PRODUCTS 98-M4 Power Sucker Rod TongsTP Mae .; CONTENTS SECTION vi vu vit SUBJECT INTRODUCTION sevens SPECIFICATIONS. Hydraulic. Ares INSTALLATION Hanging Tong Balance Adjustment. . Back-up Wrench . Hoses... Hydraulic Oi OPERATION Tong Operation Setting the Relief Vaive Calculating Preload Valves for and Coupling Joint . ‘Tong Calibration Changing Rotation Direction . MAINTENANCE Check List. Lubrication TROUBLESHOOTING Tong Out of Time Torque Indicator Malfunction... Jumping Out of Time Jaws Fail to Actuate Oil Leaking from Weep Hole... SHOP REPAIRS ‘Changing Brake Band . Replacing Outer Ring Roller Pins and Bushings...... Replace Outer Wear Rings .-. Tong Disassembly FRAME ASSEMBLY REPLACEMENT PARTS INNER RING ASSEMBLIES AND BACK-UP WRENCHES . jucker Rod Pin PAGE NO. " 1" 8 18 “4 18 15 a7 19 19 20 27 33 PRNTEDNUSATP GTS :., CONTENTS SECTION SUBJECT PAGE NO. x HYDRAULIC MOTOR AND VALVE ASSEMBLY 37 xt AIR MOTOR ASSEMBLY .. 39 xi AIR CONTROL VALVE 4a xl OPERATING RATINGS 43 xv SPARE PARTS FOR ONE YEAR'S OPERATION ........0245 45GREE. SECTION | — INTRODUCTION TP Power Sucker Rod Tongs are available in both hydraulic- and air-powered models. They provide faster, more uniform make-up and break-out of sucker rods and macaroni tubing — without dam- age to thread couplings — while delivering up to 1,850 foot-pounds of torque. This tong has a clean, functional design for bal- anced weight distribution and easy handling by fone man. A single master control handles both speed and direction of rotation. The tandem con- trol feature allows operation from the front or either side. The “swinging door" gate provides quick on- off action while eliminating hand latching, ingle unitized jaw assembly fits 5/6 and 7/8" rod sizes without change, and a fast jaw change will adapt the tong to 1/2", 1" and 1-1/8" rod sizes, The tool is equipped with a torque gauge for safe, uniform make-up. The rod tong is easily converted for macaroni ing by replacing the rotating jaw assembly with BJ macaroni tubing jaws. Jaws are available for API 1.050" 0.D. (3/4" nominal); 1.318" O.D. (1" nomi- nal); 1.660" O.D. (1-1/4" nominal), and 1.900" 0.0. (1-1/2" nominal) tubing sizes.Ga) 1 SECTION Il — SPECIFICATIONS HYDRAULIC PUMP SIZE. A hydraulic oil pump that will deliver 20 to 30 gallons per minute and 2,000 psi maximum, Pressure is recommended. However, a dual pump and unloading valve that will return one half the hy- draulic oil flow to the tank when pressure exceeds 1,000 psi may be used. Any hydraulic system suita- ble for the TP Power Tubing Tong will be satistac- tory for the TP Power Rod Tong. HYDRAULIC DRIVE/TORQUE OPTIONS OIL TANK. A 50-gallon oil tank containing at least, 35 gallons of specified hydraulic oil should be used. An important part of the hydraulic system, the oil tank must be properly designed to dissipate heat, prevent foaming and deliver clean oil to the pump suction without undue friction loss caused by an inadequate oil filter. POWER FLUID SPECIFICATIONS: Viscosity Range — 150 to 300 S.S.U.@ 100 deg. F. (Max@ starting temp. — 3000 S.S.U.); Viscosity Index — 80 or above. me Hydraulic ‘Cluster Pinion. Model Torque Motor Assy. | Gear Assy. | Gear Assy. Mark V 1370 fers. max 31908 zreat___| 27850] Mark V 1850 f.lbs. max. 31908 28618 2614 |Ga SECTION Ill — INSTALLATION HANGING TONGS Hang the tong on a suitable line (usually a 9/16" wire rope) from a point high enough to allow the tong to swing easily. The tong may be hung over a sheave either on a fixed line or a counter-weighted line. There is a spring in the suspension assembly that will allow the tong to move vertically while the joint is being made up or broken out, even if the tong is suspended on a fixed line, BALANCE ADJUSTMENT With the tong on the rod, adjust the leveling screw at the top of the hanger so the tong hangs perfectly level while threading rods. Adjust the height of the tong so the jaws in the inner ring are the same height as the top square of the rods. INNER RING Check the inner ring (jaw assembly) for size and ro- tation. Instructions for removal and installation of the inner ring are in Section IV, Operation BACK-UP WRENCH Check the back-up wrench for size. One back-up wrench fits both 3/4" and 7/8" rods. All other back- up wrenches fit only one specific rod size, Install the back-up wrench so it hangs on the back- up wrench support spring. Make sure the load cell piston of the torque indicator protrudes enough to hold the back-up wrench away from the case at least 3/8”. If necessary, add oil to the system ac- 20rding to instructions in Section V, Troubleshoot- 1ng, under “Torque Indicator Malfunction.” HOSES Connect the hoses with the power hose on the right, as viewed from the back of the tong. The hoses should be 1” x 50° when used on a trailer power unit and 1” x 15" when used on a well-ser- Vice rig power source. SELF-SEALING COUPLINGS IMPORTANT: Check all hoses to make certain that the self-sealing couplings are completely engaged and the hydraulic system is not blocked in anyway. HYDRAULIC OIL, Check the oil tank level to ensure that there is plen- ty of oil in the system. With the hoses properly hooked up to the tong, engage the pump and allow the oil to circulate for a few minutes to warm up the tong before full operation. In cold weather, allow time for warm-up as you would for an internal com- bustion engine. CAUTION: As with any tool, the TP Power Sucker Rod Tong must be handled with care. Make no ad- justments while hydraulic power Is connected. Keep fingers and hands out of rotating jaw areas. WARNING: This product could be hazardous If im- properly used. Misuse of this tool could cause seri- ous injury to personnel. This tool must be properly installed and maintained. Do not remove or alter any parts. Do not weld or alter without factory au- thorization. All replacement parts must be of TP- Products manufacture.GEIS 1.1 SECTION lV — OPERATION OPERATING THE TONG The tong can be operated from the front or either side. It is ordinarily operated from the front. All functions of the tong — including engaging the ro- tating jaws and releasing them — are controlled by the operator through the tandem throttle handle. The “swinging door” safety gates are opened and closed automatically by sucker rod contact when the tong is swung on or off the rod string. These gates are a safety guard. They should be in place and operable whenever the tong is in use, With the jaws open, position the tong so the back- up wrench lines up with the bottom square. Then guide the tong onto the rod so the back-up wrench easily slides onto the bottom square. This may re~ Quire lifting the tong slightly at the front to get the back-up wrench over the lower rod elevator and/or turning the tong to one side. If the tong is hung at the correct height, the jaws in the inner ring will au- tomatically position themselves to the top square. NOTE: Keep fingers and hands away from rotating jaws. SETTING THE RELIEF VALVE When breaking out rods, the relief valve setting on the hydraulic power system is not critical. Set it high enough to break the rods — but not more than 2000 psi The relief valve setting is critical when starting in the hole. To avoid over-torquing a rod before the correct torque setting is obtained, back off on the relief valve until the pressure is low enough to slow- ly turn the tong. Then make up the rod and adjust the pressure upward until the correct torque set- ting is obtained. API recommended torque values are marked on the torque gauge. Because of the inherent characteristics of the hy- draulic motor, its rotating torque is 15-20% higher than the stalled torque. It is suggested that the re- lief valve be reduced this amount before rotating a rod in at full speed. Again, note the torque gauge and adjust accordingly. CALCULATING PRELOAD VALUES FOR SUCKER ROD PIN AND COUPLING JOINT For optimum performance, the sucker rod pin and, coupling joint must be made up to achieve the de- sired preload. Because of the many variables in- volved — machine asperities, differences in materi~ als, variations in lubricants employed, cleanliness of connections and condition of power tong equip- ment — torque does not provide an accurate meas~ urement of the repeatable desired preload value in the sucker rod pin joint, Calculations and test data show that a more accu- rate measurement is provided by the angular or cir- cumferential displacement of a coupling and pin after shouldering from a hand-tight position. This method is preferred in the field to achieve the de- sired preload in a sucker rod pin and coupling joint. It is also a method of calibrating power sucker rod tongs. CIRCUMFERENTIAL DISPLACEMENT VALUE. Table | tabulates the circumferential displacement values necessary to achieve an optimum preload in coupling and pin joint under various field condi- tions. Note the three categories and choose the cor~ rect column to meet local field conditions. Use Col- umn 1 when installing a new string of API Class D. Rods. Use Column 2 when installing a new string of API Grade C and K rods (see footnote). Use Col umn 3 when reinstalling used rods with old or new couplings, JOINT CONDITION. To achieve satisfactory pre~ load results for sucker rod joints, the joint must be perfectly clean, undamaged, well-lubricated and have a free-running fit to shoulder contact. Ap- plied displacement will then efficiently preload the joint to prevent shoulder-face separation during pumping, CALIBRATION OF POWER TONG. The rod tong, must be calibrated to produce the recommended circumferential displacement make-up values shown in Table |. After initial calibration, check the power tong calibration each 1000 feet and recali- brate for each change in rod size.GEE». SECTION lV — OPERATION TABLE 1 SUCKER ROD JOINTS CIRCUMFERENTIAL DISPLACEMENT VALUES 1 2 3 ‘Subsequent [Now Sting of| ‘New String of | Installation Rod ‘APIGrade | API Grade | of API Class Size D Rods | Cand K Rods | C, K and D we er 32 4132 oie ese 6132 2 3a 2732 782 ise 78 11782, 9732 9732) r cd 12132, 12/32 Te 18/82 1682 16932 “For the initial run of API Class C and K rods, a set cor- rection factor cannot be recommended because of vari- lance shown by test results. To minimize these variables, ‘API Class C and K rod joints should be made up once and broken out before marking and final make-up. PROCEDURE: 4. Check condition of power tong. If hydraulic- powered, circulate hydraulic power oil system to warm up tong. 2. Set the tong’s operating pressure on the low side of the estimated value required to produce prescribed circumferential displacement value shown by Table 1 3. Screw the first joint together hand-tight. Scribe a fine vertical line across the pin and coupling shoulder to establish hand-tight reference (Fig- ure 1), 4, Make up joint with power tong operating and the tong throttle depressed to the fully open po- sition, Do not hit the throttle a second time after joint shoulder and tong have stalled 5. Remove the tong and measure the circumteren- tial displacement of the scribed, hand-tight ver- tical line (Figure 2) 6. Increase or decrease the tong operating pres- sure to achieve the selected prescribed circum- ferential displacement, as shown in Table 1. 7. Repeat Steps 4, 5, and 6 until proper displace- ment is achieved. Check calibration of tong for a minimum of 4 joints, for each 1000 feet there- after, and for each change in rod size. -+ TF oe aa ct an 1H 2 ' ' FIGURES 1 and 2. Seribing line across pin and coupling shoulder. CHANGING DIRECTION OF ROTATION DETERMINING DIRECTION OF ROTATION. The inner ring rotates a rod in the direction indicated ‘on the top and bottom of the assembly, just oppo- site the opening. The side marked “MAKE” is for making up rods, The side marked “BREAK” is for breaking out rods. A simpler and quicker way to determine the direo- tion the jaws will turn a rod is to note the jaw in the inner ring opening. This jaw points like an arrow in the direction the rods will turn (Figures 3 and 4) INNER RINGS WITH INDEXING KNOB. Rod tong inner rings have an indexing knob on the side (Fig ure 5). Its purpose is to prevent installing the inner ring upside down or out of phase with the outer ring. The knob makes it necessary to line up the ‘opening of the inner ring with the opening in the frame, as described above.GEES .. SECTION IV — OPERATION FIGURE 3. Making up rods. REMOVING THE INNER RING. Rotate the tong to close the jaws, and stop the rotation when the open= ing of the inner ring lines up with the opening in the frame (Figures 3 and 4). Next, reverse the rotation enough to free the inner ring from the resisting force of the brake. The amount of travel is equiva- lent to about one tooth on the outer ring. The inner ring is then free to be lifted out (Figures 6 and 7). NOTE: Disconnect hydraulic hoses before remov- ing inner ring REPOSITIONING INNER AND OUTER RINGS: 1. After removing the inner ring, turn it over. Do not rotate it. 2. Rotate the outer ring half way around, Caretul- ly line up the outer ring roller in the middle of the brake drum opening (Figures 6 and 7) Note that outer ring roller is in the middle of both brake drum and frame openings. INDEXING KNOB 3. Replace the inner ring. Line up the opening of Telaner ing with the brake dram opening. F'OURES.tonerring assembly 4. When the inner ring is in place and has dropped down over the brake drum pins, the top of the inner ring will be about 1/2” below the top of the outer ring. This will verity correct installa tion of inner ring.FIGURE 6. Innerring removed — outer ring roller in middle of brake drum opening, INSTALLING INNER RING FOR MACARONI TUB- ING. Macaroni inner rings are made in four sizes: 4,080", 1.315", 1.660" and 1.900" (9/4", 1", 1-1/4" and 1-1/2" nominal, respectively). The macaroni inner rings are installed in the same manner as the inner rings for sucker rods. FIGURE 7. Inner ring removed — outer ring roller in middle of brake drum opening.TP Gas. SECTION V — MAINTENANCE MAINTENANCE CHECK LIST 1 Check all throttle control linkage for loose pins. If oversize pins are needed but are not available, a new hole can be drilled with a 3/16" drill bit to accommodate a standard pin. Remove the inner ring and check the two outer ring rollers for wear. With the inner ring removed, rotate the outer ring and check the fourteen outer ring frame rollers. Check the torque gauge by prying against one side of the back-up wrench. Test the spring tension on each of the gate doors with the tong in an upright position. If the spring tension is uneven, loosen the gate spring capscrew and slide the spring to one side until the spring tension is the same on both gates. The gate spring is shown in Figure 16. " LUBRICATION There are no grease fittings on the TP Power Rod Tong because all bearings are grease-packed and sealed. Normally, the jaw pins, wear rings, outer ring gear and idler gears receive sufficient lubrica- tion from the rods. If not, oil or brush grease on these points,TP GEG. SECTION Vi — TROUBLESHOOTING TONG OUT OF TIME A tong is out of time when the brake drum does not line up with the opening of the frame (Figure 8) With the brake drum in this position, the indexing knob (Figure 5) may not allow the inner ring to go into place correctly. Align the brake drum with the frame opening by using a short piece of 2 x 4 wood (Figures 8 and 9) If @ 2 x 4 is not available, put two punches in the brake drum pin holes and pry it around into place (Figures 10 and 11). BRAKE DRUM | FIGURE 8. Tong out of time — brake drum not aligned, FIGURE 10. Tong out of ime — brake drum not aligned, NOTE: Before making any adjustments, discon- nect hydraulic hoses. TORQUE INDICATOR MALFUNCTION Like all gauges, the torque gauge should be test periodically. The torque indicator is a closed sys- tem and occasionally must be recharged with oil Oil is needed when the load cell piston will not hold, the back-up wrench away from the case when under load. When. the load cell cylinder is filled with oil, the piston should protrude about 3/6" from the case (Figure 12) FIGURE 11. Tong in time — brake drum aligned using two punches.GECLIGES .. SECTION VI — TROUBLESHOOTING To add oil, turn the tong on its side with the fill hole on the high side, Remove the filler plug (Figure 13) With the long end of an Allen wrench, push the load cell piston back until it bottoms against the seal (Figure 14). Add hydraulic oil (Figure 15) and re- place the plug. Compress the torque indicator load cell piston by prying to one side on the back-up wrench. Ifit feels “spongy,” work the air out of the system by turning the tong right side up and partially unscrewing the gauge. Again pry against the load cell piston, When all the air is expelled at the gauge, retighten it and refill the load cell cylinder. If necessary, re- peat the process two or three times to expel all air, It is very important that all air is out of the system. JUMPING OUT OF TIME ‘The tong can jump out of time if the brake cover plate becomes loose, allowing the brake drum to disengage from the inner ring. This problem can also occur if the brake drum pins have worn down ‘or moved down until they are too short. Turn the pins end for end and drive them back into place, or replace them with new pins. The pins should ex- tend 1/2” above the brake drum. FIGURE 12. Torque indicator loadcell — cylinder protrudes 3/8” when piston filed with of FIGURE 15. Filling load cell cylinder with hydraulic ol.TP Gala ., SECTION VI — TROUBLESHOCTING JAWS FAIL TO ACTUATE This is caused by a worn out brake band, by inter- ference between the jaws and the inner or outer ring, or both If there is interference between the jaws and the outer ring, something is probably holding the inner ring too high, causing the jaws to hit or drag the in- side top of the outer ring. This can be caused by: The brake drum not being down against the brake cover plate 2. A brake drum pin sticking up too high, or A jaw pin not evenly spaced in the inner ring, ‘causing the brake drum pin to contact it. 15 Foreign matter between the brake drum and the inner ring can also cause jaw failure. A loose brake cover plate could also prevent proper actuation of the jaws, by letting the inner ring set too low. OIL LEAKING FROM WEEP HOLE UNDER, MOTOR ‘An oil weep hole is provided in the frame, under the motor. It prevents the case from filling up with hy- draulic oll if the motor shaft seal leaks or blows out. Should this happen, remove the motor from the tong and replace the seal,‘TP GEE 1 SECTION Vil — SHOP REPAIRS CHANGING BRAKE BAND NOTE: Disconnect hydraulic hoses before disas- sembly. 1. Remove the small gate spring capscrew and pry the gate spring out of the slot in the brake cover plate (Figure 16) 2. Remove the two 1/4" x 3/4" capscrews in the back of the brake cover plate and the two 3/8" x 1-3/4" bottom gate capscrews in the front of the plate. 3. Remove the brake cover plate (Figure 17). + 4. Turn brake drum to remove left anchor pin (Fig- ure 18) 5. Remove anchor pin (Figure 19). 6. Turn brake drum to remove right anchor pin, 7. Remove brake drum and brake as an assembly (Figure 20). 8. Remove old brake band from brake drum (Fig- ure 21) 9. Install new brake band on brake drum (Figure 22) and reassemble tong by reversing disas- sembly procedure. moe OE ees FIGURE 18, Turning brake drum to remove left anchor 7 pin FIGURE 16, Removing gate spring, FIGURE 19. Removing anchor pinLid EGE: SECTION VII — SHOP REPAIRS REPLACING OUTER RING ROLLER PINS AND BUSHINGS It is not often necessary to replace the outer ring roller pins and bushings. But, if badly worn, they can cause a slipping or jumping problem NOTE: Disconnect hydraulic hoses before disas- sembly. To remove the roller from the tong, take out the outer ring roller pin retaining snap ring. Then lay the tong on its side and drive the pin out the top (Figure 23). It necessary, force the little snap ring out with the roller pin. This usually destroys the snap ring. Un- less a bushing tool is available, it may be necessary to out part way through the bushing with a hack~ saw blade to remove it. If a press is not available to press in the new bush ing, press it in with a vise, or drive it in, using the outer ring roller pin to supportthe bushing. Afterin~ stalling the bushing, it may be necessary to ream the bushing hole to make it free on the pin. REPLACING OUTER RING WEAR RINGS NOTE: Disconnect hydraulic hoses before disas- sembly. 4. lemove the hanger and gate assemblies (Fig- ure 24), 2. Remove the frame cover by prying up evenly (Figure 25). The main points of interference will be at the three dowel pins. 3, After removing the frame cover (Figure 26), re- move the two 1/4" x 1" wear ring screws and as many outer ring frame rollers as necessary to lift out the top outer ring (Figure 27) 4, To replace the bottom outer ring wear ring, lift ‘out the outer ring and remove the two 1/4” x 1- 3/4" wear ring screws that hold the brake cover plate. 5. Then remove as many of the outer ring frame rollers as necessary tolift outthe wear ring (Fig- ure 28). assembly. FIGURE 22. Installing new brake band on brake drum,TP [EGAN « SECTION vil — SHOP REPAIRS. TONG DISASSEMBLY NOTE: Disconnect all power before disassembly. 1. Disconnect the throttle linkage at the throttle valve, 2. Remove the hanger assembly, motor, gate as- sembly, throttle controls, frame handle and frame cover cap screws. 3. Remove frame cover. In removing the frame cover, the main points of interference will be at the three dowel pins. FIGURE 26. Frame cover removed. FIGURE 24. Hanger and gate assemblies removed, 19TP (GEESE :.. SECTION Vil — SHOP REPAIRS 4, With frame cover removed, note that the open- ing of the outer ring is lined up with one of the idler gears (Figure 29). If this line-up is re- peated during reassembly, it will be easier to get the frame cover back on the tong, Lift out the outer ring and idler gears. 6. Turn the tong over and remove the gear case cover. 7. Carefully remove the gear case cover gasket and the small O-ring over the torque indicator load cell Remove the brake assembly as described on. page 17 under “Changing Brake Band.” 9. Lift out the second reduction gear (Figure 30) 10. Remove the cluster gear shaft from the tong, Jack it out of the case with a 3/8"-16NC bolt 6” ong (extra-long threads), inserting this shaft puller in the tapped bore of the shaft (Figure 31) 11. Remove cluster gear (Figure 32) 12. Remove the snap ring and drive out the motor pinion assembly (Figures 33 and 34) NOTE: Remove the motor pinion assembly out the top of the case. FIGURE 27. Removing outer ring wear ring FIGURE 29. Outer ring opening lined up with one of the idler gears. FIGURE 30. Removing second reduction gear.TP Gia. SECTION Vil — SHOP REPAIRS FIGURE 34, Removing pinion gear assembly. FIGURE 23, Removing snap ring.REPLACEMENT PARTS AND DIAGRAMS POWER SUCKER ROD TONGSTP GEES « SECTION Vill — FRAME ASSEMBLY 25TP’ Eom. SECTION Vill — FRAME ASSEMBLYGEES .. SECTION Vill — FRAME ASSEMBLY REF. PART NUMBER NUMBER NUMBER REQUIRED DESCRIPTION S 27842 - Frame Assembly (Mark 11,IIl and IV) = 27842-5 = Frame Assembly (Mark V and VI) 1 27862 1 Frame 27868 1 Outer Ring Wear Ring 3 27869 2 Idler Gear Thrust Washer 4 27870 1 Cluster Gear Shaft 5 27871 1 2nd Reduction Gear Thrust Washer 6 28872 1 Cluster Gear Thrust Washer 7 27873 7 Thrust Washer Retainer Pin 8 942453-11 7 Outer Ring Frame Roller 9 1942392-112 1 2nd Reduction Gear Lower Needle Bearing 10 27851 1 2nd Reduction Gear 1" 1942392-53 2 Idler Gear Shaft Needle Bearing 1A 29888 2 Idler Gear Shaft Retaining Disc 1B 941156-137 2 Idler Gear Shaft Retaining Disc Snap Ring 2 940287-819 1 2nd Reduction Gear Shaft Seal 27TP ELEM». SECTION Vill — FRAME ASSEMBLY REF. NUMBER. 13 14 5 16 7 18 19 20 21 22 22 23 seee esesi PART NUMBER, 940287-12 944524-244 941068-116 944422-8 1944524-295 27850 28614 27921 29197 979384-8 1979384-10 28610 944408-87 27847 28613 27922 29196 29172 27846 27866 27867 27845 27865 29173 943631-91 1944524-50y 27843 27874 27868 942453-11 944422-8 1942392-53 1940287-12 27869 27873 NUMBER. REQUIRED DESCRIPTION Idler Gear Shaft Lower Seal Motor Pinion Lower Retaining Ring Frame To Cover Dowel Outer Ring Frame Roller Nut Motor Pinion Upper Retaining Ring Motor Pinion Assembly (Ref. 18-21) (Mark I1,II and IV) Motor Pinion Assembly (Ret. 18-21) (Mark V and VI) Motor Pinion Gear (Mark Il IItand IV) Motor Pinion Gear (Mark V only) Motor Pinion Lower Bgaring Motor Pinion Upper Bearing (Mark II-IV) Motor Pinion Bearing Adapter Ring (Mark V only) Motor Pinion Snap Ring Cluster Gear Assembly (Ref. 22 and 23) (Mark II, land IV) Cluster Gear Assembly (Ref. 22 and 23) (Mark V only) Cluster Gear (Mark II-IV) Cluster Gear (Mark V only) Cluster Gear Bearing Idler Gear Assembly (Ret. 24 and 25) Idler Gear Idler Gear Shaft Outer Ring Assembly (Ref. 26 and 29) jer Ring Gear Outer Ring Roller Assembly Outer Ring Roller Pin Outer Ring Roller Pin Retainer Snap Ring Frame Cover Assembly (Ref. 30-45) Frame Cover Outer Ring Wear Ring Outer Ring Frame Roller Outer Ring Frame Roller Nut Idler Gear Shaft Needle Bearing Idler Gear Shaft Seal 1.70 , Idler Gear Shaft Thrust Washer Thrust Washer Retainer Pin 28TP [EEN .. SECTION Vill — FRAME ASSEMBLY REF. NUMBER, 38 39 40 a 43 44 45 47 48 49 50 51 52 53. 538, 538 54 55 56 87 58 59 60 6t 62 63 64 65 PART NUMBER, 942303-84 940286-318 944047-8 941271-203 941271-126 941271-218 941285-69 27844 27875 27876 28007 939100-3 27877, 27878 941271-93 939207-4 939349-3 27909) 27908 27871 27872 27873 942271-17 1945509-17 940286-471 940968-1 27918 9at271-71 939354-3, 16377 16378 939484-8 939667-28 16682 16380 16683 27955 16379-1 16446 NUMBER REQUIRED WeOe aaa aoa waged wow ones DESCRIPTION 2nd Reducing Gear Shatt Upper Needle Bearing 2nd Reducing Gear Shaft Upper Seal Frame Cover Snap-in Seal Frame Cover Capscrew Frame Cover Capscrew Frame Cover Capscrew Frame Cover Outer Wear Ring Capscrew Gear Case Cover Assembly (Ref. 47-65) Gear Case Cover Back-up Wrench Support Spring ‘Support Spring Plate Support Spring Capscrew Back-up Wrench Pivot Spring Pivot Pin Pivot Spring Capscrew Nut Lock Washer Pivot Spring Retainer Plate Torque Indicator Load Cell Piston 2nd Reducing Gear Thrust Washer Cluster Gear Thrust Washer ‘Thrust Washer Retainer Pin Load Cell Piston O-Ring Piston O-Ring Back-up Ring Piston Seal Load Cell Pipe Plug Gasket — Gear Box Cover {Gear Case Cover Capscrew Lock Washer ‘Suspension Spring Assembly ‘Shank ‘Shank Nut Shank Cotter Washer Lower Cap Housing Inner Spring Upper Cap Assembly Outer Spring 29,TP EESES .. SECTION Vill — FRAME ASSEMBLY REF. PART NUMBER NUMBER NUMBER REQUIRED DESCRIPTION 27852 = Hanger Assembly (Ref. 71-77) n 27852-1 1 Hanger 2 15532 1 Hanger Balancing Screw 74 940917-240 1 Hanger Balancing Screw Bolt - 939207-7 1 Hanger Balancing Screw Nut 939644-12 1 Hanger Balancing Screw Washer 7 .938097-23 4 Hanger Capsorew - 27848 1 Brake Drum Assembly (Ref. 78 and 78A) 78 27879 1 Brake Drum. 780, 943733-208 2 Brake Drum Pin 79 27849 1 Brake Band 80 27861 2 Brake Band Anchor Pin at 939370-7 3 Brake Band Anchor Pin Washer 82 943732-18 2 Brake Band Anchor Pin Retainer 83, 27855 1 Brake Cover Plate 84 941271-102 2 Brake Cover Plate Capscrew 99 942271-9 1 Frame Torque Indicator O-Ring 100 27860 1 Frame Handle 101 941442-3, 6 Frame Cover Nut 102 29783 1 Control Valve Shaft +103 29143 1 Torque Indicator Gauge 29192 1 Front End Control Assembly (Ref. 104-113) 104 27853 1 Front End Control Valve Lever—Left 104 29188 1 Front End Control Valve Lever—Right 105 941066-80 6 Control Valve Lever Pin 107 940072-14 1 Elbow 108 940225-47 Nipple 109 29189 1 Front End Control Connecting Bar 110 29190 1 Front End Control Bracket 113, 940584-39 1 Front End Control Shoulder Screw 14 27856 aa Right Gate 115 27887 1 Left Gate 116 27858 1 Gate Spring 117 32984 2 Gate Bolt, Top 118 32984 2 Gate Bolt, Bottom 119 941271-47 1 Gate Spring Capscrew 120 1939363-23 2 Gate Washer 121 943732-36 2 Gate Roll Pin aTP GEE». SECTION Vill — FRAME ASSEMBLY REF. PART NUMBER NUMBER NUMBER — REQUIRED DESCRIPTION - 31908 - Hydraulic Drive Group, Mark Il and V (Ref. 122-131) - 31909 = Hydraulic Drive Group, Mark IV (Ref. 122-131) 122 970400-6 1 Motor and Valve Assembly, Mark II and V 122 970400-7 1 Motor and Valve Assembly, Mark V 123 939084-33 4 Capscrew 124 31101 4 Bushing 125 31783 2 Valve Link 128 31784 1 Valve Crank 127 31785 2 Link Pin 123 '939370-9 8 Washer 130 1939667-16 4 Cotter Pin 131 924841-44 2 ‘Swivel JointSECTION IX — INNER RING ASSEMBLI :S « AND BACK-UP WRENCHES, SUCKER F DS 86 { OM 90 SE } ¢ VS | SaleSECTION IX — INNER RING ASSEMBLIES GEES. AND BACK-UP WRENCHES, SUCKER RODS REF. PART NUMBER NUMBER NUMBER — REQUIRED DESCRIPTION = 27899-2+ 1 Inner Ring Assembly - 1/2" Rod (Ret, 85-89) 85 27B94- 1 Inner Ring 86 27895- 1 Plain Jaw 87 27896" 1 Jaw — 1/2" With Lug 88 27697 2 Jaw Spring a9- 27722- 2 Jaw Hinge Pin 90 27898- fl Back-up Wrench — 1/2" 30d = 27899+ 1 Inner Ring Assembly - 5/8", 3/4" and 7/8" Rod (Ref. 85-89) 85 27894 1 Inner Ring 86 27900 + 1 Jaw — 5/8" — 3/4" — 7/8" Plain 87 27901* 1 Jaw — 5/8" — 3/4" — 7/8" With Lug 88. 27897 + 2 Jaw Spring 89. 2722+ 2 Jaw Hinge Pin 90 27902+ 1 Back-Up Wrench — 5/8” Rod 90 27903 - 1 Back-Up Wrench — 3/4” and 7/8" Red 7 27899-3- 1 Inner Ring Assembly — */8" Rods with 1-1/8" F 85 27894 1 Inner Ring 86 2790-1 + 1 Plain Jaw a7 27901-1+ 1 Jaw with Lug 88 27807 + 2 Spring 89, 27722 + 2 Latch Pin 20 27908 « 1 Back-Up Wrench — 1" & - 27899-4 - 1 Inner Ring Assembly — 1” Rod 85, 27e94 + 1 Inner Ring 86 32967 + 2 Jaw BB 27897 + 2 Spring 89 27722 + 2 Lateh Pin 90 27906 1 Back-Up Wrench — 1 Rod - 27899-1 + 1 Inner Ring Assembly — 1/8" Rod (Ref. 85-89) 85 27e94 1 Inner Ring 86 27905 4 2 Jaw 88 27897 + 2 Jaw Spring 89 27722 + 2 Jaw Hinge Pin 90 27907 + 1 Back-Up Wrench — 1-1; 1" Rod 33SECTION X — HYDRAULIC MOTOR vs AND VALVE ASSEMBLY 368SECTION X — HYDRAULIC MOTOR GEES... AND VALVE ASSEMBLY REF. NUMBER 122 12 PART NUMBER 970400-8 970200-7 970899-5 970499-1005 970499-1003, 970499-1006 ‘970499-1002 970890-615, 70499-1009 (970499-1017 970499-1007 970499-1008 70499-1008 97049-1001 970499-1011 970499-1021 97049-270 1970499-290 970499-1027 970899-1026 970499-1035, 70499-1135 970499-1029 970499-270 9704991025 970499-280 70499-1125 970499-125 97089-1020 70499-1042 970898-1041 970499-1043 970499-1044 970499-1013 970499-1012 70499-1014 NUMBER REQUIRED DESCRIPTION Motor, Mark It and V Motor, Mark IV Shatt End Cover Assembly Snap Ring Bearing Shield Bearing Seal Shatt Bearing Drive Shatt and Key Bearing Spacer O-Ring Gasket Back-Up Ring Bronze Insert O-Ring Shaft End Cover Grease Fitting Roller Bearing Gear Housing Assembly, Mark Il and V Gear Housing Assembly, Mark IV Pocket Seals Thrust Plate Gear Set, Mark tl ang V Gear Set, Mark IV Ring Gasket Gear Housing Assembly, Mark Il and V ‘Gear Housing Gear Housing Assombly, Mark V ‘Gear Housing Port End Cover Assembly Port End Cover (O-Ring, Control Valve Contrai Valve Assembly Capserew, Mark I and V Capscrew, Mark IV ‘Check Ball Retainer Check Ball Check Ball Seat aIP SECTION XI — AIR MOTOR ASSEMBLY 9. a g aw °. & 38lates. SECTION XI — AIR MOTOR ASSEMBLY REF. PART NUMBER NUMBER = NUMBER — REQUIRED DESCRIPTIC.: - 28662 1 Air Motor Assembly (F. 1-34) = 975148-1 1 Air Motor (Ref, 1-22, 2 -29 and 31-34) 1 9751551001 1 Motor Housing 2 9751551002 2 Air Port Gasket 3 940968-1 2 Pipe Plug 4 939097-2 8 Housing Capscrew 5 939349-59 8 Housing Capscrew Lo: : Washer 6 939097-1 6 Housing Cover Capser vw 7 939349-1 6 Washer 8 9751551003, 1 Rear Rotor Bearing 9 9751551004 1 Housing Cover 10 940308-1 1 Grease Fitting " 9751551005 1 Rotor Bearing Spring 12 9751551006 1 Housing Cover Gaske: 13 9751551007 1 Rear End Plate 14 9751551008 1 Cylinder 15 9751551009 1 Rotor 16 9751551010 1 Rotor Bearing Spacer 7 9751851011 1 Rotor Bearing Lock Sc..w 18 9751551012 1 Rotor Pinion 19 9751551013, 8 Vane 20 9751551014 1 Front End Plate 21 979073-6 1 Front Rotor Bearing 22 9751551015, 1 Cylinder Dowel 23 27073 1 Drive Shatt 24 939935-535 1 Drive Gear Retaining © 25 9751551016 1 Drive Gear Retaining ‘ner 26 9751551017 1 Drive Gear 27 9751551018 1 Drive Gear Key 28 9751551019 1 Drive Shaft Bearing Sp 29 979063-5 1 Drive Shaft Bearings 30 9751551021 1 Gear Case 34 940308-1 1 Grease Fitting 32 940291-439 1 Gear Case Grease Seal 33 9751551020 1 Drive Shaft Collar 34 939994-815 1 Drive Shaft Key 39TP GES .; SECTION XII — AIR CONTROL VALVE REF. PART NUMBER NUMBER 28648 943994-16 1943994-901 1943994-802 943994-03 943994-804 1943994-805 ‘943094-906 943004-907 943994-908 943994-909 943994-910 943994-911 943994-912 943994-913 943994-914 943994-915 943994-916 28805 943904-917 943994-918 943994-919 947129-167 28650 our porTs NUMBER REQUIRED DESCRIPTION Control Valve Assembly (Ret. 1, 17, 21 and 22) Control Valve (Ref. 1A-16, 18-20) Valve Stem Valve Body Segment Link | 4aSECTION Xill — GEE: OPERATING RATINGS, HYDRAULIC 2000 1800 MARK V 1800 1700 1600 1500 | | | "400 MARK IV 1900 1200 MARK IL 1100 f .17e" aon: 1000 & 200 00k, 00| | 600 ‘TORQUE — FT. LBS. 500 br" noo. 1 400 + 300 200s! 0] [tt roo pz o 123 4 5 6 7 6 9 101 12 13 14:5 16 17 18 19 20 Olt PRESSURE PS. — x180 43SECTION XII! — GGEEM «: OPERATING RATINGS, AIR TORQUE — FT. LBS. 2000 +900 1800 1700 1600 1500 1400 1300 1200 +100 1000 900 800 00 600 500 400 300 200 100 MARK VI MARK Itt + ROO 118" ROD ae ROO 10 20 30 40 50 6070 AIR PRESSURE P'S. 80 20 300 110 120 44TP SECTION XIV — SPARE PARTS ba 1 FOR ONE YEAR'S OPERATION PART NUMBER, NUMBER REQUIRED DESCRIPTION 27848 1 Brake Drum Assembly 27849 1 Brake Band 27861 2 Brake Band Anchor Pin 27858 1 Gate Spring 27868 1 Outer Ring Wear Ring 29143 1 Torque Indicator Gauge 27871 1 2nd Reduction Gear Thrust Washer 27873 7 Thrust Washer Retainer Pin 27872 1 Cluster Gear Thrust Washer 32984 2 Top Gate Bolt 32985, 2 Bottom Gate Bolt 27897 4 Jaw Spring 27722 4 Jaw Hinge Pin 27918 1 Gear Box Cover Gasket 27902 1 5/8" Back-Up Wrench 27903 1 9/4"-1/8" Back-Up Wrench 27908 1 1" Back-Up Wrench 27907 1 1-1/8" Back-Up Wrench 27903-1 1 Back-Up Wrench w/1-1/8" Sq 970400-6 1 Hydraulic Motor, Mark I! and V '970400-7 1 Hydraulic Motor, Mark IV 942453-11 7 Outer Ring Frame Roller 975148-1 1 Air Motor, Mark III and VI 944422-8 in Outer Ring Frame Roller Nut 940287-12 2 Idler Gear Shaft Seal 942392-53 2 Bearing 942392-112 1 Bearing 1940286-819 1 2nd Reduction Gear Shaft Seal 1942399-84 1 Bearing 1940286-318 1 2nd Reduction Gear Shaft Upper Seal 942271-9 2 O-Ring 942271-17 2 Piston O-Ring 945509-17 4 Piston O-Ring Back-Up Ring 940288-471 2 Piston Seal 941285-69 2 Socket Head Capscrew 45