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TECHNICAL MANUAL
GILL MODEL 500
POWER TUBING TONG
OPERATING AND MAINTENANCE INSTRUCTIONS
WITH ILLUSTRATED PARTS LIST
WARNING
DO NOT OPERATE, ADJUST, OR REPAIR THIS TONG
WITHOUT PROPER TRAINING. READ AND UNDERSTAND ALL
OPERATING AND MAINTENANCE INSTRUCTIONS AND ALL
OTHER WARNINGS CONCERNING SAFETY BEFORE USING
THIS TONG. DO NOT REMOVE OR PAINT OVER WARNING
LABELS.
1. INTRODUCTION
This manual contains information regarding the GILL Model 500 Power Tong. Full benefit
of long life and dependability of this unit can only be realized by proper operation and
maintenance. The operator should familiarize himself thoroughly with information
contained in this manual before operating this tong. GILL SERVICES, INC. provides the
information, data, and recommendations contained in this manual as a customer service. All
are believed accurate. However, GILL SERVICES, INC. assumes no responsibility, implied
or otherwise, for errors in or for the application of the Information, data, and
recommendations presented herein.
The right is reserved to make changes in this manual at any time, without obligation.
SECTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
TITLE
PAGE
WARRANTY..
WARNING
INTRODUCTION .
GENERAL DESCRIPTION
TORQUE CURVE ...
SPECIFICATIONS ..
INSTALLATION AND OPERATION INSTRUCTIONS ..
VICKERS HYDRAULIC FLUID RECOMMENDATIONS
LUBRICATION AND MAINTENANCE .
FINAL DRIVE ASSEMBLY
TRANSMISSION ASSEMBLY ..
JAW SETS LISTS ...
TONG DRAG RING ASSEMBLY .
CLUTCH ASSEMBLY .
HYDRAULIC LIFT ASSEMBLY ..
COMMERCIAL HYDRAULICS ..
HYDRAULIC TORQUE GAUGE ASSEMBLY ..
BACKUP TOOL ...
AIR CONTROLS FOR BACKUP TOOL ....
MAINTENANCE LOG..
l
ll
1
1
2
3
4
6
7
9
11
13
16
17
20
23
26
27
30
31
2. GENERAL DESCRIPTION
GILL MODEL 500 Power Tong is a safe and accurate unit for the makeup and
breakout of tubing and casing 1-5/16 in O.D. through 7 in O.D. These power tong
features include: closed head design, allowing tong to remain in position during
the entire trip, reducing makeup and break-out time; pressure oil bath
lubrication; positive case seal; direct motor drive; roller chain final drive; two
speed operation; controlled torque; and stiff torque arm for safety.
4. SPECIFICATIONS Contd
Torque Range: 300 to 6,000 ft lb torque
High Gear...300 to 1,300ft lb
Low Gear6,000 ft lb
-
RPM
High Gear.*126
Low Gear...*27
Hydraulic Requirement..33 GPM at 2,000 psi
Tong Length.51
Space Required on Pipe
Tong.9-1/2 in
With backup.....16-1/2 in
Maximum Elevator Diameter Clearance...30
Approximate Weight
Tong...1,000 lb
* (RPM based on published requirements of motor manufacturer: 33.5
GPM to tong motor
5. INSTALLATION AND OPERATION INSTRUCTIONS
5.1 INSTALLING WITH SPRING CUSHIONED HYDRAULIC LIFT
1. Move tong to convenient position near well.
2. Lift hydraulic cylinder, set in position on tong, attach with pins, and connect
hydraulic line from control valve to cylinder.
3. Lift tong with line approximately 3 feet above well head. (Cylinder has 6 foot
travel.) The hydraulic lift is ready to operate by means of controls. The line
supporting the tong should be located so the tong head will hang over the center of
the well.
4. Weld anchor bracket on right rear corner of rig approximately 4 feet above
ground. Additional anchor brackets can be purchased for use of this tong on more
than one rig. See Figure 5-1.
5. Connect torque arm to rear of tong and to anchor bracket on rig. The torque
arm Is adjustable, so adjust the torque arm so that the tong will be at a right angle to
torque arm. See Figure 5-2. Tong should then have about 4 feet of free vertical
travel. Lower tong over tubing.
6. Attach hoses from hydraulic power source. Be sure all self-sealing hose
couplings are tight before starting engine. Tighten firmly by hand. Failure to do this
will cause engine to run at full speed when tong is not in use.
7. To level tong, use the leveling screws and compression spring nuts. If tong is
not level, it will cause excessive wear to tong jaws and Inserts. See Figure 5-3.
1. For breaking out and/or making up joints, place jaws on pins with
long side of jaw against gear teeth.
2. Inserts are reversible and should be turned around when they
become worn or replaced if reversing fails to bring sharp teeth
In contact with pipe.
5.3 SETTING HYDRAULICS FOR PROPER OPERATION
1. Check all hose connections before engaging hydraulic power
source.
2.
3.
Adjust tong relief valve. The relief valve on the tong operates
in makeup direction only.
a. Turn relief valve adjusting screw to left to
reduce pressure until tong reduces speed.
b. Place tong on tubing to be made up and
gradually increase the pressure to reach make up
required. Check manufacturers recommended
makeup torque for type of joint being
made up.
c. Lock relief valve adjusting screw and make up
second joint checking torque where tong stalls.
d. Make minor corrections as necessary until
torque readings are satisfactory.
e. If tong grips and slips, increase pressure on
drag plugs by screwing in drag screws in drag
ring. Adjust screws evenly. See Figure 5-4.
NOTE: It is not necessary to change makeup torque to
SAE
VISCOSITY
10W
20-20W
30W
10-30W
API SERVICE
CLASSIFICATION
MS
MS
MS
MS
6.3
VISCOSITY
Viscosity is the measure of fluidity. The oil must have sufficient body to provide adequate sealing
effect between working parts of pumps, valving, cylinders, etc., but not enough to cause pump
intake cavitation or sluggish valve action. Viscosity recommendations must at best be a
compromise, which takes Into consideration the working temperature range, the type of hydraulic
equipment used, and class of service. Refer to table of oil viscosity recommendations.
6.4
VISCOSITY INDEX
The viscosity Index Is a measure of the rate at which temperature changes cause a change in oil
viscosity. It is very desirable that the oil viscosity remain as nearly constant as possible under the
wide range of temperature conditions encountered in operating mobile construction machinery.
The viscosity Index (Vi.) of hydraulic oil should not be less than 90 for this type of service.
6.5
ADDITIVES
Research has developed a number of additive agents which materially improve various characteristic of oils for hydraulic systems. They may be selected for compounding with a view toward
reducing wear, Increasing chemical stability, inhibiting corrosion, depressing pour point and
improving the anti-foam characteristics. Proper use of additive agents requires specialized
knowledge, and they should be Incorporated by the oil manufacturer only, as serious trouble may
otherwise result.
Most oil companies have several brands of crankcase oils of somewhat varying formulation that
will meet the API service classification of MS. The more desirable of these oils for hydraulic service
will contain higher amounts of the type of compounding that avoids scuffing and wear of cam
lobes and valve lifters. These oils will also be formulated to be stable under oxidative conditions
and when in contact with small amounts of moisture. There should also be reasonable protection
against rust to any ferrous materials submerged in the oil or covered by the oils film.
6.6
CLEANLINESS
Thorough precautions should be taken to filter the oil in the entire hydraulic system prior to its
initial use to remove paint, metal chips, welding shot, lint, etc. If this is not done, damage to the
hydraulic system will probably result. In addition, continuing filtration is required to remove sludge
and products of wear and corrosion, throughout the life of the system.
Precautions should be taken in the design of hydraulic circuits to assure that a means is provided
to keep the oil clean. This can best be accomplished by the use of a 25-micron full-flow filter or a
10-micron bypass filter plus a micronic filter type air breather or sealed reservoir.
6.7
MISCELLANEOUS
The performance of hydraulic valves and cylinders is less affected by the lubricating quality of the
oil and, therefore, selection of the oil is less critical than for pumps and motors. It is always good
practice, however, to use the best quality oil available for all components.
7.
_______Lube Fittings___________
Oil Level
R509-1P
R501-15
9. TRANSMISSION ASSEMBLY
PARTS LIST
PART NO.
QTY.
PART
NO.
DESCRIPTION
QTY.
G503
G504
G505-A
G506-A
G507-A
K500-3
L517
M500
O500-4
P501-A
P510
P511
A501
A502
A504
A508
B501
B502
BEARING (93-32)
B503
B504
B505
B509
B510
R503-1
B511
S500
B512
SPACERPINION (58-137-1)
S501
B512-1
W500-5
B512-2
W501-5
C500
W501-11
C501
X500-6
20
C502
X500-11
C503
X500-12
30
C503-1
X500-31
C503-2
X501-13
C518
X503-7
E500
X503-13
E500-1
Y500-5
F501-2
Y500-22
F502-5
Z506-7
F505-6
F505-10
A503-A
B509-3
SINGLE-ACTING JAWSTUBING
ITEM
NO
O.D. TUBULAR
1-5/16 - 1.9
1A
2A
2B
2C
3A
3B
3C
1-5/16 - 1.9
1-7/8 - 3-1/2
1-7/8 - 3-1/2
2-3/8 - 2-7/8
2-7/8 - 3-1/2
3-1/2 - 5
3-1/2 - 4-1/2
4 - 5
5 - 6-1/16
DESCRIPTION
Drag Ring Assembly
Consists of:
Drag Ring
Cover Plate
Split Guide Bell
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
Drag Ring Assembly
Consists of:
Drag Ring
Cover Plate
Split Guide Bell
PART NO
D500-2-A
R501-15
R509-1-A
J501
N501
N507
D500-2-A
R501-15
R509-1-A
NO. REQUIRED/
TONG OR ASSY.
1/Assy.
1/Assy.
1/Assy
5
10
10
1/Assy
1/Assy
1/Assy
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
J502
N502
N507
5
10
10
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
J503
N503
N507
5
10
10
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
Drag Ring Assembly
Consists of:
Drag Ring
Cover Plate
Split Guide Bell
5/Tong
J505-2
N505-4
N507
1/Assy
1/Assy
1/Assy
D501-A
R501-2
R506-1-A
5
5
5
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
J505-2
N505
N507
5
5
5
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
J505-2
N505-1
N507
5
5
5
Jaw (solid)
J507
5/Tong
SINGLE-ACTING JAWSCASING
ITEM
NO
O.D. TUBULAR
4 - 5-1/2
1A
1B
DESCRIPTION
4 - 4-1/2
5 - 5-1/2
6-5/8 - 7
PART NO
NO. REQUIRED/
TONG OR ASSY.
1/Tong
D502-1-A
R501-3-1
R507-1-A
1/Assy.
1/Assy.
1/Assy/
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
J506
N505-2
N507
5
5
5
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
J506
N505-3
N507
5
5
5
D503-A
R501-4
R508-1-A
1/Assy
1/Assy
1/Assy
2A
6-5/8
Jaw (solid)
J508
10/Tong
2B
Jaw (solid)
J509
10/Tong
1A
1B
2-3/8 - 3-11/16
2-3/8 - 3-1/16
2-7/8 - 3-1/2
3-1/2 Only
D500-2-A
R501-15
R509-1-A
1/Assy
1/Assy
1/Assy
5/Tong
J510
N504
N507
5
5
5
N504-3
N504-1
5
5
O.D. TUBULAR
1-5/16 - 2-1/16
2-3/8 - 3-3/4
3-1/16 - 4-1/2
DESCRIPTION
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
PART NO.
NO. REQUIRED/
TONG OR ASSY
5/Backup
BU501
N501
N506
1/Assy
1/Assy
1/Assy
5/Tong
BU502
N503
N506
1/Assy
1/Assy
1/Assy
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
5/Tong
BU503
N503
N506
1/Assy
1/Assy
1/Assy
4-1/2 - 5-9/16
Jaw (solid)
BU504
5/Backup
5 - 6-1/16
Jaw (solid)
BU505
5/Backup
D507
Drag Plug
D506
Drag Spring
D505
Set Screw
Grease Fitting
D501-A
DESCRIPTION
QTY.
D508-1
Jaw Pin3/4
D507-1
Drag Plug
D506-1
Drag Spring
D505-1
Set Screw
Z503-1
Grease Fitting
DESCRIPTION
QTY.
Jaw Pin1
Drag Plug
Drag Spring
D505-1
Set Screw
Z503-1
Grease Fitting
D507-2
D506
D503-A
QTY.
D508
Z503-1
D502-1-A
DESCRIPTION
DESCRIPTION
QTY.
Jaw Pin1
10
D507-1
Drag Plug
D506-1
Drag Spring
D505-1
Set Screw
Z503-1
Grease Fitting
Clutch Assembly
C516
C513
C511
C517
C512
C509
C508
C515
C505-A
C510
C507
C514
C506-A
C507
C508
C510
C517
C511
C509
C512
C513
C516
13. CLUTCH
13.1 Adjustment For Clutch
1. Remove side panel from operators side of tong.
2. Be sure tong is in neutral position.
3. Rotate clutch with hand until slot in adjusting collar is facing toward the opening in tong.
4. Insert screwdriver or similar object in slot in the adjusting collar.
5. Pry the adjusting collar away from pressure plate so that the teeth are free from each other.
6. Rotate adjusting collar in the direction shown to adjust clutch.
7. Follow the above procedure for both ends of the clutch.
8. Adjust left end of clutch for high gear.
9. Adjust right end of clutch for low gear.
10. If the clutch slips or the disc stack heats up, adjustment is required.
PARTS LIST
PART NO. (Foster Ref. No.)
DESCRIPTION
REOD.
C504 (819-1 )
Anchor Pin
C516 (819-5)
Split Ring
C508 (819-9 )
Pressure Plate
C509 (819-10 )
Inner Disc
12
C510 (819-11 )
Outer Disc
14
C511 (819-12 )
Thrust Plate
C507 (819-13 )
Adjustment Collar
C513 (819-14)
Spring Pin
C512 (819-16 )
Separating Spring
C514 (819-17 )
Dog
C515 (819-18 )
Dog Pivot
C505-A (819-20 )
Body
C506-A (819-21)
ShIpper Sleeve
C517 (11-1186)
No.CHyProKey
V516
A506
V519-1
V500
X500-20
F503-10
T506
F501-15
T500-12
X500-13
A507
T500-12
M500
T501-A
T500-12
Q500-21
F503-17
Q500-17
T502-A
T500-A
H502
V508
V507-NSP
PARTS LIST
PART NO.
(Foster Ref. No)
DESCRIPTION
QTY.
REQD.
T500-A (10-606)
Steel Tubing
T501-A (10-607)
Steel Tubing
T502-A (10-608)
Steel Tubing
Y500-5 (11-76)
W501-5 (11-87)
F502-7 (11-90)
F501-15 (11-165)
Ell, 1 x 90 Degree,s,H.P.
F503-10 (11-254)
F507-5 (11-265)
Collar, 1 H.P.
F503-12 (11-333)
F503-17 (11-337)
Nipple, 1 x 6 H.P.
F500-5 (11-427)
Q500-18 (11-560)
Dust Cap, 1
Q500-23 (11-566)
F505-9 (11-606)
X500-26 (11-641)
Q500-4 (11-850)
Q500-1 (11-946)
Q500-17 (11-953)
Coupling Half, 1
Q500-21 (11-955)
(Continued on Page 2)
DESCRIPTION
QTY.
REQD.
T500-12 (11-963)
T500-4 (11-966)
Straight Fitting
X500-20 (11-1286)
Z501-2 (11-1401)
X500-32 (11-1363)
F500-9 (11-1563)
T506 (11-1572)
H502 (12-130)
Hose Assy
V500 (58-240-5)
Commercial Valve
T512 (76-166)
Tee
M500 (77-90)
Hydraulic Motor
V519-1 (93-117-6)
Linkage
A507 (93-125)
Counterbalance
A506 (93-126)
Valve Plate
V514 (181-24-1)
V507-NSP
V508 (183-9)
Knob
V516 (867-22)
Handle
X500-13 (11-1043)
16
I501
I500-1
F500-5
I502
H500
Y500-1
X502-4
F507-1
F500-6
F500-6
F507-1
F500-5
X502-4
Y500-1
H500
I500-1
I501
I502
F502-4
F500-6
Q500-27
F500-5
F505-3
Z502-4
Z500-2
H519-2
H519-1
H504-4
BU521-A
V523
INITIALS
INITIALS