without Backup) - Drawing No.: 0.09.557 Part I

APPENDIX
Parts list - Drawing no. 0.09.557 Part I – Tong Manifold Assembly

(without Backup)

214 VALVE MOUNTING A 35, 1 SECTION 1 541 0298
214 VALVE MOUNTING A 35, 2 SECTION (only used with backup or lift 1 541 0537
cylinder)
215 HEXAGON SCREW, M 12 X 100 3 541 0299
216 HEXAGON NUT, M 12 3 541 0177
217 HOLDER, INPUT LINE, 1 VALVE SECTION 1 541 0231
217 HOLDER, INPUT LINE, 2 VALVE SECTION (only when using a backup or 1 541 0417
lift cylinder)
299 MANIFOLD ASSEMBLY (incl. item 300 - 342) 1 541 0250
300 VALVE, 4-WAY, HYDRAULIC, TYPE A35 1 529 0551
301 HANDLE, VALVE 1 522 0202
302 SELF SEAL COUPLING, MALE 1" 1 530 0019
1
303 SELF SEAL COUPLING, MALE 1 /4" 1 530 0020
304 DUST CAP, 1" 1 530 0013
1
305 DUST CAP, 1 /4" 1 530 0014
306 SWIVEL JOINT, 1" NPT 2 522 0212
307 SEAL NUT, 1" NPT 14 522 0213
310 FITTING AEROQUIP 5 530 0212
311 CLOSE NIPPLE 1" X CL 2 522 0501
312 NIPPLE 1" X 3" 4 522 0502
313 NIPPLE 1" X 4" 2 522 0504
314 NIPPLE 1" X 6" 1 522 0508
316 NIPPLE 1" X 10" 2 522 0512
317 ELBOW 1", 90° 4 522 0516
318 STREET ELBOW 1", 90° 1 522 0522
1
319 BUSHING 1 /4" X 1" 1 522 0528
320 O-RING, 37,69 X 3,53 2 528 0301
324 SEAL HEAD ADAPTER 2 530 0105
328 ADAPTER 1 530 0245
329 ADAPTER 2 530 0195
1
333 NIPPLE /4" X 2 3/8" 1 541 0389
335 EVGE 8-L/1/4" NPT 1 533 0378
337 AS8-L 1 533 0445
339 RHD 8 - L 1 533 0496
342 NIPPLE 1" X 16,75" 1 541 0387

APPENDIX
8.2.10 Tong Manifold Assembly (with Backup) - Drawing No.: 1.09.4270

APPENDIX
Parts list - Drawing no. 1.09.4270 – Tong Manifold Assembly (with Backup)

1 A35 BACKUP SECTION MODIFIED 1 541 0227
1
2 TIE BOLT /2 -13UNC X 7 4 529 0555
3 HANDLE, 4-WAY VALVE 1 522 0202
4 REDUCER 2 530 0151
5 ANGLE SCREW-IN SCREW-JOINT 3 533 0370
6 PRESSURE CONTROL VALVE 1 521 0203
7 ADJUSTABLE SCREW-IN SOCKET 1 533 0488
8 BALL VALVE 1 541 0415
9 ANGLE SWIVEL SCREW-JOINT 2 533 3613
10 STRAIGHT SCREW-IN SCREW-JOINT 4 533 0480
11 WELD-ON SCREW-JOINT 1 533 0439
16 MANOMETER 1 533 1999
17 ANGLE SCREW-JOINT 1 533 2045
18 STRAIGHT SCREW-ON SCREW-JOINT 1 562 5083
19 RING SEAL 1 533 3170
20 MEASURING CONNECTOR 1 533 0538
22 NON-RETURN VALVE 2 533 0495
1
23 PUSH PULL COUPLING, MALE /2” 2 530 0241
1
24 DUST CAP, FEMALE /2” 2 530 0243
1
25 PUSH PULL COUPLING, FEMALE /2” 2 530 0240
1
26 DUST CAP, MALE /2” 2 530 0242
27 ADJUSTABLE ANGLE SCREW 8 533 4513
28 ADJUSTABLE T-SCREW-JOINT 2 533 4588
29 ADJUSTABLE L-SCREW-JOINT 3 533 4663
30 ADJUSTABLE SCREW-IN SOCKET 1 533 4838
31 COMBINED BALL + RELIEF VALVE 1 541 0414

APPENDIX
8.2.10.1 A35 4-Way Valve, Tong Section, modified – Drawing No.: 3.09.0661

APPENDIX
Parts list - Drawing no. 3.09.0661 – A35 4-Way Valve, Tong Section, modified

1 4-WAY VALVE A35 1 -
2 CHECK POPPET, TONG SECTION 1 541 0375
3 SPRING 1 541 0377

APPENDIX
8.2.10.2 A35 4-Way Valve, Backup Section; Part No.: 5410227 – Drawing No.: 3.09.2913

APPENDIX
Parts list - Drawing no. 3.09.0674 – A35 4-Way Valve, Backup Section

1 4-WAY VALVE, TONG SECTION 1 -
2 CHECK POPPET, BACKUP SECTION 1 541 0376
3 CUP SPRING 6 541 0374

APPENDIX
8.2.11 Hydraulic Safety Interlock System - Drawing No.: 1.09.556

APPENDIX
Parts list - Drawing no. 1.09.556 – Hydraulic Safety Interlock System

4 VALVE ACTUATING BLOCK 1 541 0378
5 VALVE CONNECTION PLATE 1 541 0194
6 SPRING FOR PISTON 1 541 0020
7 CYLINDER HOUSING 1 541 0065
8 PISTON 1 541 0066
12 CAP SCREW M 8 X 15 3 521 0061
13 CAP SCREW M 6 X 20 2 541 0232
14 DISCHARGING VALVE 1 528 0510
17 FILTER CAP 1 541 0081
18 O-RING, 25 X 2 1 521 0086
19 ORIFICE 1 528 0512
23 O-RING, 34,5 X 3,55 1 528 0300
24 ANGLE SWIVEL SCREW-JOINT WITH THROTTLE 1 528 0516
25 GE 6-SR 2 533 0463
26 AS 6-S 1 533 0440
30 PROTECTION TUBE 1 541 0021
31 PROTECTION FOR VALVE 1 541 0022
41 CHECK CAP 1 529 0562
44 O-RING, 28 X 3,5 1 522 0283
45 FILTER, HYDR. INTERLOCK 1 541 0082
146 STOP DOG, UPPER 1 541 0195
147 BOLT 16 H 11 X 40 X 33, STOP DOG 2 541 0276
149 CAP SCREW, M 10 X 30 2 521 0007
153 STOP DOG, BOTTOM 1 541 0196
154 CAP SCREW, M 10 X 35 2 541 0197

APPENDIX
8.3 FREE-FLOATING BACKUP

8.3.1 FF-BU Connection Parts - Drawing No.: 3.09.4203

APPENDIX
Parts list - Drawing no. 3.09.4203 – FF-BU Connection Parts

1 CASE BODY 1 541 3601
2 SET SCREW 4 541 3602
5 JAW PIN 2 541 0084
6 TENSION LEVER 2 541 3606
7 COTTER LINCH PIN 4 599 0152
10 CYLINDER 125 DIA ASSY 2 541 3610
13 GREASE NIPPLE 2 521 2021
14 SET SCREW 16 521 5387
15 GUIDE BUSHING TOP 2 541 3615
16 ROD WIPER 2 541 3616
18 GUIDE BUSHING BOTTOM 2 541 3618
22 THRUST SPRING 2 541 3622
24 WASHER 2 541 3624
27 HEXAGON NUT 4 521 2527
30 BALL PIVOT 2 521 2530
37 HEXAGON NUT SELFLOCK 2 541 0096
38 WASHER 2 541 3638
43 TORSION BAR 1 541 3643
44 SPHERICAL BEARING 2 541 3644
45 BUSHING 4 541 3645
46 SEAL 4 541 3646
48 BOLT 2 541 3648
50 TORQUE LASHING 1 557 1323
51 BOLT 2 541 3651
61 BUSHING, LOAD CELL 1000 IS 1 557 1327
62 BUSHING, TORQUE GAUGE 1 557 1328
63 BUSHING, TORQUE GAUGE 1 557 1332
66 CARTRIDGE BLOCK ASSY 1 541 3820
67 CAP SCREW 2 557 1045
70 FLOW DIVIDER 1 528 0554
71 HOLDER T-CONNECTION 1 541 3671
72 CAP SCREW 1 541 0293
73 CLAMP 1 557 1322
74 HEXAGON BOLT 2 541 3674

APPENDIX
8.3.1 FF-BU Connection Parts - Drawing No.: 3.09.4203 (continued)

APPENDIX
Parts list - Drawing no. 3.09.4203 – FF-BU Connection Parts

101 TORQUE TUBE 2 541 3801
102 CAP SCREW 4 521 2076
103 FLANGE 2 541 3803
105 THREADED BOLT 2 541 3626
106 BUSHING 2 541 3806
107 WASHER 2 521 2519
109 WASHER 2 521 0020
110 TRAVERSE 1 541 3810
111 SUPPORT 1 541 3811
112 BOLT 1 541 3651
115 WASHER 2 541 3815
120 HOLDER 2 557 1102
121 CAP SCREW SHALLOW HEAD 2 521 0088
122 CAP SCREW, M8 X 50 2 541 0291
126 GREASE NIPPLE 2 522 0152
127 CHAIN 1 541 3827
128 SPRING 215 IÖIÖ X 47 X 6,5 X 24 IF 1 541 3828

APPENDIX
8.3.2 Cylinder Assembly - Drawing No.: 2.09.4224

APPENDIX
Parts list - Drawing no. 2.09.4224 – Cylinder Assembly

1 CYLINDER BODY 1 541 3751
2 CYLINDER COVER 1 541 3752
3 WIPER SCRAPER 1 541 3753
4 TURCITE B WEAR RING 1 541 3754
5 TURCON GLYD RING GS 55043-0800-46-340 1 541 3755
6 O-RING 1 541 3756
7 PISTON 1 541 3757
8 TURCON GLYD RING GS 55044-1250-46N-347-8307 1 521 5358
9 RING, WEAR BS50704-1250 A47 1 521 5357
10 CAP SCREW 12 521 0048
11 LOCK WASHER 12 541 0048
12 PLUG 1 533 0634
13 PLUG 2 528 0281
15 PLUG 2 533 0635
16 ACCUMULATOR 1 528 0555
17 RETAINING RING 1 541 3767

APPENDIX
8.3.3 Backup Manifold Assembly - Drawing No.: 1.09.4202

APPENDIX
Parts list - Drawing no. 1.09.4202 – Backup Manifold Assembly

1
1 PUSH PULL COUPLING, FEMALE /2" 1 530 0240
1
2 DUST CAP, FEMALE /2" 1 530 0243
1
3 PUSH PULL COUPLING, MALE /2" 1 530 0241
1
4 DUST CAP, MALE /2" 1 530 0242
6 HOSE 2 530 0215
7 ANGLE SWIVEL SCREW-JOINT 3 533 3613
8 REDUCING CONNECTION 1 533 4759
11 ADJUSTABLE ANGLE SCREW 2 533 4513
12 TUBE 12 X 2 504 2159
13 T-SCREW-JOINT 1 533 0325
14 HOSE 4 530 0294
19 TUBE 6 X 1,5 504 2152
20 STRAIGHT SCREW-JOINT 1 533 2011
21 MEASURING CONNECTOR 1 533 0538
22 MEASURING HOSE 1 533 4581
23 CABLE CLAMP 5 560 0857

APPENDIX
8.4 ACCESSORIES
8.4.1 Lift Cylinder - Drawing No.: 2.09.0669

APPENDIX
Parts list - Drawing no. 2.09.0669 – Lift Cylinder

1 CYLINDER ZD1BSO (refer to Section 8.4.1.1) 1 541 0420
SEAL KIT FOR LIFT CYLINDER 1 541 0421
3 THREADED REDUCING SOCKET R1/2 X R3/8 2 533 0429
4 ANGLE SWIVEL SCREW-JOINT DSVW 12-PSR 2 533 4238
5 HOSE, 650 MM LONG 1 530 0214
6 HOSE, 1250 MM LONG 1 530 0215
1
7 PUSH-PULL COUPLING, MALE /2" 1 530 0241
1
8 PUSH-PULL COUPLING, FEMALE /2" 1 530 0240
1
9 DUST CAP, MALE /2" 1 530 0242
10 DUST CAP, FEMALE 1/2" 1 530 0243
1
11 STRAIGHT SCREW-IN SCREW-JOINT GE 12-PS / /2 NPT 1 533 0480

APPENDIX
8.4.1.1 Lift Cylinder, Part No.: 541 0420 - Drawing No.: 3.09.2171

APPENDIX
Parts list - Drawing no. 3.09.2171 – Lift Cylinder (Part no. 541 0420)

1 CYLINDER 1 521 5380
6 PISTON ROD 1 521 5381
7 GUIDE 1 521 5382
8 PISTON 1 521 5383
9 WASHER 2 521 5384
10 DISTANCE WASHER 1 521 5385
12 SHACKLE TOGGLE JOINT 1 541 0412
13 HEXAGON NUT 1 521 5386
14 SET SCREW 1 521 5387
16 SEAL KIT ASSEMBLY (incl. item 17, 18, 19, 20, 21) 1 541 0421
17 WIPER 1 521 5389
18 ROD SEAL 1 521 5390
19 O-RING 1 521 5391
20 O-RING 1 521 5392
21 PISTON SEAL 2 521 5393

APPENDIX
8.4.2 A-Q-TORK System

APPENDIX
Parts list – A-Q-TORK System

1 VOLUME BLOCK ASSEMBLY (incl. items 1a – 1e) 1 541 2010
1a CHANGEOVER VALVE 1 528 0542
1b CHANGEOVER VALVE 1 528 0543
1c PRESSURE CONTROL VALVE 1 528 0545
1d FLOW CONTROL VALVE 1 528 0544
1e VOLUME BLOCK 1 541 2017
2 MINIFILTER (incl. item 2a) 1 541 2012
2a FILTER ELEMENT 1 541 2009
3 HYDRAULIC MOTOR, TYPE DANFOSS 1 541 2014
4 GEAR 1 541 2015
5 FLANGE 1 541 2016
6 VALVE WITH PUSH ROD 1 528 0548
7 HOUSING 355 0100 064 1 541 2100
8 VALVE E2B 50-N 1 541 2101
9 HOUSING LT-37-06.0 1 541 2102
10 FILTER 295 A-2N50-EZ-140 (incl. items 10a – 10c) 1 541 2103
10a FILTER ELEMENT 1 541 2111
10b BACK-UP RING 1 541 2113
10c O-RING SET 1 541 2112
11 HC-D6 1 541 2301
12 O-RING 2 531 0032
13 SCREW 4 541 2024
14 STUD 2 541 2033
15 CAP SCREW 1/2" UNC X 3 1/4" 2 541 2023
16 GASKET 1 522 0235
17 CYLINDER HOUSING 1 541 0065
18 PISTON 1 541 0066
19 SPRING 1 541 0020
20 O-RING 1 528 0300
21 ORIFICE 1 528 0512
22 REDUCER 1 533 0486
23 O-RING 1 521 0086
24 COUPLING 1 530 0019
25 COUPLING 1 530 0020
26 REDUCER 1 522 0528
27 ADAPTER 2 522 0501

APPENDIX
8.4.2 A-Q-TORK System (continued)

APPENDIX
Parts list – A-Q-TORK System

31 DSVW 20 SR 2 533 0453
32 GE 20 SR 1 533 0346
33 W20S 1 533 0314
34 ev L 20 S 1 533 0389
35 ev W 20 S 2 533 0404
36 KOR 20-14 S 2 533 0425
37 KOR 25-16 S 1 533 0419
38 GE 25 S 1" NPT 1 533 0342
39 KOR 25-20 S 1 533 0418
40 GE 25 SR 1" 1 533 0353
41 ev W 25 S 2 533 0397
42 DSVW 16 SR 1 533 0594
1
43 GE 14 SR /2" 2 533 0360
1
44 GE 12 S /2" NPT 4 533 0480
45 GE 12 SR 4 533 0433
46 ev W 12 S 4 533 0459
47 DSVW 12 S 2 533 0451
48 AS 8L 1 533 0445
49 T 8L 1 533 0368
50 DSVW 8 SM 1 533 0465
51 DSVW 8 LR 1 533 0466
52 GE 6 LM 2 533 0586
53 DSVW 6 SR 1 533 0464
54 DSVT 6 SR 1 533 0595
55 REDUCER 2 530 0238
1 3
56 RI /2" X /8" 1 533 0429
57 DUST CAP 1 530 0013
58 DUST CAP 1 530 0014
59 HOLDER FILTER 1 541 2105
60 STAND 1 541 2106

APPENDIX
8.5 HYDRAULIC PARTS

8.5.1 Hydraulic Plan Tong with FF-BU and Lift Cylinder - Drawing No.: 3.09.4201 Sheet 1

APPENDIX
Parts list - Drawing no. 3.09.4201 Sheet 1 – Hydraulic Plan

1a A35 INLET SECTION 1 -
1b A35 OUTLET SECTION 1 -
1c A35 TONG SECTION MODIFIED 1 521 0218
2 A35 4-WAY VALVE MODIFIED (consists of item 1a, 1b, 1c) 1 521 0217
3 A35 BACK-UP/LIFT CYLINDER SECTION MODIFIED 1 521 0227
4 NON-RETURN VALVE RHD 8 - PL 1 533 0496
6 CARTRIDGE BLOCK ASSEMBLY (incl. item 6.1-6.4, refer to Section 8.5.3) 1 521 5409
6.1 PRESSURE RELIEF VALVE, BACKUP 1 528 0524
6.2 PRESSURE RELIEF VALVE, LIFT CYLINDER 1 528 0524
6.3 NON-RETURN VALVE 1 528 0528
6.4 THROTTLE 1 528 0527
7 MANOMETER 0 - 600 BAR 1 533 1999
8 FILTER FOR HYDRAULIC INTERLOCK 1 541 0082
9 2-WAY VALVE, INTERLOCK 1 528 0510
10 COMBINED BALL AND RELIEF VALVE 1 541 0414
11 MAIN SYSTEM INTERLOCK 1 521 9154
12 FLOW DIVIDER 1 528 0554
13 PRESSURE RELIEF VALVE 1 528 0556
14 FILTER ELEMENT 1 541 2009
15 PRESSURE BOOSTER 1 541 3822
21 THROTTLE VALVE 1 528 0503
22 CYLINDER 2 541 3610
25 NON RETURN VALVE 1 528 0528

APPENDIX
8.5.2 Cartridge Block Assembly - Drawing No.: 2.09.4230

APPENDIX
Parts list - Drawing no. 2.09.4230 – Cartridge Block Assembly

1 CARTRIDGE BLOCK 1 541 3821
2 PRESSURE BOOSTER 1 541 3822
3 PLUG 1 541 3823
5 PRESSURE RELIEF VALVE 400 BAR 1 528 0556
6 FILTER ELEMENT FOR 5412012 1 541 2009
7 SPRING 1 541 3824
8 PLUG 4 528 0281
10 0-RING 1 528 0295
11 0-RING 3 541 3825
12 CAP SCREW 4 541 3826

APPENDIX
8.5.3 Hydraulic Plan (A-Q-TORK with 12V Dump Valve)

APPENDIX
Parts list - Hydraulic Plan (A-Q-TORK with 12V Dump Valve)

1 CHANGEOVER VALVE 1 528 0542
3 FLOW CONTROL VALVE 1 528 0544
5 DISCHARGE VALVE 1 528 0547
6 DISCHARGE VALVE BOTTOM 1 541 2029
7 MINI FILTER 1 541 2012
8 VALVE 1 528 0519
10 VALVE 1 528 0548
15 FILTER 295 A-2N50-EZ-140 1 541 2103
17 VALVE E2B 50-N 1 541 2101
19 4-WAY VALVE 1 541 2104

APPENDIX
8.5.4 12V Dump Valve

APPENDIX
Parts list - 12V Dump Valve

1 DUMP VALVE 1 528 0519
2 BLOCK 1 528 0520

APPENDIX
8.5.5 Hydraulic Plan (A-Q-TORK with MOOG IS Dump Valve)

APPENDIX
Parts list – Hydraulic Plan (A-Q-TORK with MOOG IS Dump Valve)

3 FLOW CONTROL VALVE 1 528 0544
6 DISCHARGE VALVE BOTTOM 1 541 2029
7 MINI FILTER 1 541 2012
8 INTERNAL PILOT SUPPLY 1 528 0549
9 PARTS FOR NON-RETURN VALVE 1 533 0597
10 VALVE 1 528 0548
15 FILTER 295 A-2N50-EZ-140 1 541 2103
17 VALVE E2B 50-N 1 541 2101
19 4-WAY VALVE HC-D6/3-E4-L8A1 V10 1 541 2104

APPENDIX
8.5.6 MOOG IS Dump Valve (for A-Q-TORK / Danfoss motor only)

APPENDIX
Parts list – MOOG IS Dump Valve (for A-Q-TORK / Danfoss motor only)

1 DUMP VALVE; PILOT SUPPLY ON X 1 528 0549
2 VALVE BLOCK 1 541 2501
3 CHECK VALVE INNER PARTS 1 533 0597
4 BOLT 1 541 2502
6 ELT. INTERFACE (not shown, refer to Section 8.5.6.1) 1 541 2027
7 FILTER 1 528 0553
8 COVER 2 541 2109
9 TAPPET 2 541 2108
10 WIPER 2 521 5416
11 O-RING 2 521 5414
12 CAP SCREW 6 541 2107
13 LOCK WASHER 6 541 0294
Service instructions for the MOOG IS Dump Valve can be seen in Section 7.5.1.
When replacing MOOG- or discharge valve proceed as follows:

APPENDIX
8.5.6.1 Electrical Interface for MOOG IS Dump Valve (Part No.: 541 2027)

APPENDIX
Parts list – Electrical Interface for MOOG IS Dump Valve (Part no.: 541 2027)

1 INTEGRATED CIRCUIT IC 1 (7805) 1 541 2517
2 FUSE F1 1 541 2518
3 RECTIFIER D1 1 541 2514
4 RESISTOR R1 1 541 2515
5 DIODE D2 (1N4007 or 1N5337B) 1 541 1516
6 SOCKET 2 541 2524
7 DUST PLUG 2 541 2528
8 PLUG 1 541 2522
9 DUST CAP 1 541 2523
10 COUPLER PLUG 1 541 2527
11 CABLE 1 561 0823
12 PLUG 2 541 2525
13 DUST PLUG 2 541 2526

APPENDIX
8.5.7 MOOG IS Dump Valve Assy. (for Commercial motor only) - Part No.: 541 9103

APPENDIX
Parts list – MOOG IS Dump Valve Assy. (for Commercial motor only)
Part no.: 541 9103

1 FILTER 1 541 2012
1
2 GE-8-L /4 R 3 533 0351
3 EW-8-L 2 533 4501
4 ET-8-L 1 533 4576
5 T-8-L 1 533 0368
6 RED 8-6L 1 533 4700
7 WH-8-S 1 533 3611
8 WH-8-L 2 533 3601
9 MOOG IS DUMP VALVE (refer to Section 8.5.7.1) 1 -
1
10 GE-8-S- /4 NPT 1 533 0361

APPENDIX
8.5.7.1 MOOG IS Dump Valve (for Commercial motor only)

APPENDIX
Parts list – MOOG IS Dump Valve (for Commercial motor only)

1 DUMP VALVE; PILOT SUPPLY ON X 1 528 0549
2 CONNECTION PLATE 1 541 2501
3 PARTS FOR NON-RETURN VALVE 1 533 0597
4 GUIDE PIN 1 541 2502
6 ELT. INTERFACE (not shown, refer to Section 8.5.6.1) 1 541 2027
7 FILTER 1 528 0553
8 COVER 2 541 2109
9 TAPPET 2 541 2108
10 WIPER 2 521 5416
11 O-RING 2 521 5414
12 CAP SCREW 6 541 2107
13 LOCK WASHER 6 541 0294
Service instructions for the MOOG IS Dump Valve can be seen in Section 7.5.1.
When replacing MOOG- or discharge valve proceed as follows:
This Port must

be closed
Discharge Valve

APPENDIX
NOTES

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What safety precautions should be taken when operating the tubing tong?

What safety precautions should be taken when operating the tubing tong?

What are the steps to install the tubing tong?

What are the steps to install the tubing tong?

REVISION 08 2001

ALL EARLIER REVISIONS OBSOLETE

This Operating Manual is valid for the following serial numbers:

Keep this manual for future reference!

Weatherford Oil Tool GmbH

Hainhäuser Weg 150

TEL +49 (0)511-7702-0

FAX +49 (0)511-7702-187

All rights reserved.

p/n: 9110032 5.5-15 Tubing Tong with Backup/Commercial Motor Version

2 TRANSPORTATION AND INSTALLATION

2.3 JAW INSTALLATION ................................................................................. 2-10

5 PLACING OUT OF OPERATION

7 SERVICE AND MAINTENANCE

1.1 RISK INVOLVED WHEN OPERATING THE HYDRAULIC TUBING TONG

 this device and other material assets of the operating authority

 the efficient performance of this device.

 be qualified according to the requirements and authorized by the op-

 follow this operating manual thoroughly. It is recommended to the

Safety first, don’t risk anything!

Remember: If you are not part of the SOLUTION,

you are part of the PROBLEM!

Operating Manual Rev.08 2001 Page 1-1 of 12

1.2 SAFETY INSTRUCTIONS AND HINTS

describes a possibly dangerous situation.

describes a possibly dangerous situation.

describes a possibly harmful situation. Disregard can damage this device or

1.3 DESIGNATED USE

Due to extremely high gripping forces tubing can be deformed!

Page 1-2 of 12 Rev. 08 2001 Operating Manual

1.4 USE IN POTENTIALLY EXPLOSIVE ATMOSPHERE

 The equipment must be earthed.

 Observe all national and international regulations.

 Tarpaulins may not be handled where an explosive atmosphere may be present.

Operating Manual Rev.08 2001 Page 1-3 of 12

1.5 SOURCES OF DANGER

 Use only original spare parts.

Page 1-4 of 12 Rev. 08 2001 Operating Manual

1.6 OPERATOR´S POSITION

Under no circumstances may anybody stay underneath the suspended tong.

Guide the tong at the provided green handles only.

Fig.1.1 Operator’s Position

Operating Manual Rev.08 2001 Page 1-5 of 12

1.7 DANGER ZONES

declared as danger zone.

 During remote controlled operation no person must enter a danger zone.

1.7.1 Used Warning Signs

Warning Sign No.: 1

Warning Sign No.: 2

Fig.1.2 Warning Signs at Hydraulic Tubing Tong

Page 1-6 of 12 Rev. 08 2001 Operating Manual

1.7.2 Security Layout

Danger zone = Tong and backup rotating and clamping movements

Fig.1.3 Security Layout of Hydraulic Tubing Tong

o = No. of used warning sign according to Section 1.6.1

Operating Manual Rev.08 2001 Page 1-7 of 12

this device and other material assets of the operating authority

the efficient performance of this device.

be qualified according to the requirements and authorized by the op-

follow this operating manual thoroughly. It is recommended to the

The equipment must be earthed.

Observe all national and international regulations.

Tarpaulins may not be handled where an explosive atmosphere may be present.

Use only original spare parts.

During remote controlled operation no person must enter a danger zone.

the operating manual is available to all involved personnel

Place all tong equipment on the rig floor.

Connect the two lift cylinder hoses to the tong valve.

Place all tong equipment on the rig floor.

Remove the three support legs.

Start the hydraulic power unit.