© vsecveeeeeeece SF VO 0SC@e@GCOo0Oo' MODEL 631 TUBING TONG OPERATION AND SERVICE MANUALio ° 3 Qeecooo0e¢ noo @vrveseeoeeeeeoooce TABLE OF CONTENTS SECTION 1 - GENERAL, Brief description . cogeescesseg Preparation of new equipment for operation. SECTION 2 - INSTALLATION Hanging the tong SECTION 3- OPERATION General eee eeeceeceee Reversing the tong jaws... Reversing the back-up assembly Operation of the hydraulic lift ass Operation of the tong .... Make-up... " Break-out SECTION 4- PREVENTIVE MAINTENANCE General. ashe veruspuesssvisasstveusiiyss Greasing zert fittings and the control handle assembly Cleaning and greasing tong jaws, drag ring and pins Adjustment of drag ring plugs .. Replacement of tong jaw inserts... - Replacement of back-up assembly jaw Draining oil from the top case Draining oil from the bottom case Replacement of oil in the top case Replacement of oil in the bottom case - SECTION 5 - TROUBLESHOOTING ‘Troubleshooting chart SECTION 6 - SERVICE OF THE TOP CASE, BOTTOM CASE AND HYDRAULIC LIFT ASSEMBLY List of tools required for service... seed Hydraulic schematic. et led Final drive gear upper oil seal 62 Final drive gear lower oil seal 62 Final drive gear bearings ......0.. 263 Drag ring base ring and bushing « 65 Thirteen tooth sprocket bearings High range motor seal High range motor shaft support bearing. Low range motor os po Fifty-four tooth sprocket bearings and oil seal Valve bank inlet relief valve... Valve bank seals and spool : 3 een Hydraulic lift assembly packing gland and piston seals ...- snes sbeceadeenssseeetsans O14 66 lesTABLE OF CONTENTS SECTION 7- RELIEF VALVE. SECTION 8 - PARTS Replacement parts Exploded drawing of major subassemblies Parts list of the top case... Exploded drawing of the top case | Parts list of the bottom case . : Exploded drawing of the bottom case. Parts list of the valve bank .... Exploded drawing of the valve bank. Parts list of the clutch assembly... Exploded drawing of the clutch assembly. Parts list of the back-up assembly .. , Exploded drawing of the back-up assembly. Parts list of the hydraulic lift assembly . Exploded drawing of the hydraulic lift assembly Parts list of the torque arm Exploded drawing of the torque arm WARRANTYagoo0oa' 209 > (\SSCSSSSHSEOOSHOHHOBWEOOOSSOBOVOSG’ SECTION 1 GENERAL fm LJ — URE Lt MODEM 68 TUBING TONG BRIEF DESCRIPTION ‘The Peck-O-Matic Mode! 631 tubing tong is a hydraulic powered tong for 1-5/16-inch tubing through 7-inch casing (Figure 1-1) The tongs two hydraulic motors-one for speed, the other for torque, contribute to its efficient operation. With a 35 gpm hydraulic system at 2,000 psi, make-up can be performed in 3.0 seconds per joint and break-out in 4.0. Note If the tong is to operate on a system greater than 45 gpm, consult Peck-O-Matie for special Instructions. The tong produces a torque from 300 to 1,500 ft-lbs at 184 rpm in the high speed range and from 1,500 to 6,000 ft-Ibs at 45 rpm in the low speed range. Operation requires a minimum hydraulic system of 20 gpm at 2,000 psi ‘Thirty-five gpm at 2,000 psi gives optimum performance. The unit's torque curve is shown in Figure 1-2. The tong weighs 900 Ibs; the back-up assembly 95 Ibs; and the hydraulic lift assembly 180 Ibs. PREPARATION OF NEW EQUIPMENT FOR OPERATION Upon reciept of the tong, inspect thoroughly to make sureit has not been damaged during shipment. If no damage is noted, the tong is ready for operation.TORQUE (Gette) 7,000 J tov sree RANGE Le] 000 2 4 so | 4000 3000 2.00 HIGH sPeeD Les ensee 0 29 sy 750000 43501500980 2000 aa HYDRAULIC SYSTEM PRESSURE o > FIGURE 12 MODEL 6: TORQUE CURVE1D Oa SECTION 2 INSTALLATION HANGING THE TONG 1. The tong should be hung over the enter of the wellhead, ths pacer achened with 9) oak ees [sore] trungas high on the derrick as possible. such ee ee Un A gas high on the derrick as possible, such Derrick “Mounted, use I/2nch crown, hose to assure optimum speed and performance 2. To hang the tong. attach one end of the cable to the shackle on the end of the hydraulic lift assembly. Hoist the assembly until vertical and at the proper height to connect, with the tong, HYDRAULIC LIFT ASSEMBLY FIGURE 22 CONNECTING HYDRAULIC HOSE TO THE LIFT ASSEMBLY SAFETY PINs Qy Sgn LEVELING BOLT BRACKET HOLES. Ay RETURN HOSE TIGURE 2 CONNECTING THE PRESSURE AND. RETURN HOSES TO THE TONG FiGuRE 24 (CONNECTING THE HYDRAULIC LIFT ASSEMBLY TO THE TONG at3. Connect the hydraulic lift assembly to the tong by aligning four items: the lft bracket holes with the pipe on the base of the hydraulic lift assembly, and the leveling bolt bracket holes with the leveling bolt. Insert pins and secure with safety pins.(Figure 2-1) Connect the 3/8-inch hydraulic hose, using the quick disconnect coupling (Figure 2-2) Note: If the hydraulic lift assembly is derrick mounted, use 1/2. inch hose to assure optimum speed and performance. 4 Connect the hydraulic hoses to the valve bank, using quick disconnect couplings. The I-inch hydraulic pressure hose connects to the four inch long nipple at the tap of the valve bank and the I-1/4-inch hydraulic return howe connects to the eight inch long nipple at the bottom of the valve bank (Figure 2-3) 5. Fully extend the operating rod of the hydraulic fi assembly. This extension is achieved when the lift handle is pulled toward the operator. 6. With the operating rod of the hydraulic lift assembly fully, extended, raise the attached tong until the back-up assembly is 3 or 4-inches above the wellhead slips 7. With the bolt. lock washer and nut provided, attach the torque arm to the bracket at the back of the tong.(Figure 2. 4) Use the bracket hole closest to the derrick leg.(Figure 2-5) BRACKET FIGURE 24 ATTACHING THE TORQUE ARM TO THE TONG 22 8. Raise the tong, by pushing the lift handle, to normal operating height. Weld a torque arm bracket to the dertich legat the same height as the bracket on the back ofthe tong. Autach the torque arm to the derrick bracket, using the bolt, lock washer and nut provided. Adjust the length of the torque arm so that the torque arm and tong are at right angles {0 one another. Secure the torque arm length by placing a bolt through the slot in the outer sleeve of the {torque arm and the hole in the inner sleeve ofthe torque arm and fasten with a lock washer and nut (Figure 2-3) BOLT, Lock WASHER & NUT TORQUE ARM BRACKET DERRICK LEG TORQUE ARM LENGTH ADJUSTING BOLT, LOCK WASHER & NUT VIEW IN DIRECTION OF ARROW “a~ FIGURE 25 ATTACHING THE TORQUE ARM TO THE DERRICK99999009099000: ESHPSSSOSHSSVOSTEVOOOCSSOVIDGIOES LEVEL LEVELING BOLT FIGURE 6 9. Place a level on the tong and adjust the leveling bolt assembly until the tong is level.(Figure 2-6) To lower the front of the tong, tighten the top nut and loosen the bottom ‘nut on the leveling bolt. To raise the front of the tong, tighten the bottom nutand loosen the top nut on the leveling bolt. Note: The tong must be level so that it operates perpendicular to the pipe, which allows the jaws to evenly bite the pipe. 23 HE TONG19090 5 S®POSCSSSSHOOCSSOCOOOCSS@OCOSGSOEO™ SECTION 3 OPERATION (FOOT POUNDS) ‘API THREAD & COUPLE ru & Integeal Joint Graloc | Extremeline Spang Seal 0. Din, Optimum | Min. | Max. [Nominal Nominal | Nominal 23/8" 1200 | 1000 | 1700 1800 2000 1150) 1500 | 1300 |} 2000 1800 2000 1150 7 — 1800 2000 1150 2500 2500 1225 2500 2500 1225 2500 2500 1225 TUBING MAKE-UP TORQUE VALUES. (FOOT-POUNDS) [= Pape T= 4500-6500 7000 - 11500 10000 - 15000 X-Line Tenative API &RD Thread Min. | Nom, CASING MAKE-UP TORQUE VALUES FIGURE 31 (CHART OF TORQUE VALUES FOR TUBING & CASING GENERAL, 1. Before operating the tong, remove the oil fill plugs to check the top and bottom case oil level. Oil in the top case should be to the top of the chain (14 US quarts). In the bottom case, the oil should be 1/2-inch deep (I-1]2 US quarts). Ifthe oil level is low or the oil is discolored, change the oil as instructed in Section 4, “Preventive Maintenance”. 2. Determine the torque value for the size and grade of pipe being worked. When it is available, use the recommended values specified by the pipe manufacturer. ‘ chart of torque values for common sizes and grades of pipe is shown in Figure 3-1. Its torque values are hased upon the following, and should only be used as a guide: Data relating to API T and X connections compiled by Continental Oil from joints giving good performance on Loomis testing over an eight month period, May through December, 1955. Others are’ manufacturers" mendations. REVERSING THE TONG JAWS 1. Tong jaws must be reversed when changing from make-up to break-out or from break-out to make-up.} i 2. Using a 9/ 16-inch wrench, unscrew the three bolts which secure the guide bell. Lift off the guide bell and remove the cover plate. Then slip the five jaws off the drag ring pins. Figure 3 Bouts «)- COVER PLATE FINAL DRIVE ae aac aise Mt $ mins Pos 8 FIGURE 32 REVERSING THE TONG JAWS 3. The jaws are marked oneach end. One end is marked “M" for “make-up”; the other, “B" for “breakout”, After removing the jaws, turn them over and reinsert them on the drag ring pins so that the applicable letter, “M" or “B®, is visible 4. Check to make sure that the teeth on all five jaws are equidistant from the inside diameter of the final drive gear.(Figure 3-3) 5. Replace the cover plate, guide bell, and three bolts. REVERSING THE BACK-UP ASSEMBLY 41. The back-up assembly must be reversed when changing from make-up to break-out or from break-out to make-up. 2. Remove the safety pin and pin from the front of the back- up assembly, lower the assembly, and rotate it 180 degrees. 3 Q DRIVE GEAR FIGURE 43 INSTALLING TONG JAWS EQUIDISTANT FROM FINAL DRIVE GEAR Ss SAFETY PIN BACK-UP ASSEMBLY FIGURE 34 REVERSING THE BACK-UP ASSEMBLY Raise the assembly and reinsert the pin and safety pin. Figure 3-4) 3. When properly positioned, the back-up assembly jaws i the opposite direction from the tong jawsjeeeeereeseeeeseOOO0eeo00N9eECfo779 OPERATION OF THE ASSEMBLY 1. The small, lower handle on the bottom of the valve bank activates the hydraulic lift assembly.(Figure 3-5) HYDRAULIC LIFT 2. Pull the lift handle toward the operator to lower the tong; push it away from the operator to raise the tong, FIGURE +5 OPERATING THE HYDRAULIC LIFT ASSEMBLY OPERATION OF THE TONG 1. The large, upper handle controls the rotation of the tong, clockwise and counterclockwise, in high and low speed range.(Figure 3-6) 2. Atrest, the control handle is set in the high speed range neutral position, 3. The high speed range is engaged by positioning the control handle in the neutral, or horizontal, position and pushing or pulling. The low speed range is engaged by positioning the control handle in the down position and pushing or pulling, 4. For break-out, or counterclockwise rotation, in high and ow speed range, the control handle is pulled toward the operator. For make-up, or clockwise rotation, in high and low speed range, the control handle is pushed away from the operator 5. To shift from low speed range to high speed range, raise the control handle from the down position to the horizont 33 position. Do not return to the neutral position. During this shifting, rotation of the tong does not stop. 6. To shift from high speed range to low speed range, return the control handle to the neutral position. This shift stops the rotation of the tong. Lower the control handle to the down position, push the control handle for make-up; pull it for breakout FIGURE 36 OPERATING THE TONG 1, Verify that the tong jaws and back-up assembly are set in the correct position for make-up. 2. Use only the high speed range if the torque value required 1p the pipe is 1,500 ft-Ibs or less. If the torque requirements are greater than 1,500 [tbs use the high speed range to maximum capacity, then shift to low speed range. 3. Using the hydraulic lift assembly, raise the tong over the pipe joint held by the wellhead slips. Lower the tong onto the pipe. The back-up assembly jaws should be below the pipe ‘coupling so that the tong jaws will grip the joint of pipe to be made up.(Figure 3-7)PIPE TO BE MADE-UP BACK-UP ASSEMBLY PIPE JOINT HELD BY WELLHEAD SLIPS FIGURE 3-7 POSITIONING THE TONG FOR MAKE-UP. 4. Lower the joint of pipe to be made-up through the tong. Mate it with the coupling on the oint being held by the slips 5. Unscrew the relief valve lock nut by turning it counterclockwise. Turn the relief valve control. knob counterclockwise until tension is off the control knob.(Figure 3-8) 6. To engage the back-up assembly on the pipe, pull the ring gear handle until the back-up assembly jaws bite the pipe. Hold the handle in this position until the tong begins to rotate. When the tong begins to rotate and torque the pipe, the back-up assembly jaws will remain in position without being held until the tong stops rotating and the jaws are reversed.(Figure 3-9) 7. Set the torque value on the tong by operating in the high speed range. Slowly turn the relief valve knob clockwise to increase the torque until the proper value is read on the torque gauge.(Figure 3-8) Read the high speed range, or side, scale on the torque gauge if the torque value is 1,500 fi-lbs or less. Read the low speed range, of outside, seale if the torque value is greater than 1,500 ft-Ibs. Note: When setting the relief valve for low speed range, operate the tong in high speed range, but read the low speed range scale on the torque gauge. 8. When the correct torque value is reached, the tong will hydraulically stall and stop rotating. Turn the relief valve lock nut clockwise until itis tight 9. I the torque valuc is 1,500 ft-lbs or less, the joint is made- Lup with the tong operating in the high speed range and the Proper torque is reached when the tong stalls 34 10. Ifthe torque value is greater than 1.500 ft-lbs, the joint is wade-up with the tong operating in both speed ranges: the high speed range until it stalls, then the low range until it stalls again at the preset torque value, When the tong stalls the second time, the proper torque value has been achieved. 11. After the proper torque value has been achieved, reverse the tong operating direction to remove the tong jaws from the pipe. Caution; Reverse the tong operating direction only after the tong stops rotating. Otherwise, hydraulic pressure spike will damage the high range motor. 12. Check the reading on the torque gauge once every four hours to verify that the tong still stalls at the proper torque. This is necessary because changing hydraulic uid viscosity slightly alters “the torque value due to temperature Low sPEED. TORQUE GUAGE FIGURE 38 SETTING THE TORQUE VALVE BREAK-OUT 1. Verify that the tong jaws and back-up assembly are set in the correct position for break-out 2. Using the hydraulic lift assembly, raise the tong over the pipe joint held at the wellhead by the slips. Raise the pipe Joint with the elevators. Position the tong so that the back- up assembly jaws will grip the pipe coupling and the tong Jaws will grip the pipe joint to be broken out.(Figure 3-10)o o oO oO oO Qo eo 9 o o e e e 8 2 8 ® 9 9 e e e 3. To engage the back-up assembly on the pipe coupling, poll the ring gear handle until the back-up assembly jaws bite the coupling. Hold the handle in this position until the tong begins to rotate.(Figure 3-9) FIGURE 39) ENGAGING THE BACK-UP ASSEMBLY PIPE JOINT T BROKEN OUT. 8h PIPE JOINT HELD BY WELLHEAD SLIPS BACK-UP ASSEMBLY, r ‘COUPLING FIGURE 3-10 POSITIONING THE TONG FOR BREAK-OUT 35 4. Operate the tong in the low speed range, once the tension in the joint has been removed by making one or two revolutions, shift to the high speed range by raising the handle to quickly finish unscrewing the joint. Caution: Starting breakout in the high speed range causes excessive ‘wear to the tong jaw inserts. 5, After the joint is unscrewed, reverse the tong operating direction to remove the tong jaws from the pipe. Caution: Reverse the tong operating direction only after the tong stops rotating. Otherwise, hydraulic pressure spike will damage the high range motor.DocetnD a cocescoo ve@e@ecocococoo SECTION 4 PREVENTIVE MAINTENANCE ACTIVITY FREQUENCY ‘Grease zert fittings on back-up assembly Grease zert fittings on top bearing cap Grease control handle assembly Clean tong jaws Clean and grease drag ring and pins Adjust drag ring plugs Replace drag ring plugs and springs Replace tong and back-up assembly jaw inserts Replace oil in top case and bottom case Daily Twice daily As needed ‘After each trip or daily After each trip When proper jaw action is not delivered to the pipe When worn When worn Monthly or when appear- ance indicates FIGURE 41 MAINTENANCE SCHEDULE GENERAL 1. Preventive maintenance of the tong includes greasing, adjusting and replacing the drag ring plugs; replacing the jaw inserts; and replacing the top and bottom case oil 2. Preventive maintenance should be performed in accordance with the frequency outlined in the maintenance schedule.(Figure 4-1) GREASING ZERT FITTINGS AND THE CONTROL HANDLE ASSEMBLY 1. Use a grease gun to grease the seven zert fittings on the back-up assembly.(Figure 4-2) ~ ZERT FITTINGS. > Ficure +2 GREASING THE BACK-UP ASSEMBLY 2. Use a grease gun to grease the zert fitting on the top bearing cap.(Figure 4-3) 3. Apply grease to the moving parts of the control handle assembly.(Figure 4-3) PARTS TO BE GREASED. FIGURE SS GREASING THE TOP BEARING CAP AND. CONTROL HANDLE ASSEMBLYCLEANING AND. RING AND PINS 1. Using a 9/ l6-inch wrench, unscrew the three bolts which secure the guide bell. Lift off the guide bell and remove the cover plate, Then slip the five jaws off the drag ring pins. 2. Using a 9/ 16-inch Allen wrench GREASING TONG JAWS, DRAG loosen the five Allen hhead set screws inside the drag ring and lift the drag ring out of the tong.(Figure 4-4) BOLTS.) GUIDE BELL. COVER PLATE JAWS DRAG RING PINS ALLEN HEAD SET SCREWS(5) Peacrine DRAG RING. DRAG RING. BASE RING FIGURE 44 CLEANING AND GREASING THE TONG JAWS, DRAG RING AND PINS. 42 3. Clean the tong jaws, drag ring, and pins, Clean the drag ‘ing bushing and drag ring base ring inside the tong with Varsol or diesel fuel. Inspect each drag ring plug for wear and replace it if the solid end is less than 1/8-inch thiek Caution: Always replace the drag ring plugs before they wear completely away or the drag ring springs will score the drag ring bushing. 4. Apply grease on the drag ring, pins, drag ring bushing, and drag ring base ring. Place the drag ring into the tong 5. Adjust the drag ring plugs according to the instructions given below. 6. Reinsert the jaws on the drag ring pins so that the applicable letter, "M” or "B”, is visible, Make sure that the teeth onall five jaws are equidistant from the inside diameter of the final drive gear 7. Replace the cover plate, guide bell and three bolts ADJUSTMENT OF DRAG RING PLUGS 1. After reinserting the drag ring into the tong, use a 9/ 16- inch Allen wrench to tighten the first Allen head set screw until it is flush with the inside diameter of the drag ring.(Figure 4-5) Tighten the remaining Allen head set screws by skipping every other screw until slight tension is felt in the springs, which assures that the drag ting is centered in the drag ring bushing, 2, Attempt to turn the drag ring by hand. Ifitcan be turned, continue tightening the set screws until the drag ring cannot be turned by hand. The tension in each drag ring plug should be equal. Caution: Too much tension on the drag ring plugs will cause the tong to lock up or will ause excessive wear on the drag ring plugs, springs and bushing. uLen neap SHER | FIGURE 43 ADJUSTING THE DRAG RING PLUGSya SOSH OE DOHVSSOHOHECOOLOVGFSOCOOGOO: REPLACEMENT OF TONG JAW INSERTS 1. Using a 9/ 16-inch wrench, unserew the three bolts which secure the guide bell. Lift off the guide bell and remove the ccover plate. Slip the five jaws off the drag ring pins.(Figure 4-6) Note: Jaws to operate 1-1/2 through 3-1/2-inch pplaceable inserts. For larger diameter pipe the jaws and inserts are of one piece construction. GUIDE WELL COVER PLATE FIGURE 46 REMOVING THE TONG JAWS 2. Using a 5/ 16-inch Allen wrench, unserew the two Allen head capscrews to remove the inserts from the jaws.(Figure 47) 3. Place new inserts in the jaws and replace the Allen head capscrews 4. Reinsert the jaws on the drag ring pins so that the appiicabls letter, “M™ or “B”,is visible. Make sure that the teeth onall five jaws are equidistant from the inside diameter of the final drive gear, 5. Replace the cover plate, guide bell and three bolts 43 ALLEN HEAD CAPSCREWS, FIGURE +7 REPLACING THE TONG JAW INSERTS REPLACEMENT OF BACK-UP as INSERTS. MBLY JAW 1, Using a 9/16-inch wrench, remove the five bolts which secure the top cap. Remove the top cap and lift the five jaws from the back-up assembly (Figure 4-8) BOLTS(S) FIGURE 48 REMOVING THE BACK-UP ASSEMBLY JAWS 2. Using a $/16-inch Allen wi head eapserews to remove the 49) nch, unscrew the two Allen serts from the jaws.(FigureALLEN HEAD. CAPSCREWS Jaw insert FIGURE 49 REPLACING THE BACK-UP ASSEMBLY JAW INSERTS, 3. Place new inserts in the jaws and replace the Allen head capscrews. 4. Replace the jaws in the back-up assembly with the heads ofthe Allen head capscrews facing down. Make surc that all five jaws are aligned as closely as possible to the inside diameter of the ring gear.(Figure 4-10) 5. Replace the top cap and the five bolts. RING GEAR FIGURE 4.10 REPLACING THE BACK-UP ASSEMBLY JAWS DRAINING OIL, FROM THE TOP CASE 1. Place a container which will hold at least 14 US quarts of oil under the top case oil drain plug, 2. Using a I-inch wrench, unscrew the oil drain plug, Allow all of the oil to drain from the top ease.(Figure 4-11) DRAINING OIL FROM THE BOTTOM CASE. 1. Place a container which will hold at least 1-1/2 US quarts of oil under the bottom case oil drain plug. 2. Using a9/ 16-inch wrench, unscrew the oil drain plug and allow all of the eil to drain from the bottom ease (Figure 4- Dy lL FILL PLUGS OIL DRAIN PLUGS FIGURE «11 > O1L DRAIN AND OM FILL PLUGS REPLACEMENT OF OIL IN THE TOP CASE 1. Using a I-inch wrench, remove the top case oil fill plug. Fill the top case with one gallon of Varsol or diesel fuel and operate the tong in high range for two minutes to flash out any dirt or sediment. Drain the Varsol or diesel fuel ror the top case. 2. Replace the oil drain plug and fill the top case with 14 US quarts of SAE 10W40 weight motor oil(Figure 4-11) Replace the oil fill plug, REPLACEMENT OF OIL IN THE BOTTOM CASI 1. Using a I-inch wrench, remove the bottom ease oil fill plug. Fill the bottom case with one-half gallon of Varsol or diese! {uel and operate the tong in high range for two ‘minutes to flush out any dirt or sediment. Drain the Varsol or diesel fuel from the top case. @ 2. Replace the oil drain plug and fill the bottom case with 1-1/2. US quarts of SAE 10W40 weight motor oil (Figure 4-11) Replace the oil fill plug. Caution: Do not fill the bottom ease with more than I-1/2 US quarts of oil. Too ‘much oil causes the tong to operate at a lower speed and ean, damage the hydraulic motor seals."OQOoToeeSoooszeeo° SECTION 5 TROUBLESHOOTING ‘TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION [Clutch engaging when not desired, Identified by a high pitch grinding Excessive back pressure in hydraulic system, Increase the size of the return hydrau- Tic hose so that it is one size larger (i-1/4-inches) than the pressure hose (inch); oF Replace filter; or contaminated return line Unkink or clean return line hose; or Disconnect hydraulic equipment, such] as an oil cooler motor, operating on| return line downstream of the tong and reconnect to the pressure line up-| stream of the tong. Tong runs slow in both directions. 1. More than 1-1/2 US quarts of oil in the bottom case. 2. Low hydraulic pressure 3. Inlet relief valve on valve bank is set incorrectly. 4. Drag ring plugs are too tight. 5. High range motor is damaged or 1. Drain the oil in the bottom case and| replace with 1-1/2 US quarts of oil, 2. Increase hydraulic pressure of the hydraulic power unit to 2,000 psi by adjusting the hydraulic power unit rlief| valve. 5 3. Adjust inlet Felief valve on valve bank, 4. Adjust the drag ring plugs. 5. Check motor for damage or wear by stalling the tong in high range and read| hydraulic pressure on torque gauge. If the pressure is much lower that the hydraulic system pressure, repair the] motor. Disconnect the 1/4-ineh drain line on| the motor, plug the outlet section fitting, and stall the tong in high speed range. Ifa steady stream of oil emerges from the 1 /4-inch drain line hose, repair or replace the motor. Hrong runs slow in one direction, z Low hydraulic pressure because of incorrect tong make-up relief valve setting Readjust the tong make-up relief valve [Contamination of oil in the top case. Final drive gear upper oil seal is damaged Replace the seal [Oil leaking from the bottom of the top Final drive gear lower oil seal is damaged, Replace the seal stTROUBLESHOOTING CHART PROBLEM [Fons doesnot produce required torque CAUSE 1, Low hydraulic fluid pressure from the hydraulic power unit. 2. Tong relief valve is set at too low a torque value 3. Dirt in the shuttle valve, 4. Clutch surfaces are worn. 5. High range motor is damaged or 6. Drag ring plugs are too tight SOLUTION 1. Increase hydraulic fluid pressure from the hydraulic power unit to 2 psi by adjusting the hydraulic power| unit relief valve 2, Reset the tong relief valve at a higher| torque value, 3. Clean the shuttle valve, 4. Replace the worn clutch surfaces. 5. Repair the motor. 6, Adjust the drag ring plugs. [Bottom case overflowing with oil from the shuttle vaive port, 1. More than 1-1/2 US quarts of oil added to the bottom case. 2. Oilseal between topand bottom cases damaged. Identified by the oil color in both cases appearing the same. 3. High range motor shaft. seal is damaged and is permitting hydraulic fluid to fill the bottom case. 4. Clutch “O” rings are damaged and are permitting hydraulic fluid to fill the bottom case, 1. Drain the oil in the bottom ease and replace with 1-1/2 US quarts of oil. 2. Replace the seal 3. Replace the shaft seal 4. Replace the clutch “ ” rings, [Tong jaws do not bite the pipe T- Tension Ta the drag ring plugs is not sufficient or the plugs are worn. 2. The teeth ofthe five tong jaws are not ‘equidistant from the inside diameter of the final drive gear. 3. Jaw inserts are filled with metal shavings or other foreign matter, 4. Jaw inserts are worn, 5. Tong is not level 6. Tack welds which secure the drag ring bushing are broken, or the bushing is 1. Adjust the tension or replace the plug. 2. Reposition the tong jaws, 3. Clean the inserts, 4. Replace the inserts, 5. Level the tong. 6. Reweld the bushing, or replace the bushing, ltiydrautic lit assembly elevates while the tong is operating, 1. Return hydraulic hose is blocked, 2. Quick disconnect coupling of the hydraulic return hose is loose. 3. Internal leakage through the valve bank section, 4. Valve bank “O” ring is damaged, 1. Eliminate the blockage of the retura hydraulic hose. 2. Tighten hydraulic return hose quick] disconnect coupling. 43. Replace the faulty valve bank section. 4. Replace the “O" ring. ‘Spools on control valve section of the valve bank do not return tocenter when the control handle assembly is released. 1. Broken spring in the valve section, 2, Washer at the rear of spool in valve section of the valve bank is sticking inside the cap. 3. The 1/2-inch bolts which connect the three valve sections and end sections are over torqued 1. Replace the broken spring, 2. Remove and clean the washer. 3. Loosen the bolts until the spool] dislodges and retighten with the proper] torque on all bolts. $2SOOOSSSSSSSOSOEOHOOOCOSGGOOD9GGEC99909009990909990 TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION Hydraulic lift assembly operates slowly, 1. Excessive back pressure in the hydraulic system, 2. Hydraulic fluid blockage in the hydraulic lift assembly hose. 3. Hydraulic lift assembly hose diameter is too small, 33 4. Increase the size ofthe return hydrau-| lic hose so that it is one size larger| (I-1/4-inches) than the pressure hose (L-ineh); or Replace filter; or contaminated return line| Unkink return line hose; or Disconnect hydraulic equipment oper- ating on the return line downstream of| the tong and reconnect to the pressure line upstream of the tong, 2. Check for improperly mated quick disconnect couplers and reconnect, if necessary, 3. Use a I/2-inch hydraulic lift assembly hose if derrick mounted.2900 [SSCSOHSSSHHOHSHOHCOEEEOOCOSSSHOCOOE SE ON 6 SERVICE OF TOP CASE, BOTTOM CASE AND HYDRAULIC LIFT AS FIGURE 61 HYDRAULIC SCHEMATIC LIST OF TOOLS REQUIRED FOR SERVICE internal and external snap ring pliers 5/ 16-inch Allen wrench The following tools are required for servicing the top case, oy igimen anes wrenen bottom case and hydraulic lift assembly: 5/inch Allen wrench 7-16.inch wrench ball pen hammer 1/2-inch wrench rubber hammer 9) 16-inch wrench brass rod 5/8:inch wrench 10-inch gear puller 3/4inch wrench straight slotted screwdriver rach wrench, 6: pry bar /8-inch wrench uneh inch wrench chisel 1/2.inch twelve point wrench vice grips I6-inch erescent wrench, i i ISsinch pipe wrench HYDRAULIC SCHEMATIC needle nose pliers A schematic of the hydraulic system is shown in Figure 6-1 otGUIDE BELL, FIGURE 62 REMOVAL OF THE FINAL DRIVE GEAR UPPER OIL SEAL FINAL DRIVE GEAR UPPER OIL SEAL. 1. Using a 9/ 16-inch wrench, unscrew the three bolts which secure the guide bell and lift off the guide bell. Using a Straight slotied screwdriver, remove the upper oil seal (Figure 6-2) 2. Inspect the upper oil seal for damage and replace if damaged. 3. Using a rubber hammer, tap the upper oil eal into the top bearing cap being eareful not to pinch the seal. Replace the guide bell and the three bolts FINAL DRIVE GEAR LOWER OIL SEAL 1. Unscrew the oil drain plug to drain the oil from the top. 2. Using a 9/ 16-inch wrench, unserew the three bolts which Secure the guide bell. Lift off the guide bell and remove the cover plate. Slip the five jaws off the drag ring pins, 3. Using a 9/ 16-inch Allen wrench, loosen the five Allen hhead set serews inside the drag ring. Lift the drag ring out of the tong, 4. Using a 9/ 16-inch wrench, unscrew the twelve bolts which secure the bottom bearing cap. Liftoff the bottom bearing cap, ee 62 BOLTS) GUIDE BELL. > DRAG RING ALLEN HEAD SET SCREWS (5) iL DRAIN PLUG. LOWER O1L. SEAL, GASKET, BOTTOM BEARING CAP BOLTS (12) FIGURE 63. REMOVAL OF THE FINALDRIVEGEAR LOWER OIL SEAL. 5. Push on the lower oil seal through the slotted openings in the bottom bearing cap to remove the seal. from the cap.(Figure 6-3) Inspect the seal for damage and replace if damaged. 6. Replace the seal in the bottom bearing cap. Use a large open end wrench to pry the seal anda rubber hammer to tap the seal in place, 7. Place the same number of gaskets on the top case as came with the tong and replace the bottom bearing cap. Note: The number of gaskets (usually 1 or 2) varies from tong to tong, because they are used as shim stock for achieving the proper alignment of the final drive gear lower bearing.SSOCSCHSOHSSSSCEHEOOOCCSOGONSCOBSLTCIDO 8. Insert four bolts at 90 degree intervals and tighten until a slight tension is felt. Using a straight slotted screwdriver inserted through the slotted openings in the bottom beating cap, push the lip of the seal over the edge of the final drive near 9. When the lip of the seal isin position, the bottom beating cap will drop into the top case under its own weight or with slight pressure. If this does not occur, the seal is improperly seated. Caution: Do not force the bottom bearing eap into the top case. Forcing will damage the lower oil seal 10. Replace and tighten the remaining bolts. Use afour post pattern for initial tensioning; then complete the tensioning sequentially. 11. Replace the drag ring in the tong, Using a 9/ 16-inch Allen wrench, tighten the first Allen head set screw until itis flush with the inside diameter of the drag ring, Tighten the remaining Allen head set screws by skipping every other screw until slight tension is fet in the springs, which assures that the drag ring is centered in the drag ring bushing. 12. Attempt toturnthe drag ring by hand. Ifit can be tuned, continue tightening the set screws until the drag ringcannot be turned by hand. The tension in each drag ring plug should bbe equal. Caution: Too much tension on the drag ring plugs will cause the tong to lock-up or will cause excessive wear on the drag ring plugs, springs, and bushing. 13. Reinsert the jaws on the drag ring pins so that the applicable letter, "M” or “B". is visible. Make sure that the teeth onall five jawsare equidistant from theinsidediameter of the final drive gear, 14, Replace the cover plate, guide bell three bolts, and oil drain plug. 15, Refill the top ease with 14 US quarts of SAE 10W40 weight motor oil FINAL DRIVE GEAR BEARINGS 1. Unscrew the oil drain plug to drain the oil from the top 2. Using a 9/16-inch wrench, unscrew the cighteen bolts Which secure the top bearing cap. Using a straight slotted screwdriver, pry the top bearing cap from the top case and lift it off the top case.(Figure 6-4) 3. Inspect the upper bearing race in the top bearing cap for damage or wear and replace if damaged or worn. To replace the race, use a pry bar and ball pecn hammer to pry it from the top bearing cap, Tapa new race into the top bearing cap with a rubber hammer. Make sure the race is seated all the way 10 the bottom ofthe pocket machined in the top bearing cap. 4, Remove the cover plate and slip the five jaws off the drag ring pins, 5. Using a 9/ 16-inch Allen wrench, loosen the five Allen hhead set screws inside the drag ring. Lift the drag ring out of the tong. 6. Using a 9/ 16-inch wrench, unscrew the twelve bolts which secure the bottom bearing cap, Lift off the bottom bearing cap. 63 BOLTS (18) TOP BEARING UPPER BEARING FIGURE 64 REMOVAL OF FINAL DRIVE GEAR UPPER BEARING RACE 7. Remove the oil ill plug from the top case. Using needle nose pliers, remove the two cotter pins fn the master ink of the chain. Turn the final drive gear tnt the master link ines up withthe oil drain hole. Push the master link out of the chain through the drain hole. Note: The master link ean be identified by the fact that its two cotter pinsare much longer than the cotter pins of al the other links in the chain. Slip the chain off the teeth ofthe final drive gear and lift the gear out of the top case (Figure 6-5) 8. Inspect the lower bearing race in the top case and the tapered roller bearings on top and bottom of the final drive sear for damage or wear and replace any damaged or worn, parts. To replace the lower bearing race, use a rubber hammer to drive it out of the top ease. Remove the lower oil, seal from the bottom bearing cap by pushing on the seal through the slotted openings in the cap. Place the same number of gaskets on the top case as came with the tongand replace the bottom bearing cap and bolts which willactasa seating surface for the new race, Note: The number of gaskets (usually 1 or 2) varies from tong to tong because they Are used as shim stock for achieving the proper alignment of the final drive gear. Using a rubber hammer, tap the new race into the top case until the race is evel and seated against, the bottom bearing cap. To replace the tapered roller bearings, use a punch and ball peen hammer to tap them off the final drive gear. Tap the new bearings onto the final drive gear with a punch and ball peen hammer, making sure the ‘bearings are properly seated on the final drive gear. Cauti Hit the tapered roller bearings on the bearing race only when installing to prevent damage to the bearings.CONE ROLLER BEARINGS COVER PLATE ALLEN HEAD. SET SCREWS (5) BOLTS (12) MASTER DRIVE GEAR LOWER OIL SEAL FIGURE 63 REMOVAL OF THE FINAL DRIVE GEAR LOWER BEARING RACE AND TAPERED ROLLER BEARINGS. 9. Replace the final drive gear in the top case and place the chain on the final drive gear teeth. Insert the master link in the chain through the oil drain hole and replace the cotter pins in the master link. Replace the gasket, top bearing cap, and bolts 10. Remove the bottom bearing cap and replace the lower oil seal in the cap. Use a large open end wrench to pry the seal and a rubber hammer to tap the seal into place. 1. Place the same number of gaskets on the top case as came with the tong and replace the bottom bearing cap. Note: The number of gaskets (usually 1 or 2) varies from tong to tong because they are used as shim stock for achieving the proper alignment of the final drive gear lower bearing. 12, Insert four bolts at 90 degree intervals and tighten until a slight tension is felt. Using a straight slotted screwdriver inserted through the slotted openings in the bottom bearing,QO QO oO G oO So oO 8 e 2 @ 9 v ® s 6 ® e cap, push the lip of the seal over the edge of the final drive gear, 13, When the lip ofthe scalis in position, the bottom bearing. cap will drop into the top case under its own weight or with slight pressure. Ifthis does not oceur, the seal is improperly seated. Caution: Do not force the bottom bearing cap into the top case. Forcing will damage the lower oil seal 14, Replace and tighten the remaining bolts, Usea four post pattern for initial tensioning; then complete the tensioning sequentially 15, Replace the drag ring in the tong, Using a 9/ 16-inch Allen wreneh, tighten the first Allen head set serew until itis ‘Tush with the inside diameter of the drag ring. Tighten the remaining Allen head set screws by skipping every other screw until slight tension is felt in the springs, which assures that the drag ring is centered in the drag ring bushing 16. Attempt torn the drag ring by hand, Ifit can be turned, continue tightening the set screws until the drag ring eannot be turned by hand. The tension in each drag ring plugshould be equal. Caution: Too much tension on the drag ring plugs ‘will cause the tong to lock-up oF will cause excessive wear on the drag ring plugs, springs, and bushings. 17, Reinsert the jaws on the drag ring pins so that the plicable letter, "M” or “B™, is visible, Make sure that the teeth onall five jawsare equidistant from the inside diameter of the final drive gear. 18, Replace the cover plate, top bearing cap, eighteen bolts and oil drain plug. 19, Refill the top case with |4 US quarts of SAE 10W40 weight motor oil DRAG RING BASE RING AND BUSHING 1, Unscrew the oil drain plug to drain the oil from the top 2. Using a 9/16-inch wrench, unscrew the three bolts which secure the guide bell, Lift off the guide bell and remove the cover plate. Slip the five jaws off the drag ring pins 3. Using a 9/16-inch Allen wrench, loosen the five Allen hhead set screws inside the drag ring. Lift the drag ring out of the tong. 4. Clean the grease off the drag ring base ring and bushing with Varsol or diese! fuel 5. Inspect the drag ring base ring and bushing for wear and replace any worn parts, 6, To replace the drag ring base ring, use a straight slotted screwdriver to unscrew the three flat head serews which secure the ring. Lift the base ring from the bottom bearing cap.(Figure 6-6) Insert a new base ring and replace the three flat head screws, 7. To replace the drag ring bushing, use a 9/ 16-inch wrench to unscrew the twelve bolts which secure the bottom bearing, ap. Lift the bottom bearing cap from the top case, Grind of burn the tack welds which hold the bushing in the bottom bearing cap and remove the bushing. (Figure 6-7) Insert a new drag ring bushing and tack weld it in four places approximately one inch long to the bottom bearing cap. Note: Field replacement of the bushing can be accomplished 65 BOLTS 0) Oy urbe wet COVER PLATE DRAG ALLEN HEAD RING PINS, SET SCREWS (5) DRAG RING DRAG RING BASE RING on ona r.ue FIGURE 66 REMOVAL OF THE DRAG RING BASE RING ‘without removing the bottom bearing cap from the tong if care is taken to prevent damage of the lower oil seal when burning the tack welds off and when rewelding the new bushing in place. 8, Place the same number of gaskets on the top case as came with the tong and replace the bottom bearing cap. Note: The ‘umber of gaskets (usually 1 or 2) varies from tong to tong ‘because they are used as shim stock for achieving the proper alignment of the final drive gear lower bearing. 9. Insert four bolts at 90 degree intervals and tighten until a slight tension is felt. Using a straight slotted screwdriver, inserted through the slotted openings in the bottom bearing, ‘cap. push the lip of the seal over the edge of the final drive Bear.DRAG RING. BUSHING. FOUR ONE INCH LONG | TACK FIGURE 67 REMOVAL OF THE DRAG RING BUSHING 10. When the lip of the seals in position, the bottom bearing ‘cap will drop into the top case under its own weight or with slight pressure. Caution: Do not force the bottom bearing, cap into the top case. Forcing will damage the lower oil seal. 11, Replace and tighten the remaining bolts. Usea four post pattern for initial tensioning: then complete the tensioning, sequentially. 12. Replace the drag ring in the tong. Using a 9/ 16-inch Allen wrench, tighten the first Allen head set serew untilitis flush with the inside diameter of the drag ring. Tighten the Femaining Allen head set screws by skipping every other screw until slight tension is felt in the springs. which assures that the drag ring is centered in the drag ring bushing, | 13. Atempt to turn the drag ring by hand. Ifit can be wrned, ‘continue tightening the set serews until the drag ring cannot 66 be turned by hand. The tension in each drag ring plug should bbe equial. Caution: Too much tension on the drag ring plugs will cause the tong to lock-up or will cause excessive wear on the drag ring plugs, springs, and bushings. 14. Reinsert the jaws on the drag ring pins so that the applicable letter,"M™” or "B”, is visible, Make sure that the teeth onall five jaws are equidistant from the inside diameter of the final drive gear. 15. Replace the cover plate. guide bell, three bolts, and oil drain plug. 16, Refill the top case with 14 US quarts of SAE 10W40 weight motor oil THIRTEEN TOOTH SPROCKET BEARINGS 1. Unserew the oil drain plug to drain the oil from the top 2. Using a 9/ 16-inch wrench, unscrew the eighteen bolts which secure the top bearing cap. Using a straight slotted screwdriver, pry the top bearing cap from the top case and Lift it off the case. 3. Remove the oil fill plug from the top case. Using needle nose pliers. remove the two cotter pins in the master link of the chain. Turn the final drive gear until the master link lines Uup with the oil drain hole. Push the master link out of the chain through the oil drain hole, Note: The master link can be identified by its two cotter pins which are much longer than the cotter pins of all the other links in the chi 4. Using a 7; 16-inch wrench, unscrew the eight bolts which secure the side doors on either side of the top case and remove them. Reach through the openings and slip the chain off the teeth of the thiticen tooth sprocket and out of the tong. Inspect the chain for wear and replace if worn. 5. Using a 9) 16-inch wrench, unscrew the four bolts which secure the bearing cap (top). Insert two of the bolts in the two threaded holes in the cap. Tighten the bolts which will press the cap from the top case. Lift the bearing cap (top) from the top case. Using a pry bar. pry the thirteen tooth sprocket and bearings out of the top case(Figure 6-8) 6. Inspect the bearings for damage and replace if damaged. 7. Replace the bearings and thirteen tooth sprocket in the top case. Tap them in piace witha rubber hammer and make sure they are fully seated. Replace the bearing cap (top) and four bolts 8. Reach through the openings on the sides of the bottom ‘aye and place the chain on the thirteen tooth sprocket teeth, Insert the master link in the chain through the oil drain hole Replace the cotter pins in the master link and replace the top bearing cap and bolts. Replace the side doors and bolts,Dasagseocoa: o 9° 9 Q 9 9 8 ° Qo 8 9 G o o i} 9 9 o Oo 9 J o ) ) ) ) BOLTS (4), BEARING CAP (TOP) By asker BEARING GASKET Patton voursig >, 3. Using a 3/4-inch wrench, unserew the mounting bolt which secures the top end section to the tong, 4. Using a 3/4-inch wrench, unscrew the three nuts on top of the valve bank. 5. Lift the top end section off of the valve bank. Inspect the 0" rings and lead washers between the top end section and the first valve section for damage and replace any damaged parts, 6. Unfasten the hoses connected to the first valve section, Disconnect the control handle from the spool by removing. the cotter pin and linkage pin. Lift the frst valve section off of the valve bank. 7. Inspect the “O” rings and lead washers between the first and second valve sections for damage and replace any damaged parts.(Figure 6-22) 8 Using a 1/4-inch Allen head wrench, unscrew the four Allen head capscrews which secure the cap to the valve section, 9. Remove the spool from the valve section. Inspect the spool washer and spring for wear and damage and replace any worn or damaged parts, if necessaryNUTS) TOP END SECTION x LINKAGE PIN, 0” RINGS (4) LEAD WASHERS(®) FIRST VALVE “o" RINGS(A) FIGURE 622 DISASSEMBLY OF THE VALVE BANK VALVE SECTION ‘SPOOL SPRING ALLEN HEAD CAPSCREWS(4) —"® FIGURE 6.23 DISASSEMBLY OF THE VALVE SECTION ow 10. To replace the spring, use a straight slotted screwdriver to unscrew the bolt from the end of the spool. Remove the old spring and reassemble the spool with a new spring.(Figure 6-23) 11. To service the second and third valve sections, perform steps 6 through 10 on each section, 12. Reverse the disassembly steps to reassemble the valve bank HYDRAULIC LIFT ASSEMBLY PACKING GLAND AND PISTON SEALS 1. Using a pipe wrench, unscrew the packing gland. Slip the Packing gland off the operating rod and pull the operating rod out of the working barrel (Figure 6-24) SNAP RING chy WORKING BARREL BUMPER WASHER FIGURE 624 REMOVAL OF THE OPERATING ROD FROM ‘THE WORKING BARREL 2. Using snap ring pliers, remove the snap ring from the packing gland and remove the oil seal. Inspect the oil seal and “O” rings in the packing gland for damage and replace any damaged parts,oO a SSOSSSE OHH DSSS OMOOOCSSSOTV9Gs OPERATING ROD. CUP SEAL D> SLOTTED NUT — COTTER PIN FIGURE 625, REMOVAL OF THE PISTON AND SEALS FROM ‘THE OPERATING ROD. 3. Using a pair of pliers, remove the cotter pin from the slotted nut. Unscrew the slotted nut witha pipe wrench. Slip the piston and seals off the operating rod. Inspect the cup seals and "O" rings in the piston for damage and replace any damaged parts.(Figure 6-25) 4, Reassemble the hydraulic lift assembly by reversing the order of the disassembly steps. Caution: Do not remove the four bolts on the bottom of the hydraulic lift assembly. If they are removed, 2 compressed spring will be released, which could injure the person removing the bolts. esSECTION 7 RELIEF VALVE 7 COCOCEHOOOLECCOVOSCCECO980OCOOO0V88O8SCOO88008IVOoOO9O 20900 SOSGOCHOGSCOGOEOSTCOVCOSEGODSS R2V SERVICE BULLETIN FUNCTION The principal function of the R2V series relief valve is to limit the pressure in @ system toa maximum value, adjustable 100 - 3000 psi. The valve opens when the pressure ot the inlet port rises to that adjusted velve ond spills all the fluid it must to prevent the inlet pressure from rising further. The fluid is spilled from the outlet port which generally is connected to the reservoir. The valve closes when the inlet pressure falls below the age usted pressu OPERATION The R2V relief velve is @ pilot operated type of pressure control. It is essentially two valves in a single assembly. The pilot cap assembly (Valve #1) on top includes @ small edjustoble spring loaded cone (11) which controls the spool (22) of the pilot operated section (Valve #2) below. REMOTE CONTROL The lower section is cont led by the moximum pressure permitted in the “pilot” area above the spool (22). This maximum is usually estoblished by the pilot cop assembly on top. It may also be controlled ot o lecser sressure as established by remote valving connected 10 0 line to the vent port shown. If the remote valving dumps thot line directly to tank, the main spool will open at lowest pressure, 30-70 psi depending on flow and viscosity, This is called “'venring the vaive"". The remote valving need handle about 1/2 gpm te control the main spool. The remote valve may include on adjustable spring leaded cone with elements similer to those in the cop for remote pressure control. INSTALLATION If the RV relief valve is used for pump protection, it should be installed close to the pump's dischorge port. The outlet port of the relief valve should return to the sump well below the oil level to prevent eration, and ar @ point separated from the pump inlet by the longest flow path possible. The designer hes complete freedom of valve ‘mounting attitude, PRESSURE ADJUSTMENT The adjusted pressure is increased with clockwise rotation of the knob (3). Denison's assembly procedure of the adjustment ports prevents the bottoming of the spring (10) but does p: mit pressures to be odissted 10% cbove the valve's maximum 3000 psi rating. Always be sure the valve is adjusted for your desired pressure sen fing. Tighten the locknut (6) to prevent accidental changes. OUTLET PORT PRESSURE The R2V relief vaive drains its pilot cop assembly inte the outlet port which generally flows directly to tonk at low pressure. Any pressure present in that outlet por helps the spring (10) hold the cone (11) on the seat and is added to the pressure equivelent of the spring odjustment. A restricted line to tank can cause fulieflow Pressures 10 be more than opening pressures. The outlet port pressure must not exceed 150 psi. SERVICE The relief valve is extremely dependable and suffers little from years of proper use. Malfunction con occur in the Following ways: Ae caandden drops in pressure ~ possible causes: spool (22) hung open on contaminant particle, vent valve spool leaking excessively or hung in open position, broken spring (10), B. Severe pressure fluctuations ~ possible causes: eroded pilot cone (11) and sect (14), eroded spool (22) and seating edge of sleeve (20), contominction in orifices to pilot aree (16) (23), return line Whistling operation ~ possible cause: eroded pilot cone (11) and sect (1d), cir in the fluid. D. Excess oil temperatures ~ possible covses attributable to the relief volve: relief valve lecking fluid fom high pressure to low pressure side past eroded ports or parts held open with contemination, relief valve set too low so it cracks open too frequently in service, relief valve set too low (below the setting of the compenseror in © compensator pump circuit). Note: Fluid gets hotter when it spills or leoks through Oil heats about 0.8° F/100 psi pressure drop. E, Failure to reestablish pressure when devented — possible cause: speel (22) hung on contaminction, vent cirevit F. Pressure increase after valve opens — pressure fluctuations. strictions and components. differential spring (10) weak or broken, open or leaking excessively possible couse: restricted return line. 12| VENT CONNECTION 1 | THREADED BODY TYPE 171318 151411 2 109 87654 3TIODSO9 OC 0OCOOCOOOCOOHOOOOOCECOS9O0": SECTION 8 PARTS TOP CASE BACK-UP ASSEMBLY HYDRAULIC LIFT ASSEMBLY VALVE BANK, FIGURE 8.1 MODEL 631 TUBING TONG MAJOR SUBASSEMBLIES EXPLODED DRAWING. REPLACEMENT PARTS. When ordering replacement parts, specify Peck-O-Matic Mode! 631 tubing tong, the description of the replacement parts, and the part number. All replacement part orders should be placed with the Peck-O-Matic factory or an authorized representative. MODEL 631 TUBING TONG ‘An exploded drawing of the major subassemblies of the tubing tong is shown in Figure 8-1. TOP CASE ‘The parts list and exploded drawing of the top case are shown in Figure 8-2. BOTTOM CASE ‘The parts list and exploded drawing of the bottom case are shown in Figure 83, 8d VALVE BANK The parts list and exploded drawing of the valve bank are shown in Figure 8-4 CLUTCH ASSEMBLY ‘The parts list and exploded drawing of the clutch assembly are shown in Figure 8-5 BACK-UP ASSEMBLY ‘The parts list and exploded drawing of the back-up assembly are shown in Figure 8-6 HYDRAULIC LIFT ASSEMBLY AND TORQUE ARM ‘The parts lists and exploded drawings of the hydraulic lift assembly and torque arm are shown in Figure 8-7.TOP CASE PARTS LIST imew[ PART NO [OV] DESCRIPTION] [TEM PART NO Jaiv[“prscairion 1 [RioaIn6008 37 [STEIGNCx Paps] | io fora} FP Lae 2] eatto201} 1 J 1-5/16"- 3-1/2" guide spring; and bat 40" = 60" dag rng ss-io2.00] 1 [4-7 guide en one 3 631-103-01 1] 1-5/ 16" - 3-1/2" cover 631-107-03-02 5 | 7.0" - 7.625" drag ring | pine nis 631-103-02 1 ]4"- 5-1/2” cover plate 11 | 631-107-0104 5] 1.3" - 5.5" drag ring plug sieai| alaenne ssrorazos| 5] 5°. roar rng pop 4 | 631-106-01-03] 20 |3/8™-16 NC x 1” socket "2 63-15, 2 | oil seal i Maa epee 1] caring} 1 | top bearing cap 5 festsosoroi] 5 site 19am 6] 6tora0r | 2 | son presse tno sariosoaai] 5 |2ijt6"= 22/8" jw 15] “etti4} 2 | Conerolr bearing and carososoi] 5 [yas 27/4 jaw race eattosaeai| § guns caejee ve{ —arns] 1 fnt drive gear arinees| Slee laieree 7] eartis| 1 | top bearing gnsket ésibeas| $ larcasiertie che v8 [osozo0za02| 16 | 1-420 NO « 1/2" cape 631-106-07 5 | S”- 5-1/2” jaw - solid are 631-106-08 5 |S" - 61/16" jaw - solid 8 aaah 2) | sided: cues! cee 20] sarizs} 2 | sie door paste ee oleae 21 |21020r0020| 5 | 5-4:NF 4 5 xpscew See eg Tae set 2] sumone] 5) aa sar ner pes 23 | roea08 | 3 | satay pin 6 | esti0s01-02} 10 | 3/167. 1.9" jaw nse ries 24 flosiz.0200] 2) oii anagit arn pug estiveo3e2] i [aay i623, ju aleore|| Wome corineoven| 10 |23/8°- 2.7/8 nerrng 25] aaiiis| 1 sown tearing pasts bore iow ee 27 |zsoso1v.02] 3] inane sete fat ead 631-106-03-03] 10 | 2-3/8" - 2-7/8" diamond omg! atone nue 2s | ext} | Srp ving base sing 7 feattorovoa] 5 [tars 40" drag cng pin 2 | cariog| | rag sing bushing satior-ona2| 5 |40"~ sara vine pn ao} oa] | etiam teeing cap catcior.on01 5 |oo- 70° drag sing pn aw} era} 1] pm # [esiiozoroi] 1 [15+ aon ame ane n| eras] i] fe caisoroz0i| 1 |aon.ssmame sng af arie] 1] Gain cororaz0i| 1 [6o"-70-arg rng ae] oottttoz] 2) searing 9 |2uizon.00a) 5 [ime 12" Alen ned set as] esttitor] 1] ehieen tooth sprocket ee 36 ca120] 1 bearing ca (op) ste aiizoroooe| 5 [rs Aten head set a] aiis| _i[ mine apo sreSOSOCOOCOOOCS CSCO 9YOCOO0909000910 0080888089808| BOTTOM CASE PARTS LIST 84 [item] rartno. Jory] besceprion ] trem} part no. [ory] _ DEscRIPTION 1 | 631-801-01 | 1 [high range motor 2 631-216] 1 | bottom case id gasket 1A J631-soz-01-01 | 1 | nigh range motor seat kit 30 631-607] 1 | spring pin 2 |2-113.006-006 | 4 | bot u 631-601] 1 | control handle 3 | 631-801-081 | nigh range motor gasket 2 631-608] 3 | cone spring 4 fic-112002.007] 1 | oi ft plug 3 | 3101-013] 1 | washer 5 | 631-803.01] 1 frorque gauge M 831-609] 1 | spring 6 ]2-105-001-002 | 3 | alten head capscrew 35} 1107-006] 1 | nex tock nut 7 631-201 | 1 | bottom ease 36 631-602] 1 | handle bracket 8 631.213 | 1 fehain 37 | 202-006-014] 1 | 1/2"-13 NC x 31/2" 9 631-203 | 1 | fty-four tooth sprocket capscrew 10 | sat-111-02 | 2 |rity-tour tooth sprocket 38 | 631-605] 2 | tinkage bar bearing x» 631-604] 1 | handle bracket small 11 | 631-111-083 | 1 | fifty-four tooth sprocket 40 |7-106-008-010] 1 | spring dowel pin oil seal 41 |2-108-001-002] 3 | boit 2 631-204] 1 | splined shaft 2 631-603] 1 | mounting bracket B 631-207 | 1 | high rangemotor sprocket 43 |2-102-006003] 2 | pote 14 | 631-802-05] 1 | highrangemotorsprocket 44 | 7104002] 2 | inkage pin key 45. | 7-103-007-004] 2 | cotter pin 1 | earaieat | 1 Jiow range moror sprocket is 631-606] 2 | valve unkage “7 63701] 1 | lift handie ist wenaenell i —— 48 |7103.012.006] 4 | cotter pin > 18 |2-102-004-008 | 32 |3/8%16 NCx Icapscrew pad [a accel (A faire Ll 9 631-206 | 1 | bearing cap (bottom) 0 | ape ets 2 | | raleesbank a wiiaas | lecunigap Ramet st | 631-2601] 1 | etutch housing zasket 32 |2-102-004.005] 6 | eapserew 21 631-209 | 1 caring cap (high range 53 | o31-21418] 1 |elutch housing gasket motor) 54 | 631-801-08] 1 | low range motor gasket 2 631-219 | 1 [bearing cap (high range 55 | 2-113-006-006] 4 | twelve point bolt motor) gasket 56 3102-007] 4 | lock washer 23 631-210 | 1 |bearing 37 631-801] 1 | low range motor 24 [10-112-002-004) 1 oil drain plug STA. | 631-801-01-01] 1 | tow range motor repairkit 25 631-211 | 1 [bearing cap (low range 38 631-214] 1 | clutch assembly rare 59 | 631-21419] 1 | clutch shaft 36 | estate| 1 Poeaing cap dow range cw | @12ie20] 1 Joanne =| ae fe a Be) et — Se? |_t [bowom ease fi 62a_[631-s02-02-01| 1 | relict valve repair kitFIGURE 63 BOTTOM CASE EXPLODED DRAWING 8S sooeecoccece]]dc(y “VOCCO9990O0991199008888008808)| VALVE BANK PARTS LIST ITEM] PART NO. DESCRIPTION (631-803-0205 top end seetion 631-803-02-01 first and second valve sections j 631-803-02.02 thied valve section | 631-803-02-08 bottom end section | 631-803-02-03 washer 631-803-02-07 #0" ring 631-803-02.09 inlet relief valve 631-803-02.06 spring 631-803-02-11 “O" ring 631-803-02-04 lead washerercoo0o009e0coe9000asS SSCOSHSOVHSOBIOOSMOCOOCSECODDSCLUTCH ASSEMBLY PARTS LIST 1TEM| PARTNO. |QTy.| DESCRIPTION 1] 631-21416] 2 [snap ring 2] 63121410 bearing 3. |2-104-014-003] 6 | 1/4%20x 3/4” Allen head i Jcapserew 4 | 631-21404) 1 [bearing cap S| 6312-21414] 2 |*or ring 6 [210-014-002] 6 | 1/4"20x 1/2” Allen head Jcapscrews 7 | 631-214-03] 1 Jupper piston 8 | 613-21405] 1 Jeylinder 9 | 6321412] 1 fro" ring 10 | 6314-21413] 1 |*o* ring 11 | 631-21402) 1 fiower piston 12 | 631-2161] 1 [bearing 1 Jdtive ring 14 | 631-21406] 1 drive shaft 15 | 631-21409] 4 |Betivile washer 16 | 631-214-08] 1 spring adapter 17} 3102-003] 6 |1/4" lock washer i 13, | 631-21407FiGuRE 8s CLUTCH EXPLODED DRAWING 89 eqgooeecccoocecs O4S00O99900000N9009008028068008)A CK-UP ASSEMBLY PARTS LIST PART NO. 2-102-004-004] 631-303 631-304.01 DESCRIFHON 3/8"-16 NCx Icapsorew top cap 2.3/8" - 2-7/8" back-up jaw 1-1/2 back-up jaw 3-1/2" back-up jaw 23"- 2.8" back-up jaw insert 1-5/ 16" ~ 1.9” back-up jaw insert 21/16" ~ 2-3/8" back-up jaw insert 3/8°-16 NC x 1” Allen head capscrew zert grease fitting pin ring gear back-upassembly housing, 1/2"-13 NC hex nut swivel block 1/2%-13 NC x 2-3/4" cap- screw safety pin pin 631-304-02| 631-304-03, 631-304-04 631-304.05| 631-304-06} 631-106-16} 6-101-001 631-304-07| 631-302] 631-301 1101-006) 631-305] 2-102-006-011 7-106-008) 631-307] 631-306} pin 3-102-007) lock washer 631-308-5; bushing 8.104] spring 810*SOOCOEOOHOS SSE OCOvoooooseo0c0ag 998034 08060800006HYDRAULIC LIFT ASSEMBLY PARTS LIST ITEM | PARTNO. | Qry. DESCRIPTION 1 631-506] 1 | teveting bolt 2 1101-008 | 2 | nut 3 631-513] 2 | spring guide 4 631-507] 2 | leveling spring 5 631-505] 1 | lift bracket 6 1101-007] 4 | nut 7 631-504] 1 | spring 8 | 2-102-007-007] 4 | bolt 9 631-501 | 1 | spring barrel 10 631-502} 1 | cylinder barrel 11 | 10-100-002-003 1-3/8" x 32" tube 12 | 103-011-015} 1 | cotter pin 13 1-108-012 | 1 | flex tock mut 4 631-503-08 | 3 | “oO” ring 1s 631-503-07 | 2 | “o" ring 16 631-503-06 | 1 | piston 0 631-503-05 | 2 | cup 18 631-503-04 | 2 | cup retainer 19 631-503-01 | 1 | operating rod 20 631-503-03 | 1 | bumper washer 21 631-508 | 1 | packing gland 2 631-509 | 1 | oil seal 23 631-510 | 1 | snap ring 4 13-101-006 | 1 | shackle 25 631-403 | 1 | derrick mount TORQUE ARM PARTS LIST ITeM| PARTNO. | QryY. DESCRIPTION 1 631-402 | 1 | torque arm 2 631-401 | 1 | torque arm bracket 3 | 2102007014 | 2 | vow 4 1-101-007 | 2 | tock washer 5 3102-009 | 2 | nut 82Figure 87 HYDRAULIC LIFT ASSEMBLY AND TORQUE ARM EXPLODED DRAWINGS LEC OCEEOCOOSCOCLO0VO800090000 999006938