Gill Model 500 Technical Manual

GILL SERVICES, INC.
TECHNICAL MANUAL
GILL MODEL 500
POWER TUBING TONG
OPERATING AND MAINTENANCE INSTRUCTIONS
WITH ILLUSTRATED PARTS LIST
Model 500 Serial No. ________________________________________
Customer Reference No. _____________________________________
Gill Services, Inc. * 650 Aldine Bender, Houston, TX 77060

Phone: 281-820-5400 * Fax: 281-820-0034 * Website: www.gillservicesinc.com
IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all GILL SERVICES
equipment. The service procedures recommended by GILL SERVICES and described in the
technical manuals are recommended methods of performing service operations. Some of these
service operations require the use of tools especially designed for the purpose. The special tools
should be used when and as recommended.
It is important to note that some warnings against the use of specific service methods that can
damage the equipment or render it unsafe are stated in the manuals. It is also important to
understand that these warnings are not exclusive. GILL SERVICES could not possibly know,
evaluate, and advise the service people of all conceivable ways in which service might be done or
of the possible hazardous consequences of each way. Accordingly, anyone who uses service
procedures or tools which are not recommended by GILL SERVICES must first satisfy himself
thoroughly that neither his safety nor his equipment’s safety will be jeopardized by the method
selected.
WARRANTY AND GUARANTEE

GILL SERVICES, INC. warrants and guarantees that all equipment furnished hereunder and
manufactured or reconditioned by GILL SERVICES, INC. (hereinafter called “Vendor”) is
warranted to be free from defects in workmanship and material for a warranty period of six (6)
months from date of receipt of the original retail purchaser. If, under normal use and service, any
failure of any parts by reason of a defect in workmanship or material shall appear within such
warranty period, Purchaser shall notify Vendor thereof immediately, and if so requested by
Vendor, shall return the defective part to Vendor, transportation charges prepaid, and Vendor
shall, upon verifying that the cause of the failure is within the terms hereof, correct any such
defects by repairing the defective part at its works or by supplying a replacement thereof F.O.B.
Vendor’s works or warehouse. This guarantee does not apply to any parts or items thereof which
shall have been repaired or altered by other than Vendor in any way so as, in Vendor’s judgment,
to affect same or which has been subjected to negligence, accident or other than normal use and
service. The liability of Vendor arising out of the supplying of any material hereunder or its use,
whether on warranties or otherwise, shall not exceed the cost of correcting defects as herein
provided, and shall not include transportation charges, Purchasers’ labor or materials (except as
authorized in wiring in advance), loss of use or revenue, or any indirect or consequential
damages. Upon expiration of said warranty period, all such liability shall terminate. Vendor
shall have no liability, other than as specifically herein provided, upon warranties, expressed or
implied, of any nature whatsoever, (exclusive, however, of its warranty of title) including, but
without limitation, warranties with respect to workmanship, material performance and fitness for
use. Upon the expiration of said six (6) month period after the original receipt to retail purchaser
of the machinery, all liability hereunder with respect to the machinery or any part or parts thereof
repaired or replaced by reason of this guarantee shall terminate. Any parts or material not of
Vendor’s manufacture is covered only to the extent of any guarantee given to the Vendor by the
seller of said material and enforceable by the Vendor against said seller.
WARNING
DO NOT OPERATE, ADJUST, OR REPAIR THIS TONG

WITHOUT PROPER TRAINING. READ AND UNDERSTAND ALL
OPERATING AND MAINTENANCE INSTRUCTIONS AND ALL
OTHER WARNINGS CONCERNING SAFETY BEFORE USING
THIS TONG. DO NOT REMOVE OR PAINT OVER WARNING
LABELS.
1. DO NOT OPERATE TONG UNTIL ANCHOR ARM IS

ATTACHED TO THE TONG AND ANCHOR POST.
2. DO NOT CRAWL OR STAND UNDER TONG.
3. CAUTION: KEEP HANDS CLEAR OF TONG HEAD

WHILE TONG IS IN OPERATION, AS PARTS INSIDE
TONG HEAD ROTATE. KEEP ALL PARTS OF THE
BODY AND CLOTHING AWAY FROM MOVING
PARTS.
4. SHUT OFF POWER SUPPLY TO THIS UNIT BEFORE

PERFORMING ANY WORK, (i.e., CHANGING TONG
DIES OR JAWS, ADJUSTMENTS, MAINTENANCE,
OR LUBRICATION).
5. FAILURE TO COMPY WITH WARNINGS COULD

RESULT IN EQUIPMENT DAMAGE AND
PERSONAL INJURY.
1. INTRODUCTION
This manual contains information regarding the GILL Model 500 Power Tong. Full benefit
of long life and dependability of this unit can only be realized by proper operation and
maintenance. The operator should familiarize himself thoroughly with information
contained in this manual before operating this tong. GILL SERVICES, INC. provides the
information, data, and recommendations contained in this manual as a customer service. All
are believed accurate. However, GILL SERVICES, INC. assumes no responsibility, implied
or otherwise, for errors in or for the application of the Information, data, and
recommendations presented herein.
The right is reserved to make changes in this manual at any time, without obligation.
SECTION TITLE PAGE
WARRANTY……………………………………………….. l
WARNING ………………………………………………… ll
1. INTRODUCTION …………………………………………. 1
2. GENERAL DESCRIPTION ……………………………… 1
3. TORQUE CURVE ………………………………………... 2
4. SPECIFICATIONS ……………………………………….. 3
5. INSTALLATION AND OPERATION INSTRUCTIONS .. 4
6. VICKERS HYDRAULIC FLUID RECOMMENDATIONS 6
7. LUBRICATION AND MAINTENANCE …………………. 7
8. FINAL DRIVE ASSEMBLY ……………………………… 9
9. TRANSMISSION ASSEMBLY ………………………….. 11
10. JAW SETS LISTS ………………………………………... 13
11. TONG DRAG RING ASSEMBLY ………………………. 16
12. CLUTCH ASSEMBLY ……………………………………. 17
13. HYDRAULIC LIFT ASSEMBLY …………….……………. 20
14. COMMERCIAL HYDRAULICS ………………………….. 23
15. HYDRAULIC TORQUE GAUGE ASSEMBLY ……..…… 26
16. BACKUP TOOL ……………………………………..……. 27
17. AIR CONTROLS FOR BACKUP TOOL ……………….... 30
MAINTENANCE LOG…………………………………….. 31
2. GENERAL DESCRIPTION
GILL MODEL 500 Power Tong is a safe and accurate unit for the makeup and
breakout of tubing and casing 1-5/16 in O.D. through 7 in O.D. These power tong
features include: closed head design, allowing tong to remain in position during
the entire trip, reducing makeup and break-out time; pressure oil bath
lubrication; positive case seal; direct motor drive; roller chain final drive; two
speed operation; controlled torque; and stiff torque arm for safety.
Gill Services, Inc.
Model 500 and 500HT
Torque vs. Hydraulic Pressure
8000
(10848)
7000
(9492) Low Gear – Model 500HT
6000
(8136)
5500
(7458)
5000
(6780) Low Gear – Model 500
4500
Torque – Ft. Lbs. (Nm)
(6102)
4000
(5424)
3500
(4746)
3000
(4068)
2500
(3390)
2000
High Gear – Model 500HT
(2712)
1500
(2034)
1000
(1356)
High Gear – Model 500
500
(678)
0 200 400 600 800 1000 1200 1400 1600 1800 2000
(14) (28) (41) (55) (69) (83) (96) (110) (124) (138)
Hydraulic Pressure, psi (Bars)

External measurement of Model 500 Gear Housing is 2-1/4”
External measurement of Model 500 Hi-Torque Gear Housing is 2-3/4”
Since 1977 Gill Services has
built a reputation for excellence
within the oilfield industry by
Model 500 Features
providing dependable products "Power Shift" Transmission - Enables
of the highest quality backed by operator to change gears during
unparalleled service to meet Tong Operation .
the unique requirements of
each customer for standard Improved Drive Alignment - Minimizes
selling new products , reliable wasted power and provides quieter
parts, repairs and innovative running with less friction .
conversions to existing
equipment look to Gill Services Speed - Allows joint make-up in as little
for committed response. as 5 seconds and break-out in 7 seconds .
Spit Guide Ring - Provides easier and

safe access to jaws and
final drive gear
components .
Pressurized Oil Bath - Insures

uniform lubrication
of moving parts
Adjustable Clutch - Extends

the life of transmission
components .
Available with air or

hydraulic assist for
back-up tool .
SPECIFICATIONS
Size Range 1 5/16" to 7" (33.3mm to 177.8mm )
Torque @ 2000 psi (138 bars ) High Gear Low Gear
Ft Lbs 1300 6000

(Nm) ( 1763 ) ( 8136 )
Speed (rpm) @ 33.5 gpm (127 LPM ) 126 27
Weight W/Back-up Tool and Transport Rack

Model 500 ht - 8000 ft. lbs (10848 Nm)
4. SPECIFICATIONS Cont’d -
Torque Range: 300 to 6,000 ft lb torque

High Gear……………………………………………………………………...300 to 1,300ft lb
Low Gear………………………………………………………………………………6,000 ft lb
RPM
High Gear……………………………………………………………………….……………*126
Low Gear……………………………………………………………………………..….……*27
Hydraulic Requirement………………………………………….……….33 GPM at 2,000 psi
Tong Length…………………………………………………………………………….………51”
Space Required on Pipe

Tong…………………………………………………………………………………….…9-1/2 in
With backup……………………………………………………………………...……..16-1/2 in
Maximum Elevator Diameter Clearance…………………………………………………...30”

Approximate Weight
Tong……………………………………………………………………………………...1,000 lb
* (RPM based on published requirements of motor manufacturer: 33.5
GPM to tong motor

5. INSTALLATION AND OPERATION INSTRUCTIONS
5.1 INSTALLING WITH SPRING CUSHIONED HYDRAULIC LIFT

1. Move tong to convenient position near well.
2. Lift hydraulic cylinder, set in position on tong, attach with pins, and connect
hydraulic line from control valve to cylinder.
3. Lift tong with line approximately 3 feet above well head. (Cylinder has 6 foot
travel.) The hydraulic lift is ready to operate by means of controls. The line
supporting the tong should be located so the tong head will hang over the center of
the well.
4. Weld anchor bracket on right rear corner of rig approximately 4 feet above
ground. Additional anchor brackets can be purchased for use of this tong on more
than one rig. See Figure 5-1.
5. Connect torque arm to rear of tong and to anchor bracket on rig. The torque
arm Is adjustable, so adjust the torque arm so that the tong will be at a right angle to
torque arm. See Figure 5-2. Tong should then have about 4 feet of free vertical
travel. Lower tong over tubing.
6. Attach hoses from hydraulic power source. Be sure all self-sealing hose
couplings are tight before starting engine. Tighten firmly by hand. Failure to do this
will cause engine to run at full speed when tong is not in use.
7. To level tong, use the leveling screws and compression spring nuts. If tong is Fig. 5-1. Hydraulic Lift
not level, it will cause excessive wear to tong jaws and Inserts. See Figure 5-3.
5.2 JAW ARRANGEMENT
Tubing
1. For breaking out and / or making up joints , place jaws
on pins with long side of jaw against gear teeth .
2. Inserts are reversible and should be turned around
when they become worn or replaced if reversing
fails to bring sharp teeth In contact with pipe .
5.3 SETTING HYDRAULICS FOR PROPER OPERATION 90°
1. Check all hose connections before engaging

hydraulic power source .
2. Engage hydraulic power source . Tong Anchor

Fig. 5-2 Tong at Right Angle
3. Adjust tong relief valve. The relief valve on the to Torque Arm
tong operates in makeup direction only.
a. Turn relief valve adjusting screw to left to reduce To Level Unit
pressure until tong reduces speed.
b. Place tong on tubing to be made up and gradually
increase the pressure to reach make up required.
Check manufacturers' recommended makeup
torque for type of joint being made up.
c. Lock relief valve adjusting screw and make up
second joint checking torqe when tong stalls.
d. Make minor corrections as necessary until torque
readings are satisfactory.
e. If tong grips and slips , increase pressure on
drag plugs by screwing in drag screws in drag
ring. Adjust screws evenly. See Figure 5-4 .
NOTE : It is not necessary to change makeup torque to

break-out. Tong operates at system pressure
for breakout. System pressure is controlled by Fig 5-3 Compression Spring
a relief valve set at 2200 PSI in power unit tank. and Leveling Screws
PSI should not exceed 2500 PSI .
4. If pump fails to pick up oil after hoses have been
connected or if tong runs in surges, screw out relief DRAG RING
valve all the way and let pressure back to tank. SCREW
Circulate to remove air. Screw In pressure screw
until tong operates. Repeat if necessary.
5. In operating tong, stop operating lever in center position

one second before reversing motor. This reduces
fluid shock in motor.
Fig. 5-4 Drag Screw

in Drag Gear
5.4 STEPS TO DISMANTLE
1. Raise tong to top of hydraulic lift travel.

2. Use a line to lower tong and hydraulic lift to ground.
3. Shut off hydraulic source to tong. Engage lever on control valve for lift to release pressure off lift
hose.
4. Disconnect hoses and prepare unit for transporting.
6. VICKERS HYDRAULIC FLUID RECOMMENDATIONS
6.1 OIL-TYPE
Oils used in hydraulic systems perform the dual function of lubrication and transmission of power.
Oil must be selected with care and with the assistance of a reputable supplier.
Crankcase oils meeting or exceeding the “Five Engine Test Sequence” for evaluating oils for API
(American Petroleum Institute) service MS (Maximum Severity) best serve the needs of mobile
hydraulic systems. These engine sequence tests were adopted by the Society of Automotive
Engineers, American Society for Testing Materials, and automotive engine builders. The MS
classification is the key to selection of oils containing the type of compounding that will extend the
operating life of the hydraulic system. Oils meeting Diesel engine requirements, DG through DS
classifications, may or may not have the type of compounding desired for high performance
hydraulic systems.
HYDRAULIC SYSTEM SAE API SERVICE

OPERATING RANGE VISCOSITY CLASSIFICATION
(Mm. to Max.)
0°F to 180°F 10W MS

15°F to 210°F 20-20W MS
32°F to 230°F 30W MS
0°F to 210°F 10-30W MS
Automatic Transmission Fluid, Type “A,” is usually satisfactory for power steering
systems or those systems operating under moderate hydraulic service.
6.2 OPERATING TEMPERATURES
These temperature ranges for each grade of oil are satisfactory If suitable procedures
are followed for low temperature start-up conditions and if sustained operation is
avoided at the upper temperature limits. Operation in excess of these temperatures
results in increased wear of the system components and causes more rapid
deterioration of the oil. For optimum operation, a maximum oil viscosity of 4,000 SSU
at the low temperature start-up condition and a minimum oil viscosity of 60 SSU for the
sustained high temperature operating condition are recommended.
Good oils are the most economical. Specifications can be set up which will indicate, to
a limited degree, the characteristics essential in a good hydraulic oil. These are listed
herein and should be checked with the oil manufacturer prior to the use of their
product.
6.3 VISCOSITY
Viscosity is the measure of fluidity. The oil must have sufficient body to provide adequate sealing
effect between working parts of pumps, valving, cylinders, etc., but not enough to cause pump
intake cavitation or sluggish valve action. Viscosity recommendations must at best be a
compromise, which takes Into consideration the working temperature range, the type of hydraulic
equipment used, and class of service. Refer to table of oil viscosity recommendations.
6.4 VISCOSITY INDEX
The viscosity Index Is a measure of the rate at which temperature changes cause a change in oil
viscosity. It is very desirable that the oil viscosity remain as nearly constant as possible under the
wide range of temperature conditions encountered in operating mobile construction machinery.
The viscosity Index (Vi.) of hydraulic oil should not be less than 90 for this type of service.
6.5 ADDITIVES
Research has developed a number of additive agents which materially improve various charac-
teristic of oils for hydraulic systems. They may be selected for compounding with a view toward
reducing wear, Increasing chemical stability, inhibiting corrosion, depressing pour point and
improving the anti-foam characteristics. Proper use of additive agents requires specialized
knowledge, and they should be Incorporated by the oil manufacturer only, as serious trouble may
otherwise result.
Most oil companies have several brands of crankcase oils of somewhat varying formulation that
will meet the API service classification of MS. The more desirable of these oils for hydraulic service
will contain higher amounts of the type of compounding that avoids scuffing and wear of cam
lobes and valve lifters. These oils will also be formulated to be stable under oxidative conditions
and when in contact with small amounts of moisture. There should also be reasonable protection
against rust to any ferrous materials submerged in the oil or covered by the oil’s film.
6.6 CLEANLINESS
Thorough precautions should be taken to filter the oil in the entire hydraulic system prior to its
initial use to remove paint, metal chips, welding shot, lint, etc. If this is not done, damage to the
hydraulic system will probably result. In addition, continuing filtration is required to remove sludge
and products of wear and corrosion, throughout the life of the system.
Precautions should be taken in the design of hydraulic circuits to assure that a means is provided
to keep the oil clean. This can best be accomplished by the use of a 25-micron full-flow filter or a
10-micron bypass filter plus a micronic filter type air breather or sealed reservoir.
6.7 MISCELLANEOUS
The performance of hydraulic valves and cylinders is less affected by the lubricating quality of the
oil and, therefore, selection of the oil is less critical than for pumps and motors. It is always good
practice, however, to use the best quality oil available for all components.
7. LUBRICATION AND MAINTENANCE

LUBRICATION REQUIREMENTS
TRANSMISSION:
Oil meeting API classification MS:
Temperature above 32°F SAE 30W

Temperatures below 32°F SAE low
TRANSMISSION CAPACITY…...10 quarts
GREASE FITTINGS…………..Any soft gun lubricant
Lube Fitting in
Drag Ring
remove
Guide Bell
OIL LEVEL
LUBE FITTINGS
Fig. 7-1. Tong Lube Fitting & Oil Level
7.2 OPERATION MAINTENANCE
1. Grease lube fittings weekly. (Fig. 7-1).

2. Check the transmission after every trip. If water or dirt is found in transmission,
change oil. Under normal conditions, oil should be changed every 100 work-hours.
3. Clean and grease toug head and backup tool after every trip. Use kerosene
or solvent and a wire brush for cleaning. After cleaning, apply cup grease
to jaws, pins, ring gear, and top seal.
4. Do not steam clean tong head. Steam cleaning tong head will force water by the
top seal into the transmission, removing all of the lubricants from top seal and
causing it to harden. If steam cleaning is used, guide bell should be pinned in
place. After cleaning, check the transmission for the presence of water.
7.3 SAFETY POINTS AND WARNINGS

CAUTION : Keep hands clear of Tong Head while Tongs are in operation.
Caution should be taken while operating this equipment, as
parts inside the Tong Head rotate.
1. Do not crawl or stand under Tongs as hydraulic line could be cut or broken,
and Tongs will fall.
2. Do not operate Power Tongs until the Anchor Arm is attached to the Tong
and Anchor Post.
3. Power should be OFF before any size equipment change, maintenance,
or any work is done to this equipment.
X503-16
R509-1P
SEE JAW
D506-1
LIST
D507
D505
O500
D500-2-A
B500
X500-13
W501-3 R502
B507 W500-5
O504
G500-A Z506-7
RC500 L517
O504
R502
A500
B500 B506
O503 W501-3
O500
D509
X500-14
B508
X500-18
Gill Model 500 Final drive Assembly

MODEL 500 FINAL DRIVE ASSEMBLY
PART NUMBER DESCRIPTION # REQUIRED WEIGHT
A500 Transmission Case 1
B500 Roller Bearing, Final Drive 2

B506 Bearing Race (Bottom) 1
B507 Bearing Race (Top) 1
B508 Bearing Cap (Bottom) 1
D500-A Drag Ring Assembly 1

D505 Skt. Set Screw (1" x 1") 5
D506-1 Drag Ring Spring 5
D507 Drag Ring Plug 5
D509 Drag Ring Sleeve 1
G500-A Final Drive Gear 1
L517 Leveling Pin 2
O500 Oil Seal 2

O503 Oil Seal Protector 1
O504 Oil Seal Ware Band 2
R509-1P Guide Ring (5-1/2" Bore) 1

R501-15 Cover Ring (5-1/2" Bore) 1
R502 Base Ring 2
RC500 Roller Chain (TPL-60-88P) 1
W501-3 LockWasher 3/8" 42
X500-13 Capscrew (3/8-16 x 1-1/4" Hex) 18

X500-14 Capscrew (3/8" x 1-1/2" Hex) 12
X500-18 Capscrew (3/8" x 2-1/4") 12
X503-16 Flt Hd Capscrew (5/8" x 2") 2
Model 500 Transmission Assembly
X500-12 P510
F502-5
B509
P511
A508
X500-11 X500-31
P501A
M500
A504 X501-13
B501 F501-2
B511G
X500-6 K500-3
E500-2 G504 A502
B503
B502
G503 B505
S501 B501
F505-10 B504 B512-2
C503
B512 G505-A
C500
X501-7 C503-1 C502 G506-A W501-5
F505-6
C501 R503-1
G503 E500-1
B512-2 O500-4 X500-12

S500
R503-1
B510
A503-A
X500-11 x 2
C518
A501
B501
B509-3
X500-12
MODEL 500 TRANSMISSION ASSEMBLY
PART NUMBER DESCRIPTION REF. NO. # REQ.D
A501 Ring Gear Cover 93-18 1

A502 Transmission End Plate 58-17-3 1
A503-A Side Plate Assy, 6-1/2" x 9-1/2" 58-295 2
A504 Side Plate for Chain 93-295-1 1
A508 Guard Cover 93-122 1
B501 Timken Bearing 50-32-1 3

B502 Bearing 93-32 1
B503 Timken Bearing 93-183 1
B504 Ball Bearing 58-25 4
B505 Timken Bearing 92-183 1
B509 Bearing Cap, Top 58-23-1 1
B509-3 Bearing Cap, Bottom 58-23 1
B510 Bearing Cap, Back 58-29-1 1
B511 Bearing Cap Motor Mount 93-37-2 1
B512 Spacer, Pinion 58-137-1 1
B512-1 Pinion Shim (Not Pictured) 58-83 3
B512-2 Bearing Spacer 50-45-1 2
C500 Clutch Assy 50-13-1 1

C501 Clutch Shifting Yoke 50-193 1
C502 Clutch Shifting Fork 50-28-3 1
C503 Clutch Shaft 58-14-2 1
C503-1 Clutch Shaft Nut, 1" 58-363-1 1
C503-2 Clutch Shaft Pinion Key (Not Pictured) 1
C518 Clutch Lever w/Shaft 58-27-10 1
E500 Oil Sight Gauge 56-81 1

E500-1 Pet Cock (1/8" Pipe) 11-299 1
F501-2 Ell, 1/4" Std. Blk Street 11-321 1

F502-5 Str. 1/4" OK x 1/4" Pipe 11-59 1
F505-6 Plug, 1/2" Skt. Pipe 11-601 1
F505-10 Plug, 1-1/4" XQ Hd Pipe 11-324 2
G503 Ring & Pinion Gear 50-20 1

G504 High Drive Gear 58-10 1
G505-A High Clutch Gear Assy 50-9-1 1
G506-A Low Clutch Gear Assy 50-12-2 1
G507-A Oil Pump Gear 58-143-1) 1
K500-3 Hy Pro Key #18 11-1760 3

MODEL 500 TRANSMISSION ASSEMBLY
PART NUMBER DESCRIPTION REF. NO. # REQ.D
M500 Motor M25X (1-1/2) 77-90 1
O500-4 O-Ring 1/8" x 1" x 1-1/4" 11-349 1

P501-A Oil Pump Assy 119-202 1
P510 Oil Pump Line (5/16") 93-114 1
P511 Oil Pump Line (1/4") 93-115 1
R503-1 Spirolox Ring 11-900 3

S500 Ring Gear & Hub Sprocket 93-19 1
S501 Drive Shaft 93-11 1
W500-5 Flat Washer, 3/4" 11-255 2

W501-5 Lock Washer, 1/2" 11-87 2
W501-11 Int. Lock Washer, 1" N/A 1
X500-6 Capscrew (5/16" x 1/2" Hex) 11-662 20

X500-11 Capscrew (3/8" x 3/4" Hex) 11-604 8
X500-12 Capscrew (3/8" x 1" Hex) 11-603 30
X500-31 Capscrew (1/2" x 2-1/4" Hex) 11-1492 2
X501-13 Socket HD Screw (3/8" x 1") 11-113 4
X503-7 Skt Set Screw (5/16" x 5/16") 11-595 2
X503-13 Sq Hd Skt Set Screw (3/8" x 2") 11-578 2
Y500-5 Hex Nut, 3/4" 11-76 2

Y500-22 Jam Nut (1" SAE) 11-1137 1
Z506-7 Safety Pin 11-920 2

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

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

Consists of:
Jaw J502 5
Insert N502 10
2B 2-3/8” - 2-7/8” Jaw Assembly

Consists of:
Jaw J503 5
Insert N503 10
2C 2-7/8” - 3-1/2” Jaw Assembly 5/Tong

Consists of:
Jaw J505-2 1/Assy
Insert N505-4 1/Assy
Insert Screw N507 1/Assy
3 3-1/2” - 5” Drag Ring Assembly
Consists of:
Drag Ring D501-A 5
Cover Plate R501-2 5
Split Guide Bell R506-1-A 5
3A 3-1/2” - 4-1/2” Jaw Assembly
Consists of:
Jaw J505-2 5
Insert N505 5
Insert Screw N507 5
3B 4” - 5” Jaw Assembly
Consists of:
Jaw J505-2 5
Insert N505-1 5
Insert Screw N507 5
3C 5” - 6-1/16” Jaw (solid) J507 5/Tong

SINGLE-ACTING JAWS—CASING
ITEM O.D. TUBULAR DESCRIPTION PART NO NO. REQUIRED/
NO TONG OR ASSY.
1 4” - 5-1/2” Drag Ring Assembly 1/Tong

Consists of:
Drag Ring D502-1-A 1/Assy.
Cover Plate R501-3-1 1/Assy.
Split Guide Bell R507-1-A 1/Assy/
1A 4” - 4-1/2” Jaw Assembly

Consists of:
Jaw J506 5
Insert N505-2 5
Insert Screw N507 5
1B 5” - 5-1/2” Jaw Assembly

Consists of:
Jaw J506 5
Insert N505-3 5
Insert Screw N507 5
2 6-5/8” - 7” Drag Ring Assembly

Consists of:
Drag Ring D503-A 1/Assy
2A 6-5/8” Jaw (solid) J508 10/Tong
2B 7” Jaw (solid) J509 10/Tong
DOUBLE ACTING JAWS—TUBING

1 2-3/8” - 3-11/16” Drag Ring Assembly
Consists of:
Drag Ring D500-2-A 1/Assy
1A 2-3/8” - 3-1/16” Jaw Assembly 5/Tong

Consists of:
Jaw J510 5
Insert N504 5
Insert Screw N507 5
1B 2-7/8” - 3-1/2” Insert N504-3 5
3-1/2” Only Insert N504-1 5
JAW LIST—BACKUP TOOL
ITEM O.D. TUBULAR DESCRIPTION PART NO. NO. REQUIRED/

NO. TONG OR ASSY
1 1-5/16” - 2-1/16” Jaw Assembly 5/Backup

Consists of:
Jaw BU501 1/Assy
Insert N501 1/Assy
2 2-3/8” - 3-3/4” Jaw Assembly 5/Tong

Consists of:
Jaw BU502 1/Assy
Insert N503 1/Assy
3 3-1/16” - 4-1/2” Jaw Assembly 5/Tong

Consists of:
Jaw BU503 1/Assy
Insert N503 1/Assy
4 4-1/2” - 5-9/16” Jaw (solid) BU504 5/Backup
5 5” - 6-1/16” Jaw (solid) BU505 5/Backup
When more than one drag ring assembly is required, do not

duplicate the same items included in other drag ring assemblies.
Example: Running tubing 1-5/16” through 1.9” O.D. requires a
D500-2-A Drag Ring, an R501-15 Cover Plate, and an R509-1-A
Split Guide Bell. To change over to run 3-1/2”” through 5” O.D.,
you would need to change to P/N D501-A Drag Ring; P/N R501-2
Cover Plate; and P/N R506-1-A Split Guide Bell.
The Backup Tool must have a 6-1/4” bore through the head to
use the 4-1/2” through 6-1/16” O.D. Jaw Sets. The BU509-2
Housing Adapter is used on the other equipment size to reduce
the bore from 6-1/4” O.D. to 5” O.D.
The sizes listed are the actual O.D. size for tubing, upset, or collar
that the jaws will catch.
11. TONG DRAG RING ASSEMBLY
PARTS LIST
D500-2- A DRAG RING ASSEMBLY 1-5/16” - 3-1/2” O.D. (5-1/2” BORE)
PART NO. DESCRIPTION QTY.
D508 Jaw Pin—1” 5
D507 Drag Plug 5
D506-1 Drag Spring 5
D505 Set Screw 5
Z503-1 Grease Fitting 1
D502-1-A DRAG RING ASSEMBLY 4” - 5-1/2” O.D. (7-1/4” BORE)
D508-1 Jaw Pin—3/4” 5
D507-1 Drag Plug 5
D505-1 Set Screw 5
D501-A DRAG RING ASSEMBLY 3-1/2” - 6-1/16” O.D. (6-1/4” BORE)
D508 Jaw Pin—1” 5
D507-2 Drag Plug 5
D505-1 Set Screw 5
D503-A DRAG RING ASSEMBLY 6-5/8” - 7” O.D. (7-7/8” BORE)
D104 Jaw Pin—1” 10
D507-1 Drag Plug 5

D505-1 Set Screw 5

Clutch Assembly
C516
C511
C513
C517
C512
C509 C510
C508
C507
C515 C505-A
C514
C506-A
C507
C508
C510 C509
C512
C517
C513
C511
C516
13. CLUTCH
13.1 Adjustment For Clutch
1. Remove side panel from operator’s side of tong.
2. Be sure tong is in neutral position.
3. Rotate clutch with hand until slot in adjusting collar is facing toward the opening in tong.
4. Insert screwdriver or similar object in slot in the adjusting collar.
5. Pry the adjusting collar away from pressure plate so that the teeth are free from each other.
6. Rotate adjusting collar in the direction shown to adjust clutch.
7. Follow the above procedure for both ends of the clutch.
8. Adjust left end of clutch for high gear.
9. Adjust right end of clutch for low gear.
10. If the clutch slips or the disc stack heats up, adjustment is required.
PARTS LIST
PART NO. (Foster Ref. No.) DESCRIPTION REO’D.
C504 (819-1 ) Anchor Pin 1
C516 (819-5) Split Ring 4
C508 (819-9 ) Pressure Plate 2
C509 (819-10 ) Inner Disc 12
C510 (819-11 ) Outer Disc 14
C511 (819-12 ) Thrust Plate 2
C507 (819-13 ) Adjustment Collar 2
C513 (819-14) Spring Pin 6
C512 (819-16 ) Separating Spring 6
C514 (819-17 ) Dog 6
C515 (819-18 ) Dog Pivot 6
C505-A (819-20 ) Body 1
C506-A (819-21) ShIpper Sleeve 1
C517 (11-1186) No.CHyProKey 6

Pressure Plate
Adjusting Collar
Rotate to Tighten Rotate to Loosen
Rotate to Loosen Rotate to Tighten
To Adjust Tong Clutch

1. Remove side panel from operator's side of Tong.
2. Be sure tong is in neutral position.
3. Rotate clutch with hand until slot in adjusting collar is facing

toward the opening in tong.
4. Insert screwdriver or similar object in slot in the adjusting collar.
5. Pry the adjusting collar away from pressure plate so that the
teeth are free from each other.
6. Rotate adjusting collar in the direction shown to adjust clutch.
Follow the above procedure for both ends of the clutch.

Adjust left end of clutch for high gear.
Adjust right end of clutch for low gear.
If the clutch slips or the disc stack heats up , adjustment is required .

L500A Hydraulic Lift Assembly
O500-10
L502-1
R504-1
O501-1
O505 O500-16
O501-1
L502-A F501-4
O500-20
L519
L503
L515
H502
L518
Q500-2
Q500-1
Q500-4 Q500-3
F500-10 L504
L505
V514
Y500-6
L501
Y500-8
L513 Y500-8
L510 L509
L511 L508
L510-1
L509
L511
L506
O500-16
L509
L512
L508
O500-18
166-16 X500-39
L509
Z502-8
Y500-8
L514
L507
(Foster Ref. No. 123-3-1)
(Foster Ref. No. 123-23)

(Foster Ref. No. 126-7
(Foster Ref. No. 74-73 & 58-72)
(Foster Ref. No. 11-1076 & 123-6)
(Foster Ref. 11-361)

Foster Ref. No. 11-946)
(Foster Rerf. No. 11-803)

Commercial Hydraulics
V507-NSP
(RELIEF VALVE)
BLOCK F503-17
T500-12 Q500-17
RETURN Q500-18
(PRESSURE)
T512
( RETURN TEE)
Q500-21
Q500-23
V516 (RETURN)
T500-A
T501-A
T500-12 M500
See Parts List For Quantities Required

V507-NSP
T500-A
T500-12 F503-17
Q500-17
F501-15 T502-A
Q500-21
T506
T500-12
T501-A
F503-10
X500-20 M500
V500 T500-12
V519-1
A507
A506
X500-13
V516
SEE PARTS LIST FOR QUANTITIES REQUIRED
Fig. 15.1 Commercial Hydraulics

VALVE BODY ASSEMBLY
TO MOTOR CHECK VALVE

V500
F503-10
INLET PRESSURE
RETURN TEE
F503-10
TO MOTOR PLUG
A506
15. COMMERCIAL HYDRAULICS
PARTS LIST
(Foster Ref. No) REQ’D.
T500-A (10-606) Steel Tubing 1
Y500-5 (11-76) Hex Nut, 3/8” (not pictured) 3
W501-5 (11-87) Lock Washer, 1/2” (not pictured) 5
F502-7 (11-90) Str. Fitting, 3/8” Flare to 3/8” Pipe (not pictured) 1
F501-15 (11-165) Ell, 1” x 90 Degree,s,H.P. 1
F503-10 (11-254) Nipple, 1” Close H.P. 1
F507-5 (11-265) Collar, 1” H.P. 1
F503-12 (11-333) Nipple, 1” x 2-1/2” H.P. 1
F503-17 (11-337) Nipple, 1” x 6” H.P. 1
F500-5 (11-427) Ell, 1/4” Flare to 1/4” Pipe, 45-Degrees 1
Q500-18 (11-560) Dust Cap, 1” 1
Q500-23 (11-566) Dust Cap, 1-1/4” 1
F505-9 (11-606) Pipe Plug, 1” Socket (not pictured) 2
X500-26 (11-641) Capscrew 1/2” X 1” Hex (not pictured) 3
Q500-4 (11-850) Dust Plug (not pictured) 1
Q500-1 (11-946) Coupling Half, 1/2” (not pictured) 1
Q500-17 (11-953) Coupling Half, 1” 1
Q500-21 (11-955) Coupling Half, 1-1/4” 1
(Continued on Page 2)
15. COMMERCIAL HYDRAULICS
PARTS LIST (cont.)

(Foster Ref. No) REQ’D.
T500-12 (11-963) Ell, 1” Pipes 1” Tube, 90-Degrees 4
T500-4 (11-966) Straight Fitting 1
X500-20 (11-1286) Capscrew, 3/8” x 4” Hex 3
Z501-2 (11-1401) Yoke Pin, 3/8” x 1” 4
X500-32 (11-1363) Capscrew, 1/2” x 2-1/4” Hex 2
F500-9 (11-1563) Ell, 3/8” Flare to 3/8” Pipe, 45-Degrees (not pictured) 1
T506 (11-1572) Tee, 3/4” x 3/4” x 1” Bax w/1/4” NPT 1
H502 (12-130) Hose Assy 1
V500 (58-240-5) Commercial Valve 1
T512 (76-166) Tee 1
M500 (77-90) Hydraulic Motor 1
V519-1 (93-117-6) Linkage 4
A507 (93-125) Counterbalance 1
A506 (93-126) Valve Plate 1
V514 (181-24-1) Check Valve Assy (not pictured) 1
V507-NSP Cartridge Style Relief Valve 1
V508 (183-9) Knob 1
V516 (867-22) Handle 2
X500-13 (11-1043) Capscrew, 3/8” x 1-1/4” Hex Hd 16

16. HYDRAULIC TORQUE GAGE ASSEMBLY
H500
X502-4
F500-5
Y500-1
I502
I500-1
I501
F500-6
F507-1
Fig. 16-1. Hydraulic Torque Gage Assembly
PARTS LIST
PART NO. DESCRIPTION QTY
REQ'D
F500-6 Ell 1/4" Flare to 1/4" Pipe (Foster Ref. No. 11-162 ) 1
F507-1 Collar 1/4" Std. Blk. (Foster Ref. No. 11-323 ) 2
F500-5 Ell 1/4"Flare to 1/4" Pipe 45° (Foster Ref. No. 11-427 ) 1
X502-4 Flat Hd. Screw 6/32" x 1" (Foster Ref. No. 11-1580 ) 3
Y500-1 Nut 6/32" ( Foster Ref. No. 11-1581 ) 3
H500 Hose 1/4" x 10" Stainless (Foster Ref. No. 12-249 ) 1
I500-1 Pressure Gage 2-1/2" - 2000 # (Foster Ref. No. 236-2 ) 1
I501 Gage Mount (Foster Ref. No. 236-4 ) 1
I502 Engraved Dial Face ( Foster Ref. No. 236-8 ) 1

17. BACKUP TOOL
Fig. 17-1 BU500-A BACKUP TOOL
17.1 INSTRUCTIONS FOR BU500-A BACKUP TOOL
1. To reverse Backup from Breakout to Makeup, pull the pin

and let Backup Tool drop down, as shown in picture .
2. Handle will swivel to turn Backup Tool over .
3. Lift Backup Tool back into position and replace pin.

MANUAL
BU500A BACKUP TOOL
W501-3 X500-12
BU509-2
W501-3
X500-12
BU508
SCREW
SEE BACKUP BU520
INSERT
JAW LIST
JAWS X501-25
BU517
X501-25
W501-5
W501-5
BU507 X500-41
W501-6
Z503-3
BU519 BU506-A Y500-6
Z506-7 BU510
BU517
X501-22
Z506-7
BU516
BU512-A
BU513 BU513-1


AIR CONTROL
BU500 AIR BACKUP TOOL
X500-12
BU509-2
W501-3 W501-3
BU508
X500-12
X501-25
SCREW
SEE BACKUP BU520
INSERT
JAWS LIST
JAWS X501-25
BU517
X501-25
W501-5 W501-5
BU507
Z506-7 X500-41
BU519
Z503-3 W501-6
BU506-A Y500-6
BU517
BU521-A X501-22
Z506-7 BU510
BU516
BU512-2-A
AIR CONTROLS FOR BU500-A BACKUP TOOL
F502-4
F500-6
Q500-27
F500-5
F505-3
Z502-4 Cotter Pin, 1/2” x 1-1/2” (Foster Ref. No. 11-796)
Z500-2 Foster Ref. No. 11-1300)
H519-2 (Foster Ref. No. 12-11)
H519-1 (Foster Rerf. No. 12-91)
H504-4
BU521-A (Foster Ref. No. 105)
V523
GILL SERVICES, INC. MODEL 500 MAINTENANCE LOG
MODEL 500 SERIAL NO.______________________________
DATE TYPE OF MAINTENANCE PERFORMED INITIALS

GILL SERVICES, INC. MODEL 500 MAINTENANCE LOG
MODEL 500 SERIAL NO.______________________________
DATE TYPE OF MAINTENANCE PERFORMED INITIALS

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GILL SERVICES, INC.

Model 500 Serial No. ________________________________________

Customer Reference No. _____________________________________

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

WARRANTY AND GUARANTEE

DO NOT OPERATE, ADJUST, OR REPAIR THIS TONG

1. DO NOT OPERATE TONG UNTIL ANCHOR ARM IS

2. DO NOT CRAWL OR STAND UNDER TONG.

3. CAUTION: KEEP HANDS CLEAR OF TONG HEAD

4. SHUT OFF POWER SUPPLY TO THIS UNIT BEFORE

5. FAILURE TO COMPY WITH WARNINGS COULD

SECTION TITLE PAGE

Hydraulic Pressure, psi (Bars)

Spit Guide Ring - Provides easier and

Pressurized Oil Bath - Insures

Adjustable Clutch - Extends

Available with air or

Torque @ 2000 psi (138 bars ) High Gear Low Gear

Ft Lbs 1300 6000

Speed (rpm) @ 33.5 gpm (127 LPM ) 126 27

Weight W/Back-up Tool and Transport Rack

Torque Range: 300 to 6,000 ft lb torque

Hydraulic Requirement………………………………………….……….33 GPM at 2,000 psi

Space Required on Pipe

Maximum Elevator Diameter Clearance…………………………………………………...30”

GPM to tong motor

5.1 INSTALLING WITH SPRING CUSHIONED HYDRAULIC LIFT

5.3 SETTING HYDRAULICS FOR PROPER OPERATION 90°

1. Check all hose connections before engaging

2. Engage hydraulic power source . Tong Anchor

NOTE : It is not necessary to change makeup torque to

5. In operating tong, stop operating lever in center position

Fig. 5-4 Drag Screw

1. Raise tong to top of hydraulic lift travel.

HYDRAULIC SYSTEM SAE API SERVICE

0°F to 180°F 10W MS

6.2 OPERATING TEMPERATURES

6.4 VISCOSITY INDEX

7. LUBRICATION AND MAINTENANCE

Temperature above 32°F SAE 30W

7.2 OPERATION MAINTENANCE

1. Grease lube fittings weekly. (Fig. 7-1).

7.3 SAFETY POINTS AND WARNINGS

Gill Model 500 Final drive Assembly

PART NUMBER DESCRIPTION # REQUIRED WEIGHT

A500 Transmission Case 1

B500 Roller Bearing, Final Drive 2

D500-A Drag Ring Assembly 1

G500-A Final Drive Gear 1

L517 Leveling Pin 2

O500 Oil Seal 2

R509-1P Guide Ring (5-1/2" Bore) 1

RC500 Roller Chain (TPL-60-88P) 1

W501-3 LockWasher 3/8" 42

X500-13 Capscrew (3/8-16 x 1-1/4" Hex) 18

B512-2 O500-4 X500-12

PART NUMBER DESCRIPTION REF. NO. # REQ.D

A501 Ring Gear Cover 93-18 1

B501 Timken Bearing 50-32-1 3

C500 Clutch Assy 50-13-1 1

E500 Oil Sight Gauge 56-81 1

F501-2 Ell, 1/4" Std. Blk Street 11-321 1

G503 Ring & Pinion Gear 50-20 1

K500-3 Hy Pro Key #18 11-1760 3