model 500 technical manual

7/23/2019 Model 500 Technical Manual

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GILL SERVICES, INC.TECHNICAL MANUAL

GILL MODEL 500

POWER TUBING TONG

OPERATING AND MAINTENANCE INSTRUCTIONSWITH ILLUSTRATED PARTS LIST

Gill Services, Inc. 650 Aldine Bender, Houston, TX 77060

Phone: 281-820-5400 Fax: 281-820-0034 Website: www.gillservicesinc.com

Model 500 Serial No.________________________Customer Reference No._____________________


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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 theseservice 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 suchdefects 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 foruse. 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.


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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 WARNINGLABELS.

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 INSIDETONG 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 ANDPERSONAL INJURY.

WARNING


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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..

2. GENERAL DESCRIPTION

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1

2

3

4

6

7

9

11

13

16

1720

23

26

27

30

31

SECTION TITLE PAGE

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.13.

14.

15.

16.

17.

GILL MODEL 500 Power Tong is a safe and accurate unit for the makeup andbreakout of tubing and casing 1-5/16 in O.D. through 7 in O.D. These power tongfeatures include: closed head design, allowing tong to remain in position duringthe entire trip, reducing makeup and break-out time; pressure oil bathlubrication; positive case seal; direct motor drive; roller chain final drive; twospeed operation; controlled torque; and stiff torque arm for safety.

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.


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4. SPECIFICATIONS - ContdTorque Range: 300 to 6,000 ft lb torque

High Gear...300 to 1,300ft lbLow Gear6,000 ft lb

RPMHigh Gear.*126

Low Gear...*27

Hydraulic Requirement..33 GPM at 2,000 psi

Tong Length.51

Space Required on PipeTong.9-1/2 inWith backup.....16-1/2 in

Maximum Elevator Diameter Clearance...30Approximate Weight

Tong...1,000 lb

* (RPM based on published requirements of motor manufacturer: 33.5GPM 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 connecthydraulic line from control valve to cylinder.

3. Lift tong with line approximately 3 feet above well head. (Cylinder has 6 foottravel.) The hydraulic lift is ready to operate by means of controls. The linesupporting the tong should be located so the tong head will hang over the center ofthe well.

4. Weld anchor bracket on right rear corner of rig approximately 4 feet aboveground. Additional anchor brackets can be purchased for use of this tong on morethan one rig. See Figure 5-1.

5. Connect torque arm to rear of tong and to anchor bracket on rig. The torquearm 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 verticaltravel. Lower tong over tubing.

6. Attach hoses from hydraulic power source. Be sure all self-sealing hosecouplings are tight before starting engine. Tighten firmly by hand. Failure to do thiswill 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 isnot level, it will cause excessive wear to tong jaws and Inserts. See Figure 5-3.

Fig. 5-1. Hydraulic Lift


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5.2 JAW ARRANGEMENT

1. For breaking out and/or making up joints, place jaws on pinswithlong 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 operatesin 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 letpressure 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


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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 torelease pressure off lifthose.4. Disconnect hoses and prepare unit for transporting.

6. VICKERS HYDRAULIC FLUIDRECOMMENDATIONS

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 mobilehydraulic systems. These engine sequence tests were adopted by the Society of AutomotiveEngineers, American Society for Testing Materials, and automotive engine builders. The MSclassification 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 DSclassifications, may or may not have the type of compounding desired for high performancehydraulic systems.

Automatic Transmission Fluid, Type A, is usually satisfactory for power steeringsystems or those systems operating under moderate hydraulic service.

6.2 OPERATING TEMPERATURES

These temperature ranges for each grade of oil are satisfactory If suitable proceduresare followed for low temperature start-up conditions and if sustained operation isavoided at the upper temperature limits. Operation in excess of these temperaturesresults in increased wear of the system components and causes more rapiddeterioration 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 thesustained high temperature operating condition are recommended.

Good oils are the most economical. Specifications can be set up which will indicate, toa limited degree, the characteristics essential in a good hydraulic oil. These are listedherein and should be checked with the oil manufacturer prior to the use of theirproduct.

HYDRAULIC SYSTEMOPERATING RANGE

(Mm. to Max.)

SAEVISCOSITY

API SERVICECLASSIFICATION

0F to 180F15F to 210F32F to 230F0F to 210F

10W20-20W30W10-30W

MSMSMSMS


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6.3 VISCOSITY

Viscosity is the measure of fluidity. The oil must have sufficient body to provide adequate sealingeffect between working parts of pumps, valving, cylinders, etc., but not enough to cause pumpintake cavitation or sluggish valve action. Viscosity recommendations must at best be acompromise, 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 oilviscosity. It is very desirable that the oil viscosity remain as nearly constant as possible under thewide 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 charac-teristic of oils for hydraulic systems. They may be selected for compounding with a view towardreducing wear, Increasing chemical stability, inhibiting corrosion, depressing pour point andimproving the anti-foam characteristics. Proper use of additive agents requires specializedknowledge, and they should be Incorporated by the oil manufacturer only, as serious trouble mayotherwise result.

Most oil companies have several brands of crankcase oils of somewhat varying formulation thatwill meet the API service classification of MS. The more desirable of these oils for hydraulic servicewill contain higher amounts of the type of compounding that avoids scuffing and wear of camlobes and valve lifters. These oils will also be formulated to be stable under oxidative conditionsand when in contact with small amounts of moisture. There should also be reasonable protectionagainst rust to any ferrous materials submerged in the oil or covered by the oils film.

6.6 CLEANLINESSThorough 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 thehydraulic system will probably result. In addition, continuing filtration is required to remove sludgeand 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 providedto keep the oil clean. This can best be accomplished by the use of a 25-micron full-flow filter or a10-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 theoil and, therefore, selection of the oil is less critical than for pumps and motors. It is always goodpractice, however, to use the best quality oil available for all components.

7. LUBRICATION AND MAINTENANCELUBRICATION REQUIREMENTSTRANSMISSION:Oil meeting API classification MS:

Temperature above 32F SAE 30WTemperatures below 32F SAE lowTRANSMISSION CAPACITY...10 quartsGREASE FITTINGS..Any soft gun lubricant


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Lube Fitting in Drag Ring,

remove Guide Bell

Oil Level_______Lube Fittings___________

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. Undernormal 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 wirebrush for cleaning. After cleaning, applycup 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 thetransmission, removing all of the lubricants from top seal and causing It to harden. If steam cleaning isused, guide bell should be pinned in place. After cleaning, check the transmission for the presence ofwater.

7.3 SAFETY POINTS AND WARNINGS

CAUTION:Keephands clear of Tong Head while Tongs are in operation. Caution should be taken whi!e operating thisequipment, 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 thisequipment.


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R509-1P

R501-15

Gill Model 500 Final Drive Assembly


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Model500TransmissionAssembly


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PART NO. DESCRIPTION / (Foster Ref. No) QTY.

A501 RING GEAR COVER (93-18) 1

A502 TRANSMISSION END PLATE (58-17-3) 1

A503-A SIDE PLATE ASSY 6-1/2x9-1/2 (58-295) 2

A504 SIDE PLATE FOR CHAIN (93-295-1) 1

A508 GUARD COVER (93-122) 1

B501 TIMKEN BEARING (50-32-1) 3

B502 BEARING (93-32) 1

B503 TIMKEN BEARIING (93-183) 1

B504 BALL BEARING (58-25) 4

B505 TIMKEN BEARING (92-183) 1

B509 BEARING CAP, TOP (58-23-1) 1

B509-3 BEARING CAP, BOTTOM (58-23) 1

B510 BEARING CAP, BACK (58-29-1) 1

B511 BEARING CAP MOTOR MOUNT (93-37-2) 1

B512 SPACERPINION (58-137-1) 1

B512-1 PINION SHIM (NOT PICTURED) (58-83) 3

B512-2 BEARING SPACER (50-45-1) 2

C500 CLUTCH ASSY (50-13-1) 1

C501 CLUTCH SHIFTIING YOKE (50-193) 1

C502 CLUTCH SHIFTIING FORK (50-28-3) 1

C503 CLUTCH SHAFT (58-14-2) 1

C503-1 CLUTCH SHAFT NUT, 1 (58-363-1) 1

C503-2 CLUTCH SHAFT PINION KEY, (NO PICTURE) 1

C518 CLUTCH LEVER WITH SHAFT (58-27-10) 1

E500 OIL SIGHT GAUGE (56-81) 1

E500-1 PET COCK (1/8 PIPE) (11-299) 1

F501-2 ELL 1/4 STD. BLK STREET (11-321) 1

F502-5 STR. 1/4 OD x 1/4 PIPE (11-59) 1

F505-6 PLUG, 1/2 SKT PIPE (11-601) 1

F505-10 PLUG, 1-1/4 XQ. HD. PIPE (11-324) 2

PART

NO.

DESCRIPTION QT

G503 RING & PINION GEAR (50-20) 1

G504 HIGH DRIVE GEAR (58-10) 1

G505-A HIGH CLUTCH GEAR ASSY (50-9-1) 1

G506-A LOW CLUTCH GEAR ASSY (50-12-2) 1

G507-A OIL PUMP GEAR (58-143-1) 1

K500-3 HYPRO KEY #18 (11-1760 3

L517 LEVELING PIN (123-27) 2

M500 MOTOR M25X (1-1/2) (77-90) 1

O500-4 O-RING 1/8 x 1 x 1-1/4 (11-349) 1

P501-A OIL PUMP ASSY (119-202) 1

P510 5/16 OIL PUMP LINE (93-114) 1

P511 1/4 OIL PUMP LINE (93-115) 1

R503-1 SPIROLOX RING (11-900) 3

S500 RING GEAR & HUB SPROCKET (93-19) 1

S501 DRIVE SHAFT (93-11) 1

W500-5 WAHSER, 3/4 FLAT (11-255) 2

W501-5 WASHER, 1/2 LOCK (11-87) 2

W501-11 WASHER, 1 INT LOCK (N/A) 1

X500-6 CAPSCREW (5/16x1/2 HEX) (11-662) 2

X500-11 CAPSCREW (3/8x3/4 HEX) (11-604) 8

X500-12 CAPSCREW (3/8x1 HEX) (11-603) 3

X500-31 CAPSCREW _1/2x2-1/4 HEX) (11-1492) 2

X501-13 SCREW 3/8x1 SKT HD (11-113) 4

X503-7 SCREW, 5/16x5/16 SKT SET (11-595) 2

X503-13 SCREW, 3/8x2 SQ. HD SET (11-1578) 2

Y500-5 NUT, 3/4 HEX (11-76) 2

Y500-22 NUT, 1 SAE JAM (11-1137) 1

Z506-7 SAFETY PIN (11-920) 2

9. TRANSMISSION ASSEMBLY

PARTS LIST


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ITEM

NO

O.D. TUBULAR DESCRIPTION PART NO NO. REQUIRED/

TONG OR ASSY.

1 1-5/16 - 1.9 Drag Ring Assembly

Consists of:

Drag Ring

Cover Plate

Split Guide Bell

D500-2-A

R501-15

R509-1-A

1/Assy.

1/Assy.

1/Assy

1A 1-5/16 - 1.9 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

J501

N501

N507

5

10

10

2 1-7/8 - 3-1/2 Drag Ring Assembly

Consists of:Drag Ring

Cover Plate

Split Guide Bell

D500-2-A

R501-15

R509-1-A

1/Assy

1/Assy

1/Assy

2A 1-7/8 - 3-1/2 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

J502

N502

N507

5

10

10

2B 2-3/8 - 2-7/8 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

J503

N503

N507

5

10

10

2C 2-7/8 - 3-1/2 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

J505-2

N505-4

N507

5/Tong

1/Assy

1/Assy

1/Assy

3 3-1/2 - 5 Drag Ring Assembly

Consists of:

Drag Ring

Cover Plate

Split Guide Bell

D501-A

R501-2

R506-1-A

5

5

5

3A 3-1/2 - 4-1/2 Jaw AssemblyConsists of:

Jaw

Insert

Insert Screw

J505-2

N505

N507

5

5

5

3B 4 - 5 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

J505-2

N505-1

N507

5

5

5

3C 5 - 6-1/16 Jaw (solid) J507 5/Tong

10. JAW SETS LISTS

SINGLE-ACTING JAWSTUBING


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ITEM

NO

O.D. TUBULAR DESCRIPTION PART NO NO. REQUIRED/

TONG OR ASSY.

1 4 - 5-1/2 Drag Ring Assembly

Consists of:

Drag Ring

Cover Plate

Split Guide Bell

D502-1-A

R501-3-1

R507-1-A

1/Tong

1/Assy.

1/Assy.

1/Assy/

1A 4 - 4-1/2 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

J506

N505-2

N507

5

5

5

1B 5 - 5-1/2 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

J506

N505-3

N507

5

5

5

2 6-5/8 - 7 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 7 Jaw (solid) J509 10/Tong

1 2-3/8 - 3-11/16 Drag Ring Assembly

Consists of:

Drag Ring

Cover Plate

Split Guide Bell

D500-2-A

R501-15

R509-1-A

1/Assy

1/Assy

1/Assy

1A 2-3/8 - 3-1/16 Jaw AssemblyConsists of:

Jaw

Insert

Insert Screw

J510

N504

N507

5/Tong

5

5

5

1B 2-7/8 - 3-1/2

3-1/2 Only

Insert

Insert

N504-3

N504-1

5

5

SINGLE-ACTING JAWSCASING

DOUBLE ACTING JAWSTUBING


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1 1-5/16 - 2-1/16 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

BU501

N501

N506

5/Backup

1/Assy

1/Assy

1/Assy

2 2-3/8 - 3-3/4 Jaw Assembly

Consists of:

Jaw

Insert

Insert Screw

BU502

N503

N506

5/Tong

1/Assy

1/Assy

1/Assy

3 3-1/16 - 4-1/2 Jaw Assembly

Consists of:Jaw

Insert

Insert Screw

BU503

N503

N506

5/Tong

1/Assy

1/Assy

1/Assy

4 4-1/2 - 5-9/16 Jaw (solid) BU504 5/Backup

5 5 - 6-1/16 Jaw (solid) BU505 5/Backup

JAW LISTBACKUP TOOL

ITEM

NO.

O.D. TUBULAR DESCRIPTION PART NO. NO. REQUIRED/

TONG OR ASSY

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.


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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. DESCRIPTION QTY.

D508 Jaw Pin1 5

D507 Drag Plug 5

D506 Drag Spring 5

D505 Set Screw 5

Z503-1 Grease Fitting 1

D502-1-A DRAG RING ASSEMBLY 4 - 5-1/2 O.D. (7-1/4 BORE)


D508-1 Jaw Pin3/4 5

D507-1 Drag Plug 5

D506-1 Drag Spring 5

D505-1 Set Screw 5



D508 Jaw Pin1 5

D507-2 Drag Plug 5

D506 Drag Spring 5

D505-1 Set Screw 5



D104 Jaw Pin1 10

D507-1 Drag Plug 5

D506-1 Drag Spring 5

D505-1 Set Screw 5


D501-A DRAG RING ASSEMBLY 3-1/2 - 6-1/16 O.D. (6-1/4 BORE)

D503-A DRAG RING ASSEMBLY 6-5/8 - 7 O.D. (7-7/8 BORE)


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C516

C513

C512

C509

C508

C515

C505-A

C507

C510

C517

C511

C511

C517

C510

C507

C514

C506-A

C508

C509

C512

C513

C516

Clutch Assembly


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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.

PART NO. (Foster Ref. No.) DESCRIPTION REOD.

C504 (819-1 ) Anchor Pin 1

C516 (819-5) Split Ring 4

C508 (819-9 ) Pressure Plate 2

C509 (819-10 ) Inner Disc 12

C510 (819-11 ) Outer Disc 14

C511 (819-12 ) Thrust Plate 2

C507 (819-13 ) Adjustment Collar 2

C513 (819-14) Spring Pin 6

C512 (819-16 ) Separating Spring 6

C514 (819-17 ) Dog 6

C515 (819-18 ) Dog Pivot 6

C505-A (819-20 ) Body 1

C506-A (819-21) ShIpper Sleeve 1

C517 (11-1186) No.CHyProKey 6

PARTS LIST


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(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)







25/35

Foster Ref. No. 11-946)








(Foster Rerf. No. 11-803)




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---------

X500-13

V516---

T506

F501-15

T500-12


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PART NO.(Foster Ref. No)

DESCRIPTION QTY.REQD.

T500-A (10-606) Steel Tubing 1



Y500-5 (11-76) Hex Nut, 3/8 (not pictured) 3

W501-5 (11-87) Lock Washer, 1/2 (not pictured) 5

F502-7 (11-90) Str. Fitting, 3/8 Flare to 3/8 Pipe (not pictured) 1

F501-15 (11-165) Ell, 1 x 90 Degree,s,H.P. 1

F503-10 (11-254) Nipple, 1 Close H.P. 1

F507-5 (11-265) Collar, 1 H.P. 1

F503-12 (11-333) Nipple, 1 x 2-1/2 H.P. 1

F503-17 (11-337) Nipple, 1 x 6 H.P. 1

F500-5 (11-427) Ell, 1/4 Flare to 1/4 Pipe, 45-Degrees 1

Q500-18 (11-560) Dust Cap, 1 1

Q500-23 (11-566) Dust Cap, 1-1/4 1

F505-9 (11-606) Pipe Plug, 1 Socket (not pictured) 2

X500-26 (11-641) Capscrew 1/2 X 1 Hex (not pictured) 3

Q500-4 (11-850) Dust Plug (not pictured) 1

Q500-1 (11-946) Coupling Half, 1/2 (not pictured) 1

Q500-17 (11-953) Coupling Half, 1 1

Q500-21 (11-955) Coupling Half, 1-1/4 1

15. COMMERCIAL HYDRAULICS

PARTS LIST

(Continued on Page 2)


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PART NO.(Foster Ref. No)

DESCRIPTION QTY.REQD.

T500-12 (11-963) Ell, 1 Pipes 1 Tube, 90-Degrees 4

T500-4 (11-966) Straight Fitting 1

X500-20 (11-1286) Capscrew, 3/8 x 4 Hex 3

Z501-2 (11-1401) Yoke Pin, 3/8 x 1 4

X500-32 (11-1363) Capscrew, 1/2 x 2-1/4 Hex 2

F500-9 (11-1563) Ell, 3/8 Flare to 3/8 Pipe, 45-Degrees (not pictured) 1

T506 (11-1572) Tee, 3/4 x 3/4 x 1 Bax w/1/4 NPT 1

H502 (12-130) Hose Assy 1

V500 (58-240-5) Commercial Valve 1

T512 (76-166) Tee 1

M500 (77-90) Hydraulic Motor 1

V519-1 (93-117-6) Linkage 4

A507 (93-125) Counterbalance 1

A506 (93-126) Valve Plate 1

V514 (181-24-1) Check Valve Assy (not pictured) 1

V507-NSP Cartridge Style Relief Valve 1

V508 (183-9) Knob 1

V516 (867-22) Handle 2

X500-13 (11-1043) Capscrew, 3/8 x 1-1/4 Hex Hd 16

15. COMMERCIAL HYDRAULICS

PARTS LIST (cont.)


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F500-6 (Foster Ref. No. 11-162)

F507-1 (Foster Ref. No. 11-323)

F500-5 (Foster Ref. No11-427)

X502-4 (Foster #11-1580)

Y500-1 (Foster Ref. No. 11-1581)

H500 (Foster Ref. No. 12-249)

I500-1 (Foster Ref. No. 236-2)

I501 (Foster Ref. No. 236-4)

I502 (Foster Ref. No. 236-8)

F500-5

H500

F507-1

F500-6

I501 I500-1

I502Y500-1

X502-4


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INSTRUCTIONS FOR BU500-A BACKUP TOOL

BU50O-A BACKUP TOOL


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AIR CONTROLS FOR BU500-A BACKUP TOOL

F502-4

F500-6

Q500-27

F500-5

F505-3

Z502-4

Z500-2

H519-2

H519-1

H504-4

BU521-A

V523






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

Foster Ref. No. 11-1300)


(Foster Rerf. No. 12-91)


(Foster Ref. No. 105)



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GILL SERVICES, INC. MODEL 500 MAINTENANCE LOG

MODEL 500 SERIAL NO.______________________________

DATE TYPE OF MAINTENANCE PERFORMED INITIALS


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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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