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 equipment’s 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.
Vendor’s 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 Vendor’s 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
Vendor’s 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 TITLE PAGE

WARRANTY……………………………………………….. l
WARNING ………………………………………………… ll
1. INTRODUCTION …………………………………………. 1
2. GENERAL DESCRIPTION ……………………………… 1
3. TORQUE CURVE ………………………………………... 2
4. SPECIFICATIONS ……………………………………….. 3
5. INSTALLATION AND OPERATION INSTRUCTIONS .. 4
6. VICKERS HYDRAULIC FLUID RECOMMENDATIONS 6
7. LUBRICATION AND MAINTENANCE …………………. 7
8. FINAL DRIVE ASSEMBLY ……………………………… 9
9. TRANSMISSION ASSEMBLY ………………………….. 11
10. JAW SETS LISTS ………………………………………... 13
11. TONG DRAG RING ASSEMBLY ………………………. 16
12. CLUTCH ASSEMBLY ……………………………………. 17
13. HYDRAULIC LIFT ASSEMBLY …………….……………. 20
14. COMMERCIAL HYDRAULICS ………………………….. 23
15. HYDRAULIC TORQUE GAUGE ASSEMBLY ……..…… 26
16. BACKUP TOOL ……………………………………..……. 27
17. AIR CONTROLS FOR BACKUP TOOL ……………….... 30
MAINTENANCE LOG…………………………………….. 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 Cont’d -

Torque Range: 300 to 6,000 ft lb torque

High Gear……………………………………………………………………...300 to 1,300ft lb
Low Gear………………………………………………………………………………6,000 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 Fig. 5-1. Hydraulic Lift

not level, it will cause excessive wear to tong jaws and Inserts. See Figure 5-3.
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.

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

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.
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 SAE API SERVICE

OPERATING RANGE VISCOSITY CLASSIFICATION
(Mm. to Max.)

0°F to 180°F 10W MS

15°F to 210°F 20-20W MS
32°F to 230°F 30W MS
0°F to 210°F 10-30W 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 charac-
teristic 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 oil’s 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 32°F SAE 30W

Temperatures below 32°F 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 DESCRIPTION QTY.
NO.
A501 RING GEAR COVER (93-18) 1
G503 RING & PINION GEAR (50-20) 1
A502 TRANSMISSION END PLATE (58-17-3) 1
G504 HIGH DRIVE GEAR (58-10) 1
A503-A SIDE PLATE ASSY 6-1/2”x9-1/2” (58-295) 2
G505-A HIGH CLUTCH GEAR ASSY (50-9-1) 1
A504 SIDE PLATE FOR CHAIN (93-295-1) 1
G506-A LOW CLUTCH GEAR ASSY (50-12-2) 1
A508 GUARD COVER (93-122) 1
G507-A OIL PUMP GEAR (58-143-1) 1
B501 TIMKEN BEARING (50-32-1) 3
K500-3 HYPRO KEY #18 (11-1760 3
B502 BEARING (93-32) 1
L517 LEVELING PIN (123-27) 2
B503 TIMKEN BEARIING (93-183) 1
M500 MOTOR M25X (1-1/2) (77-90) 1
B504 BALL BEARING (58-25) 4
O500-4 O-RING 1/8” x 1” x 1-1/4” (11-349) 1
B505 TIMKEN BEARING (92-183) 1
P501-A OIL PUMP ASSY (119-202) 1
B509 BEARING CAP, TOP (58-23-1) 1
P510 5/16” OIL PUMP LINE (93-114) 1
B509-3 BEARING CAP, BOTTOM (58-23) 1
P511 1/4” OIL PUMP LINE (93-115) 1
B510 BEARING CAP, BACK (58-29-1) 1 R503-1 SPIROLOX RING (11-900) 3
B511 BEARING CAP MOTOR MOUNT (93-37-2) 1 S500 RING GEAR & HUB SPROCKET (93-19) 1
B512 SPACER—PINION (58-137-1) 1 S501 DRIVE SHAFT (93-11) 1

B512-1 PINION SHIM (NOT PICTURED) (58-83) 3 W500-5 WAHSER, 3/4” FLAT (11-255) 2

B512-2 BEARING SPACER (50-45-1) 2 W501-5 WASHER, 1/2” LOCK (11-87) 2

C500 CLUTCH ASSY (50-13-1) 1 W501-11 WASHER, 1” INT LOCK (N/A) 1

C501 CLUTCH SHIFTIING YOKE (50-193) 1 X500-6 CAPSCREW (5/16”x1/2” HEX) (11-662) 20

C502 CLUTCH SHIFTIING FORK (50-28-3) 1 X500-11 CAPSCREW (3/8”x3/4” HEX) (11-604) 8

C503 CLUTCH SHAFT (58-14-2) 1 X500-12 CAPSCREW (3/8”x1” HEX) (11-603) 30

C503-1 CLUTCH SHAFT NUT, 1” (58-363-1) 1 X500-31 CAPSCREW _1/2”x2-1/4” HEX) (11-1492) 2

C503-2 CLUTCH SHAFT PINION KEY, (NO PICTURE) 1 X501-13 SCREW 3/8”x1” SKT HD (11-113) 4

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

C518 CLUTCH LEVER WITH SHAFT (58-27-10) 1
X503-13 SCREW, 3/8”x2” SQ. HD SET (11-1578) 2
E500 OIL SIGHT GAUGE (56-81) 1
Y500-5 NUT, 3/4” HEX (11-76) 2
E500-1 PET COCK (1/8” PIPE) (11-299) 1
Y500-22 NUT, 1” SAE JAM (11-1137) 1
F501-2 ELL 1/4” STD. BLK STREET (11-321) 1
Z506-7 SAFETY PIN (11-920) 2
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

10. JAW SETS LISTS

SINGLE-ACTING JAWS—TUBING
ITEM O.D. TUBULAR DESCRIPTION PART NO NO. REQUIRED/
NO TONG OR ASSY.
1 1-5/16” - 1.9” Drag Ring Assembly
Consists of:
Drag Ring D500-2-A 1/Assy.
Cover Plate R501-15 1/Assy.
Split Guide Bell R509-1-A 1/Assy

1A 1-5/16” - 1.9” Jaw Assembly

Consists of:
Jaw J501 5
Insert N501 10
Insert Screw N507 10
2 1-7/8” - 3-1/2” Drag Ring Assembly
Consists of:
Drag Ring D500-2-A 1/Assy
Cover Plate R501-15 1/Assy
Split Guide Bell R509-1-A 1/Assy

2A 1-7/8” - 3-1/2” Jaw Assembly

Consists of:
Jaw J502 5
Insert N502 10
Insert Screw N507 10

2B 2-3/8” - 2-7/8” Jaw Assembly

Consists of:
Jaw J503 5
Insert N503 10
Insert Screw N507 10

2C 2-7/8” - 3-1/2” Jaw Assembly 5/Tong

Consists of:
Jaw J505-2 1/Assy
Insert N505-4 1/Assy
Insert Screw N507 1/Assy
3 3-1/2” - 5” Drag Ring Assembly
Consists of:
Drag Ring D501-A 5
Cover Plate R501-2 5
Split Guide Bell R506-1-A 5
3A 3-1/2” - 4-1/2” Jaw Assembly
Consists of:
Jaw J505-2 5
Insert N505 5
Insert Screw N507 5
3B 4” - 5” Jaw Assembly
Consists of:
Jaw J505-2 5
Insert N505-1 5
Insert Screw N507 5

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

 SINGLE-ACTING JAWS—CASING
ITEM O.D. TUBULAR DESCRIPTION PART NO NO. REQUIRED/
NO TONG OR ASSY.

1 4” - 5-1/2” Drag Ring Assembly 1/Tong

Consists of:
Drag Ring D502-1-A 1/Assy.
Cover Plate R501-3-1 1/Assy.
Split Guide Bell R507-1-A 1/Assy/

1A 4” - 4-1/2” Jaw Assembly

Consists of:
Jaw J506 5
Insert N505-2 5
Insert Screw N507 5

1B 5” - 5-1/2” Jaw Assembly

Consists of:
Jaw J506 5
Insert N505-3 5
Insert Screw N507 5

2 6-5/8” - 7” Drag Ring Assembly

Consists of:
Drag Ring D503-A 1/Assy
Cover Plate R501-4 1/Assy
Split Guide Bell R508-1-A 1/Assy

2A 6-5/8” Jaw (solid) J508 10/Tong

2B 7” Jaw (solid) J509 10/Tong

DOUBLE ACTING JAWS—TUBING

1 2-3/8” - 3-11/16” Drag Ring Assembly
Consists of:
Drag Ring D500-2-A 1/Assy
Cover Plate R501-15 1/Assy
Split Guide Bell R509-1-A 1/Assy

1A 2-3/8” - 3-1/16” Jaw Assembly 5/Tong

Consists of:
Jaw J510 5
Insert N504 5
Insert Screw N507 5
1B 2-7/8” - 3-1/2” Insert N504-3 5
3-1/2” Only Insert N504-1 5
 JAW LIST—BACKUP TOOL

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

NO. TONG OR ASSY

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

Consists of:
Jaw BU501 1/Assy
Insert N501 1/Assy
Insert Screw N506 1/Assy

2 2-3/8” - 3-3/4” Jaw Assembly 5/Tong

Consists of:
Jaw BU502 1/Assy
Insert N503 1/Assy
Insert Screw N506 1/Assy

3 3-1/16” - 4-1/2” Jaw Assembly 5/Tong

Consists of:
Jaw BU503 1/Assy
Insert N503 1/Assy
Insert Screw N506 1/Assy

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

5 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. DESCRIPTION QTY.

D508 Jaw Pin—1” 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)

PART NO. DESCRIPTION QTY.

D508-1 Jaw Pin—3/4” 5

D507-1 Drag Plug 5

D506-1 Drag Spring 5

D505-1 Set Screw 5

Z503-1 Grease Fitting 1

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

PART NO. DESCRIPTION QTY.

D508 Jaw Pin—1” 5

D507-2 Drag Plug 5

D506 Drag Spring 5

D505-1 Set Screw 5

Z503-1 Grease Fitting 1

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

PART NO. DESCRIPTION QTY.

D104 Jaw Pin—1” 10

D507-1 Drag Plug 5

D506-1 Drag Spring 5

D505-1 Set Screw 5

Z503-1 Grease Fitting 1

 Clutch Assembly
C516 C511

C513
C517
C512

C509 C510

C508
C507

C515
C514

C505-A C506-A

C507
C508

C510 C509

C512
C517
C513

C511 C516
13. CLUTCH

13.1 Adjustment For Clutch

1. Remove side panel from operator’s 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 REO’D.

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

 (Foster Ref. No. 123-3-1)

(Foster Ref. No. 123-1-1)

(Foster Ref. No. 123-23)

(Foster Ref. No. 123-2-1)

(Foster Ref. No. 126-7

(Foster Ref. No. 136-8-1)

(Foster Ref. No. 123-13-7)

(Foster Ref. No. 58-91-1)

(Foster Ref. No. 58-71)

(Foster Ref. No. 74-73 & 58-72)

(Foster Ref. No. 123-4)

(Foster Ref. No. 123-4-1)

(Foster Ref. No. 123-5-1)

(Foster Ref. No. 123-9)

(Foster Ref. No. 123-10)

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

(Foster Ref. No. 11-148)

(Foster Ref. No. 123-20)

(Foster Ref. No. 11-1563)

(Foster Ref. No. 11-317)

(Foster Ref. No. 12-130)

(Foster Ref. 11-361)

(Foster Ref. 11-356)

(Foster Ref. 11-355)

(Foster Ref. No. 11-353)

(Foster Ref. No. 11-1367)

(Foster Ref. No. 123-26)

 Foster Ref. No. 11-946)

(Foster Ref. No. 11-947)

(Foster Ref. No. 11-849)

(Foster Ref. No. 11-850)

(Foster Ref. No. 11-816)

(Foster Ref. No. 181-24-1)

(Foster Ref. No. 11-1293)

(Foster Ref. No. 11-145)

(Foster Rerf. No. 11-803)

(Foster Ref. No. 11-1153)

(Foster Ref. No. 11-18)

 V507-NSP
V508
H502
T500-12 T500-A
T502-A
F501-15

T506 Q500-17

F503-17
F503-10
Q500-21
X500-20
V500 T500-12

T501-A
V519-1
M500
A506

V516 T500-12

A507

X500-13
15. COMMERCIAL HYDRAULICS

PARTS LIST
PART NO. DESCRIPTION QTY.
(Foster Ref. No) REQ’D.
T500-A (10-606) Steel Tubing 1

T501-A (10-607) Steel Tubing 1

T502-A (10-608) 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

(Continued on Page 2)
15. COMMERCIAL HYDRAULICS

PARTS LIST (cont.)

PART NO. DESCRIPTION QTY.
(Foster Ref. No) REQ’D.
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

 I501 I500-1

F500-5 I502 Y500-1

H500
X502-4
F507-1

F500-6

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)

 BU50O-A BACKUP TOOL

INSTRUCTIONS FOR BU500-A BACKUP TOOL

 (Foster Ref. No. 147-7)

(Foster Ref. No. 147-6)

(Foster Ref. No. 147-1-1)

(Foster Ref. No. 147-2-10)

(Foster Ref. No. 147-19)

(Foster Ref. No. 147-20)

(Foster Ref. No. 147-5-80)

(Foster Ref. No. 121-10)

(Foster Ref. No. 11-1335)

(Foster Ref. No. 147-43)

(Foster Ref. No. 147-40)

(Foster Ref. No. 147-41)

(Foster Ref. No. 50-48-1)

(Foster Ref. No. 50-49-2)

(Foster Ref. No. 11-196)

(Foster Ref. No. 11-87)

(Foster Ref. No. 11-806)

(Foster Ref. No. 11-603)

(Foster Ref. No. 11-1575)

(Foster Ref. No. 11-878)

(Foster Ref. No. 11-188)

(Foster Ref. No. 11-145)

(Foster Ref. No. 11-131)

(Foster Ref. No. 11-920)

AIR CONTROLS FOR BU500-A BACKUP TOOL

F502-4
(Foster Ref. No. 11-161)
F500-6
(Foster Ref. No. 11-162)
Q500-27
(Foster Ref. No. 11-296)
F500-5
(Foster Ref. No. 11-427)
F505-3
(Foster Ref. No. 11-574)
Z502-4 Cotter Pin, 1/2” x 1-1/2” (Foster Ref. No. 11-796)
Z500-2 Foster Ref. No. 11-1300)

H519-2 (Foster Ref. No. 12-11)

H519-1 (Foster Rerf. No. 12-91)

H504-4
(Foster Ref. No. 12-126)
BU521-A (Foster Ref. No. 105)

V523
(Foster Ref. No. 195-6)
 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