1 oo © 3 ©4D O ) 03/94 OPERATION 5500c Co Oy OY 4D Ee} OD eo V. OPERATION To ensure reliable operation of the tong, it is essential that is is suspended properly. Hydraulic hoses must be hooked up correctly, and the following instructions concerning tong start-up must be followed. A. JAW INSTALLATION To install the jaws remove the two jaw pivot bolts from the cage plate. Place one jaw at a time between the upper and lower cage plates with the jaw roller pin facing upward. Align the hole in the jaw with the matching hole in the cage plates, and insert the jaw pivot bolt. (See illustration) Jew pleat bolt cage pte 03/94 5.1 5500B. TONG RIG-UP 03/94 i HANG LINE. The tong should be suspended by a 5/8" diameter (min.) wire rope, and from a location in the derrick high enough to assure easy handling and maneuvering of the tong. The hang line should be placed in a position as near the center of the rotary as possible without interfering with the movement of the hoisting equipment. This line may either be extended over a pulley and balanced by a counter weight equal to the weight of the tong, or simply tied off in the derrick to form a dead line. In cases where the dead line arrangement is used, it is necessary to use a Farr Spring Hanger Assembly. This spring hanger allows the tong to compensate for the downward movement of the casing as the threads make up. (See illustration) LEVELING TONGS To insure even gripping action of the dies, and smooth running of the rotary gear, it is essential that the tong be hung level. This can be accomplished by making a few simple adjustments once the tong is hung. (See illustration) To keep the tong level, two alignment methods are provided: a. One method of alignment is to adjust the helix where the hand line is attached to the hang bar. The helix has a shaft around which the helix freely rotates. When alignment is required, simply rotate the helix which, due to the helix design, moves the hanging shackle within the adjustment range and aligns the tong from side to side. 5.2 5500 ce cH CL ce cH Cc ce cho Ch th he Oe Oe CL707 ©9 od ©7 C The other method of alignment is provided at the base of the hanging bar where the hanging bar attaches to the tong. A lug is welded to the top plate of the tong and serves as the means of attaching the hanging bar to the tong. A sling end is welded to the base of the hanging bar, and assembly of the hanging bar to the tong is accomplished by installing a sling pin through the sling end and plate lig and securing with a hitch pin. An adjustment bolt is used which is threaded upward through the bolt lug and is secured with a nut. When end to end alignment is necessary, this can be accomplished by backing off the nut a few turns which then allows true alignment to take place as the adjust- ment bolt is turned with a wrench. With the tong hung in position, and by looking down at the top plate of the tong, clockwise rotation of the adjustment bolt will result in lowering the door end of the tong and raising the motor end. Counter-clockwise rotation of the adjustment bolt will reverse the results. = 5.3 550003/94 BACK-UP LINE The use of a 5/8" dia. (min.) wire rope is recommended for the tong back-up line. It should be securely connected to the load cell at the rear of the tong and tied off to a suitable anchor. To assure accurate operation of the load cell and torque gauge, the back-up line should be connected at a 90 degree angle with the tong, and in the same horizontal plane. (Square and level) (See illustration) : 5.4 5500 Cc. co Cc ce ke he oe th Ole Oe Oe Ce CC Cc. co cho Ch fC CH4. HYDRAULIC HOSES When the power unit is not running, or the hydraulic pump is disengaged, the hydraulic hoses may be installed to the tong. The possibility of error in interchanging the high pressure supply hose and the return hose has been eliminated by using a 1" high pressure hose and a 1-1/4" return hose. These hose couplings are the self-seal type, and care should be taken to insure complete engagement to prevent partial closure of the check valve in the coupling. (See illustration). When the 1" high pressure hose is made up completely, dimension (A) should be 7/16". When the 1-1/4" return hose is made: up completely, dimension (A) should be 1/2". (See illustration ~ below) — 03/94 5.5 5500 eoC. TONG OPERATION 03/94 a START UP PROCEDURE NOTE: BE SURE THE DOORS ARE CLOSED AND SECURELY LATCHED BEFORE THE POWER UNIT IS STARTED TO INSURE SAFETY FOR OPERATION PERSONNEL. Use start up procedures as recommended by the power unit engine operator's manual. Prior to starting engine, an inspection should be made to assure proper lube oil level in the engine and hydraulic oil level in the hydraulic reservoir. Open the By-pass valve on the hydraulic system. Check all pressure and return line hose connections to make sure they are securely installed. NOTE: FAILURE TO HAVE THESE HOSE CONNECTIONS TIGHT WILL STOP OR RESTRICT OIL FLOW AND THE FOLLOWING FAILURES COULD occur: a. If the pressure supply hose restricts or stops flow, it will result in high pressure on the power unit hydraulic system which will activate the hydraulic governor and speed the engine up to maximum RPM. b, If the return line flow is stopped or restricted, it will result in high pressure on the power unit and the tong hydraulic system, causing the engine to speed up to maximum RPM and possible failure of the motor seal. After the hoses are checked, start the engine and allow it to idle until warm. After the power unit engine has been started and hydraulic oil has circulated for approximately 10 minutes, slowly close the by-pass valve which will allow oil to circulate through the hoses and to the tong. (Circulating pressure should not exceed 200 PSI.) Place the tong gear shifter in low gear and rotate the tong slowly forward and then reverse with the throttle valve control lever. Once this has been done and the proper size jaws have been installed, the tong is then ready to run pipe. 5.6 5500 cc co Cc CH i ee cs ce03/94 DIRECTION AND SPEED CONTROL The 4-way valve assembly controls direction, speed of rotation, and torque output. For clockwise rotation, push the valve handle forward, and for reverse rotation, pull the valve handle in the opposite direction. Speed in either direction is proportional to the distance that the valve handle is moved from the center or neutral position. (See illustration) HIGH AND LOW GEAR The primary gear box provides for high and low gear operation. For high gear, the shifting shaft is simply moved upward from neutral position, and for low gear, the shifting shaft is moved down from neutral position. (See illustration) ~ 5.7 550003/94 MAKE-UP OF CASING For proper make-up of a casing joint, the following procedure may be used: a. Place tong around casing. b. Close and latch door completely. c. Place the backing pin in the hole for make up.° d. Shift transmission into high gear. e. Push the throttle valve handle forward slightly until casing threads begin to make up. f. When casing threads begin to make-up, push the valve handle to full forward until the tong begins to stall. g. Release the throttle. h. Shift gear box into low gear. i. Engage throttle and make up casing to desired torque. j. Reverse tong to disengage jaws and rotate until the rotary gear aligns with the door opening. k. Unlatch the door and remove the tong from pipe. 5.8 5500 c. ch che te tL c = Cc —— ™m 03/94 BREAK-OUT OF CASING For proper break-out of a casing joint, the following procedure may be used. a. Place tong around casing. b. Close and latch door completely. c. Place the backing pin in the hole for break-out. BREAK OUT d. shift the transmission into low gear. e. Pull the throttle valve into full reverse position. f. Under most "Break-out" conditions, it is recommended to leave the tong in low gear until the joint is completely unscrewed. g. Reverse direction of tong until the rotary gear aligns with the door opening. h. Unlatch the door and remove the tong from pipe. 5.9 55006. GENERAL COMMENTS a) When tong is being used to break out joints or collars where high torques are required, operator should position rotary gear so that it is in contact with both idler gears. (See illustration) rolury ater ges rotary gear’ FOR SAFETY OF RIG PERSONNEL, MAKE SURE THE DOOR IS SECURELY CLOSED AND LATCHED AT ALL TIMES. b) When making-up integral (shouldered) joints, it is essential to make up the last turn of the threads in low gear. This reduces the tendency of an instant stop or a sudden increase in torque, which induces high stresses to the gear train. ¢) When pulling a string, do not employ the "snap break" method of breaking-out joints. By definition, the “snap break" method is a procedure used by some operators to break-out connections. This is accomplished by leaving slack in the "jaw-pipe" engagement, and then quickly pulling the throttle valve control lever allowing the tong to snap into its loaded or high torque condition. This method, although very effective in breaking out joints, highly stresses the gear train and very frequently causes gear breakage. THIS METHOD IS ALSO DANGEROUS TO OPERATING PERSONNEL. 03/94 5.10 5500 ce cco cy Cc tC CH CL ionSoreness nares eet ears arene eee Perera errr earner eee eee co moos d) When making up or breaking out joints, the backing pin must be inserted into the proper cage plate hole to allow engagement with the limit grooves of the rotary gear. This eliminates over-camming of the jaw by preventing the jaw roller from rolling beyond the cam surface of the rotary gear. (See illustration) D. EXTREME COLD WEATHER OPERATION PROCEDURES 1) 2) 3) 4) 5) 03/94 The power unit engine operator's manual should be consulted for any possible cold weather operation precautions. A gear and bearing lubricant should be selected which is compatible with expected operating climate. A hydraulic oil should be selected which is compatible with expected operating climate. After the power unit has been started, in cold weather climates, the hydraulic oil should be allowed to circulate up to approximately 20 minutes prior to activating the by-pass valve allowing fluid to circulate to the tong. When cleaning tong parts in extreme cold climates, allowance for proper drying of moisture is important prior to lubricating. 5.11 5500