Model 500 Technical Manual

GILL SERVICES, INC.
TECHNICAL MANUAL
GILL MODEL 500
POWER TUBING TONG
OPERATING AND MAINTENANCE INSTRUCTIONS
WITH ILLUSTRATED PARTS LIST
Model 500 Serial No.________________________

Customer Reference No._____________________
Gill Services, Inc. 650 Aldine Bender, Houston, TX 77060
Phone: 281-820-5400 Fax: 281-820-0034 Website: www.gillservicesinc.com
IMPORTANT SAFETY NOTICE

Proper service and repair is important to the safe, reliable operation of all GILL SERVICES
equipment. The service procedures recommended by GILL SERVICES and described in the
technical manuals are recommended methods of performing service operations. Some of these
service operations require the use of tools especially designed for the purpose. The special tools
should be used when and as recommended.
It is important to note that some warnings against the use of specific service methods that can
damage the equipment or render it unsafe are stated in the manuals. It is also important to
understand that these warnings are not exclusive. GILL SERVICES could not possibly know,
evaluate, and advise the service people of all conceivable ways in which service might be done or
of the possible hazardous consequences of each way. Accordingly, anyone who uses service
procedures or tools which are not recommended by GILL SERVICES must first satisfy himself
thoroughly that neither his safety nor his equipments safety will be jeopardized by the method
selected.
WARRANTY AND GUARANTEE

GILL SERVICES, INC. warrants and guarantees that all equipment furnished hereunder and
manufactured or reconditioned by GILL SERVICES, INC. (hereinafter called Vendor) is
warranted to be free from defects in workmanship and material for a warranty period of six (6)
months from date of receipt of the original retail purchaser. If, under normal use and service, any
failure of any parts by reason of a defect in workmanship or material shall appear within such
warranty period, Purchaser shall notify Vendor thereof immediately, and if so requested by
Vendor, shall return the defective part to Vendor, transportation charges prepaid, and Vendor
shall, upon verifying that the cause of the failure is within the terms hereof, correct any such
defects by repairing the defective part at its works or by supplying a replacement thereof F.O.B.
Vendors works or warehouse. This guarantee does not apply to any parts or items thereof which
shall have been repaired or altered by other than Vendor in any way so as, in Vendors judgment,
to affect same or which has been subjected to negligence, accident or other than normal use and
service. The liability of Vendor arising out of the supplying of any material hereunder or its use,
whether on warranties or otherwise, shall not exceed the cost of correcting defects as herein
provided, and shall not include transportation charges, Purchasers labor or materials (except as
authorized in wiring in advance), loss of use or revenue, or any indirect or consequential
damages. Upon expiration of said warranty period, all such liability shall terminate. Vendor
shall have no liability, other than as specifically herein provided, upon warranties, expressed or
implied, of any nature whatsoever, (exclusive, however, of its warranty of title) including, but
without limitation, warranties with respect to workmanship, material performance and fitness for
use. Upon the expiration of said six (6) month period after the original receipt to retail purchaser
of the machinery, all liability hereunder with respect to the machinery or any part or parts thereof
repaired or replaced by reason of this guarantee shall terminate. Any parts or material not of
Vendors manufacture is covered only to the extent of any guarantee given to the Vendor by the
seller of said material and enforceable by the Vendor against said seller.
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. DO NOT OPERATE TONG UNTIL ANCHOR ARM IS

ATTACHED TO THE TONG AND ANCHOR POST.
2. DO NOT CRAWL OR STAND UNDER TONG.
3. CAUTION: KEEP HANDS CLEAR OF TONG HEAD
WHILE TONG IS IN OPERATION, AS PARTS INSIDE
TONG HEAD ROTATE. KEEP ALL PARTS OF THE
BODY AND CLOTHING AWAY FROM MOVING
PARTS.
4. SHUT OFF POWER SUPPLY TO THIS UNIT BEFORE
PERFORMING ANY WORK, (i.e., CHANGING TONG
DIES OR JAWS, ADJUSTMENTS, MAINTENANCE,
OR LUBRICATION).
5. FAILURE TO COMPY WITH WARNINGS COULD
RESULT IN EQUIPMENT DAMAGE AND
PERSONAL INJURY.
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.
Fig. 5-1. Hydraulic Lift
5.2 JAW ARRANGEMENT
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.
Engage hydraulic power source.
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
break-out. Tong operates at system pressure for breakout.

System pressure is controlled by a relief valve set at 2200
PSI in power unit tank. PSI should not exceed 2500 PSL
4. If pump fails to pick up oil after hoses have been connected or
if tong runs in surges, screw out relief valve all the way and let
pressure back to tank. Circulate to remove air. Screw In pressure
screw until tong operates. Repeat if necessary.
5. In operating tong, stop operating lever in center position one
second before reversing motor. This reduces fluid shock In
motor.
Fig. 5-2. Tong at Right Angle to Torque Arm
5.4 STEPS TO DISMANTLE

1. Raise tong to top of hydraulic lift travel.
2. Use a line to lower tong and hydraulic lift to ground.
3. Shut off hydraulic source to tong. Engage lever on control valve for lift to release pressure off lift
hose.
4. Disconnect hoses and prepare unit for transporting.
6. VICKERS HYDRAULIC FLUID RECOMMENDATIONS

6.1 OIL-TYPE
Oils used in hydraulic systems perform the dual function of lubrication and transmission of power.
Oil must be selected with care and with the assistance of a reputable supplier.
Crankcase oils meeting or exceeding the Five Engine Test Sequence for evaluating oils for API
(American Petroleum Institute) service MS (Maximum Severity) best serve the needs of mobile
hydraulic systems. These engine sequence tests were adopted by the Society of Automotive
Engineers, American Society for Testing Materials, and automotive engine builders. The MS
classification is the key to selection of oils containing the type of compounding that will extend the
operating life of the hydraulic system. Oils meeting Diesel engine requirements, DG through DS
classifications, may or may not have the type of compounding desired for high performance
hydraulic systems.
HYDRAULIC SYSTEM
OPERATING RANGE
(Mm. to Max.)
0F to 180F
15F to 210F
32F to 230F
0F to 210F
SAE
VISCOSITY
10W
20-20W
30W
10-30W
API SERVICE
CLASSIFICATION
MS
MS
MS
MS
Automatic Transmission Fluid, Type A, is usually satisfactory for power steering

systems or those systems operating under moderate hydraulic service.
6.2 OPERATING TEMPERATURES
These temperature ranges for each grade of oil are satisfactory If suitable procedures
are followed for low temperature start-up conditions and if sustained operation is
avoided at the upper temperature limits. Operation in excess of these temperatures
results in increased wear of the system components and causes more rapid
deterioration of the oil. For optimum operation, a maximum oil viscosity of 4,000 SSU
at the low temperature start-up condition and a minimum oil viscosity of 60 SSU for the
sustained high temperature operating condition are recommended.
Good oils are the most economical. Specifications can be set up which will indicate, to
a limited degree, the characteristics essential in a good hydraulic oil. These are listed
herein and should be checked with the oil manufacturer prior to the use of their
product.
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.
LUBRICATION AND MAINTENANCE

LUBRICATION REQUIREMENTS
TRANSMISSION:
Oil meeting API classification MS:
Temperature above 32F SAE 30W
Temperatures below 32F SAE low
TRANSMISSION CAPACITY...10 quarts
GREASE FITTINGS..Any soft gun lubricant
Lube Fitting in Drag Ring,

remove Guide Bell
_______Lube Fittings___________
Oil Level
Fig. 7-1. Tong Lube Fittings & Oil Level
7.2 OPERATIONAL MAINTENANCE

1. Grease lube fittings weekly, (Fig. 7-1).
2. Check the transmission after every trip. If water or dirt is found in transmission, change oil. Under
normal conditions, oil should be changed every 100 work-hours.
3. Clean and grease tong head and backup tool after every trip. Use kerosene or solvent and a wire
brush for cleaning. After cleaning, apply
cup grease to jaws, pins, ring gear, and top seal.
4. Do not steam clean tong head. Steam cleaning tong head will force water by the top seal Into the
transmission, removing all of the lubricants from top seal and causing It to harden. If steam cleaning is
used, guide bell should be pinned in place. After cleaning, check the transmission for the presence of
water.
7.3 SAFETY POINTS AND WARNINGS
CAUTION: Keep hands clear of Tong Head while Tongs are in operation. Caution should be taken whi!e operating this
equipment, as parts inside the Tong Head rotate.
1. Do not crawl or stand under Tongs as hydraulic line could be cut or broken, and Tongs will fall.
2. Do not operate Power Tongs until the Anchor Arm is attached to the Tong and Anchor Post.
3. Power should be OFF before any size equipment change, maintenance, or any work Is done to this
equipment.
R509-1P
R501-15
Gill Model 500 Final Drive Assembly
Model 500 Transmission Assembly
9. TRANSMISSION ASSEMBLY
PARTS LIST
PART NO.
DESCRIPTION / (Foster Ref. No)
QTY.
PART
NO.
DESCRIPTION
QTY.
G503
RING & PINION GEAR (50-20)
G504
HIGH DRIVE GEAR (58-10)
G505-A
HIGH CLUTCH GEAR ASSY (50-9-1)
G506-A
LOW CLUTCH GEAR ASSY (50-12-2)
G507-A
OIL PUMP GEAR (58-143-1)
K500-3
HYPRO KEY #18 (11-1760
L517
LEVELING PIN (123-27)
M500
MOTOR M25X (1-1/2) (77-90)
O500-4
O-RING 1/8 x 1 x 1-1/4 (11-349)
P501-A
OIL PUMP ASSY (119-202)
P510
5/16 OIL PUMP LINE (93-114)
P511
1/4 OIL PUMP LINE (93-115)
A501
RING GEAR COVER (93-18)
A502
TRANSMISSION END PLATE (58-17-3)
SIDE PLATE ASSY 6-1/2x9-1/2 (58-295)
A504
SIDE PLATE FOR CHAIN (93-295-1)
A508
GUARD COVER (93-122)
B501
TIMKEN BEARING (50-32-1)
B502
BEARING (93-32)
B503
TIMKEN BEARIING (93-183)
B504
BALL BEARING (58-25)
B505
TIMKEN BEARING (92-183)
B509
BEARING CAP, TOP (58-23-1)
BEARING CAP, BOTTOM (58-23)
B510
BEARING CAP, BACK (58-29-1)
R503-1
SPIROLOX RING (11-900)
B511
BEARING CAP MOTOR MOUNT (93-37-2)
S500
RING GEAR & HUB SPROCKET (93-19)
B512
SPACERPINION (58-137-1)
S501
DRIVE SHAFT (93-11)
B512-1
PINION SHIM (NOT PICTURED) (58-83)
W500-5
WAHSER, 3/4 FLAT (11-255)
B512-2
BEARING SPACER (50-45-1)
W501-5
WASHER, 1/2 LOCK (11-87)
C500
CLUTCH ASSY (50-13-1)
W501-11
WASHER, 1 INT LOCK (N/A)
C501
CLUTCH SHIFTIING YOKE (50-193)
X500-6
CAPSCREW (5/16x1/2 HEX) (11-662)
20
C502
CLUTCH SHIFTIING FORK (50-28-3)
X500-11
CAPSCREW (3/8x3/4 HEX) (11-604)
C503
CLUTCH SHAFT (58-14-2)
X500-12
CAPSCREW (3/8x1 HEX) (11-603)
30
C503-1
CLUTCH SHAFT NUT, 1 (58-363-1)
X500-31
CAPSCREW _1/2x2-1/4 HEX) (11-1492)
C503-2
CLUTCH SHAFT PINION KEY, (NO PICTURE)
X501-13
SCREW 3/8x1 SKT HD (11-113)
C518
CLUTCH LEVER WITH SHAFT (58-27-10)
X503-7
SCREW, 5/16x5/16 SKT SET (11-595)
E500
OIL SIGHT GAUGE (56-81)
X503-13
SCREW, 3/8x2 SQ. HD SET (11-1578)
E500-1
PET COCK (1/8 PIPE) (11-299)
Y500-5
NUT, 3/4 HEX (11-76)
F501-2
ELL 1/4 STD. BLK STREET (11-321)
Y500-22
NUT, 1 SAE JAM (11-1137)
F502-5
STR. 1/4 OD x 1/4 PIPE (11-59)
Z506-7
SAFETY PIN (11-920)
F505-6
PLUG, 1/2 SKT PIPE (11-601)
F505-10
PLUG, 1-1/4 XQ. HD. PIPE (11-324)
A503-A
B509-3
10. JAW SETS LISTS
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
Drag Ring Assembly

Consists of:
Drag Ring
Cover Plate
Split Guide Bell
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
Drag Ring Assembly

Consists of:
Drag Ring
Cover Plate
Split Guide Bell
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
DOUBLE ACTING JAWSTUBING

1
1A
1B
2-3/8 - 3-11/16
2-3/8 - 3-1/16
2-7/8 - 3-1/2
3-1/2 Only
Drag Ring Assembly

Consists of:
Drag Ring
Cover Plate
Split Guide Bell
Jaw Assembly
Consists of:
Jaw
Insert
Insert Screw
Insert
Insert
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
JAW LISTBACKUP TOOL

ITEM
NO.
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
When more than one drag ring assembly is required, do not

duplicate the same items included in other drag ring assemblies.
Example: Running tubing 1-5/16 through 1.9 O.D. requires a
D500-2-A Drag Ring, an R501-15 Cover Plate, and an R509-1-A
Split Guide Bell. To change over to run 3-1/2 through 5 O.D.,
you would need to change to P/N D501-A Drag Ring; P/N R501-2
Cover Plate; and P/N R506-1-A Split Guide Bell.
The Backup Tool must have a 6-1/4 bore through the head to
use the 4-1/2 through 6-1/16 O.D. Jaw Sets. The BU509-2
Housing Adapter is used on the other equipment size to reduce
the bore from 6-1/4 O.D. to 5 O.D.
The sizes listed are the actual O.D. size for tubing, upset, or collar
that the jaws will catch.
11. TONG DRAG RING ASSEMBLY

PARTS LIST
D500-2- A
DRAG RING ASSEMBLY 1-5/16 - 3-1/2 O.D. (5-1/2 BORE)

PART NO.
Jaw Pin1
D507
Drag Plug
D506
Drag Spring
D505
Set Screw
Grease Fitting
DRAG RING ASSEMBLY 4 - 5-1/2 O.D. (7-1/4 BORE)

PART NO.
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
DRAG RING ASSEMBLY 3-1/2 - 6-1/16 O.D. (6-1/4 BORE)

PART NO.
D508
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
DRAG RING ASSEMBLY 6-5/8 - 7 O.D. (7-7/8 BORE)

PART NO.
D104
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
(Foster Ref. No. 123-3-1)

(Foster Ref. No. 123-23)
(Foster Ref. No. 126-7
(Foster Ref. No. 74-73 & 58-72)

(Foster Ref. No. 11-1076 & 123-6)
(Foster Ref. 11-361)
Foster Ref. No. 11-946)


(Foster Rerf. No. 11-803)
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
15. COMMERCIAL HYDRAULICS
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)
Hex Nut, 3/8 (not pictured)
W501-5 (11-87)
Lock Washer, 1/2 (not pictured)
F502-7 (11-90)
Str. Fitting, 3/8 Flare to 3/8 Pipe (not pictured)
F501-15 (11-165)
Ell, 1 x 90 Degree,s,H.P.
F503-10 (11-254)
Nipple, 1 Close H.P.
F507-5 (11-265)
Collar, 1 H.P.
F503-12 (11-333)
Nipple, 1 x 2-1/2 H.P.
F503-17 (11-337)
Nipple, 1 x 6 H.P.
F500-5 (11-427)
Ell, 1/4 Flare to 1/4 Pipe, 45-Degrees
Q500-18 (11-560)
Dust Cap, 1
Q500-23 (11-566)
Dust Cap, 1-1/4
F505-9 (11-606)
Pipe Plug, 1 Socket (not pictured)
X500-26 (11-641)
Capscrew 1/2 X 1 Hex (not pictured)
Q500-4 (11-850)
Dust Plug (not pictured)
Q500-1 (11-946)
Coupling Half, 1/2 (not pictured)
Q500-17 (11-953)
Coupling Half, 1
Q500-21 (11-955)
Coupling Half, 1-1/4
(Continued on Page 2)
15. COMMERCIAL HYDRAULICS
PARTS LIST (cont.)

PART NO.
(Foster Ref. No)
DESCRIPTION
QTY.
REQD.
T500-12 (11-963)
Ell, 1 Pipes 1 Tube, 90-Degrees
T500-4 (11-966)
Straight Fitting
X500-20 (11-1286)
Capscrew, 3/8 x 4 Hex
Z501-2 (11-1401)
Yoke Pin, 3/8 x 1
X500-32 (11-1363)
Capscrew, 1/2 x 2-1/4 Hex
F500-9 (11-1563)
Ell, 3/8 Flare to 3/8 Pipe, 45-Degrees (not pictured)
T506 (11-1572)
Tee, 3/4 x 3/4 x 1 Bax w/1/4 NPT
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)
Check Valve Assy (not pictured)
V507-NSP
Cartridge Style Relief Valve
V508 (183-9)
Knob
V516 (867-22)
Handle
X500-13 (11-1043)
Capscrew, 3/8 x 1-1/4 Hex Hd
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

(Foster Ref. No11-427)
(Foster #11-1580)
BU50O-A BACKUP TOOL
INSTRUCTIONS FOR BU500-A BACKUP TOOL




AIR CONTROLS FOR BU500-A BACKUP TOOL
F502-4
F500-6
Q500-27
F500-5
F505-3
Z502-4

Cotter Pin, 1/2 x 1-1/2 (Foster Ref. No. 11-796)

Foster Ref. No. 11-1300)
Z500-2
H519-2
H519-1
(Foster Rerf. No. 12-91)
H504-4
BU521-A
V523

(Foster Ref. No. 105)
GILL SERVICES, INC. MODEL 500 MAINTENANCE LOG

MODEL 500 SERIAL NO.______________________________
DATE
TYPE OF MAINTENANCE PERFORMED
INITIALS
GILL SERVICES, INC. MODEL 500 MAINTENANCE LOG

MODEL 500 SERIAL NO.______________________________
DATE
TYPE OF MAINTENANCE PERFORMED
INITIALS

Model 500 Technical Manual

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Model 500 Technical Manual

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GILL SERVICES, INC.

Model 500 Serial No.________________________

IMPORTANT SAFETY NOTICE

WARRANTY AND GUARANTEE

1. DO NOT OPERATE TONG UNTIL ANCHOR ARM IS

Fig. 5-1. Hydraulic Lift

5.2 JAW ARRANGEMENT

Engage hydraulic power source.

break-out. Tong operates at system pressure for breakout.

Fig. 5-2. Tong at Right Angle to Torque Arm

5.4 STEPS TO DISMANTLE

6. VICKERS HYDRAULIC FLUID RECOMMENDATIONS

Automatic Transmission Fluid, Type A, is usually satisfactory for power steering

LUBRICATION AND MAINTENANCE

Lube Fitting in Drag Ring,

Fig. 7-1. Tong Lube Fittings & Oil Level

7.2 OPERATIONAL MAINTENANCE

Gill Model 500 Final Drive Assembly

Model 500 Transmission Assembly

DESCRIPTION / (Foster Ref. No)

RING & PINION GEAR (50-20)

HIGH DRIVE GEAR (58-10)

HIGH CLUTCH GEAR ASSY (50-9-1)

LOW CLUTCH GEAR ASSY (50-12-2)

OIL PUMP GEAR (58-143-1)

HYPRO KEY #18 (11-1760

LEVELING PIN (123-27)

MOTOR M25X (1-1/2) (77-90)

O-RING 1/8 x 1 x 1-1/4 (11-349)

OIL PUMP ASSY (119-202)

5/16 OIL PUMP LINE (93-114)

1/4 OIL PUMP LINE (93-115)

RING GEAR COVER (93-18)

TRANSMISSION END PLATE (58-17-3)

SIDE PLATE ASSY 6-1/2x9-1/2 (58-295)

SIDE PLATE FOR CHAIN (93-295-1)

GUARD COVER (93-122)

TIMKEN BEARING (50-32-1)

TIMKEN BEARIING (93-183)

BALL BEARING (58-25)

TIMKEN BEARING (92-183)

BEARING CAP, TOP (58-23-1)

BEARING CAP, BOTTOM (58-23)

BEARING CAP, BACK (58-29-1)

SPIROLOX RING (11-900)

BEARING CAP MOTOR MOUNT (93-37-2)

RING GEAR & HUB SPROCKET (93-19)

DRIVE SHAFT (93-11)

PINION SHIM (NOT PICTURED) (58-83)

WAHSER, 3/4 FLAT (11-255)

BEARING SPACER (50-45-1)

WASHER, 1/2 LOCK (11-87)

CLUTCH ASSY (50-13-1)

WASHER, 1 INT LOCK (N/A)

CLUTCH SHIFTIING YOKE (50-193)

CAPSCREW (5/16x1/2 HEX) (11-662)

CLUTCH SHIFTIING FORK (50-28-3)

CAPSCREW (3/8x3/4 HEX) (11-604)

CLUTCH SHAFT (58-14-2)

CAPSCREW (3/8x1 HEX) (11-603)

CLUTCH SHAFT NUT, 1 (58-363-1)

CAPSCREW _1/2x2-1/4 HEX) (11-1492)

CLUTCH SHAFT PINION KEY, (NO PICTURE)

SCREW 3/8x1 SKT HD (11-113)