7.6 Single

OPERATING MANUAL
Hydraulic Tubing Tong
Model
TT 7.6 - 15/30
Issue/Rev. Date: August 2005 ALL EARLIER REVISIONS OBSOLETE
This Operating Manual is valid for the following serial numbers:
Tubing Tong 7.6 Serial Numbers (WL 7-): Free-Floating Backup 7.6 Serial Numbers (7-):
215 - 218 248 - 266 331 - 343 412 - 420 110 - 115 140 - 141 169, 171 230 - 242 319 - 320
220 - 229 268 - 287 345 - 349 423 - 445 117 - 124 143 173 - 186 244 - 265 324 - 329
231 - 233 291 352 - 368 450 - 456 126 - 128 145 - 146 190 271 - 296 331 - 334
235 - 238 295 - 315 374 - 402 467 - 494 130 - 132 148 - 151 195 - 214 299, 301 340 - 359
241 - 244 317- 319 405, 407 135 153 - 157 216 - 218 304 - 305 370 - 380
246 321 - 328 409 - 410 137 - 138 161 - 167 220 - 227 308 - 316 382 - 394
Keep this manual for future reference!
Publisher: Weatherford Oil Tool GmbH
Hainhäuser Weg 150
D -30855 Langenhagen
+49 (0) 5 11 - 77 02 - 0
FAX +49 (0) 5 11 - 77 02 - 187

WEATHERFORD OPERATING MANUAL
TERMS AND CONDITIONS OF USE
A. The materials contained in this Weatherford Operating Manual are protected by copyright,
trademark and other forms of proprietary rights. Nothing contained herein shall be con-
strued as conferring any license or right to use or practice any copyright, trademark, patent
or other forms of proprietary rights. This Operating Manual may not be copied or converted
to any mechanical, electronic or machine-readable form, in whole or in part, without
Model TT 7.6 - 15/30
Weatherford’s consent.
B. This Operating Manual is not intended to address every issue that may arise in the course
of operations of the device described therein or the planning of same. Each well and each
job are unique and have numerous variables. Experience and other specialized training can
complement the materials used in this Operating Manual.
C. Weatherford makes no representation as to the accuracy or completeness of the materials

in this Operating Manual. All materials are provided “AS IS” WITHOUT WARRANTY OF
ANY KIND WHATSOEVER, EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIM-
ITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PAR-
TICULAR PURPOSE OR NON-INFRINGEMENT. Weatherford expressly disclaims all re-
sponsibility for the consequences, direct, indirect, consequential or otherwise, of any errors
or omissions in the materials.
D. This information is confidential and proprietary property of Weatherford. Do not disclose to

unauthorized parties. Do not use except as permitted by Weatherford. Copyright 2005
Weatherford. All rights reserved.
Tong Part- TT 7.6 – 15 TT 7.6 - 30

No.: Lift Cyl-
Commercial Commercial Dinamic A-Q-TORK & FFBU 7.6
inder
Single Motor Tandem Motor Motor Danfoss Motor
911 0101 X - - - - -
911 0115 X - - - X X
911 0154 - X - - - X
911 0170 - X - - X X
911 0172 - - - X X X
911 0175 - - X - X X
X = available / - = not available
August 2005 BW
SUMMARY OF CONTENTS
Contents Page
Preface
1 Safety
1.1 Risks involved when operating the hydraulic 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 Signs .......................................................... 1-6
1.7.2 Safety Layout ..................................................................... 1-7
1.8 Qualification of Personnel .......................................................... 1-8
1.9 Protective Clothing ..................................................................... 1-8
Model TT 7.6 - 15/30

1.10 Safety Measures for Installation ................................................ 1-9
1.11 Protective Devices ............................................................................ 1-11
2 Transportation and Installation
2.1 Transportation Devices .............................................................. 2-2
2.1.1 Hanging the Tong .............................................................. 2-3
2.2 Installation of the hydraulic Tubing Tong ................................... 2-4
2.2.1 Installation Procedure ........................................................ 2-4
2.2.2 Hydraulic Supply ................................................................ 2-5
2.2.3 Backup Line Installation ..................................................... 2-8
2.2.4 Installation Summary ......................................................... 2-9
2.3 Jaw Installation ..........................................................................2-11
2.3.1 Jaw Assembly Types ......................................................... 2-11
2.3.2 Tong Jaws .......................................................................... 2-19
2.3.3 Backup Jaws ...................................................................... 2-23
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, Tong Speed Control System ............................. 3-11
SUMMARY OF CONTENTS
Contents Page
3.5 Technical Data .......................................................................... 3-13

3.5.1 Technical Specification ...................................................... 3-13
3.5.2 Technical Details ............................................................... 3-15
3.5.3 Hydraulic Oil Specification ................................................. 3-15
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 Tong Versions ........................... 4-4
4.3 Pre-operating Adjustments ........................................................ 4-5
4.3.1 General hydraulic Adjustments ......................................... 4-5
Model TT 7.6 - 15/30
4.3.2 Specific hydraulic Adjustments .......................................... 4-6

4.4 Sequence of Operation ............................................................. 4-8
4.4.1 Preparation......................................................................... 4-8
4.4.2 Makeup Operation ............................................................. 4-11
4.4.3 Breakout 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
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 ................................................ 6-7
6.3.6 No Moog IS Dump Valve Operation .................................. 6-8
SUMMARY OF CONTENTS
Contents Page
7 Service and Maintenance

7.1 Daily Inspection ......................................................................... 7-2
7.2 Monthly Maintenance ................................................................. 7-2
7.3 Cleaning ..................................................................................... 7-3
7.4 Recommended Lubricants ......................................................... 7-4
7.5 Points of Lubrication .................................................................. 7-5
7.5.1 Rotary Drag Brake Band .................................................... 7-7
7.5.2 Oil Change of the Gearshift Box ........................................ 7-8
7.6 Hydraulic Piping ......................................................................... 7-9
7.7 Hydraulic Adjustments ............................................................... 7-9
7.7.1 Servicing the Moog IS Dump Valve ................................... 7-10
7.8 Jaw Die or Insert Exchanging ....................................................7-18
7.8.1 Standard Jaws ................................................................... 7-18
Model TT 7.6 - 15/30

7.8.2 Micro-Grip and Diamond Grip Jaws ................................... 7-19
7.9 Pre-operation Test .....................................................................7-20
7.9.1 Shifting Locator Pin Adjustment ......................................... 7-20
7.9.2 Torque-Up Test .................................................................. 7-21
7.10 Torque Measuring System .........................................................7-22
7.11 Maintenance Plan and Intervals ................................................7-25
8 Appendix
SUMMARY OF CONTENTS
NOTES
Model TT 7.6 - 15/30
PREFACE
PREFACE
With your new WEATHERFORD "Hydraulic Tubing Tong - Model TT 7.6 - 15/30" you have pur-
chased a piece of equipment leading the field in performance and dependability.
This operating manual applies to the WEATHERFORD "Hydraulic Tubing Tong - Model TT 7.6 -
15/30". 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 7.6 - 15/30".
In the interest of continued development WEATHERFORD reserve the right to incorporate modifi-
Model TT 7.6 - 15/30

cations 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 7.6 - 15/30". The illustrations used in this manual are for explanation pur-
poses only and did not show always the actual state of your machine. For the exact scope of deliv-
ery see your purchasing contract.
All persons involved in operation or maintenance of this device must read and understand this op-
erating manual thoroughly before starting operation. The contents of this manual have to be com-
plied 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 7.6 - 15/30", 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.
NOTES
PREFACE
Model TT 7.6 - 15/30
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 …
Model TT 7.6 - 15/30

… be qualified according to the requirements and authorized by the operating authority.
… follow this operating manual thoroughly. It is recommended to the operating authority, that
all persons having read the operating manual confirm the knowledge with their signature.
Safety is not a PROBLEM … it's the ANSWER!
Remember: If you are not part of the SOLUTION,

you are part of the PROBLEM!
Operating Manual Rev. August 2005 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.
Model TT 7.6 - 15/30
1.3 DESIGNATED USE
The WEATHERFORD 'Hydraulic Tubing Tong Model 7.6 - 15/30' is designed exclusively for
making up and breaking out joints of tubing ranging from 2-3/8 to 7 5/8-inch in diameter. Tong
Model TT 7.6 - 15 is capable to generating torque up to 15 000 ft-lb in either makeup or breakout
mode and Tong Model TT 7.6 – 30 is capable to generating torque up to 30 000 ft-lb in either
makeup or breakout 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 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!
Operating the machine outside the limits of its designated use or with unau-
thorized conversions can lead to death, severe injury and/or material dam-
age.
Page 1-2 of 12 Rev. August 2005 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-
Model TT 7.6 - 15/30

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 7.6 - 15/30 is a powerful hydro-mechanical tool. Insufficient or
improper maintenance of the hydraulic system can result in damages or malfunctions of the Tubing
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.

Model TT 7.6 - 15/30
Prior to service, maintenance, repair or conversion work, the sources of hydraulic and elec-
tric power must be disabled and disconnected from the tong. Even if the unit is de-energized,
the hydraulic system may remains under pressure. Depressurize the system before any ser-
vice and maintenance work in these areas.
NEVER make any modifications, additions, or conversions without the manufacturer’s written
approval. In particular, no welding or torch cutting of pressure-containing components is al-
lowed. This also applies to the installation and adjustment of safety devices. For safety rea-
sons, unauthorized conversions to the unit are expressly forbidden.
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 designated green handles only.
All other personnel must stay clear of the working range of the tong.
Failure to observe this safety precaution can cause severe injury or death.
Model TT 7.6 - 15/30
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 the danger zone.
Only objects, which are essential to the operation of the unit are allowed to be placed inside
the danger zone.
Model TT 7.6 - 15/30
1.7.1 Used Warning Signs
The following warning signs are used on the Hydraulic Tubing Tong Model 7.6 - 15/30:
Warning Sign No.: 1
Warning Sign No.: 2

(Part no.: 541 3901)
Fig. 1.2 Warning Signs on the Tong

SAFETY
1.7.2 Safety Layout
Danger zone = Tong and backup rotating and clamping movements
Model TT 7.6 - 15/30

2
1
Fig. 1.3 Safety Layout of the Tong
R = Number 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 tong. The individual responsibilities
of the personnel who operate, set-up, maintain and repair this tool must be stated clearly. Remem-
ber, 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.
Model TT 7.6 - 15/30
1.9 PROTECTIVE CLOTHING

The protective clothing required for using the Hydraulic Tubing Tong Model 7.6 - 15/30 is the same
as those typically used on drilling rigs:
Hardhat to protect the head against falling parts and overhead equipment.
Eye protection glasses must be worn to protect against flying particles.
Safety boots to protect against erroneous rest of the equipment.
Safety gloves to protect the hands against aggressive grease, lubricants and mud.

SAFETY
1.10 SAFETY MEASURES FOR INSTALLATION
The Hydraulic Tubing Tong Model 7.6 - 15/30 must hang from a WEATHERFORD Lift Cylin-
der during operation (see Fig. 1.4).
Model TT 7.6 - 15/30

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 repairs,
replacement of components or expiration of warranty claims.
The unit must only be used if it has been set up in accordance with regulations and in con-
formity with the manual.

SAFETY
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 may remains under pressure. Before starting
such work depressurize the system 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 4 500 kg.
The weight of the tong with backup is approx. 1 500 kg. For safety reasons
the lifting capacity is multiplied by a safety factor of 3.
A lower safety margin is up to the responsibility of the operating authority.
Ensure that no other rig equipment is rested in the operating area of the tong.
Model TT 7.6 - 15/30

SAFETY
1.11 PROTECTIVE DEVICES
The tong is equipped with a Safety Interlock System on the tong door. Opening the tong
door blocks the tong motor function immediately. Thus the Safety Interlock System prevents
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 a defective safety interlock
function.
This disabling function does not apply to any positioning device attached to
the tong (e.g. PowerScope or PowerMaster).
Model TT 7.6 - 15/30
Fig. 1.5 Safety Interlock System on the Tong Door
The door is equipped with a safety catch to prevent clamping of fingers while opening the
door.

SAFETY
During makeup or breakout operation, the clamping pressure of the backup is always moni-
tored by a pressure control valve (see Fig. 1.6 current version or Fig. 1.7 previous version). 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 Section 6 for troubleshooting).
Model TT 7.6 - 15/30
Fig. 1.6 Pressure Control Valve (current version)
Fig. 1.7 Pressure Control Valve (previous version)

TRANSPORTATION AND INSTALLATION
2 TRANSPORTATION AND INSTALLATION

The Weatherford Hydraulic Tubing Tong Model TT 7.6 - 15/30 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 4 500 kg.
Ensure that all lifting equipment is in proper condition.
Model TT 7.6 - 15/30

During lifting and transportation obey local regulations.

2.1 TRANSPORTATION DEVICES

For transportation and lifting, the housing of the 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 re-
moved.
Model TT 7.6 - 15/30
Fig. 2.1 Transportation Safety Devices

2.1.1 Hanging the Tong
Model TT 7.6 - 15/30

Fig. 2.2 Tong suspended by Lift Cylinder
1 The suspension line for the tong must be at least a 5/8-inch diameter steel cable.
1 Always use the WEATHERFORD lift cylinder for tong suspension (see Fig. 2.2).
1 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.
1 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
1 Place all tong equipment on the rig floor.
1 The Hydraulic Tubing Tong Model TT 7.6 - 15/30 must hang from a WEATHERFORD Lift
Cylinder during operation (refer to Section 2.1.1).
All lifting gear must have a minimum lifting capacity of 4 500 kg.
Ensure that all lifting equipment is in proper working condition.
1 Check the horizontal balance of the tong system while at the well center. For proper opera-
tion the tong must be as horizontal as possible when gripping the tubing. The balance can
be readjusted with two adjustment screws at each side of the base points of the hanger (see
Model TT 7.6 - 15/30
Fig. 2.3).
Fig. 2.3 Horizontal Balancing
1 Make sure the correct jaws are installed (refer to Section 2.3) and the tong door is closed.
1 Loosen the screws and adjust tong position horizontally. Then tighten the screws. Make sure
both screws are in contact with the hanger strut.
1 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
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-inch quick-disconnect coupling, female
• Return Line 1 1/4-inch quick-disconnect coupling, female
• Drain 3/4-inch quick-disconnect coupling, female,

only ‘DINAMIC / Piston’ motor version
• Lift Cylinder Up/Makeup Thread Compensation 1/2-inch quick-disconnect coupling, male
• Lift Cylinder Down 1/2-inch quick-disconnect coupling, female
• Backup Grip 1/2-inch quick-disconnect coupling, female
• Backup Release 1/2-inch quick-disconnect coupling, male
Model TT 7.6 - 15/30

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. 7.6 - 15 COMMERCIAL – Hydraulic Motor Version, Standard (single motor)

Max Hydraulic Flow 300 liter / minute 80 gpm
Hydraulic Pressure 175 bar 2 500 PSI
2. 7.6 - 30 COMMERCIAL – Hydraulic Motor Version, High Torque (tandem motor)

3. 7.6 - 30 DINAMIC/PISTON – Hydraulic Motor Version

Model TT 7.6 - 15/30
General Characteristics for the above Motor Versions

Viscosity / 40° C ISO – 32
Operating Oil Temperature 20 – 70° C 68 – 158° F
External Filtration on the
20 µm; SAE class 5 (17/14 – ISO 4406)
Power Unit
4. 7.6 - 30 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 on 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, Shel 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.
1 Connect the two lift cylinder hoses to the tong valve.

1 Connect the two backup hoses to the tong valve (only if backup is used otherwise install the
backup line according to Section 2.3).
1 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.
1 Start the hydraulic power unit. The tong is now ready for operation.
Model TT 7.6 - 15/30

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

torque cylinder. Tong arm length is 36 in. / 914 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.
Model TT 7.6 - 15/30
Fig. 2.5 Backup Line
1 Use a steel cable of at least 5/8" diameter as backup line (see Fig. 2.5).
1 Connect backup line to a torque gauge to restrain tong rotation and to provide torque read-
ings for operation (tong arm length = 36-inch / 914mm).
1 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.
1 Secure the other end of the backup line to a solid part of the rig structure at a 90° angle with
the tong centerline (see Fig. 2.5). Deviation from the 90° angle introduces torque measure-
ment errors.
1 Fig. 2.5 shows backup line configuration for makeup. For breakout, 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 makeup.

2.2.4 Installation Summary
If you need support or additional information, please contact the Weatherford technical department.
For subsequent installation, proceed as follows:
1 Place all tong equipment on the rig floor.
1 Fix the lifting equipment to the lifting points of the tong for installation (see Section 2.1).
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.
Model TT 7.6 - 15/30

1 Fix the tong with the backup (if backup is used) to the lift cylinder (see Section 1.9).
1 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.
1 Connect the main hydraulic hoses from power unit to the power tong (see Section 2.2.2).
1 Connect the lift cylinder hoses to the tong valve (see Section 2.2.2).
1 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.

1 Loosen the nut at the torque post on each side of the backup (if backup is used).
1 Check the horizontal balance of the tong system at the well center. If necessary, adjust the
position according to Section 2.2.1.
1 Remove the three support legs.

Model TT 7.6 - 15/30
1 Make sure valve handles are in neutral position. Start the hydraulic power unit.
1 The 7.6 – 15/30 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.
2.3.1 Jaw Assembly Types
Model TT 7.6 - 15/30

Three 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.
Combination possibilities of these clamping elements are listed in table 2.2. This type of jaws
eliminates 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.
• Diamond Grip Jaws offers ultra-fine non-marking grip technology with diamond-coated jaw
surfaces. Combination possibilities of these clamping elements are listed in table 2.3.
The installation procedure is described in Section 2.3.2 (for tong installation) and Section 2.3.3 (for
backup installation).

2.3.1.1 Standard Jaws
The jaws of some particular sizes can be used in the tong as well in the backup (take care of the
caution notes). Attention must be paid for the right and left side markings (e.g. 4“ R = right side, 4-
inch 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. Standard jaw sizes avail-
able are listed in Table 2.1.
Model TT 7.6 - 15/30
Fig. 2.6 Standard Jaw with Die and Spring Straight Pin

Table 2.1 Standard Jaw Parts List

Pipe Size
Item 1 Description Qty. * Part No.
(inch)
JAW SET ASSEMBLY 2-3/8" (incl. items 1 – 3) 1 521 0121
1 PAIR OF JAWS (LEFT AND RIGHT JAW) 1 521 0800
2-3/8
2 DIE 3/8-INCH STANDARD 6 541 0180
3 SPRING STRAIGHT PIN 6 521 0156
2-7/8
3-1/2
4-0/0
Model TT 7.6 - 15/30

4-1/2
5-0/0
5-1/2
JAW SET ASSEMBLY 6.05" (incl. items 1 – 3) 1 521 0134
6.05
6-5/8
7-0/0
7-5/8
1
refer to Fig. 2.6 / * Quantity per Jaw Set Assembly.
When using the 2-3/8 or 2-7/8 Jaw Set ALWAYS install three chucking wedges Mark II
(Part No.: 521 0897, marked by 2 holes) inside the rotor (refer to Section 8.2.6, items
44).
DO NOT use the 7-5/8 or 6.05 Standard Jaw in the tong; it is for backup use only.

Table 2.1.1 Jaw Parts List (Special Sizes)
Coupling
Item 1 Description Qty. * Part No.
Size (inch)
1.9
2.162
3.063
Model TT 7.6 - 15/30
JAW SET ASSEMBLY 3.668” (incl. items 1 – 3) 1 521 0128

3.668
3-3/4
JAW SET ASSEMBLY 4-3/4“ (incl. items 1 – 3) 1 521 0141
4-3/4
5.2
1
refer to Fig. 2.6
* Quantity per Jaw Set Assembly.
Tong and Backup Jaw Sets are identical and must be exchanged simulta-
neously depending on the pipe / tool joint diameter to be gripped.
Exception: DO NOT use the 2.162, 3.063, 3.668 or 5.2 Special Jaw in the
tong, it is for backup/coupling use only!

2.3.1.2 Micro-Grip Jaws
caution notes). Attention must be paid for the right / left side markings (e.g. L 4-1/2“ = for left side
and 4 1/2-inch pipe diameter). Sides are determined by looking at the tong/backup from the front
opening. DO NOT mix up right and left side as well as diameters.
Jaw size requirements vary according to the size of pipe to be gripped. Micro-Grip jaw sizes avail-
able are listed in Table 2.2.
Model TT 7.6 - 15/30

Fig. 2.7 3-1/2 to 6 5/8-inch Micro-Grip Jaw Set
Fig. 2.8 7 to 7 5/8-inch Micro-Grip Jaw Set

Table 2.2 Micro-Grip Jaw Parts List, Standard Sizes
Pipe Size
Item Description Qty. Part No.
(inch)
MICRO-GRIP JAW SET ASSEMBLY 3-1/2" (incl. items 1 – 4) 1 521 1905
1 MICRO-GRIP JAW SET (same as NON-MARKING JAW SET) 1 521 1455
3-1/2 1 2 MICRO-GRIP INSERT 2 541 1855
3 LOCK RING SET (= 2 pcs) 2 521 1255
4 CAP SCREW 16 541 0520
1
4-0/0 2 MICRO-GRIP INSERT 2 541 1856
3 LOCK RING SET (= 2 pcs) 2 541 1256
4 CAP SCREW 16 541 0520
3 LOCK RING SET (= 2 pcs) 2 541 1557
4 CAP SCREW 16 541 0520
Model TT 7.6 - 15/30

3 LOCK RING SET (= 2 pcs) 2 521 1558
4 CAP SCREW 24 541 0520
3 LOCK RING SET (= 2 pcs) 2 521 1559
4 CAP SCREW 24 541 0520
MICRO-GRIP JAW SET ASSEMBLY 6.05" (incl. items 1 – 4) 1 521 1913
6.05 1 2 MICRO-GRIP INSERT 2 521 1863
3 LOCK RING SET (= 2 pcs) 2 521 1263
4 CAP SCREW 16 541 0520
3 LOCK RING SET (= 2 pcs) 2 521 1260
4 CAP SCREW 16 541 0520
2 MICRO-GRIP INSERT 2 521 1861
7-0/0 2
3 LOCK RING SET (= 2 pcs) 2 521 1261
4 CAP SCREW 16 541 0520
5 JAW PIN 2 521 1471
2 2 MICRO-GRIP INSERT 2 521 1861
7-5/8
3 LOCK RING SET (= 2 pcs) 2 521 1262
4 CAP SCREW 16 541 0520
5 JAW PIN 2 521 1471
1 2
Quantity shown per Micro-Grip Jaw Set Assembly (left and right Jaw) / refer to Fig. 2.7 / refer to Fig. 2.8
DO NOT use the 7-5/8 or 6.05 Micro-Grip Jaw in the tong; it is for backup use
only. Take care of the further information in Sections 8.1.1.2 and 8.1.1.2.1.

2.3.1.3 Diamond Grip Jaws
caution notes). Attention must be paid for the right / left side markings (e.g. 5-0/0 L = for left side
and 5 0/0-inch pipe diameter). Sides are determined by looking at the tong/backup from the front
opening. DO NOT mix up right and left side as well as diameters.
Jaw size requirements vary according to the size of pipe to be gripped. Diamond Grip jaw sizes
available are listed in Table 2.3.
Model TT 7.6 - 15/30

Fig. 2.9 5-0/0 and 5 1/2-inch Diamond Grip Jaw Set
Fig. 2.10 7 0/0-inch Diamond Grip Jaw Set Fig. 2.11 7 5/8-inch Diamond Grip Jaw Set

Table 2.3 Diamond Grip Jaw Parts List
Pipe Size
Item Description Qty. * Part No.
(inch)
DIAMOND GRIP JAW SET ASSEMBLY 5-0/0" (incl. items 1 – 10) 1 521 2910
1 DG JAW SET 5-0/0 1 521 2920
2 LOCKING RING DG 5-0/0 4 521 2930
3 CLAMPING RING DG 5-0/0 2 521 2940
4 RUBBING STRAKE DG 5-0/0 2 521 2950
5-0/0 1 5 CLAMP, MESH, DG 5-0/0 2 521 2960
6 CAP SCREW, ISO 4762 - M8 X 20 20 521 0199
7 CAP SCREW, ISO 4762 - M6 X 16 8 541 0213
8 SPRING, COMPRESSION, VD-151 4 521 2970
9 SLOTTED PAN HEAD SCREW, DIN 923 - M6 X 12 4 521 2971
10 DG INSERT 5-0/0 8 522 2510
1 DG JAW SET 5-1/2 1 521 2921
2 LOCKING RING DG 5-1/2 4 522 4671
5-1/2 1
Model TT 7.6 - 15/30
5 CLAMP, MESH, DG 5-1/2 2 521 2961

6 CAP SCREW, ISO 4762 - M8 X 20 20 521 0199
7 CAP SCREW, ISO 4762 - M6 X 16 8 541 0213
10 DG INSERT 5-1/2 8 522 2511
1 DG JAW SET 7-0/0 1 521 2923
2 LOCKING RING DG 7-0/0 4 521 2933
5 CLAMP, MESH, DG 7-0/0 2 521 2963
6 CAP SCREW, ISO 4762 - M8 X 20 20 521 0199
7-0/0 2
7 CAP SCREW, ISO 4762 - M6 X 16 8 541 0213
10 DG INSERT 7-0/0 8 521 2983
11 JAW PIN, LONG 2 521 1471
12 STOP 1 521 0157
13 HEX. SCREW W/HOLE, ISO 4017 - M10 X 20 2 519 1088
1 DG JAW SET 7-5/8 1 521 2924
2 LOCKING RING DG 7-5/8 4 521 2934
7-5/8 3 4 RUBBING STRAKE DG 7-5/8 4 521 2954
6 CAP SCREW, ISO 4762 - M8 X 20 25 521 0199
7 CAP SCREW, ISO 4762 - M6 X 16 20 541 0213
10 DG INSERT 7-5/8 8 522 2574
11 JAW PIN, LONG 2 521 1471
Mesh - MESH, FOR ALL DG JAW ASSEMBLY SIZES 2 521 1749
* Quantity shown per Diamond Grip Jaw Set Assembly (left and right Jaw)
1
refer to Fig. 2.9 / 2 refer to Fig. 2.10 / 3 refer to Fig. 2.11
DO NOT use the 7-5/8 Diamond Grip Jaw in the tong; it is for backup use only.
Take care of the further information in Section 8.1.1.4.

2.3.2 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), table 2.2 (Micro-Grip Jaws) and table 2.3 (Diamond Grip
Jaws).
1 Turn tong to the starting position that means the opening of the tong body has to correspond
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. 2.12.
Model TT 7.6 - 15/30

Fig. 2.12 Parts Identification
1 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
removal!
1 Remove the cotter pin from the lower end of the jaw pin.
1 Pull the jaw pin and remove the jaw. Lubricate the jaw pin with a thin oil film.
1 Insert the new jaw set depending on the pipe size to be gripped. DO NOT mix up different
jaw sizes, different jaw types (standard, Micro-Grip or Diamond Grip) or the left and right jaw
assignment.

For 7 0/0-inch Diamond Grip Jaw Assembly only!

When installing the 7 0/0-inch Diamond Grip Jaw Assembly to the tong, install
the stop bracket delivered with the assembly first (see figure below). Secure it
with two screws (top and bottom side) to the tong housing.
Top Fixing Screw
Stop Bracket
Bottom Fixing Screw

Model TT 7.6 - 15/30
Fig. 2.13 Stop Bracket (when using 7 0/0-inch Diamond Grip Jaws in the Tong)
Note: If Micro-Grip or Diamond Grip jaw assemblies with included jaw pins (for pipe sizes
equal or bigger than 7-inch) are used, take care that they are vertical centered and use only
the specific jaw pins delivered with the assembly (see Fig. 2.14).
Jaw Pin
Diamond Grip Jaw, left Side
Cotter Linch Pin
Fig. 2.14 Vertical Alignment of Micro-Grip or Diamond Grip Jaws in the Tong; Front View
DO NOT use 7-5/8 or 6.05-inch Micro-Grip jaw or …

7-5/8-inch Diamond Grip jaw
in the tong; it is for backup use only.

1 Press the jaw spring behind the jaw pin and fully insert the jaw pin.
Jaw Pin
Jaw Spring
Standard Jaw, right Side
Fig. 2.15 Installation of a Standard Tong Jaw
Model TT 7.6 - 15/30

1 Secure the jaw pin with the cotter pin.
1 Repeat the abovementioned steps with the jaw set on the opposite side.
1 Check that the jaws are turned towards the body opening to ensure a good integration of the
pipe.
Fig. 2.16 Jaws turned towards the Body Opening

For 5-0/0 to 7 0/0-inch Diamond Grip Jaw Assemblies only!

To increase the lifetime of the Diamond Grip Inserts and the force transmis-
sion to the pipe, a mesh must be installed in front of each jaw.
Proceed as follows:
Mesh Clamp
Mesh
Diamond Grip Jaw, right

Side
Model TT 7.6 - 15/30
Fig. 2.17 Mesh and Mesh Clamp (when using Diamond Grip Jaws)
1 Push down the mesh clamp at the rear side and insert a mesh into the opened slot.
1 Release the mesh clamp and stripe the mesh onto the jaw surface.
Mesh Clamp
Mesh
Diamond Grip Jaw, right

Side
Fig. 2.18 Mesh in Front of the Diamond Grip Jaw
1 Repeat these steps with another mesh on the opposite jaw.
Meshes are wear parts and should be changed regularly.

Take care to have enough spares in the stock (part no. 521 1749).

2.3.3 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), table 2.2 (Micro-Grip Jaws) and table 2.3
(Diamond Grip Jaws).
1 Ensure that the clamping cylinders of the backup are retracted.
1 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 re-
moval!
1 Remove the cotter pin from the lower end of the jaw pin. Pull out the jaw pin and remove the
jaw. Lubricate the jaw pin with a thin oil film.
Model TT 7.6 - 15/30

1 Insert the new jaw set depending on the pipe size to be gripped. DO NOT mix up different
jaw sizes, different jaw types (standard, Micro-Grip or Diamond Grip) or the left and right jaw
assignment.
1 Insert the jaw pin and secure the jaw pin with the cotter pin.
Jaw Pin
Standard Jaw
Jaw Spring
Cotter Linch Pin
Fig. 2.19 Installation of Backup Jaws
1 If Micro-Grip and Diamond Grip jaws for a diameter ≥ 7-inch are used, take care that they
are vertical centered and use only the specific jaw pins delivered with the assembly (Note:
When installing 7 0/0-inch Diamond Grip Jaws into the backup, no stop bracket is needed).
1 Micro-Grip and Diamond Grip jaws need to set the backup into the lower position (refer to
Section 4.4.1.2).

1 Clamp the jaw spring behind the jaw that the jaw is turned towards the body opening to en-
sure a good integration of the pipe.
Jaw Pin
Jaw Spring
Standard Jaw
Model TT 7.6 - 15/30
Fig. 2.20 Installation of the Jaw Spring
Fig. 2.21 Part Numbers Jaw Springs
1 Repeat the abovementioned steps with the other jaw set.

GENERAL DESCRIPTION
3 GENERAL DESCRIPTION
3.1 POWER TONG
The Weatherford Hydraulic Tubing Tong Model TT 7.6 - 15/30 is a hydraulic motor-driven tong ca-
pable of running tubing from 2 3/8 to 7 5/8 inch in diameter. The tong TT 7.6 – 15 can produce up
to 15 000 ft-lb in low gear, forward or reverse operation and the tong TT 7.6 – 30 can produce up to
30 000 ft-lb in low gear, forward or reverse operation. Optional the 7.6 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 developed
during make-up and breakout operations. The case body and rollers provide axial and radial sup-
port for the rotary, which guides the cage plates through bronze slides around the circumference
instead of using common cam followers.
Model TT 7.6 - 15/30

The system is driven by a hydraulic motor located on the tong casing. Four different hydraulic mo-
tor versions are available on request:
Motor Version Description

Commercial Standard Single Gear Wheel Motor for tong 7.6 – 15
Commercial High-Torque Tandem Gear Wheel Motor for tong 7.6 – 30
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 vertical
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 elimi-
nates shear and bending loads across the tool joint, thereby subjecting the joint only to torsion
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 cylinder
(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.

GENERAL DESCRIPTION
3.2 DESCRIPTION OF THE MAIN COMPONENTS

Model TT 7.6 - 15/30
Fig. 3.1 TT 7.6 – 15/30 Tubing Tong, Front View (shown without backup)
Fig. 3.2 TT 7.6 – 15/30 Tubing Tong, Side View, Right (shown with Commercial motor)

GENERAL DESCRIPTION
Item Parts Description Explanation
1 Hydraulic Motor with Powerful main hydraulic motor with gear to drive the rotor clockwise or
Gear counterclockwise in two different speeds. Motor version depending on
costumer request.
2 Tong Case Body Houses the rotary gear and guides the rotor with its mechanical
clamping system.
3 Load Cell with Optional application if used with backup, not included if used with A-
Compression Link Q-TORK System or without backup. Tension type load cell to measure
the torque reaction between the tong and the backup during makeup
(if the load cell is mounted on the right side) or during breakout (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 (36-inch with and without 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.
Model TT 7.6 - 15/30

5 Manual Valve Arrangement depends on used motor version. All functions can be
Handles executed by using this manual handles at the valve block.
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 handgrips for easy positioning of the
tong while hanging. Do not grip elsewhere.
8 Door Snap-On Door snap-on with two spring assemblies for secure door closing and
locking during operation.
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 makeup and breakout operation.
12 Lift Cylinder Optional lift cylinder assembly for raising and lowering of the tong. If
the tong is ordered with lift cylinder, the tong contains an additional
manual valve handle for controlling the lift cylinder.

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. Four different motor versions are available on request. The heart of the tong is a jaw-
closing system, which moves the jaws towards 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 gearbox located under the hy-
draulic motor. The gear drive incorporates high and low gear. It can be shifted via a handle.
The throttle handle (make / break) controls the throttle valve for the unit. Pushing the handle ap-
plies pressure to drive the motor forward (for makeup operation) and pulling the handle applies
pressure in a reverse direction (for breakout operation). While the handle is in a neutral position,
fluid circulates freely through the valve and back to the return line.
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’
Model TT 7.6 - 15/30
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 consists
of a hydraulic motor mounted on a shiftable two-stage gearbox in a separate housing mounted on
the tong top plate. The hydraulic motor drives a pinion directly through the high (1:1) or low (1:4.3)
ratio of the gearbox. Through a cluster and an intermediate gear the input pinion drives a pair of ro-
tary idlers, which in turn drive the rotary gear.
Shifting from high to low gear ratios is accomplished by lowering the gearshift handle.

GENERAL DESCRIPTION
Model TT 7.6 - 15/30
Fig. 3.3 Gear Train in high and low Gear

GENERAL DESCRIPTION
3.3.3 Tong Jaw System
The Model TT 7.6 - 15/30 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 ex-
tension of the jaw lever carries a cam roller. In this system the hook jaw and the jaw lever are
structurally 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 further
movement possible, this jaw becomes the reactive jaw. A slight additional rotation cams the sec-
ond jaw (power jaw) into engagement with the pipe.
Model TT 7.6 - 15/30
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
system 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
1. Rotary Opening
Makeup Breakout
2. Rotary System Rotates - Clamping System Stationary
Model TT 7.6 - 15/30

3. Clamping System in Rotating Position
Fig. 3.4 Tong Jaw System

GENERAL DESCRIPTION
3.3.4 Description of the Pressure Indicators
The standard 7.6 – 15/30 Tubing Tong contains the following pressure gauges:
Model TT 7.6 - 15/30
Fig. 3.5 Pressure Indicators on 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 7.6 – 15/30 tong and is self-
compensating for connection thread travel in make-up direction. An optional load cell (torque cylin-
der) can be fitted between tong and backup and, by selection, can be used to record makeup or
breakout 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
diameters within 2 3/8 to 7 5/8-inch, 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 re-
quirements. A pressure booster increases the pressure set by the control valve (100 bar) by a fac-
tor of four (400 bar) before it reaches the clamping cylinder.
Model TT 7.6 - 15/30

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 makeup or breakout 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 makeup or breakout 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 makeup operation, install the hydraulic load cell on the right side of the tong (as seen from the
Model TT 7.6 - 15/30
tong door) between the torsion bar and torque tube.
If torque measurement is required during breakout 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
angle 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 – Makeup 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
makeup for special requirements to thread or material. This applies e.g. to premium connections
including corrosion resistant alloy (CRA) materials and specialty premium threads. Pipe manufac-
turers are now specifying extremely low makeup speeds and this system will enable us to meet this
requirements. A low torque spin-in feature is provided along with a controlled low speed high
torque makeup capability.
If the Hydraulic Tubing Tong Model TT 7.6 - 15/30 is ordered with this A-Q-TORK System the tong
is fitted with the A-Q-TORK drive module consisting of a Danfoss hydraulic motor, a computerized
connection monitoring / display system, JAM and a pressure relieving dump valve.
Model TT 7.6 - 15/30

Fig. 3.8 Tong with A-Q-TORK System

GENERAL DESCRIPTION
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 breakout operations. Included into the module is an automatic
changeover valve, which is operated simultaneously with the gearshift handle (see Fig. 4.2, lever
V5) to allow the operator to shift from high gear (spin-in) to the low gear (final torque) mode. During
high gear (spin-in) only the max pressure is limited. During low gear (makeup) the A-Q-TORK
mode is activated to provide speed and pressure limitation.
There is an electronic solenoid 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 ex-
ceeds the pre-set parameters or a ‘good signal’ if the information from the connection is between
the min and max preset parameters.
The module provides:

• Sensitive initial spin-in speeds (5 – 25 rpm) at 20 gpm max.
Model TT 7.6 - 15/30
• Final makeup speed (5 – 0.3 rpm) at 20 gpm max.
• Controlled breakout operation
A separate valve section bypasses the flow control block and provides:
• Spin-in speed 40 rpm at 30 gpm max.
• Final makeup 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
8.5.7.1). 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 8.5.5).

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 to +158
°C 0 to +70
7.6 – 15/30 Tubing Tong System Comments

Pipe size range in. 2-3/8 to 7-5/8
mm 60 to 193
Max. make-up/break-out torque 7.6 – 15 ft-lb 15 000
Commercial Single
Nm 20 340
Max. make-up/break-out torque 7.6 - 30 ft-lb 30 000 Commercial Tandem (in
Nm 40 680 low-speed mode only),
Dinamic, Danfoss
Model TT 7.6 - 15/30

Max. rotor speed Commercial rpm
19 / 88 Low gear / high gear
Single motor Upm
Commercial rpm
High-speed mode 20 / 90 Low gear / high gear
Tandem motor Upm
rpm
(refer to Sec. 4.2.1) Low-speed mode 10 / 45 Low gear / high gear
Upm
Dinamic / Piston rpm
Upm
Danfoss rpm
Upm
Tong arm length in. 36
mm 914
Weight approx. lb 2 600
with backup
kg 1 180
Dimensions Length in. 53
with backup
mm 1 346
Width in. 35
with backup
mm 889
Height in. 81
with backup
mm 2 050
7.6 Backup only

Weight lb 992
kg 450
Dimensions Length in. 32.3 / 21.3 with/without support
mm 820 / 540 legs
Width in. 43.9
mm 1 114
Height in. 48
mm 1 220
Max. clamping pressure at backup PSI 5 875
bar 400
Pressure booster on backup 1:4 input / output ratio
Technical specifications are subject to change without prior notice.

GENERAL DESCRIPTION
Model TT 7.6 - 15/30
Fig. 3.9 7.6 – 15/30 Tubing Tong, Dimensions All dimensions in mm [inches]

GENERAL DESCRIPTION
3.5.2 Technical Details
7.6 – 15/30 Tubing Tong System Comments

Jaw Assemblies Available jaw assemblies from 2-3/8 to 7 5/8-inch pipe
diameter. Identical jaw assemblies for tong and backup.
Hydraulic Motor Versions Four hydraulic motor versions available:
• Commercial Standard (single gear wheel motor)
• Commercial High-Torque (tandem gear wheel motor)
• 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
Model TT 7.6 - 15/30

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.
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. 7.6 - 15 COMMERCIAL – Hydraulic Motor Version, Standard (single motor)

2. 7.6 - 30 COMMERCIAL – Hydraulic Motor Version, High Torque (tandem motor)
3. 7.6 - 30 DINAMIC/PISTON – Hydraulic Motor Version
General Characteristics of the above Motor Versions
External Filtration of the
20 µm; SAE class 5 (17/14 – ISO 4406)
Power Unit

GENERAL DESCRIPTION
4. 7.6 - 30 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 on 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, Shel 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
Model TT 7.6 - 15/30
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.
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.
Note that the pressure output (PSI) of the power source is related directly to
the max torque output of the tong.
The power source flow output (GPM) is directly related to the output speed
of the tong.

GENERAL DESCRIPTION
Model TT 7.6 - 15/30
Fig. 3.10 Commercial Standard – Single Tong Motor Performance Diagram

GENERAL DESCRIPTION
Model TT 7.6 - 15/30
Fig. 3.11 Commercial High-Torque – Tandem Tong Motor Performance Diagram

GENERAL DESCRIPTION
Model TT 7.6 - 15/30
Fig. 3.12 Danfoss - Tong Motor Performance Diagram

GENERAL DESCRIPTION
Model TT 7.6 - 15/30
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.
Model TT 7.6 - 15/30

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 malfunctions.
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 explain the functions of the con-
trols, the shown pictorial representation can vary.
4.2.1 Control Handles for Commercial and Dinamic Motor Version

Model TT 7.6 - 15/30
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 this note may result in damage of parts.
Lever Settings Description

Lift cylinder; push lever forward to lower lift cylinder
V 1 – Lift cylinder up – down
or pull lever backward to lift it.
Backup; push lever forward to open backup jaws
V 2 – Backup open – close
or pull lever backward to close them.
Push lever forward for clockwise rotation of rotary
V 3 – Make / Break* (makeup); pull lever backward for counterclock-
Makeup – Breakout
Throttle wise rotation of rotary (breakout). Center position
is neutral.
Selects the speed of the hydraulic drive. Turn han-
dle upward for high gear and downward for low
V 4 – Gear Shift Low – High
gear. Center position is neutral, motor and clutch
shaft turn, but rotary does not rotate.
(only available on tongs with Commercial tandem
One – Two motor)
V 5 – Motor Selector
motor mode Screw out – selects motor mode one (15 000 ft-lb)
Screw in – selects motor mode two (30 000 ft-lb)
* 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)
Model TT 7.6 - 15/30

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 (makeup); pull lever backward for counterclock-
wise rotation of rotary (breakout). Center position
is neutral.
V 4 – A-Q-TORK (makeup); pull lever backward for counterclock-
Makeup – Breakout
Speed Control* wise rotation of rotary (breakout). 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 7.6 –15/30 Tong Versions
The make-break catch assembly allows the tong to bite when operating in the corresponding
mode.
Model TT 7.6 - 15/30
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 breakout operation; push it right for makeup 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.
1 Visually inspect all connections. Check unit for correct clamping elements (see Section 2).
Make sure that shifting lever and throttle handle is in neutral position.
1 Switch on hydraulic power unit.
1 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 / 5800 PSI (shown on
the clamping pressure indicator, see Fig. 4.4) is sufficient for almost all torque and pipe con-
ditions. DO NOT exceed this pressure!
Model TT 7.6 - 15/30

How to set the correct Clamping Pressure
1 Loosen the lock nut at the clamping pressure control valve.
1 Turn the adjustment nut counter-clockwise to its end.
1 Push the valve handle of the backup section (backup clamp). Turn the adjustment nut clock-
wise until the desired clamping pressure is shown on the pressure gauge.
1 Release the valve handle of the backup section and tighten the lock nut.
1 Pull the valve handle until the clamping cylinders (backup jaws are completely retracted;
push the handle and verify the adjustment.
Fig. 4.4 Clamping Pressure Adjustment

OPERATION
4.3.2 Specific Hydraulic Adjustments for A-Q-TORK
1 Visually inspect all connections. Check unit for correct clamping elements (see Section 2).
1 Disconnect the power unit throttle either hydraulically or mechanically. Connect the hydraulic
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 minutes to
reach operation temperature in the hydraulics 86° F / 30° C as minimum. Optimum tempera-
ture is 122° F / 50° C.
How to set the correct spin-in torque
1 Ensure tong is in high gear.

Model TT 7.6 - 15/30
1 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.
1 Remove the tong from the pipe.
How to set the correct make-up torque
1 Change to low gear.
1 Back-out the following valves: make-up torque (item 2, Fig. 4.5) and bypass valve (item 3).
The valves for makeup speed (item 4) and breakout speed (item 5) are pre-set to standard
operation and can be adjusted at the job to an optimum. Ensure that the dump valve connec-
tor 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.
1 Disable the JAM dump valve and adjust the makeup torque valve (item 2) to just above the
required optimum make-up torque.
1 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)
Model TT 7.6 - 15/30

1 Spin-in torque 5 Brakeout final speed
2 Makeup torque 6 Torque selector valve
3 Bypass valve 7 Dump valve
4 Makeup 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 ro-
tary.
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 configura-
tion, 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!
Model TT 7.6 - 15/30
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
1 Make sure the correct clamping elements are installed and that the three support legs are
removed. Shifting lever and throttle handle must be in neutral position.
1 Make sure the hydraulic power unit is adjusted properly and switched on. See power unit
operating manual.
4.4.1.1 Lift Cylinder Setting
1 Set switch to lift cylinder operation.
1 Pull backup/lift cylinder lever back to lift the tong to the top final position.
1 Adjust pressure relief valve of lift cylinder in such a way that the tong just starts to drop slow-
ly. 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 accord-
ing table 2.1 and normal tool joints (with installed bushings (items 2, Section 8.5.1) at the two
torque tubes).
• Lower Backup Position (bigger distance between tong and backup) for Micro-Grip/non-
marking/Diamond Grip jaws and specific tool joints (without bushings (items 2, Section 8.5.1)
at the two torque tubes).
1 Position tong around pipe and close door.
1 Close the backup and clamp it on the pipe. Tong must be unclamped.
Model TT 7.6 - 15/30

1 To increase the distance between tong and backup, lower tong and remove the bushings of
the two torque tubes.
1 To decrease the distance between tong and backup, lower tong and reinstall the bushings of
the two torque tubes.
1 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.

OPERATION
4.4.1.3 Functional Check
1 Position tong around pipe that the tool joint is between tong and backup and close door.
1 Make sure the make/break catch is set to “MAKE”.
1 Move gearshift handle up to select high gear.
1 Push tong lever forward and check that the jaws bite and that the rotary rotates in clockwise
direction at high speed.
1 Return tong lever to neutral position and move gearshift lever down to select low gear.
1 Push tong lever forward and check that the jaws bite and that the rotary rotates in clockwise
direction at low speed.
Model TT 7.6 - 15/30
1 Return tong lever to neutral position.
1 Carefully operate the tong lever to align the rotary gear with cage plate and tong body open-
ing.
1 Shift make/break catch to “BREAK”.
1 Gearshift handle is still in low gear position.
1 Pull tong lever back and check that the jaws bite and that the rotary rotates in counterclock-
wise direction at low speed.
1 Return tong lever to neutral position and move gearshift lever to select high gear.
1 Pull tong lever back and check that the jaws bite and that the rotary rotates in counterclock-
wise direction at high speed.
1 Return tong lever and gearshift handle to neutral position.

OPERATION
4.4.2 Makeup Operation
1 Operate tong lever to rotate tong into starting position. In this process, all openings cover
themselves.
1 Pull the make/break catch to “MAKE”.
1 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, Diamond Grip or non-marking jaws are used it is strongly rec-

ommended 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 im-
mediately.
Model TT 7.6 - 15/30

1 Close the tong door.
1 Move gearshift handle up to select high gear.
1 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.
1 Push tong lever slightly forward until the thread starts to make up.
1 Then push tong lever forward fully to make up the thread until the tong begins to stall.
1 Return tong lever to neutral position and move gearshift lever down to select low gear.
1 Push tong lever forward until you reach the required torque.
1 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.
1 Open door and remove tong from pipe.

OPERATION
4.4.3 Breakout Operation
1 Operate tong lever to rotate tong into starting position. In this process, all openings cover
themselves.
1 Pull the Make/break catch to “BREAK”.
1 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, Diamond Grip or non-marking jaws are used it is strongly rec-

ommended 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 im-
mediately.
Model TT 7.6 - 15/30
1 Close the tong door.
1 Move transmission shift handle down to select low gear.
1 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.
1 Pull tong lever slightly back until the connection has been broken out.
1 Return tong lever to neutral position and move gearshift lever up to select high gear.
1 Then pull tong lever back fully to unscrew the pipe completely.
1 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.
1 Open door and remove tong from pipe.
4.4.4 Changing the Rotating Direction in between
1 Set tong lever to the opposite direction to reverse the rotary movement until the jaws have
disengaged and tong reaches its starting position.
1 Shift the Make/break catch to the desired setting.
1 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-lb.
Adjustable spin-in speed: Speeds from 5 to 45 rpm are attainable.
Accurate endpoint 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 breakout: Prevents galling normally associated with this operation. There is
Model TT 7.6 - 15/30

no high-speed rotation of the connection after the connection has
broken, as there is with the conventional tongs.
Makeup in High Gear
1 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.
Makeup in Low Gear
1 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. Makeup will then proceed at the pre-set final makeup speed
(set with valve item 4, Fig. 4.5) until the JAM system dumps at optimum torque.
Breakout
1 The breakout 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 "makeup/breakout" (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-lb)

Model TT 7.6 - 15/30
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 malfunctions.
After the job, proceed as follows:
When the tong is not needed for operation it must be properly secured.
1 Switch off the hydraulic power unit.
Model TT 7.6 - 15/30

Disconnect lift cylinder hydraulic hoses from the tong.
1 Disconnect main hydraulic hoses from the tong.
1 Make sure to bleed the hoses. Keep the connectors clean.
1 Ensure that tong door is closed.
1 Tighten the nut at the torque post on each side of the Backup (see Fig. 5.1)
1 Remove the lift cylinder from the tong.
1 Fasten lifting equipment to the tong hanger and remove the tong from the rig floor
(see Fig. 2.1).
Ensure that all lifting equipment is in proper condition.
1 Remove tong from the operation area.
1 Clean the tong; see Section 7 'Service and Maintenance'.
1 Visually inspect the complete tong system for damage. Replace or repair broken parts (see
Section 8 'Appendix' for part numbers).

PLACING OUT OF OPERATION
1 Lubricate the tong; see Section 7 'Service and Maintenance'.
1 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.
Model TT 7.6 - 15/30
Fig. 5.1 Rigging down the 7.6 Tong

TROUBLESHOOTING
6 TROUBLESHOOTING
The HydraulicTubing Tong Model TT 7.6 - 15/30 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 HydraulicTubing Tong Model TT 7.6 - 15/30 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 - 77 02 - 0 Technical Department
Fax: + 49 (0) 511 - 77 02 - 187
e-mail: techsupport-germany@eu.weatherford.com
Model TT 7.6 - 15/30

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 mainte-
nance 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:
1 The oil is not changed at the required intervals. Observe maintenance intervals.
1 Oil is contaminated by cuttings and/or grinding fluids.
1 Air leaks within the hydraulic circuit.
1 The wrong hydraulic oil is used. Select the proper oil.
1 Defective packing or seals.
1 The operator(s) have insufficient knowledge about the components of the hydraulic system.
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-
Model TT 7.6 - 15/30
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
Model TT 7.6 - 15/30

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.
Model TT 7.6 - 15/30
(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 backpressure
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
7.5.1.
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.
Model TT 7.6 - 15/30

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 or 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 or 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 backpressure
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 36" (with
or without 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.
Model TT 7.6 - 15/30
Adjust pressure switch, (Allen key, d = 5 mm).

Clean the filter element of the pressure booster
according to Section 7.3.
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 backpressure due to quick-
Model TT 7.6 - 15/30

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 7.7.1) ?
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.?
Model TT 7.6 - 15/30
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 7.7.1). Clean or replace the inlet orifices (see Section 7.7.1).
BEFORE mounting the valve and starting up, always check the filter system and flush the system (see Sec-
tion 7.7.1).
If the valve is still inoperative, return it to the works for repair.

SERVICE AND MAINTENANCE
7 SERVICE AND MAINTENANCE
Qualification of Troubleshooting and Maintenance Personnel.

Only WEATHERFORD trained personnel may carry out troubleshooting, ser-
vice and maintenance tasks.
Other personnel may be unaware of required methods and expertise, possi-
ble leading to dangerous situations.
Cleaning and maintenance intervals are crucial for the operational safety of
the unit and must therefore be strictly adhered to.
Disregarding this caution will cause a potentially hazardous situation, which
can result in personal injury and/or material damage.
We strongly recommend to check all bearings and other wear parts in two-
year intervals independent of the hours operated.
Model TT 7.6 - 15/30

For Tongs older than 15 years consider taking them out of service.
ALWAYS DISABLE the hydraulic power unit BEFORE starting service or

maintenance work!
If it is necessary, to remove protection covers to reach the relevant service

points, always refit these covers BEFORE putting back into operation.
Switch off the unit at all maintenance, adjustment or repair work and secure the main switch
against unintentional activation.
• Switch off main power switch, lock with padlock and mark it with a warning sign.
• Close hydraulic isolation valves (supplied by customer) and secure against opening.
• Secure large components during exchange with a lifting device.
• Check that all loosened screwed connections are retightened again after maintenance or repair
work.
• Check all safety devices after service or maintenance.
• Check the systems functionality (see Section 4.5.1).

7.1 DAILY INSPECTION
1 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.
1 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.
1 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.
Model TT 7.6 - 15/30
7.2 MONTHLY MAINTENANCE

Once each month make the following checks and take appropriate corrective action:
1 Check rotary gear guide rollers for wear or breakage, and replace if necessary.
1 Check jaw rollers for wear or breakage, and replace if necessary.
1 Check shifting operation, shifting shaft nuts and shifting shaft detent operation as described
in Section 7.9.1.
1 Inspect rotary gear.
1 Check oil level in gearbox (refer to Section 7.5.2).
1 Check torque gauge cylinder for low fluid volume. Fluid level is low if 1/2-inch or more of the
cylinder rod is exposed when under tension.
1 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.
1 All exposed surfaces of the tong system should be cleaned with a steam jet or other suitable
cleaning agents after each job.
1 Clean all tong and backup jaw dies with a steel brush after a job is finished or when filthy.
1 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 petroleum
Model TT 7.6 - 15/30

or diesel. (see Fig. 7.1)
Fig. 7.1 Pressure Booster on the Backup Housing

1 Replace oil filter element (only A-Q-TORK Version) when the contamination indicator on the
oil filter housing is visible, (see Fig 7.2).
Model TT 7.6 - 15/30
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

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.
Model TT 7.6 - 15/30

Observe the product-related safety regulations when handling oil and grease
products.
Number of
Item Lubrication Point Method
Lubrication Points
1 Cluster gear shaft bearings nipples 4
2 Pinion shaft bearing nipples 1
Door bearing (from top side and from under-
3 nipples 2
neath)
4 Cylinder, tong door nipples 2
5 Tension lever bearing, left (from top side) nipples 1
Tension lever bearing, right (from top side and
6 nipples 2
from underneath)
7 Cam followers nipples 22
8 Backup torsion bar nipples 2
9 Backup ball pivots nipples 2
10 Backup torque tubes nipples 2
11 Brake band brush 2
12 Pins brush 4
13 Pin, tong support brush 3
14 Gear box, oil change 1.25 liter

Model TT 7.6 - 15/30
Fig. 7.3 Lubrication Points

7.5.1 Rotary Drag Brake Band
The brake bands have to be disassembled for maintenance:
1 Remove the upper and the lower brake band from the rotary housing.
1 Wash the brake bands surfaces with petrol based cleaner.
1 Check brake band for thickness, t min = 11.5 mm (across the entire band)
1 Roughen the surfaces with abrasive paper.
1 Grease the brake bands surfaces with a brush.
1 Fix the brake bands back to the rotary housing. Tighten the adjustment nuts hand-tight.
1 Start the hydraulic power unit and operate the tong without having inserted a pipe.
Push the handle of valve section "Makeup" and check, whether the cage plate stops turning
Model TT 7.6 - 15/30

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 levers starts
clamping from the beginning of rotation on.
1 Keep in mind that the smaller the pipe size the higher the brake effect must be.
Nominal thickness 14 mm
Brake band coating 4 mm
Adjustment nut Limit of wear 11.5 mm
Brake band
Carrier
t
Fig. 7.4 Drag Brake Band

7.5.2 Oil Change of the Gear Shift Box
1 The oil of the gear box has to be changed every 6 month:
1 Remove the upper plug from the gearbox; see Fig. 7.5.
1 Remove the lower plug from the gearbox and catch the oil in a collecting tank.
1 Tighten the lower plug and refill the gearbox with gear oil (SAE 85W-90)
1 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.
Model TT 7.6 - 15/30
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. Only persons having special knowledge and ex-
perience in hydraulic systems may carry out work on hydraulic equipment.
Remove hydraulic pressure before performing any repair work!
Model TT 7.6 - 15/30

7.7 HYDRAULIC ADJUSTMENTS
The hydraulic system of the Model TT 7.6 - 15/30 is pre-adjusted in the factory and checked before
shipment. The maximum working pressure is set to
• 145 bar / 2100 PSI with the Commercial High-Torque Motor (tandem motor) or
• 175 bar / 2500 PSI on all other motor versions.
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 re-
adjustment of these settings.
In case of replacement or repair work it could be necessary to readjust the pressure and flow set-
ting.
A pressure relief valve protects the pressure booster on the backup.

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:
Model TT 7.6 - 15/30
Fig. 7.6 Exploded View – MOOG IS Dump Valve
Needed Tools and Material

5 mm screwdriver 2.5, 3 and 5 mm Allen wrench
3 Nm and 10 Nm torque wrenches 7/16-inch 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.
1 Clean the valve externally. Use clean tools!
1 Disconnect the electrical mating connector.
1 Remove the pan head screw (item 33, Fig. 7.6).
Model TT 7.6 - 15/30

Fig. 7.7 Turning the Adapter on the MOOG IS Dump Valve
1 Using a 3 mm Allen wrench, turn the adapter (item 93, Fig. 7.6) in a clockwise or counter-
clockwise direction to locate null.
1 NORMAL ADJUSTMENT SHOULD REQUIRE LESS THAN ± 1 TURN. (20° corresponds

approximately to 10 % null adjustment).
1 Screw in the pan head screw (item 33, Fig. 7.6).
1 Connect the mating connector.
When adjusting valve null, it must be distinguished between axis cut and
overlapped valve spools.
1 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.

1 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 pres-
sure 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 movements 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 pres-
sure starts to rise in the load ports.
Model TT 7.6 - 15/30

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.
1 Cut off the pressure supply and relieve the accumulator.
1 Clean the valve externally.
1 Disconnect the mating connector and dismount the valve.
1 IMMEDIATELY PROTECT THE VALVE PORTS WITH THE SUPPLIED SHIPPING PLATE
(item 92, Fig. 7.6) AND PROTECT THE CONNECTING FLANGE WITH THE FLUSHING
Model TT 7.6 - 15/30

PLATE or mask with oil-resistant adhesive tape.
1 Clean the valve with clean solvent, containing no acids or residues, and dry it off with
lint-free paper cloth.
1 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 uni-directionally or will be completely in-
operative. In this case, replace the filter element. DO NOT clean it!
1 Remove the four socket head cap screws and lock washers (items 29 and 34, Fig. 7.6).
1 Remove the filter retainer (item 9, Fig. 7.6).
1 Remove the filter disk (item 10, Fig. 7.6, Part No. 5280553).
1 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.
1 Clean the filter bore in the valve body carefully and thoroughly with lint-free paper cloth.
Model TT 7.6 - 15/30
1 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.
1 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).
1 Insert a NEW filter disk (item 10, Fig. 7.6, Part No. 5280553).
1 Fit the filter retainer (item 9, Fig. 7.6).
1 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.
1 Remove the 3 hexagon head screws and the lock washers (items 28 and 35, Fig. 7.6).
1 Remove the end plate, seal plate and 0-ring (item 6, 7 and 49, Fig. 7.6).
Model TT 7.6 - 15/30

Fig. 7.10 Inlet Orifices in the MOOG IS Dump Valve
1 Carefully remove the inlet orifice (item 11, Fig. 7.6) using the extractor tool 66356-002
(thread 4-40 UNC).
1 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.
1 Clean all disassembled parts carefully.
1 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.
1 Fit a new 0-ring (item 51, Fig. 7.6) to the inlet orifice (item 11, Fig. 7.6) and lubricate the
0-ring.
1 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).
1 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.

1 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.
1 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).
1 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 let-
ter of the type code on the nameplate.
I = Internal pilot connection
E = External pilot connection
Model TT 7.6 - 15/30
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:
1 In the case of internal pilot oil supply (I): in 1 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).
1 When changing the pilot connection from internal to external or vice versa, fit the screw plug
into the other threaded bore.
In the case of the version with setscrew, this screw is fitted with Loctite and
must be locked again with Loctite when refitted.

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.
1 Clean the mounting manifold.
1 Remove the flushing plate.
1 Clean the mounting pad with lint-free paper cloth.
1 Remove the shipping plate (item 92, Fig. 7.6) from the valve base.
1 Clean the valve base with lint-free paper cloth.
1 Install new 0-rings (items 47 and 48, Fig. 7.6) if required.
Model TT 7.6 - 15/30

1 Torque the mounting screws uniformly to 10 Nm.

7.8 JAW DIE OR INSERT EXCHANGING
7.8.1 Standard Jaw - Die Exchanging
Inspect jaw dies to ensure that the biting edges are not worn excessively and are capable of biting
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 Jaw Dies
1 Push back the retaining pin.
1 Pull out the worn die and put in a new die.
1 Move retaining pin back to initial position.

Model TT 7.6 - 15/30
1 Repeat with all dies of a jaw set.
Fig. 7.11 Die Replacement at Tong and Backup

7.8.2 Micro-Grip and Diamond Grip Jaws - Insert Exchanging
The jaw inserts can be pushed out after the cap screws of the locking ring are removed. ALWAYS
change dull or worn inserts simultaneously.
Cap Screws
(accessible through holes)
Locking Ring
Jaw Inserts
Model TT 7.6 - 15/30

Jaw complete Locking Ring and upper Insert removed
Fig. 7.12 Insert Exchanging (Example: Diamond Grip Jaw 7 0/0-inch, left Side)
Inspect jaw inserts to ensure that the surface is not worn excessively and is capable of gripping ef-
fectively. If wear of the inserts is excessive, the inserts must be replaced. The inserts cannot be
reworked.
Replacement Procedure for Diamond Grip Inserts
1 Remove all cap screws of the upper locking ring and remove the ring. Note: On Diamond
Grip jaws with mesh clamp the cap screws are accessible through the holes in the mesh
clamp (see Example in Fig. 7.12).
1 Pull out all inserts and put in new inserts.
1 Replace the locking ring in its position and screw in and tighten the cap screws.
1 Repeat this procedure with all inserts of the complete jaw set.

7.9 PRE-OPERATION TEST
7.9.1 Shifting Locator Pin Adjustment
The shifting locator pin that holds the shifting mechanism in the selected speed is adjustable. This
adjustment should be checked at the beginning of each job and at the start of each shift thereafter.
To check operation of shifting locator pin, raise shifting handle to high-speed position and verify
that control snaps into position. Exert force on shifting lever and verify that the lever remains in
high-speed position until considerable force is exerted when it will give way to slide freely to next
position. Repeat this operational check in low-speed and neutral positions.
When an operational check indicates the need to adjust the shifting locator pin, adjust by tightening
the spring plunger body one-half turn. Repeat the locator pin operational check. If additional ad-
justment is indicated, repeat adjustment procedure until proper operation is achieved.
Model TT 7.6 - 15/30
7.9.2 Free Run Test
Test Recommendations
A pre-operation test of the WEATHERFORD Hydraulic Tubing Tong Model TT 7.6 - 15/30 is rec-
ommended subsequent to motor replacement or repair, control valve replacement or repair, and
major parts replacement.
1 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.
1 During these tests, listen for any unusual noises or grinding and watch for any misalignment
or erratic operation.
1 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.
1 Repeat the test procedure with the tong switched to breakout mode.
If a problem is detected during the free run test, correct the problem (see Section 6 “Troubleshoot-
ing”) and repeat the test to ensure that the corrective action was effective.

7.9.3 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.
1 Close tong door and clamp the lower pipe end with the backup.
1 Set „Makeup/Breakout“ to “Makeup”.
1 Set gearshift handle to low-gear position.
1 Slowly push the throttle handle forward to „Makeup”.
1 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
Model TT 7.6 - 15/30

pressure according to the ratios shown in the lower diagrams of Figures 3.10 – 3.13. Ob-
serve only the black graph, which corresponds to low gear.
1 Continue pushing the throttle handle forward until approx. 70% of determined max torque is
reached.
1 Back off the throttle handle, then advance to the 70% max torque. Repeat this step once.
1 Advance the throttle handle and run pipe up to specified makeup torque.
1 Breakout joint and re-run to the required joint torque.

7.10 TORQUE MEASURING SYSTEM

Check the torque measuring system for leakage after each job.
Leakage can be detected …
1 at the piston rod of the hydraulic load cell
1 at the vent hole of the hydraulic load cell
1 at the hose connectors between the load cell and the torque indicator
1 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.
Model TT 7.6 - 15/30
When oil is leaking at the piston rod or vent hole, the load cell has to be disassembled and the pis-
ton o-rings have to be replaced, see Fig. 7.13.
Fig. 7.13 Load Cell

Repairing the Load Cell
Ensure that the torque gauge is pressureless BEFORE disassembling!

Open the vent screw carefully!
1 Remove the lock screw and the hose connector.
1 Disassemble the load cell housing by unscrewing.
1 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.
1 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“
Model TT 7.6 - 15/30

O-Ring: 1.50“ x 1.750“ x 0.125“ (all o-rings are included in the REPAIR KIT)
1 Reassemble the load cell and fix the lock screw and the hose with connector.
1 Check the vent hole with a needle for being open.
Bleeding the Load Cell
1 Fix the load cell in a vice, (vent screw to the top); see Fig. 7.14.
1 Put the torque indicator to a lower level (floor).
1 Attach the hand pump to the check valve at the torque indicator; see Fig 7.15.
1 Open the torque indication stabilizer valve.
1 Pump a couple of strokes until the torque indicator displays approximately 500 ft-lb.
1 Open the vent screw carefully and pump until the fluid streams clearly.
1 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.

Load Cell
Vice
Hose
Torque Indicator
Fig. 7.14 Bleeding the torque measuring system

Model TT 7.6 - 15/30
Torque Indicator
Stabilizer Valve
Check Valve
Hand Pump
Fig. 7.15 Hand pump
Use Martin-Decker W 15 fluid only!

7.11 MAINTENANCE PLAN AND INTERVALS
Cleaning and maintenance intervals are crucial for the operational safety of
the unit and must therefore be adhered to.
Disregarding this caution will cause a potentially hazardous situation, which
can result in personal injury and/or material damage.
We strongly recommend to check all bearings and other wear parts in two-
year intervals independent of the hours operated.
For Tongs older than 15 years consider taking them out of service.
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
Model TT 7.6 - 15/30

3y = inspection or execution every 3 years
o = inspection or execution only after service work


Maintenance Plan List no.: 1
Model TT 7.6 - 15/30
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 inspection after each job
1.2 Check fastenings (mountings) w
Screws tight? 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
Model TT 7.6 - 15/30
d replace, if necessary Visual inspection

covers
1.7 Lubricate according to Section 7.5 a Type of lubricant: see Section 7.4
1.8 Check all bearings and wear parts 2y replace, if necessary Visual inspection
After a lifecycle of 15 years consider taking
the tong out of service. Note: Dispose of
1.9 Taking out of service 15y
the tong by an approved specialist com-
pany. Observe national regulations.
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 Tightness of shaft sealing w
2.7 Oil change according to Section First oil change after 60 operating hours; afterwards
7.5.6 every 500 – 1500 operating hours
2.8 Leak oil d
3 Rotor Drag Brake Band

3.1 Clean brake band surface a
3.2 Check thickness w T min = 11.5 mm Visual inspection
3.3 Grease brake band d Visual inspection


Model TT 7.6 - 15/30
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
Model TT 7.6 - 15/30

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
7.4 Oil change 6m


Model TT 7.6 - 15/30
Execution
(Inspection)
8 Pipes 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)

Model TT 7.6 - 15/30
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 Check function of the units o Visual inspection
9.5 Adjusted values o Visual inspection
9.6 Condition of the oil circulation sys- w
tem
10 Torque Measuring System

1 000 ft-lb (max ± 500
10.1 Check preload pressure d ft-lb) at torque gauge.
Visual inspection

APPENDIX
8 APPENDIX
Contents Page
8.1 Overview – Parts Lists ........................................................................ 8-3
8.1.1 Clamping Elements, Tong and Backup ....................................... 8-6
8.1.1.1 Standard Jaws ....................................................................... 8-6
8.1.1.2 Micro-Grip Jaws ................................................................ 8-10
8.1.1.3 Non-Marking Jaws (obsolete, for reference only) .............. 8-14
8.1.1.4 Diamond Grip Jaws ............................................................ 8-20
8.2 Tong up to Gear Box ........................................................................ 8-22
8.2.1 Body Assembly .......................................................................... 8-24
8.2.2 Cup Pinion Assembly ................................................................ 8-26
8.2.3 Cluster Gear Assembly .............................................................. 8-28
8.2.4 Intermediate Gear Assembly ..................................................... 8-30
8.2.5 Rotary Drive Assembly .............................................................. 8-32
Model TT 7.6 - 15/30

8.2.6 Rotary Gear Assembly .............................................................. 8-34
8.2.7 Gripping System Assembly ....................................................... 8-36
8.2.8 Catch Assembly ........................................................................ 8-38
8.2.9 Brake System Assembly ............................................................ 8-40
8.2.10 Door Assembly .......................................................................... 8-42
8.2.10.1 Door, Snap-On .................................................................. 8-44
8.2.11 Guide Roller Assembly .............................................................. 8-46
8.2.12 Guide Roller, Case .................................................................... 8-48
8.2.13 Guide Roller, Door ..................................................................... 8-50
8.3 Hanger Assembly ............................................................................. 8-52
8.4 Accessories ...................................................................................... 8-54
8.5 Drive Assembly ................................................................................ 8-56
8.6 A-Q-TORK System C12M, IS Dump ................................................ 8-60
8.7 Manifold Plans, Tong ....................................................................... 8-68
8.7.1 Manifold, Standard; Model 7.6-15 .............................................. 8-68
8.7.2 Manifold, High-Torque; Model 7.6-30 ........................................ 8-70
8.7.2.1 A35 4-Way Valve, Tong Section, modified ........................ 8-72
8.7.2.2 Manifold, High-Torque (for Tong 911 0175 only) ............... 8-73
8.7.3 Manifold, Lift Cylinder & Backup on the Tong ............................ 8-74
8.7.3.1 A35 4-Way Valve, Backup Section, modified ..................... 8-76
8.7.3.2 Manifold, Lift Cylinder & Backup on Tong
(for Tong 911 0175 only) .................................................... 8-77
8.7.4 Manifold, Lift Cylinder on the Tong ............................................ 8-78
8.7.5 Hydraulic Safety Interlock .......................................................... 8-80

APPENDIX
Contents Page
8.7.6 Manifold on the Tong (incl. Lift Cylinder, Backup, Interlock and
8-82
High-Torque) .............................................................................
8.7.6.1 Valve Block A35 Assembly ................................................ 8-84
8.7.6.2 Hydraulic Interlock .............................................................
8-86
8.7.6.3 Manifold, Lift Cylinder / Backup ......................................... 8-88
8.7.6.4 Manifold Tong, High-Torque .............................................. 8-90
8.8 Free-Floating Backup ....................................................................... 8-92
8.8.1 Backup, Sheet 1 ....................................................................... 8-92
8.8.2 Backup, Sheet 2 ....................................................................... 8-94
8.8.3 Cylinder .................................................................................... 8-96
8.8.4 Manifold Plan, Free-Floating Backup ........................................ 8-98
8.9 FF-BU Connection Parts ................................................................. 8-100
8.10 Lift Cylinder Assembly .................................................................... 8-100
8.10.1 Lift Cylinder ............................................................................. 8-104
8.11 Safety Marks ................................................................................... 8-106
Model TT 7.6 - 15/30
8.12 Hydraulic Plans ............................................................................... 8-108

8.12.1 Tong with Backup and Lift Cylinder ........................................ 8-108

APPENDIX
8.1 OVERVIEW – PARTS LISTS

Tubing Tong 7.6-15/30 Versions – Tong Part Numbers:
TT 7.6 – 15 TT 7.6 - 30
Parts Lists
Tong Commercial Commercial Dinamic A-Q-TORK & FFBU 7.6 Lift
Overview
Part-No.: Single Motor Tandem Motor Danfoss Motor Cylinder
see table:
Motor
911 0101 X - - - - - 8.1
911 0115 X - - - X X 8.2
911 0154 - X - - - X 8.3
911 0170 - X - - X X 8.4
911 0172 - - - X X X 8.5
911 0175 - - X - X X 8.6
X = available / - = not available
Table 8.1: Tong Part No. 911 0101 – TT 7.6-15 without FF-Backup & Lift Cyl.
Model TT 7.6 - 15/30

Drawing
Item Description Qty.
No.
1 TONG UP TO GEAR BOX (refer to Section 8.2) 1 -
2 HANGER ASSEMBLY, STANDARD (refer to Section 8.3) 1 -
3 ACCESSORIES (refer to Section 8.4) 1 -
4 DRIVE ASSEMBLY (refer to Section 8.5) 1 1.07.0149
5 MANIFOLD, STANDARD (refer to Section 8.7.1) 1 1.09.0671
6 HYDRAULIC SAFETY INTERLOCK (refer to Section 8.7.5) 1 1.09.0620
7 SAFETY MARKS (refer to Section 8.11) 1 1.09.2509
Table 8.2: Tong Part No. 911 0115 – TT 7.6-15 with FF-Backup & Lift Cylinder
Drawing
No.
2 HANGER ASSEMBLY, STANDARD (refer to Section 8.3) 1 -
5 MANIFOLD, STANDARD (refer to Section 8.7.1) 1 1.09.0671
7 FREE-FLOATING BACKUP (refer to Section 8.8) 1 0.09.4900
8 CONNECTION PARTS FFBU (refer to Section 8.9) 1 0.09.4920
9 MANIFOLD, LIFT CYL. & FFBU ON TONG (refer to Section 8.7.3) 1 1.09.4932
10 MANIFOLD, FFBU (refer to Section 8.8.4) 1 1.09.4930
11 MANIFOLD LIFT CYLINDER (refer to Section 8.10) 1 2.09.0669

APPENDIX
Table 8.3: Tong Part No. 911 0154 – TT 7.6-30 without FF-Backup
Drawing
No.
2 HANGER ASSEMBLY, HIGH-TORQUE (refer to Section 8.3) 1 -
5 MANIFOLD, HIGH-TORQUE (refer to Section 8.7.2) 1 1.09.0670
6 MANIFOLD, LIFT CYLINDER ON TONG (refer to Section 8.7.4) 1 1.09.4899
7 MANIFOLD, LIFT CYLINDER (refer to Section 8.10) 1 2.09.0669
Table 8.4: Tong Part No. 911 0170 – TT 7.6-30 with FF-Backup
Drawing
Model TT 7.6 - 15/30

No.
5 MANIFOLD ON TONG, COMPLETE (refer to Section 8.7.6) 1 1.09.2961
Table 8.5: Tong Part No. 911 0172 – TT 7.6-30 with FF-BU & A-Q-TORK
Drawing
No.
4 DRIVE ASSEMBLY (refer to Section 8.5) 1 -
5 A-Q-TORK SYSTEM (refer to Section 8.6) 1 0.09.0602
9 ADDITIONAL MANIFOLD, FFBU ON TONG (refer to Section 8.7.3) 1 -

APPENDIX
Table 8.6: Tong Part No. 911 0175 – TT 7.6-30 with FF-BU & Dinamic Motor
Drawing
No.
5 MANIFOLD, HIGH-TORQUE, BH200 (refer to Section 8.7.2.2) 1
9 MANIFOLD, FFBU & LIFT CYLINDER (refer to Section 8.7.3.2) 1 -
10 MANIFOLD, FFBU (refer to Section 8.8.4) 1 -
11 MANIFOLD, LIFT CYLINDER (refer to Section 8.10) 1 -
Model TT 7.6 - 15/30

12 ACCESSORIES UK STANDARD (refer to Section 8.4) 1 -
ADDITIONAL PARTS (NOT SHOWN) Part No.

15 ADAPTER, RENOLD/DINAMIC MOTOR GEAR BOX 1 541 2201
16 SPLINE SHAFT FOR RENOLD/DINAMIC MOTOR 1 541 2200
17 HEXAGON SCREW M10 X 35 5 521 1181
18 WASHER B10.5 5 521 0091
19 BEARING, BALL 1 541 2202
20 COUPLING BUSHING FOR BH200 1 528 2001
21 RADIAL PISTON MOTOR 1 528 2000
22 BALL HEAD 1 521 0055
23 HOLDER FOR MEASURING CONNECTOR 1 521 0887
24 PLUG 1 521 5366

APPENDIX
8.1.1 Clamping Elements, Tong and Backup
8.1.1.1 Standard Jaws

Model TT 7.6 - 15/30
Tong and Backup Jaw Sets are identical and must be exchanged
simultaneously depending on the pipe / tool joint diameter to be gripped.
Exception: DO NOT use the 7-5/8 or 6.05-inch Standard Jaw in the tong; it is
for backup/coupling use only!
When using the 2-3/8 or 2 7/8-inch Jaw Set ALWAYS install three chucking
wedges Mark II (Part No.: 521 0897, marked by 2 holes) inside the rotor.
Refer to Section 8.2.6, Items 44.

APPENDIX
Parts list – Standard Jaws
Pipe Size
(inch)
2-3/8 **
2-7/8 **
3-1/2
Model TT 7.6 - 15/30

4-0/0
4-1/2
5-0/0
5-1/2
6.05 **
6-5/8
7-0/0
7-5/8 **
* Quantity per Jaw Set Assembly / ** Refer to the Caution Notes on the left page

APPENDIX
8.1.1.1.1 Special Jaw Sizes

Model TT 7.6 - 15/30
Tong and Backup Jaw Sets are identical and must be exchanged
Exception: DO NOT use the 2.162, 3.063, 3.668 or 5.2-inch Special Jaw in the
tong; it is for backup/coupling use only!

APPENDIX
Parts list – Special Jaw Sizes
Coupling
Size (inch)
1.9
2.162 **
3.063 **
Model TT 7.6 - 15/30

JAW SET ASSEMBLY 3.668” (incl. items 1 – 3) 1 521 0128
3.668 **
3-3/4
JAW SET ASSEMBLY 4-3/4“ (incl. items 1 – 3) 1 521 0141
4-3/4
5.2 **
* Quantity per Jaw Set Assembly.

** Refer to the caution note on the left page

APPENDIX
8.1.1.2 Micro-Grip Jaws, Standard Sizes

Model TT 7.6 - 15/30
3-1/2 to 6 5/8-inch Micro-Grip Jaw Set (left and right Jaw)
7-0/0 to 7 5/8-inch Micro-Grip Jaw Set (left and right Jaw incl. Jaw Pin)
Tong and Backup Micro-Grip Assemblies are identical and must be

exchanged simultaneously depending on the pipe / tool joint diameter to be
gripped.
Exception: DO NOT use the 7-5/8 or 6.05-inch Micro-Grip Assembly in the
tong; it is for backup/coupling use only!

APPENDIX
Parts list – Micro-Grip Jaws, Standard Sizes

Pipe Size
(inch)
MICRO-GRIP JAW SET ASSEMBLY 3 1/2" (incl. items 1 – 4) 1 521 1905
3 LOCK RING SET (= 2 pcs) 2 521 1255
4 CAP SCREW 16 541 0520
MICRO-GRIP JAW SET ASSEMBLY 4" (incl. items 1 – 4) 1 521 1906
3 LOCK RING SET (= 2 pcs) 2 541 1256
4 CAP SCREW 16 541 0520
3 LOCK RING SET (= 2 pcs) 2 541 1557
Model TT 7.6 - 15/30

4 CAP SCREW 16 541 0520
3 LOCK RING SET (= 2 pcs) 2 521 1558
4 CAP SCREW 24 541 0520
3 LOCK RING SET (= 2 pcs) 2 521 1559
4 CAP SCREW 24 541 0520
6.05 ** 2 MICRO-GRIP INSERT 2 521 1863
3 LOCK RING SET (= 2 pcs) 2 521 1263
4 CAP SCREW 16 541 0520
3 LOCK RING SET (= 2 pcs) 2 521 1260
4 CAP SCREW 16 541 0520
7-0/0
3 LOCK RING SET (= 2 pcs) 2 521 1261
4 CAP SCREW 16 541 0520
5 JAW PIN 2 521 1471
7-5/8 **
3 LOCK RING SET (= 2 pcs) 2 521 1262
4 CAP SCREW 16 541 0520
5 JAW PIN 2 521 1471
* Quantity per Micro-Grip Jaw Set Assembly (left and right Jaw) / ** Refer to the Caution Note on the left page

APPENDIX
8.1.1.2.1 Special Micro-Grip Jaw Sizes

Model TT 7.6 - 15/30
5.152 to 6-0/0 and 6.5-inch Micro-Grip Jaw Set (left and right Jaw)
6.278 and 7.73 to 7.882-inch Micro-Grip Jaw Set (left and right Jaw incl. Jaw Pin)
Tong and Backup Micro-Grip Assemblies are identical and must be

gripped.
Exception: DO NOT use the 5.152, 5.606, 6.278, 7.73 or 7.882-inch Micro-Grip
Jaw in the tong; it is for backup/coupling use only!

APPENDIX
Parts list – Special Micro-Grip Jaw Sizes

Coupling
Item Description Qty.* Part No.
Size (inch)
5.152 **
3 LOCK RING SET (= 2 pcs) 2 521 1272
4 CAP SCREW 24 521 0199
5 LOCK WASHER (not shown) 24 521 0089
5.606 **
3 LOCK RING SET (= 2 pcs) 2 521 1265
4 CAP SCREW 24 521 0199
3
MICRO-GRIP JAW SET ASSEMBLY 5 /4" (incl. items 1 – 5) 1 521 1919
5-3/4
3 LOCK RING SET (= 2 pcs) 2 521 1269
Model TT 7.6 - 15/30

4 CAP SCREW 24 521 0199
3 LOCK RING SET (= 2 pcs) 2 521 1263
4 CAP SCREW 16 541 0520
6.278 ** 3 LOCK RING SET (= 2 pcs) 2 521 1266
4 CAP SCREW 24 521 0199
6 JAW PIN 2 521 1471
6.5
3 LOCK RING SET (= 2 pcs) 2 521 1270
4 CAP SCREW 24 521 0199
7.73 ** 3 LOCK RING SET (= 2 pcs) 2 521 1267
4 CAP SCREW 24 521 0199
6 JAW PIN 2 521 1471
7.882 ** 3 LOCK RING SET (= 2 pcs) 2 521 1268
4 CAP SCREW 24 521 0199
6 JAW PIN 2 521 1471
* Quantity per Micro-Grip Jaw Set Assembly (left and right Jaw).
** Refer to the caution note on the left page

APPENDIX
8.1.1.3 Non-Marking Jaws (obsolete, for reference only)

Model TT 7.6 - 15/30
Chucking Wedges Mark II and Stop Lever for use with Non-Marking Jaws
The use of non-marking jaws requires the installation of specific chucking

wedges and a stop lever into the tong.
Torque MUST be limited to 15 000 ft-lb when using these parts!

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

1 CHUCKING WEDGE MARK II 3 521 0897
2 CAP SCREW 3 521 0199
3 CAP SCREW 3 521 0048
4 CAP SCREW 3 541 0105
5 STOP LEVER 1 521 0895
* Quantity per tong.
When changing back to standard jaws or Micro-Grip jaws the chucking

wedges Mark II and the stop lever must be also changed back to standard.
Otherwise exists the risk of crimping the pipe being run.
Model TT 7.6 - 15/30

APPENDIX
Non-Marking Jaws (obsolete, for reference only) (continued)

Model TT 7.6 - 15/30
3-1/2 to 7 5/8-inch Non-Marking Jaws (left and right Jaw) shown in Makeup Configuration
Tong and Backup Non-Marking Jaws are identical and must be exchanged
Backup Non-Marking Jaws must be installed opposite to tong installation!

APPENDIX
Parts list – Non-Marking Jaws, Tong and Backup
Pipe Size
(inch)
NON-MARKING JAW SET ASSEMBLY 3 1/2" (incl. items 1 – 5) 1 521 1505
1 NON-MARKING JAW SET 1 521 1455
2 INSERT SET (FOR LEFT AND RIGHT JAW) 1 541 1605
3-1/2
3 LOCK RING SET (= 2 pcs, not shown) 2 521 1255
4 CAP SCREW (not shown) 16 541 0520
NON-MARKING JAW SET ASSEMBLY 4" (incl. items 1 – 5) 1 521 1506
4-0/0
Model TT 7.6 - 15/30

4-1/2
5-0/0
5-1/2
5
NON-MARKING JAW SET ASSEMBLY 6 /8" (incl. items 1 – 5) 1 521 1510
6-5/8
7-0/0 3 LOCK RING SET (= 2 pcs, not shown) 2 521 1261
6 JAW PIN (not shown) 2 521 1471
* Quantity per Non-Marking Jaw Set Assembly (left and right Jaw).

APPENDIX
Non-Marking Jaws (obsolete, for reference only) (continued)

Model TT 7.6 - 15/30
3-1/2 to 7 5/8-inch Non-Marking Jaws (left and right Jaw) shown in Makeup Configuration
Tong and Backup Non-Marking Jaws are identical and must be exchanged
Backup Non-Marking Jaws must be installed opposite to tong installation!

APPENDIX
Parts list – Non-Marking Jaws, Tong and Backup
Pipe Size
(inch)
7-5/8 3 LOCK RING SET (= 2 pcs, not shown) 2 521 1262
6 JAW PIN (not shown) 2 521 1471
NON-MARKING JAW SET ASSEMBLY 6.05" (incl. items 1 – 5) 1 521 1513

6.05
Model TT 7.6 - 15/30

* Quantity per Non-Marking Jaw Set Assembly (left and right Jaw).
DO NOT use the 7-5/8 or 6.05-inch Non-Marking Jaw Set in the tong; it is for
backup use only.
Use the 6.05-inch Non-Marking Jaw Set only for coupling.

APPENDIX
8.1.1.4 Diamond Grip Jaws

Model TT 7.6 - 15/30
5-0/0 and 5 1/2-inch Diamond Grip Jaw Set (left and right Jaw)
7 0/0-inch Diamond Grip Jaw Set (left and right Jaw) 7 5/8-inch Diamond Grip Jaw Set (left and right Jaw)
Tong and Backup Diamond Grip Jaw Assemblies are identical and must be
gripped.
Exception: DO NOT use the 7 5/8-inch Diamond Grip Jaw in the tong; it is for
backup/coupling use only!

APPENDIX
Parts list – Diamond Grip Jaws
Pipe Size
(inch)
DIAMOND GRIP JAW ASSEMBLY 5-0/0" (incl. items 1 – 10) 1 521 2910
1 DG JAW SET 5-0/0 1 521 2920
2 LOCKING RING DG 5-0/0 4 521 2930
5-0/0 5 CLAMP, MESH, DG 5-0/0 2 521 2960
6 CAP SCREW, ISO 4762 - M8 X 20 20 521 0199
7 CAP SCREW, ISO 4762 - M6 X 16 8 541 0213
10 DG INSERT 5-0/0 8 522 2510
1 DG JAW SET 5-1/2 1 521 2921
2 LOCKING RING DG 5-1/2 4 522 4671
Model TT 7.6 - 15/30

5-1/2 5 CLAMP, MESH, DG 5-1/2 2 521 2961
6 CAP SCREW, ISO 4762 - M8 X 20 20 521 0199
7 CAP SCREW, ISO 4762 - M6 X 16 8 541 0213
10 DG INSERT 5-1/2 8 522 2511
1 DG JAW SET 7-0/0 1 521 2923
2 LOCKING RING DG 7-0/0 4 521 2933
5 CLAMP, MESH, DG 7-0/0 2 521 2963
6 CAP SCREW, ISO 4762 - M8 X 20 20 521 0199
7-0/0
7 CAP SCREW, ISO 4762 - M6 X 16 8 541 0213
10 DG INSERT 7-0/0 8 521 2983
11 JAW PIN, LONG 2 521 1471
12 STOP 1 521 0157
13 HEX. SCREW W/HOLE, ISO 4017 - M10 X 20 2 519 1088
1 DG JAW SET 7-5/8 1 521 2924
2 LOCKING RING DG 7-5/8 4 521 2934
7-5/8 ** 4 RUBBING STRAKE DG 7-5/8 4 521 2954
6 CAP SCREW, ISO 4762 - M8 X 20 25 521 0199
7 CAP SCREW, ISO 4762 - M6 X 16 20 541 0213
10 DG INSERT 7-5/8 8 522 2574
11 JAW PIN, LONG 2 521 1471
Spare not
MESH, FOR ALL DG JAW ASSEMBLY SIZES - 521 1749
Mesh shown
* Quantity per Diamond Grip Jaw Set Assembly (left and right Jaw) / ** Refer to the Caution Note on the left page

APPENDIX
8.2 TONG UP TO GEAR BOX

Model TT 7.6 - 15/30

APPENDIX
Parts list – Tong up to Gear Box

1 BODY ASSEMBLY (refer to Section 8.2.1) 1 -
2 CUP PINION ASSEMBLY (refer to Section 8.2.2) 1 -
3 CLUSTER GEAR ASSEMBLY (refer to Section 8.2.3) 1 -
4 INTERMEDIATE GEAR ASSEMBLY (refer to Section 8.2.4) 1 -
5 ROTARY DRIVE ASSEMBLY (refer to Section 8.2.5) 2 -
6 ROTARY GEAR ASSEMBLY (refer to Section 8.2.6) 1 -
7 GRIPPING SYSTEM ASSEMBLY (refer to Section 8.2.7) 1 -
8 DOOR ASSEMBLY (refer to Section 8.2.10) 1 -
9 BRAKE SYSTEM ASSEMBLY (refer to Section 8.2.9) 2 -
15 GUIDE ROLLER, CASE (refer to Section 8.2.12) 7 -
16 GUIDE ROLLER, DOOR (refer to Section 8.2.13) 1 -
Model TT 7.6 - 15/30

17 PLATE, IDENTIFICATION 1 522 0400
18 LIFTING EYE BOLT DIN 580 – M24 1 2 522 3115
19 CATCH ASSEMBLY * (refer to Section 8.2.8) 1 521 0052
* not shown

APPENDIX
8.2.1 Body Assembly

Model TT 7.6 - 15/30

APPENDIX
Parts list – Body Assembly

1 CASE BODY COMPLETE 1 521 0204
2 HANDLE 1 541 0116
3 LOCK WASHER – S10 2 521 0005
4 HEXAGON SCREW M10 X 25 2 533 0616
5 HANDLE 2 521 0112
6 BASE 3 521 2074
7 LOCK WASHER – S16 3 521 2006
8 CAP SCREW ISO 4762 – M16 X 70 3 521 2077
9 HOLDER FOR HANGER * 2 521 2075
* not shown
Model TT 7.6 - 15/30

APPENDIX
8.2.2 Cup Pinion Assembly - Drawing No.: 3.09.5387

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.5387 – Cup Pinion Assembly

1 CUP, PINION SHAFT 1 521 0119
2 LOCK WASHER – S10 6 521 0005
3 CAP SCREW ISO 4762 – M10 X 30 6 521 0007
4 BALL BEARING 1 522 0035
5 LOCK WASHER – S8 2 521 0089
6 CAP SCREW ISO 4762 – M8 X 10 2 522 0028
7 GREASE NIPPLE 1 521 2021
Model TT 7.6 - 15/30

APPENDIX
8.2.3 Cluster Gear Assembly - Drawing No.: 3.09.5397

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.5397 – Cluster Gear Assembly

9 RETAINING RING 1 521 0009
10 SHAFT, CLUSTER GEAR 1 521 0010
11 BEARING SEAL 1 521 0011
12 BEARING NEEDLE 2 522 0007
13 BEARING 1 521 0013
14 BUSHING 1 521 0014
16 BUSHING 2 521 0012
17 GEAR, CLUSTER 1 521 0017
18 HEXAGON NUT SELF LOCK 2 521 0018
Model TT 7.6 - 15/30

20 WASHER DIN 125 – B25 2 521 0020

APPENDIX
8.2.4 Intermediate Gear Assembly - Drawing No.: 3.09.5396

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.5396 – Intermediate Gear Assembly

20 WASHER DIN 125 – B25 2 521 0020
21 SHAFT, INTERMEDIATE 1 521 0021
22 GEAR, INTERMEDIATE 1 521 0022
23 BEARING, NEEDLE 2 521 0023
24 RETAINING RING DIN 472 – 72 X 2.5 2 521 0024
25 BUSHING 1 521 0025
29 BUSHING 1 521 0029
Model TT 7.6 - 15/30

APPENDIX
8.2.5 Rotary Drive Assembly - Drawing No.: 3.09.5395

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.5395 – Rotary Drive Assembly

20 WASHER DIN 125 – B25 2 521 0020
24 RETAINING RING DIN 472 – 72 X 2.5 2 521 0024
27 BUSHING 1 521 0027
28 SHAFT, ROTARY DRIVE PINION 1 521 0028
29 BUSHING 1 521 0029
30 GEAR, ROTARY DRIVE PINION 1 521 0030
Model TT 7.6 - 15/30

APPENDIX
8.2.6 Rotary Gear Assembly - Drawing No.: 2.09.5398

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 2.09.5398 – Rotary Gear Assembly

41 PIN, ROTOR 3 521 0044
43 ROTARY 7.6 1 521 0046
44 CHUCKING WEDGE (for jaw sets 3-1/2 to 7-5/8) 3 521 0185
44 CHUCKING WEDGE MARK II (for jaw sets 2-3/8 to 2-7/8) 3 521 0897
45 CAP SCREW DIN 912 – M12 X 40 3 521 0048
46 CAP SCREW DIN 912 – M8 X 20 3 521 0199
48 CAP SCREW DIN 912 – M12 X 35 3 541 0105
82 LOCK WASHER – S8 3 521 0089
112 LOCK WASHER – S12 6 541 0048
Model TT 7.6 - 15/30

APPENDIX
8.2.7 Gripping System Assembly - Drawing No.: 1.09.4998

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.4998 – Gripping System Assembly

40 HOOK 1 521 0041
42 CAGE PLATE, TOP 2 521 0045
53 SLIDE RING 20 521 0060
54 CAP SCREW DIN 912 – M8 X 16 20 541 0520
55 WASHER DIN 9021 – 8.4 – 100HV 20 521 0062
56 CAM FOLLOWER 22 521 0063
57 NUT 11 521 0064
59 WASHER DIN 433 22 521 0066
60 CAP SCREW DIN 912 – M12 X 30 8 521 0067
Model TT 7.6 - 15/30

62 TENSION LEVER, RIGHT 1 541 0172
63 SHAFT, JAW ROLLER 2 521 0070
65 JAW ROLLER 2 521 0072
66 TENSION LEVER, LEFT 1 541 0171
67 SHAFT, JAW ROLLER 1 521 0074
68 STOP LEVER 1 521 0895
69 JAW ROLLER 1 521 0076
70 TENSION LEVER PIN 2 521 0077
71 PIN, SPRING STEEL 3 521 0159
72 GROOVED PIN ISO 8740 – 12 X 28 4 521 0079
89 JAW PIN 2 541 0084
92 JAW SPRING, LEFT 1 521 0104
93 JAW SPRING, RIGHT 1 521 0105
95 CAP SCREW DIN 912 – M10 X 16 2 521 0158
98 WASHER DIN 125 – B10.5 2 521 0091
108 COTTER LINCH PIN 4 523 0481

APPENDIX
8.2.8 Catch Assembly

Model TT 7.6 - 15/30

APPENDIX
Parts list – Catch Assembly

50 CATCH ASSEMBLY (incl. items 1, 4, 5, 6) 1 521 0052
1 WELDING PART, CATCH 1 521 0053
4 THREADED PIN, CATCH 1 521 0054
5 THRUST PIECE, M 16 X 24 1 521 0056
6 BALL HEAD 1 521 0055
51 SEALING V 20 A 1 541 0059
87 HEXAGON NUT, M 10 1 521 0097
107 WASHER 10,5 1 541 0058
Model TT 7.6 - 15/30

APPENDIX
8.2.9 Brake System Assembly

Model TT 7.6 - 15/30

APPENDIX
Parts list – Break System Assembly

90 BRAKE BAND ASSEMBLY 4 541 0278
117 BUSHING 2 541 0109
118 LASHING 4 541 0108
119 HEXAGON SCREW 4 541 0110
120 WASHER 4 521 0062
Model TT 7.6 - 15/30

APPENDIX
8.2.10 Door Assembly

Model TT 7.6 - 15/30

APPENDIX
Parts list – Door Assembly

1 DOOR, WELDING 1 521 0080
2 GUIDE ROLLER ASSEMBLY (refer to Section 8.2.11) 1 521 0032
3 DOOR SHAFT, GUIDE ROLLER 1 521 0040
4 BEARING, DOOR 2 521 2073
5 COVER, UPPER 1 521 2062
6 COVER, LOWER 1 521 2063
7 O-RING 2 533 0505
8 GAMMA RING 2 521 2069
10 CAP SCREW, SHALLOW HEAD 4 521 0088
11 CAP SCREW 5 521 0049
Model TT 7.6 - 15/30

12 CAP SCREW, SHALLOW HEAD 1 541 0005
13 LOCK WASHER – S8 9 521 0089
14 LOCK WASHER – S10 1 521 0005

APPENDIX
8.2.10.1 Door, Snap-On

Model TT 7.6 - 15/30

APPENDIX
Parts list – Door, Snap-On

73 DOOR 1 521 0080
77 SHAFT, DOOR SPRING 1 521 0084
83 HEXAGON NUT 1 521 0090
84 WASHER 1 521 0091
85 DOOR SPRING ASSEMBLY 1 521 9018
140 SNAP ON, DOOR 1 521 0212
141 BOLT, SNAP ON, DOOR 1 521 0213
142 WASHER 2 521 0091
143 HEXAGON NUT, SELF LOCK 2 521 0097
145 SPRING HOUSING TUBE, DOOR ASSEMBLY 2 541 0355
146 PLUNGER DOOR CYLINDER 2 541 0356
Model TT 7.6 - 15/30

147 SPRING, ROT. SPRING BLOCK 2 522 0225
149 WASHER 12 541 0212
152 CAP SCREW 1 562 4027

APPENDIX
8.2.11 Guide Roller Assembly, Part No.: 521 0032 - Drawing No.: 3.09.5392
Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.5392 – Guide Roller Assembly (Part no. 521 0032)

1 GUIDE ROLLER 1 521 0033
3 BEARING, THRUST 2 521 0035
4 BEARING, SEAL 2 521 0036
5 SEALING DISC 2 521 0037
Model TT 7.6 - 15/30

APPENDIX
8.2.12 Guide Roller, Case - Drawing No.: 3.09.5393

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.5393 – Guide Roller, Case

2 SHAFT, GUIDE ROLLER 1 521 0031
3 WASHER DIN 125 – B21 1 521 0039
Model TT 7.6 - 15/30

APPENDIX
8.2.13 Guide Roller, Door - Drawing No.: 3.09.5394

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.5394 – Guide Roller, Door

2 DOOR SHAFT, GUIDE ROLLER 1 521 0040
3 STOP DOG, LOWER 1 521 2081
4 STOP DOG, UPPER 1 521 0207
5 LOCK WASHER – S10 4 521 0005
6 CAP SCREW DIN 912 – M10 X 25 4 521 0109
7 WASHER DIN 125 – B21 2 521 0039
Model TT 7.6 - 15/30

APPENDIX
8.3 HANGER ASSEMBLY

Model TT 7.6 - 15/30

APPENDIX
Parts list – Hanger Assembly

103 HEXAGON BOLT M20 X 90 2 533 0623
104 HEXAGON NUT M20 4 521 0094
109 HANGER (FOR HANGER ASSEMBLY, STANDARD) 1 521 0092
109 HANGER (FOR HANGER ASSEMBLY, HIGH-TORQUE) 1 521 0187
110 SHACKLE 1 541 0114
128 HOLDER FOR HANGER 2 521 2075
129 CAP SCREW M16 X 30 4 521 5083
130 LOCK WASHER S16 4 521 2006
Model TT 7.6 - 15/30

APPENDIX
8.4 ACCESSORIES
Model TT 7.6 - 15/30

APPENDIX
Parts list – Accessories

115 NOMENCLATURE PLATE 1 522 0400
180 HOLDER FOR 4-WAY VALVE A35 (not for A-Q-TORK) 3 521 0221
181 HOLDER FOR INLET/OUTLET (not for A-Q-TORK) 1 521 0219
HOLDER FOR COUPLING LIFT CYLINDER (only for tong with lift
182 1 521 0222
cylinder)
183 HOLDER FOR TORQUE INDICATOR (not for A-Q-TORK) 1 521 0223
184 HOLDER FOR TORQUE INDICATOR (for tong 911 0101/0172) 1 521 0224
HOLDER FOR TORQUE INDICATOR (for tong 911
184 1 541 0422
0115/0154/0170/175)
HOLDER F. CARTRIDGE BLOCK (only for tong with lift cyl. and/or
185 1 521 0220
backup)
186 PLATE, ‘MAKE’ * 1 522 0245
187 PLATE, ‘BREAK’ * 1 522 0246
Model TT 7.6 - 15/30

188 TAG, WARNING ‘BODY INJURY’ * 1 541 0423
193 TAG, ‘OUTLET’ * 1 521 0230
194 TAG, ‘INLET’ * 1 521 0231
* not shown
Parts list – Accessories (for Tong 9110175 only, not shown)

8 WASHER * 2 521 2654
9 GUARD FOR REAR SUPPORT * 1 521 2655
* not shown

APPENDIX
8.5 DRIVE ASSEMBLY

Model TT 7.6 - 15/30

APPENDIX
Parts list – Drive Assembly

1 GEAR BOX & COVER 1 522 0167
3 SHAFT, GEAR PINION 1 522 0328
4 GEAR, CLUTCH (not for A-Q-TORK) 1 522 0182
5 RING, GEAR BOX 1 522 0171
6 BEARING, ROLLER 1 522 0169
8 SEAL, PINION SHAFT 1 522 0317
9 CAP SCREW 4 522 0172
10 GEAR, PINION 1 522 0325
12 BUSHING. PINION SHAFT 1 521 0164
Model TT 7.6 - 15/30

14 GEAR, HI-LO CLUSTER 1 522 0177
16 SHAFT, HI-LO CLUSTER 1 522 0181
19 BUSHING, CLUSTER GEAR 1 522 0176
20 O-RING 1 522 0242
21 THRUST WASHER 1 522 0180
22 LOCK, CLUSTER GEAR 1 522 0193
23 HEXAGON BOLT 1 522 0650
27 BREATHER, GEAR BOX 1 522 0186
29 SHIFTING FORK ASSEMBLY 1 522 0183
30 LOCATOR PIN ASSEMBLY 1 522 0184
31 O-RING 1 522 0234
33 MAGNETIC PLUG, GEAR BOX 1 522 0188
34 PLUG 1 533 0630
36 GASKET, GEAR BOX 1 522 0233
37 GASKET, GEAR BOX - TONG 1 522 0236
38 GASKET, GEAR BOX EXTENSION RING TO GEAR BOX 1 522 0237
43 SPRING WASHER 4 522 0195
45 GASKET, MOTOR 1 522 0235
60 PLUG, GEAR BOX 2 522 0232
151 STUD, GEAR BOX & MOTOR 2 522 0164
151 STUD (only for tong with A-Q-TORK) 2 541 2033

APPENDIX
DRIVE ASSEMBLY (CONTINUED)

Model TT 7.6 - 15/30

APPENDIX
Parts list – Drive Assembly (continued)

152 STUD, GEAR BOX 2 522 0165
153 CAP SCREW (only for tong with A-Q-TORK) 2 541 2023
154 BRACKET, SHIFT HANDLE 1 521 0113
155 BLOCK, SHIFTING FORK 1 521 0114
157 CAP SCREW 1 521 0115
158 HANDLE, SHIFT 1 522 0201
159 ROLL PIN, STAINLESS 1 522 0200
Model TT 7.6 - 15/30

APPENDIX
8.6 A-Q-TORK SYSTEM C12M, IS DUMP – DRAWING NO.: 0.09.0602

Model TT 7.6 - 15/30

APPENDIX
Parts list – Drawing no. 0.09.0602 – A-Q-TORK System C12M, IS Dump

1 DUST CAP 1 530 0013
2 SELF SEAL COUPLING, MALE 1 530 0019
3 NIPPLE 2 522 0501
4 SWIVEL JOINT, 1NPT 2 522 0212
5 NIPPLE 1 522 0502
6 ADJUSTABLE ANGLE SCREW-JOINT 1 533 4515
7 ADAPTER 1 530 0238
8 FILTER 1 541 2103
9 STRAIGHT SCREW-IN SCREW-JOINT 1 533 0353
10 REDUCING CONNECTION 1 533 4776
12 4-WAY VALVE 1 541 2301
14 DUST CAP 2 530 0242
Model TT 7.6 - 15/30

15 PUSH-PULL COUPLING 2 530 0240
20 DUST CAP 2 530 0243
22 FLOW VALVE 1 541 2101
23 CASE FOR FLOW VALVE 1 541 2102
24 ADJUSTABLE SCREW-IN SOCKET + SHANK 1 533 0379
26 GASKET, MOTOR 1 522 0235
29 ANGLE SWIVEL SCREW-JOINT NO THROTTLE 3 533 3616
30 ANGLE SCREW-IN SCREW-JOINT 1 533 0474
35 ANGLE SCREW-JOINT 1 533 0314
36 DUST CAP 1 530 0014
37 SELF-SEAL COUPLING, MALE 1 530 0020
38 BUSHING REDUCER 1 522 0528
41 ADJUSTABLE L-SCREW-JOINT 2 533 4666

APPENDIX
A-Q-TORK System C12M, IS Dump (continued) - Drawing No. 0.09.0602

Model TT 7.6 - 15/30

APPENDIX
Parts list – Drawing no. 0.09.0602 – A-Q-TORK C12M System (continued)

46 ADJUSTABLE T-SCREW-JOINT 1 533 4011
49 ANGLE SWIVEL SCREW-JOINT 1 533 3536
54 VALVE WITH PUSH ROD 1 528 0548
55 CAP SCREW 2 541 0371
58 DISCHARGE VALVE 2 528 0547
59 PLUG 1 533 0635
Model TT 7.6 - 15/30

60 PRESSURE RELIEF VALVE 1 528 0514
61 CONNECTION PLATE 1 541 2501
62 CHECK VALVE, INNER PARTS 1 599 0482
62.1 PARTS FOR NON-RETURN VALVE 1 533 0597
63 GUIDE PIN 1 541 2502
65 COVER FOR HAND-OPERATING MOOG 2 541 2109
66 TAPPET 2 541 2108
67 WIPER 2 521 5416
68 O-RING 2 521 5414
69 CAP SCREW 6 541 2107
70 LOCK WASHER 6 541 0294
72 DUMP VALVE 1 528 0549
73 CAP SCREW 2 541 0359
74 PIPE CLAMP 1 541 0372
77 MINI FILTER 1 541 2012
78 CASE FOR INTERLOCK 1 541 2100
79 O-RING 1 521 0086
80 ORIFICE 1 528 0512
81 PISTON 1 541 0066
82 O-RING 1 528 0300
83 SPRING FOR PISTON 1 541 0020
84 CYLINDER HOUSING 1 541 0065
85 FILTER CAP 1 541 0081
86 FILTER FOR HYDRAULIC INTERLOCK 1 541 0082
87 T-SWIVEL SCREW-JOINT NO THROTTLE 1 533 3660
88 STRAIGHT SCREW-JOINT 1 533 0591
90 2-WAY VALVE, INTERLOCK 1 528 0565

APPENDIX
A-Q-TORK System C12M, IS Dump (continued) - Drawing No. 0.09.0602

Model TT 7.6 - 15/30

APPENDIX
Parts list – Drawing no. 0.09.0602 – A-Q-TORK C12M System (continued)

92 PRESSURE CONTROL VALVE 1 521 0203
94 PRESSURE GAUGE CON. SCREW-JOINT 1 533 0410
95 MANOMETER, 250 BAR 1 599 0100
103 GASKET RING 1 560 0755
104 CAP SCREW 1 521 0107
105 VOLUME BLOCK ASSEMBLY, A-Q-TORK 1 541 2010
106 CAP SCREW 4 541 2024
107 O-RING 2 531 0032
108 CAP SCREW 1 560 0031
109 HEXAGON THIN NUT 1 560 0041
Model TT 7.6 - 15/30

112 HOLDER FOR FILTER 1 541 0348
113 DISTANCE BUSHING 4 541 0362
118 WASHER 6 521 0091
119 CAP SCREW 1 541 0519
120 CAP SCREW 1 562 4027
121 WASHER 1 541 0212
123 COVER, A-Q-TORK 1 541 0349
125 WASHER 7 533 0625
126 HEXAGON NUT 1 521 0090
127 HOLDER FOR SWIVEL JOINT 1 521 2303
128 HOLDER FOR 4-WAY VALVE, BOSCH 1 521 2304
129 HOLDER FOR 4-WAY VALVE, BOSCH 2 521 2305
131 LOCK WASHER 3 521 0005
132 HOLDER FOR BU COUPLING 1 521 2306
133 PIPE CLAMP 1 521 0195
140 HYDRAULIC MOTOR, MODIFIED 1 521 2401
140.1 HYDRAULIC MOTOR 1 521 2301
141 FLANGE 1 541 2016
142 GEAR 1 541 2015
143 ELECTRIC INTERFACE (refer to Section 8.6.1) 1 541 2027
147 WELD-ON SCREW-JOINT 1 533 0445

APPENDIX
8.6.1 Electrical Interface for MOOG IS Dump Valve (Part No.: 541 2027)
Model TT 7.6 - 15/30

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

1 INTEGRATED CIRCUIT IC 1, VOLTAGE CONTROL 1 541 2517
2 FUSE F1 1 541 2518
3 RECTIFIER D1 1 541 2514
4 RESISTOR R1 1 541 2515
5 DIODE D2 1 541 1516
6 SOCKET 2 541 2524
7 DUST PLUG 2 541 2528
8 FIXED PLUG CICULAR 1 541 2522
9 DUST CAP FOR FIXED PLUG CICULAR 1 541 2523
10 COUPLER PLUG 1 541 2527
11 DUMP CABLE 1 561 0823
Model TT 7.6 - 15/30

12 PLUG 2 541 2525
13 DUST PLUG 2 541 2526
14 AL CASE FOR ELECTRIC INTERFACE * 1 541 2510
15 BOARD FOR ELECTRIC INTERFACE * 1 541 2511
16 CONNECTING STRIP * 1 541 2512
17 CONNECTING STRIP * 1 541 2513
18 HOLDER FOR FUSE * 1 541 2519
19 SCREW CAP * 1 541 2520
20 COOLING BLOCK * 1 541 2521
* not shown

APPENDIX
8.7 MANIFOLD PLANS, TONG
8.7.1 Manifold, Standard; Model 7.6-15 – Drawing No.: 1.09.0671

Model TT 7.6 - 15/30
* see manifold plan ‘Hydraulic Safety Interlock’ – Drawing No.: 1.09.0620

APPENDIX
Parts list - Drawing no. 1.09.0671 – Manifold, Standard

3 DUST CAP 1 530 0013
4 DUST CAP 1 530 0014
6 NIPPLE 2 522 0501
8 NIPPLE 1 521 0225
9 NIPPLE 1 521 0226
10 ELBOW 3 522 0516
11 ELBOW 2 522 0522
Model TT 7.6 - 15/30

13 NIPPLE 2 522 0504
14 ADAPTER 2 530 0212
15 ADAPTER, SEAL HEAD 2 530 0105
16 SEAL NUT, 1NPT 8 522 0213
17 NIPPLE 1 522 0510
19 NON-RETURN VALVE 1 533 0496
23 MOTOR, STANDARD 1 529 0541
24 COUPLING, FLANGE 2 522 0214
25 CAP SCREW, MOTOR FLANGE 8 522 0250
26 O-RING 2 528 0301
28 A35 4-WAY VALVE MODIFIED (refer to Section 8.7.2.1) 1 521 0217
29 HANDLE, VALVE 1 522 0202
30 PLUG 1 530 0160
31 NIPPLE 1 541 0389
32 ADAPTER 1 530 0245
34 NIPPLE 2 522 0669

APPENDIX
8.7.2 Manifold, High-Torque; Model 7.6-30 – Drawing No.: 1.09.0670

Model TT 7.6 - 15/30
* see manifold plan ‘Hydraulic Safety Interlock’ – Drawing No.: 1.09.0620

APPENDIX
Parts list - Drawing no. 1.09.0670 – Manifold, High-Torque

3 DUST CAP 1 530 0013
4 DUST CAP 1 530 0014
6 NIPPLE 2 522 0501
8 NIPPLE 1 521 0225
9 NIPPLE 1 521 0226
14 ADAPTER 2 530 0212
Model TT 7.6 - 15/30

26 SEAL NUT, 1NPT 2 522 0213
27 MOTOR FOR 7.6-30 1 529 0540
36 PLUG 1 530 0160
38 ADAPTER 1 530 0245
51 SCREW HIGH-TORQUE/SPEED COMMERCIAL MOTOR 1 521 0214

APPENDIX
8.7.2.1 A35 4-Way Valve, Tong Section, modified – Drawing No.: 3.09.0661
Model TT 7.6 - 15/30

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

1 4-WAY VALVE A35 1 529 0551
2 CHECK POPPET, TONG SECTION 1 541 0375
3 SPRING 1 541 0377
4 PLATE FOR HANDLE, A35 4-WAY VALVE 1 521 0216
5 CAP SCREW 4 541 0520
8.7.2.2 Manifold, High-Torque (for Tong 911 0175 with Dinamic Motor only)
Parts list – Manifold, High-Torque (for Tong 911 0175 with Dinamic Motor only)

Model TT 7.6 - 15/30

3 DUST CAP 1 530 0016
4 DUST CAP 1 530 0017
5 ADAPTER 2 530 0179
6 ADAPTER 2 530 0180
40 T-SWIVEL SCREW-JOINT NO THROTTLE 1 533 3651
42 COUPLING 1 530 0515
43 DUST CAP 1 554 1066
44 T-SCREW-JOINT 1 533 0368
46 COUPLING 2 530 0514
47 DUST PLUG 1 554 1063

APPENDIX
8.7.3 Manifold, Lift Cylinder & Backup on the Tong – Drawing No.: 1.09.4932
Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.4932 – Manifold, Lift Cyl. & Backup on the Tong
1 BALL VALVE 1 533 0096
9 DUST CAP 2 530 0242
10 DUST CAP 2 530 0243
Model TT 7.6 - 15/30

16 PLUG 1 533 0635
18 CARTRIDGE BLOCK ASSEMBLY 1 521 9061
21 PLUG 1 521 5366
23 REDUCER 2 530 0151
24 A35 4-WAY VALVE, BACKUP SECTION (refer to Section 8.7.3.1) 1 521 0227
25 MANOMETER, 600 BAR 1 533 1999
26 RING SEAL 1 533 3170
27 STRAIGHT SCREW-ON SCREW-JOINT 1 562 5083
30 MEASURING CONNECTOR 1 533 0538
38 TIE BOLT 4 529 0555
39 HANDLE, MODIFIED 1 521 0228
Parts list – Additional Manifold for Backup on the Tong (for A-Q-TORK only, not shown)
1 MANOMETER, 600 BAR * 1 533 1999
2 STRAIGHT SCREW-ON SCREW-JOINT * 1 562 5083
3 RING SEAL * 1 533 3170
4 STRAIGHT BULKHEAD SCREW-JOINT * 1 533 0584
5 MEASURING CONNECTOR * 1 533 0538
6 ADJUSTABLE L-SCREW-JOINT * 2 533 4663
7 ADJUSTABLE SCREW-IN SOCKET + SHANK * 1 533 0379
8 PRESSURE CONTROL VALVE + 1 528 0558
9 STRAIGHT SCREW-IN SCREW-JOINT * 1 533 0364
10 ADJUSTABLE ANGLE SCREW-JOINT + 1 533 4513
11 NON-RETURN VALVE * 1 533 0495
12 ADJUSTABLE T-SCREW-JOINT * 1 533 4588

APPENDIX
8.7.3.1 A35 4-Way Valve, Backup Section; Part No.: 521 0227 – Drawing No.: 3.09.0674
Model TT 7.6 - 15/30

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

1 4-WAY VALVE, TONG SECTION 1 529 0552
2 CHECK POPPET, BACKUP SECTION 1 541 0376
3 CUP SPRING 6 541 0374
4 PLATE FOR HANDLE 1 521 0216
5 CAP SCREW 4 541 0520
8.7.3.2 Manifold, Lift Cylinder & Backup on the Tong (for Tong 911 0175 only)
Parts list – Manifold, Lift Cyl. & Backup on the Tong (for Tong 911 0175 only)
Model TT 7.6 - 15/30

1 CARTRIDGE BLOCK 1 599 2649
8 HANSEN BRASS SOCKET 2 544 1028
9 HANSEN BRASS PLUG 2 544 1029
16 COMBINED BALL + RELIEF VALVE 1 541 0414
23 REDUCER 2 530 0151
25 TIE BOLT 4 529 0556
31 STRAIGHT SCREW-ON SCREW-JOINT 1 562 5083
32 MANOMETER, 600 BAR 1 533 1999
34 RING SEAL 1 533 3170

APPENDIX
8.7.4 Manifold, Lift Cylinder on the Tong – Drawing No.: 1.09.4899

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.4899 – Manifold, Lift Cylinder on the Tong

9 DUST CAP 1 530 0242
10 DUST CAP 1 530 0243
13 PLUG 1 521 5366
Model TT 7.6 - 15/30

16 PLUG 1 533 0635
23 REDUCER 2 530 0151
38 TIE BOLT 4 529 0555
39 HANDLE, MODIFIED 1 521 0228

APPENDIX
8.7.5 Hydraulic Safety Interlock – Drawing No.: 1.09.0620

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.0620 – Hydraulic Safety Interlock

1 CYLINDER HOUSING 1 541 0065
2 PISTON 1 541 0066
2.1 SEALING FOR PISTON 1 541 0067
3 ORIFICE 1.0 1 528 0512
4 FILTER CAP 1 541 0081
5 O-RING 1 528 0300
6 O-RING 1 521 0086
7 2-WAY VALVE, INTERLOCK 1 528 0565
7.1 SEAL KIT FOR 2-WAY VALVE 1 528 0522
14 HEXAGON SCREW M8 X 45 2 541 0110
15 ANGLE SWIVEL SCREW-JOINT WITH THROTTLE 1 528 0516
Model TT 7.6 - 15/30

17 WASHER 2 533 0625
30 SPRING FOR PISTON 1 541 0020
44 PIPE CLAMP 1 521 0195
50 ANGLE SWIVEL SCREW-JOINT NO THROTTLE * 1 533 3600
50 ANGLE SWIVEL SCREW-JOINT NO THROTTLE (for tong 911 0175
1 533 3611
only) *
51 ANGLE SCREW-IN SCREW JOINT * 1 533 2562
REPAIR KIT FOR INTERLOCK CARTRIDGE *
1 521 5420
(consists of item 3, 5, 6 and 30)
* not shown

APPENDIX
8.7.6 Manifold on the Tong (incl. Lift Cylinder, Backup, Interlock and High-Torque);
Model 7.6-30 – Drawing No.: 1.09.2961
Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.2961 – Manifold on the Tong, complete

(incl. Lift Cylinder, Backup, Interlock and High-Torque)
Drawing
No.
1 VALVE BLOCK A35 ASSEMBLY (refer to Section 8.7.6.1) 1 3.09.2952
2 HYDRAULIC INTERLOCK (refer to Section 8.7.6.2) 1 1.09.2957
3 MANIFOLD LIFT CYLINDER / BACKUP (refer to Section 8.7.6.3) 1 1.09.2958
4 MANIFOLD, TONG HIGH-TORQUE (refer to Section 1 1.09.2959
8.7.6.4)
Model TT 7.6 - 15/30

APPENDIX
8.7.6.1 Valve Block A35 Assembly – Drawing No.: 3.09.2952

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.2952 – Valve Block A35 Assembly

1 4-WAY VALVE A35 MOD. 1 521 0217
2 BACK UP SECTION, MOD. 2 521 0227
3 INTERLOCK CARTRIDGE 1 521 9236
4 TIE BOLT 1/2-13 UNC X 9 4 529 0556
5 HOLDER 3 521 0221
6 HEXAGON SCREW ISO 4017 - M12 X 100 3 541 0299
7 HANDLE 3 521 0228
Model TT 7.6 - 15/30

APPENDIX
8.7.6.2 Hydraulic Interlock – Drawing No.: 1.09.2957

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.2957 – Hydraulic Interlock

1 2 WAY VALVE 1 528 0565
2 NIPPLE 1/4X2 3/8 1 541 0389
3 RHD-8-PL-A3C 1 533 0496
4 WH 8-PSR-A3C 3 533 3611
5 GE 8-PLR-A3C 1 533 0351
6 PIPE 8X1.5 3500 504 2305
7 EW 8-PL-A3C 2 533 4501
8 T 8-PL-A3C 1 533 0368
9 WE 8-PL/ 1/4NPT-A3C 1 533 0585
10 ADAPTER 1 530 0192
11 EGE 8-PL/ 1-4NPT-A3C 1 533 4876
Model TT 7.6 - 15/30

12 EL 8-PL-A3C 2 533 4651
13 HEXAGON SCREW ISO 4017 - M8 X 45 2 541 0110
14 WASHER DIN125-B8.4 2 533 0625

APPENDIX
8.7.6.3 Manifold Lift Cylinder / Backup – Drawing No.: 1.09.2958

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.2958 – Manifold Lift Cylinder / Backup

2 PUSH PULL COUPLING 2 530 0240
3 PUSH PULL COUPLING 2 530 0241
4 DUST CAP 2 530 0243
5 DUST CAP 2 530 0242
6 REDUCER, 1 X 3/8 4 530 0151
7 GE 12-PSR-A3C 4 533 0434
8 EW 12-PS-A3C 1 533 4513
9 GE 12 PS/ 1-2NPT-A2C 4 533 0480
10 GE 12 PS/ 3-8NPT-A3C 4 533 0362
11 WH 12-PSR-A3C 2 533 4238
Model TT 7.6 - 15/30

12 PRESSURE GAUGE 63MM 600 BAR 1 533 1999
13 RING SEAL 1 533 3170
14 AG-6-S 1 562 5083
16 W 6-PS-A3C 1 533 2045
17 HOLDER 1 599 2650
18 CAP SCREW DIN 912-M8 X 20 2 521 0199
19 WASHER DIN125-A8.4 2 560 0029
20 PIPE 12 X 1.5 3000 504 2312
21 PIPE 6 X 1.5 1000 504 2302

APPENDIX
8.7.6.4 Manifold Tong, High-Torque – Drawing No.: 1.09.2959

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.2959 – Manifold Tong, High-Torque

1 SELF SEAL COUPLING MALE 1 530 0019
2 SELF SEAL COUPLING MALE 1 530 0020
3 DUST CAP 1 530 0013
4 DUST CAP 1 530 0014
6 PIPE 25X2 1500 504 2328
7 GE 25 PS/ 1 0/0NPT-A3C 4 533 0342
8 RED 30/25-PS-A3C 2 533 4785
9 GE 30-PS/ 1 5/8-12UN 2 533 0339
10 EW 25-PS-A3C 2 533 4517
16 WE 25-PS/ 1 0/0NPT-A3C 2 533 0354
Model TT 7.6 - 15/30

17 ADAPTER, MALE, STRAIGHT, 1 1/4 - 1 1 530 0180
18 ADAPTER, MALE, STRAIGHT, 1 - 1 1 530 0179
19 EL 25-PS-A3C 1 533 4667
20 RED 25/8-PS-A3C 1 533 4772

APPENDIX
8.8 FREE FLOATING BACKUP
8.8.1 Backup - Drawing No.: 0.09.4900 Sheet 1

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 0.09.4900 Sheet 1 – Free Floating Backup

1 CASE BODY 1 521 2501
2 SET SCREW 4 541 3602
5 JAW PIN 2 541 0084
6 TENSION LEVER 2 541 3606
8 DISTANCE PIECE 2 521 2508
9 CAP SCREW 4 521 0067
10 CYLINDER (refer to Section 8.8.3) 2 541 3610
14 SET SCREW 16 521 2514
Model TT 7.6 - 15/30

15 GUIDE BUSHING TOP 2 521 2515
16 ROD WIPER 2 521 2516
18 GUIDE BUSHING BOTTOM 2 521 2518
66 CARTRIDGE BLOCK ASSEMBLY, PRESSURE BOOSTER 1 541 9073
67 CAP SCREW 2 557 1045
68 JAW SPRING, LEFT 1 521 2568
69 JAW SPRING, RIGHT 1 521 2569
70 FLOW DIVIDER 1 528 0554
71 HOLDER T-CONNECTION 1 541 3671
72 CAP SCREW 1 541 0293
73 PIPE CLAMP 1 557 1322
75 SPRING, LEFT 1 521 2575
76 SPRING, RIGHT 1 521 2576
77 HEXAGON SCREW * 2 557 1498
78 WASHER * 2 521 0091
100 NOMENCLATURE PLATE, SMALL * 1 522 0401
101 SAFETY LABEL * 2 541 3901
* not shown

APPENDIX
8.8.2 Backup - Drawing No.: 0.09.4900 Sheet 2

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 0.09.4900 Sheet 2 – Free Floating Backup

19 WASHER 2 521 2519
22 THRUST SPRING 2 521 2522
24 WASHER 2 521 2524
30 SPHERICAL BEARING 2 521 2530
38 WASHER 2 521 2538
43 TORSION BAR 1 521 2543
44 SPHERICAL BEARING 2 541 3644
45 BUSHING 4 541 3645
Model TT 7.6 - 15/30

46 SEAL, CELLASTO 4 541 3646
48 BOLT 2 541 3648
50 TORQUE LASHING 1 521 2550
51 BOLT 2 541 3651
56 ADAPTER 1 521 2556
57 ADAPTER 1 521 2557
58 WASHER 1 521 0020
61 BUSHING, LOAD CELL 1000 IS 1 557 1327
62 BUSHING, LOAD CELL 1000 IS 1 521 2562
63 BUSHING, TORQUE GAUGE 1 557 1332

APPENDIX
8.8.3 Cylinder, Part No.: 541 3610 - Drawing No.: 2.09.4224

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 2.09.4224 – Cylinder (Part No. 541 3610)

1 CYLINDER CASE 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 1 541 3755
6 O-RING 1 541 3756
7 PISTON 1 541 3757
8 TURCON GLYD RING 1 521 5358
9 RING, WEAR 1 521 5357
10 CAP SCREW 12 519 1093
11 LOCK WASHER 12 541 0048
Model TT 7.6 - 15/30

12 PLUG 1 533 0634
13 PLUG 2 528 0281
14 NON RETURN VALVE 1 528 0528
15 PLUG 2 533 0635
16 ACCUMULATOR 1 528 0555

APPENDIX
8.8.4 Manifold Plan, Free-Floating Backup - Drawing No.: 1.09.4930

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.4930 – Manifold, Free-Floating Backup

1 PUSH PULL COUPLING, FEMALE 1 530 0240
1 HANSEN BRASS PLUG (for Tong 911 0175 only) 1 544 1029
2 DUST CAP 1 530 0243
3 PUSH PULL COUPLING, MALE 1 530 0241
3 HANSEN BRASS SOCKET (for Tong 911 0175 only) 1 544 1028
4 DUST CAP 1 530 0242
6 HOSE 2 530 0253
Model TT 7.6 - 15/30

13 T-SCREW JOINT 1 533 0325
14 HOSE 2 530 0296
15 HOSE 2 530 0297
22 MEASURING HOSE 1 533 4581
23 CABLE CLAMP 5 560 0857

APPENDIX
8.9 FF - BU CONNECTION PARTS - DRAWING NO.: 0.09.4920

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 0.09.4920 – FF - BU Connection Parts

1 TORQUE TUBE 2 521 2601
2 CAP SCREW 8 521 0109
3 FLANGE 2 521 2603
5 THREADED BOLT 2 521 2605
6 BUSHING 2 521 2606
9 WASHER 2 521 0020
10 TRAVERSE 1 541 3810
11 SUPPORT 1 521 2611
12 BOLT 1 541 3651
Model TT 7.6 - 15/30

15 WASHER 2 541 3815
27 CHAIN 1 541 3827
28 SPRING 1 541 3828

APPENDIX
8.10 LIFT CYLINDER - DRAWING NO.: 2.09.0669

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 2.09.0669 – Lift Cylinder

1 CYLINDER ZD1BSO (refer to Section 8.10.1) 1 541 0420
SEAL KIT FOR LIFT CYLINDER 1 541 0421
2 SNACKLE TOGGLE JOINT (included in item 1) 1 541 0412
1 3
3 THREADED REDUCING SOCKET R /2 X R /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
7 HANSEN BRASS SOCKET (for Tong 911 0175 only) 1 544 1028
8 PUSH-PULL COUPLING, FEMALE 1/2" 1 530 0240
8 HANSEN BRASS PLUG (for Tong 911 0175 only) 1 544 1029
Model TT 7.6 - 15/30

1
9 DUST CAP, MALE /2" 1 530 0242
1
10 DUST CAP, FEMALE /2" 1 530 0243
1
11 STRAIGHT SCREW-IN SCREW-JOINT GE 12-PS / /2 NPT 1 533 0480

APPENDIX
8.10.1 Lift Cylinder, Part No.: 541 0420 - Drawing No.: 3.09.2171
Model TT 7.6 - 15/30

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
14 SET SCREW 1 521 5387
16 SEAL KIT ASSEMBLY (consists of item 17, 18, 19, 20, 21) 1 541 0421
17 WIPER 1 521 5389
Model TT 7.6 - 15/30

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
8.11 SAFETY MARKS - DRAWING NO.: 1.09.2509

Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 1.09.2509 – Safety Marks

1 FRONT GUARD RIGHT, RIGID 1 521 2656
2 FRONT GUARD LEFT, RIGID 1 521 2650
3 PLASTIC FRONT GUARD 2 521 0453
4 STRIP FOR FRONT GUARD 2 521 2657
5 STRIP FOR FRONT GUARD 4 521 2658
6 HANDLE, TONG CASE 2 522 0216
7 HOLDER 2 521 2653
8 LEG 2 521 2652
9 BOLT 2 541 3651
Model TT 7.6 - 15/30

14 CAP SCREW 14 541 0232
15 HANDLE RETROFIT 2 521 2659

APPENDIX
8.12 HYDRAULIC PLANS
8.12.1 Hydraulic Plan, Tong with Backup and Lift Cylinder – Drawing No.: 3.09.0682
Model TT 7.6 - 15/30

APPENDIX
Parts list - Drawing no. 3.09.0682 – Hydraulic Plan,

Tong with Backup and Lift Cylinder

1a A35 OUTLET SECTION 1 -
1b A35 INLET SECTION 1 -
1c A35 TONG SECTION MODIFIED 1 521 0218
A35 4-WAY VALVE MODIFIED (refer to Section 8.7.2.1)
2 1 521 0217
(consists of item 1a – 1c)
A35 BACKUP/LIFT CYLINDER (refer to Section 8.7.3.1)
3 1 521 0227
SECTION MODIFIED
CARTRIDGE BLOCK ASSEMBLY
6 1 521 5409
(consists of item 6.1 – 6.4)
Model TT 7.6 - 15/30

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 – 250 BAR 1 599 0100
9 2-WAY VALVE INTERLOCK 1 528 0521
10 NON-RETURN SUCTION VALVE 1 528 0500
11 MAIN SYSTEM INTERLOCK 1 541 0065
1 541 0066
1 528 0512
1 541 0081
1 528 0300
1 528 0086
1 541 0082
(only for standard tong) 1 541 0020

APPENDIX
NOTES
Model TT 7.6 - 15/30

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OPERATING MANUAL

Hydraulic Tubing Tong

FAX +49 (0) 5 11 - 77 02 - 187

C. Weatherford makes no representation as to the accuracy or completeness of the materials

D. This information is confidential and proprietary property of Weatherford. Do not disclose to

Tong Part- TT 7.6 – 15 TT 7.6 - 30

X = available / - = not available

Model TT 7.6 - 15/30

3.5 Technical Data .......................................................................... 3-13

4.3.2 Specific hydraulic Adjustments .......................................... 4-6

7 Service and Maintenance

Model TT 7.6 - 15/30

Model TT 7.6 - 15/30

 … this device and other material assets of the operating authority

 … the efficient performance of this device.

Model TT 7.6 - 15/30

Safety is not a PROBLEM … it's the ANSWER!

Remember: If you are not part of the SOLUTION,

Operating Manual Rev. August 2005 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. August 2005 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.

Model TT 7.6 - 15/30

Operating Manual Rev. August 2005 Page 1-3 of 12

1.5 SOURCES OF DANGER

 Use only original spare parts.

Page 1-4 of 12 Rev. August 2005 Operating Manual

1.6 OPERATOR’S POSITION

Under no circumstances may anybody stay underneath the suspended tong.

Guide the tong at the designated green handles only.

Model TT 7.6 - 15/30

Fig. 1.1 Operator’s Position

Operating Manual Rev. August 2005 Page 1-5 of 12

1.7 DANGER ZONES

1.7.1 Used Warning Signs

Warning Sign No.: 1

Warning Sign No.: 2

Fig. 1.2 Warning Signs on the Tong

Page 1-6 of 12 Rev. August 2005 Operating Manual

1.7.2 Safety Layout

Danger zone = Tong and backup rotating and clamping movements

Model TT 7.6 - 15/30

R = Number of used warning sign according to Section 1.6.1

Operating Manual Rev. August 2005 Page 1-7 of 12

1.8 QUALIFICATION OF PERSONNEL

Unclear responsibilities are a safety hazard.

 … the operating manual is available to all involved personnel

1.9 PROTECTIVE CLOTHING

Eye protection glasses must be worn to protect against flying particles.

Safety boots to protect against erroneous rest of the equipment.

Page 1-8 of 12 Rev. August 2005 Operating Manual

… this device and other material assets of the operating authority

… the efficient performance of this device.

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.

… the operating manual is available to all involved personnel