a commitment to quality

HYDRAULIC TUBING TONG

45000-100

OPERATION AND SERVICE MANUAL

Oil Country Manufacturing, Inc.
300 W. Stanley Avenue
Ventura, CA 93001 USA
TEL: (805) 643 1200
FAX: (805) 643 6832

OSM-001
Last Revised Date: 10-12-01

TABLE OF CONTENTS
PAGE

INTRODUCTION .. 2
WARNING . 3
GENERAL DESCRIPTION . 4
SPECIFICATIONS 4-5
COMPONENT DESCRIPTIONS 6-7
FIRST TIME START UP PROCEDURE ...
8
OPERATING INSTRUCTIONS .. 9-14
CHANGING JAW SYSTEM 15-16
CHANGING BRAKE BAND 17-18
RUNNING THE TONG . 19
TONG LINKAGE ADJUSTMENT 20
GEAR SHIFT TENSION ADJUSTMENT . 20
HYDRAULIC OIL SPECIFICATIONS . 20-21
GREASE SPECIFICATIONS .. 21
STEPS TO AVOID CORROSION .. 21
LUBRICATION AND PREVENTIVE MAINTENANCE SCHEDULE . 22
TROUBLESHOOTING GUIDE 23-24
STORAGE INSTRUCTIONS ... 25
HOW TO ORDER PARTS 26
SAFETY PRECAUTIONS 26
TUBING TONG REPLACEMENT PARTS LIST .. 27-40
TUBING TONG SPARE PARTS LIST FOR ONE YEAR
41
M/S MANUAL BACK-UP ACCESSORY .. 42-45
HDS BACK-UP 1.05-5 9/16 . 46-54
STANDARD BACK-UP MOUNTS ... 55-58
CONTROL VALVE ASSEMBLY . 59
MOTOR M25 REPLACEMENT PARTS LIST ..
60-61
TUBING TONG GAUGE ASSEMBLYS 62-63
(ILLUSTRATIONS 175, 145)
TORQUE CHARTS .
64-65
TECHNICAL CHARACTERISTICS OF OIL COUNTRY HYDRAULIC .. 66
TUBING TONGS

INTRODUCTION
This manual contains instructions on the maintenance and operation of the Oil Country Models
45000 Hydraulic Tubing Tongs. Photographs with explanatory notes are included for assembly
and disassembly of these tongs. Full benefit of the long life and dependability of these units can
only be realized by proper operation and maintenance. The operator should familiarize himself
thoroughly with the contents of this manual before operating, making adjustments, or performing
maintenance procedures on this equipment.
For information regarding equipment operation, maintenance/repair, refer to theTable of
Contents.
Oil Country Manufacturing, Inc. provides the information, data, and recommendations contained
in this manual as a customer service. All are believed accurate; however, Oil Country
Manufacturing, 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.

WARNING
1. DO NOT OPERATE, ADJUST, OR REPAIR THIS EQUIPMENT WITHOUT PROPER
TRAINING.
2. ADHERE TO ALL SAFETY WARNINGS.
3. DO NOT REMOVE GUARD DOORS.
4. A STIFF ARM BACK-UP IS STRONGLY RECOMMENDED, BUT IF A FLEXIBLE
LINE (CHAIN OR CABLE) MUST BE USED, THE LINE MUST BE HORIZONTAL AND
AT RIGHT ANGLES TO THE LONGITUDINAL AXIS WITH NO SLACK IN THIS LINE.
5. SHUT OFF ALL POWER AND DISCONNECT HYDRAULIC HOSES BEFORE
CHANGING TONG DIES/JAWS, MAKING ADJUSTMENTS, REPAIRS, OR
LUBRICATING THIS EQUIPMENT.
6. KEEP ALL PARTS OF THE BODY AND CLOTHING AWAY FROM MOVING PARTS.
7. FAILURE TO COMPLY WITH THIS WARNING COULD RESULT IN PERSONAL
INJURY AND EQUIPMENT DAMAGE.

WARNING
DO NOT OPERATE WHEN FRONT GUARD DOOR IS OPEN OR MISSING. KEEP HANDS
CLEAR OF ROTATING PARTS. FAILURE TO COMPLY WITH THIS WARNING MAY
CAUSE SERIOUS BODILY HARM.

WARNING
SNUB LINE MUST BE SECURELY ATTACHED TO REAR OF TONG AND TO ANCHOR
POINT. ALL SLACK MUST BE OUT OF SNUB LINE BEFORE TONG IS OPERATED.
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE SERIOUS BODILY HARM.

GENERAL DESCRIPTION
The Oil Country Models 45000 Hydraulic Tubing Tongs are fast, safe, and accurate tongs for
making up and breaking out 1.315 to 4.75 (Model 45000) O.D. tubing 100) O.D. tubing.
Hydraulic power is directed to a manually controlled throttle valve and hydraulic motor unit.
Fluid power input is converted to the rotary mechanical output which drives the tongs gear train.
The simple, but rugged gear train consists of a planetary type gear box mounted directly beneath
the motor, and a gear reduction system which provides the extra torque capacity. The tong is
suspended in the derrick or mast by a wire line and swung onto the tubing. Tong jaws grip
automatically and the safety guard door closes. Operate the throttle in the forward position, and
the tubing is automatically made up to the required specifications as indicated on the torque
indicator gauge. The tong may also be used for light drilling, cutting, or remedial work.

SPECIFICATIONS
These specificatiions comprise the Oil Country 45000 Tongs.

Tong Performance Characteristics:

Maximum RPM (40 GPM, 151.4 LPM, Hi Gear)
Running RPM (34 GPM, 128.7 LPM, Hi Gear)
Make-Up Torque (ft.-lbs.)
Kg/m)
(Low Gear, 2000 PSI, 140.6 Kg/sq. cm)
*Refer to Torque Curve charts on
Pages 61-62 for more detailed information.

105
93
5,440 FT LBS (750

Tong Equipment:
Four-Way Control Valve............................................................Manual Control
for direction of tong rotation
Hydraulic Motor.............................................................................. Gear Type,
Fixed displacement, 1 1/2 gears (3.8 cm) 2500 PSI
Maximum working pressure (175.8 Kg/sq.cm)
Gear Box......................................................Planetary Type, 5-1/2 to 1 reduction
High Pressure Hydraulic Hose........................................................1 (2.54 cm)
2250 PSI (148.2 Kg/sq. cm) working pressure
9000 PSI burst (632.8 Kg/sq. cm)
Hydraulic Hose Couplings...........................Self-Sealing Quick Disconnect Type
Tong Weight..............................................................................560 lbs (254 Kg)

COMPONENT DESCRIPTION
Location of components described in this section can be located by referring to Hydraulic Tubing Tong
illustration on Page 7.

Four-Way Control Valve:

A four-way control valve is mounted on the tong for the purpose of controlling the direction of the tong
rotation. It is manually operated by the throttle lever.

Hydraulic Motor:
The hydraulic motor is mounted directly in front of the four-way valve on the tong. It converts hydraulic
power input to a rotary mechanical output and drives the tongs gear train.

Hydraulic Hose Couplings:

The couplings on the tong are self-sealing and must be used whenever the hoses are disconnected. Use of this
type of coupling insures that the pressure and return hoses, four-way valve, and hydraulic motor being full of
oil, minimizing spillage.

Torque Gauge
There is a torque indicator assembly available to mount on the tong. The gauge provides accurate and direct
readings of torque applied to tubing. NOTE: The torque gauge is calibrated, based on PSI vs ft/lbs. This
gauge is for operator reference only. PSI must be adjusted at pressure relief control valve per charts on Pages
64-65.

FIRST TIME START-UP PROCEDURE

The operator should read and follow these instructions before attempting to operate the tong the first time.
When preparing to operate a new or re-conditioned hydraulic tubing tong, or an assembly that has been in
storage, perform all of the operations listed below. Before operating (at the beginning of each shift), perform
Daily Operations in Lubrication and Preventive Maintenance procedure as described on Page 22.

Tong:
Clean tong and remove any packing material. Grease, oil, and lubricate brake band. Refer to figure 8 on
Page 18. Function test linkage and shift mechanism for free operation. Suspend in derrick.

Hydraulic Hoses:
1. Adjust hydraulic system pressure to 500 PSI or less.
2. Shift tong to neutral position.
3. Engage hydraulic system clutch.
4. Push throttle lever toward tong.
5. Allow hydraulic fluid to circulate with tong gear shift lever in neutral position and the throttle advanced
for approximately five (5) minutes.
6. Set system pressure.
7. Check system for leaks.
8. If operating in cold weather, engage tong in high gear and rotate 2-3 minutes for warm-up. Check tong
linkage adjustments.

OPERATING INSTRUCTIONS
Tongs are assembled with parts carefully machined from selected materials. Each tong is thoroughly tested
and inspected and is shipped from the factory with confidence that it will efficiently perform any job for
which it is rated. The ensuing pages have been prepared for your guidance. These procedures are necessary
and should be followed for proper operation and maximum life of your tong.

Fluid Requirements:
To obtain the proper torque in making up and breaking out, the Tubing Tong requires a fluid volume of
approximately 35 to 40 gallons per minute (132.5 LPM to 151.4 LPM) at 2000 PSI (70.3 Kg/sq. cm) and a
minimum of 10 GPM (37.8 LPM) at 1000 to 2000 PSI (70.3 to 140.6 Kg/sq. cm). Every effort should be
made to keep the hydraulic system clean. The couplings on the tong are self-sealing and should be used
whenever the hoses are disconnected. Use of this type of coupling insures the pressure and return hoses, fourway valve, and hydraulic motor being full of oil, minimizing spillage. Reference Page 20 for hydraulic oil
specifications.

Hose and Hose Connections:

When connecting the hoses, ensure there is no pressure in the system. Detach the fluid pump from the engine
or shut the whole system down. ALWAYS CONNECT THE 1 (2.54 CM) FLUID RETURN HOSE TO
THE TONG FIRST, then connect the fluid supply hose. ALWAYS DISCONNECT THE FLUID SUPPLY
HOSE FIRST (refer to Page 4). This prevents any pressure from building up in the hydraulic motor and seal.
When attaching the hoses to the tong , DUST CAPS SHOULD ALWAYS BE USED WHENEVER HOSES
ARE DISCONNECTED. Should the open end of the coupling be allowed to come in contact with any dirt, it
should be very carefully cleaned before re-connecting and installing dust caps. A very small amount of dirt,
sand, or foreign material can cause serious damage to the pump, hydraulic motor, and valves.

INSTALLATION AND MAINTENANCE OF TONG

1. Always wear eye protection prior to replacing dies.
2. Clean dies with wire brush daily to prevent damage to outside of tubing.
3. Inspect and change worn dies periodically to prevent slippage and damage to tubing.
4. Remove jaw and bushing from tong before changing dies.
5. Install dies correctly to ensure gripping on tubing. Dies must be installed with the teeth facing the
direction of rotation.
6. Roll pins in jaw and bushing must be installed correctly to prevent dies from falling down well when
operating tong.

SUSPENSION OF TONGS IN DERRICK

1. Suspend the tong in the derrick with as long a line as possible, at a height to grip the
tubing at least 6 ABOVE THE UPSET. The angle of hanging line from vertical when
tongs are on tubing MUST NOT be great enough to pull the tong off the pipe.
2. Attach Back-up Line
A back-up line, automatic or retraction, is attached to the back-up ring. The back-up line must be of
sufficient strength and be properly secured.
BACK-UP LINE MUST BE HORIZONTAL TO TONG: THAT IS, IT MUST NOT PULL UP
OR DOWN ON TONG WHILE IN OPERATION.
For correct torque readings, the back-up line MUST BE ON A 90 DEGREE ANGLE WITH
TONG.
Oil Country recommends the use of a safety sling to prevent injury of personnel caused by failure of
main back-up line or stiff arm assembly. The safety sling must be attached to the safety eye on the
back of the tong and fastened to the rig or to a secure tie down.
NOTE: A back-up line must always be used, with or without the coupling back-up
assembly.
3.

Connect hydraulic hoses and start power unit.

4.

Swing tong on tubing joint. Advance the throttle enough to take the slack out of the
back-up line. This will put the tong in a level position.

NOTE: Tong must be leveled on tubing and over the hole by adjusting bolts (ref. 121) on hanger assembly
(Page 27). Spring hanger should not be completely compressed from the weight of the tong. Tong should
have some bounce. If spring is completely compressed from the weight of the tong, it should be replaced.

10

STIFF ARM ASEMBLY

OPERATION AND INSTALLATION
ILLUSTRATION 032 PAGE 12
The Oil Country Stiff Arm is designed to help pull tubing tong on and off pipe and hold tong away
from well when tripping pipe. When running tong the operator can shift valve to pull off position
allowing the tong to swing away from well when the grip of the tong is released thus the floor hand
does not have to pull or push the tongs.
Stiff arm, post, item #2 is to be mounted on rig in vertical position on right or left derrick leg. Item
#1 will be welded to clamps provided by customer.
Clamps are made to clamp on derrick leg. Three are required, one to hold the back of pull back
cylinder, two pieces of metal are provided, cut desired length item #14 and wielded to clamp. Two
pieces item #1 are to be cut to length and wielded to clamps and installed on derrick leg. Now post
item #2 can be installed in bearings. Item #5, item #12 plate can be welded in place, the plate can
be wielded in any place up and down the post, where the back of the cylinder can be hooked to
clamp.
Now install stiff arm item #3 and #4, connect with bolt and nut item #8 and #9. Now the safety
sling item # 6 can be connected to rig. With tong hanging from crown the stiff arm can now be
connected to back of tong at the swivel eye with nut and bolt #7 and #9. Now connect other end of
safety sling item #6 to eye on left or right side of tong. Item #4 can be adjusted in or out by
removing pin and clip items #10 & #11.
Now hoses can be connected to air cylinder item #13 and to hand valve two hoses hook between air
cylinder and hand valve the other is connected to main air supply.
IMPORTANT: THE TONG MUST HANG LEVEL AND THE STIFF ARM LEVEL WITH
TONG, STIFF ARM MUST BE 90 DEGREE ANGLE WITH TONG.
IF THIS IS NOT ESTABLISHED THE TUBING WILL BE MARKED MORE THEN
NECESSARY AND DIE LIFE WILL BE GREATLY SHORT.

11

12

12-1

13

PART NUMBER 58019-101

UNIVERSAL STIFF ARM ASSEMBLY
FOR OPEN FACE TONG
REF. NO.
1
2
3
4
5
6
7
8
9
10
11

PART NO.
58019-101
58019-201
58022-300
58021-300
992252-84
992331-3A-06
58028-300
58025-400
992164-17
992047-13
992007-07
992047-11
992164-15

DESCRIPTION
Stiff Arm Assembly Complete
Stiff Arm Assembly Less Rig Bracket (Ref. 5)
Female Arm Weldment Assembly
Male Arm Weldment
Safety Sling 84
Shackle 1/2
Bracket, Rig
Anchor, Pin Assembly (Ref.6, 7, 8)
Nut, 3-1/4
Hair Pin
Bolt 5/8
Haif Pin
Nut, 5/8

14

QTY.
1
1
1
1
1
2
1
2
2
2
1
1
1

Tong Fails to Go on Tubing:

If the tong fails to go onto the tubing, it is probably because the jaw is partially closed. In this
case, run the motor in the direction that will fully open the jaw, and then proceed to install the
tong on the tubing. If this fails to work, check both the jaw and bushing for proper size and
installation. Refer to chart below.

Jaw and Bushing Sizes:

Jaw and bushing sizes are stamped according to the actual O.D. of the tubing that they will fit not the nominal size of the tubing.
NOMINAL
3/4
1
1-1/4
1-1/2
2

STAMPED
1.050
1.315
1.660
1.750
1.990
2-1/16
2-3/8

NOMINAL
2-1/2
3
3-1/2
4

STAMPED
2-7/8
3-1/2
4
4-1/2

CHANGING OR REVERSING JAW AND BUSHING

The jaw and bushing are reversible, depending upon the desired direction of rotation. If the jaw
is installed on the left side (Figure 5, Page 16) (standing in front of the tong, as you look into the
opening of the tong), the tong will rotate the tubing to the left. When the jaw is installed on the
right side (Figure 4), it will rotate the tubing to the right (the direction of tubing rotation when
going into the hole).

Removal of Jaw and Bushing:

Position the tong as if it were to go onto the tubing. Reverse the bushing as indicated in Figure 2.
Reverse the motor and move the outer ring slightly. This will remove any force against the pivot
pin of the jaw so it will come out easily (Figure 3). Remove the pivot pin and jaw.
NOTE: It is difficult to remove or install the jaw while the bushing is still
in place.

Reversal of Jaw and Bushing:

Remove the jaw and bushing as outlined above. Move the outer ring slightly so there will be
room to get the lip of the jaw in back of the front roller of the outer ring. Make certain that the
jaw and bushing are the correct size. Install the jaw as shown in Figure 3. Install the bushing as
shown in Figure 2.

15

16

CHANGING THE TUBING TONG BRAKE BAND

Align the opening of the inner and outer rings with the opening in the tong frame, reference
Figures 6-9 on Page 18. Remove the two cap screws from the brake band cover plate and lift
cover plate. Remove the old brake band, which is located directly under the cover plate. Apply
grease liberally to the lining of the new brake band and to the inside of the eye on each end of the
band. Put the new brake band on the inner ring and remove the wooden spacer. If the new
brake band does not have a spacer, a piece of wood 5-1/2 long can be inserted. The brake band
cover can then be closed and the two cap screws installed.
NOTE: When the cover plate is down, ensure that the two brake pins in the cover
plate enter the eye openings at each end of the brake band.

17

18

RUNNING THE TONG

Before operating the tong for the first time, refer to First Time Start-Up Procedure on Page 6.

Making Up the Tubing

With the tong suspended, position gear shift lever (located towards the front of the tong) in high
gear (refer to illustration on Page 7). With the safety guard on the front of the tong open,
position tong onto the tubing. (The safety guard will automatically close as tubing enters.) It
is necessary for the tong to be in this positiion for the jaws to grip. DO NOT SWING THE
TONG ONTO THE TUBING TOO HARD, AS IT MAY CAUSE THE TONG TO
BOUNCE OFF. Engaging the throttle causes the jaws to grip and rotate the tubing. The
pressure at which the pump unit is set determines the make-up torque.
Reference the torque curve charts on Pages 64-65 for the hydraulic pressure required for specific
torque values.

TORQUE CURVE
OIL PRESSURE
On high pressure well, stall pressures should be higher. High torque and critical joints should be
made up using the manufacturers recommended torque values and taking direct readings from
the torque indicator gauge. Accurate readings are also dependent upon proper tong suspension.
To release the tongs from the tubing, reverse tong by pushing the throttle back until the gap in the
rotor comes in alignment with that of the case. The jaws will automatically release.

19

TONG LINKAGE ADJUSTMENT

SHIFT ROD ADJUSTMENT
Shift rod adjustment is accomplished with jam nuts (ref. 120) located on each end of rod (ref.
120). Adjust gear shift handle (ref. 304) in neutral position (handle is tilted slightly forward).
See illustration on Page 27.

THROTTLE ADJUSTMENT
The throttle rod adjustment is set with the safety arm (ref. 186) and with the door (ref. 99) in open
position. Adjust safety bar (ref. 187) to match the slot in the safety arm and secure by tightening
jam nut (ref. 171).
NOTE: Proper adjustment allows full throttle in both directions with the door closed and
prevents throttling when door is open.

GEAR SHIFT TENSION ADJUSTMENT

Adjusting gear shift tension is accomplished by turning set screw (ref. 60) in until gears will not
shift and backing out set screw until shifting is smooth. There will be approximately three
threads of the set screw exposed beyond the transmission cover (ref. 11) when shifting
mechanism is new. Set screw position is also a wear indicator for the shift rod fork.

HYDRAULIC OIL SPECIFICATIONS

Performance and service life of all other components of a hydraulic system are affected by the
hydraulic system fluid. Some of the factors especially important in the selection of oil for use in
a hydraulic system are:
1. The oil must contain the necessary additives to ensure high anti-wear characteristics. Not all
hydraulic oils contain these in sufficient amounts.
2. The oil must have proper viscosity to maintain adequate sealing and lubricating quality at the
expected operating temperatures of the hydraulic system.
3. The oil must have rust and oxidation inhibition for satisfactory system operation.
Viscosity of fluid is a measure of its resistance to flow as well as its ability to prevent metalto-metal contact of moving parts. It is recommended that the following maximum and minimum
viscosity ranges of the oil at start-up and during running be maintained:
Nominal:
Running:
At Start-up:

150-3000 viscosity at 100 F. (38 C)

70-250 viscosity
4000 viscosity maximum

An anti-wear type of heavy-duty industrial hydraulic oil is recommended. This anti-wear type of
oil offers superior protection against pump and motor wear, and has the advantage

20

of long service life. In addition, these oils provide good dumulsibility as well as protection
against rust. A good grade SAE 20 MS automotive crankcase oil can be substituted. For
most efficient operation, the temperature of the oil should not exceed 150 F. (66 C).

GREASE SPECIFICATIONS
Due to the operating environment of the tong, a water insoluble grease is required. The grease
should have high pumpability to permit application during very cold weather. The grease
recommended for cold weather operation is Shell B&B Code 70919, which conforms to
Government Specification MIL-G-10924-C. In milder climates, an all-purpose grease such
as Shell Alvina #2 is recommended.

STEPS TO AVOID CORROSION

Every trip, lubricate all grease fittings with the recommended grease. With an oil can, lubricate
the following: throttle mechanism and the shift mechanism. Lubricate brake band and
friction surface with only enough light oil to keep the surface from rusting when the tong is
not in service. If the tong does not grip the pipe, the cause may be too much grease on the
brake band. This can be remedied by wiping the brake band and friction surfaces clean of all
grease, later re-lubricating with grease. The tong should be cleaned periodically or after each
shift when used around salt water.

21

21-1

21-2

IMPORTANT
LUBRICATION AND PREVENTIVE MAINTENANCE
To obtain the long life and best performance from a tong, the operator must adhere to the following instructions on
lubrication and preventive maintenance. Areas to be oiled or greased, and proper care of the hydraulic hoses and
couplings. The daily instructions pertain to routine or daily operation of a tong and not to new equipment. For
new tongs, follow instructions given in First Time Start-Up Procedures on Page 8. The time intervals given in
the instructions refer to actual hours on the tong.
Item 1:
After every trip, lubricate the following with 30W oil or equivalent; throttle mechanism shift mechanism, guard door
spring, front end of reverse rod, and jaw pins.
Item 2:
After every trip, all grease fittings should be lubricated with the recommended grease. (See Page 21). In addition to
those shown, there are fittings on each guide roller shaft, one on the bottom transmission cover and one on the
underside of the handle. There is no danger of over-greasing the tong. Under continuous operations, such as
when tong is used for light drilling operations, grease the tong every hour.
Item 3:
During assembly and disassembly, inspect couplings to ensure that all openings are free of dirt and debris. Use clean
rag and solvent when cleaning, if required. Take proper precautions to ensure that the solvent does not enter hose.
Hoses should be wiped clean, and if storage is necessary, install dust covers and store in a clean, warm climate
protected from direct sunlight.

22

TROUBLESHOOTING
A. TONG RUNNING TOO SLOWLY
1.
2.
3.
4.

Pump intake line plugged

Reservoir oil level too low
Air leak in pump intake line
(Oil in reservoir may be too
foamy).
Pump speed too slow

5.

Excessively worn or damaged

pump or tong

6.

Pump control improperly set

(variable delivery pumps)
Viscosity of oil too high

7.
8.

Viscosity too low:

a. Excessive heat
b. Contamination of oil; i.e.,
diesel, gasoline, etc.
c. Improper grade of oil

9.

Restriction in line between

power unit and tong

10.

Hose connections not made up

properly.

Clean intake line and filter.

Add oil.
Identify source of leak and make necessary repairs.
Check manufacturers speed recommendations and actual
speed of pump. Vane type pumps will not prime if
running too slowly.
Replace. Follow manufacturers recommendations.
NOTE: To determine which is defective, disconnect
pump from motor, test pressure and volume of pump.
Check position of control.
Some pumps will not prime if the oil is too heavy. Check
manufacturers recommendations and viscosity of oil
used.
See No. 9 below (restriction in line between power unit
and tong).
Change oil.
Change to oil of a higher viscosity or of a better viscosity
index.
This condition may be detected when pump pressure is not
reaching the tong or when excessive back pressure is
created in the return line. The return line pressure should
be approximately 100-150 PSI (7.03 - 10.54 Kg/sq.cm).
Check self-seal couplings to ensure they are properly
engaged. Check self-seal couplings for rubber pieces
lodged in valves. If couplings are clear, check for
collapsed inner layers of the return hose.
Check hose connection procedure in Operating
Instructions on Page 9.

B. TONG WILL NOT DEVELOP SUFFICIENT TORQUE

1.

Tong valve or relief valve on

tong not working:
a. Valve stuck
b. Valve leaking

Check for dirty or gummy sludge. Check for contamination of oil. Check for broken spring valve.
Check valve seat for scouring. Check oil seals. Check for
particles stuck under valve stem.

23

2.
3.
4.

Stuck, worn, or damaged pump

parts
Pump speed too slow
Oil viscosity too high.

5.

Oil viscosity too low

6.

Oil by-passed to reservoir

7.

Tong motor worn or damaged,

allowing excessive slippage.
Excessive drag in tong due to
damaged bearings or gears
Restriction in line between
power unit and tong

8.
9.

Inspect and clean. Replace worn or broken parts. Check

relief valve.
Check motor speed.
Some pumps will not prime if oil is too heavy. Check
viscosity at working temperature (also at initial
temperature, if this is considerably lower).
See No. 9 below (restriction in line between power unit
and tong).
Check relief valve for proper operation. Check directional
valves; open center neutral position should return oil to
the reservoir.
Repair and/or replace worn or damaged parts.
Repair and/or replace worn or damaged parts.
This condition may be detected when pump pressure is not
reaching the tong or when excessive back pressure is
created in the return line. Check self-seal couplings to
make certain they are properly engaged.

C. FAILURE OF JAWS TO GRIP TUBING

1.
2.
3.
4.

Improper tong suspension

Dull dies
Brake band worn
Improper jaw size

Refer to Page 10.

Replace or clean with wire brush.
Replace. Refer to Page 17.
Refer to Page 3.

D. FAILURE OF TONG TO SHIFT OR DIFFICULTY OF SHIFTING

1.
2.

Shifting mechanism is worn

Shift is attempted at too high an
R.P.M.

Replace.
Shift at lower R.P.M. or after momentary stop. Shift with
rotor opening at rear of tong.

E. POOR DIE LIFE

1.
2.
3.

Improperly suspended tong;

tong hanger bottomed out
Tong worn excessively
Improperly reconditioned dies

Refer to hanging procedure in Operating Instructions on

Page 9.
Replace and/or repair tong, as required.
Replace jaw.

24

STORAGE
Preparing Tong for Storage:
When a tong is to be stored or removed from operation, special precautions should be taken to protect the interior and
exterior of the tong from rust accumulation and corrosion. It will be necessary to remove all rust or corrosion
completely from any exposed part before applying a rust preventive compound. Therefore, it is recommended that the
tong be processed for storage as soon as possible after removal from operation. Storage should be in a building which
is dry and can be heated during the winter months. Moisture absorbing chemicals are available commercially for use
when excessive dampness prevails in the storage area. The recommended storage preparation is detailed below.

TEMPORARY STORAGE:
To protect a tong during storage for periods of 30 days or less:
1. Clean entire exterior of tong with solvent and thoroughly dry. Cleaning is especially important if unit has been
used around salt water.
2. Grease and oil the tong as recommended under Lubrication and Preventive Maintenance procedure on Page 22.
3. Cover the entire unit with a good weather-resistant tarpaulin or other cover if it must be stored outdoors. A clear
plastic cover is recommended for indoor storage.

EXTENDED STORAGE:
To protect a tong for storage for periods exceeding 30 days, proceed as follows:
1. Perform Steps 1, 2, and 3 of Temporary Storage procedure above.
2. Spray all exterior surfaces of the tong and power unit with a suitable liquid automobile body wax, a synthetic
resin varnish, or a rust preventive compound.
3. Cover the tong and power package with a good weather-resistant tarpaulin or other cover if it must be stored
outdoors. A clear plastic cover is recommended for indoor storage. The stored unit should be inspected
periodically. If there are any indications of rust or corrosion, corrective steps must be taken to prevent damage to
the parts. Perform a complete inspection at the end of one year and apply additional treatment, as required. For
restoring the tong to service, refer to First Time Start-Up Procedure on Page 6.

25

HOW TO ORDER PARTS

When ordering parts for your tubing tong, refer to Parts Lists. Use schematic illustrations to locate correct item
number and part number from list.
When ordering include:
Quantity required
Part Number (NOT item number)
Part Name
Tong Model Number
Tong Serial Number

SAFETY PRECAUTIONS
Your tubing tong has been carefully designed with safety features built into your unit. Realizing, however, that
power-driven equipment is only as safe as the operator who is at the controls, it is extremely important that the
operator observe the following safety precautions.
1. Operate the tong from the back-up line side only (does not apply to front control tongs).
2. Never change a jaw or put hands within the rotating parts of the tong while tongs are connected to hydraulic
hoses.
3. Never remove or operate the tong without the guard doors in place.
4. Do not exceed the maximum pressure for which this system is rated.
5. Always use a back-up line for all tong operations.
6. Keep loose fitting clothing away from the rotating parts of the tong.

26

29

TUBING TONG REPLACEMENT PARTS LIST FOR

45000
REF. NO.

PART NUMBER
55011-100

NO.
REQD
1

11
12
15
16
17
18

45011
45012
45015
45016
45017
45018
45022-100

1
1
1
1
1
4
1

19
20
22

45019
992093-12
45022-200
45023-100

1
1
1
1

23
24
25
26
27
28
29
30
31
32
33
34
40
41
42

45023-1
45024-200
45025
45026
45027
45028
45029
45030
45031
45032
45033
45034
45040-01
45041
45042
45042-200

1
1
1
2
2
2
2
4
2
1
1
1
6
6
1
1

44
47
48
50

45044-200
45047-200
45048
45050

1
1
1
1

DESCRIPTION
Bottom Transmission Assembly (Ref. 11,
12, 17, 48, 50-52, 61-64, 72, 78, 97)
Bottom Transmission Cover
Bushing
Bearing Spacer
Thrust Washer
Shift Fork
Gear Shaft Bushing
Hanger Assembly (Ref. 19, 22, 70, 121, 127,
132, 169)
Hanger Balancing Screw
Nut
Hanger
Hanger Suspension Assembly (include Ref.
127, 160, 223-229)
Safety Sling
Door
Door Spring
Idler Gear
Idler Gear Shaft
Thrust Washer
Thrust Washer
Guide Roller Shaft
Guide Roller Shaft
Cluster Gear Shaft
Thrust Washer
Thrust Washer
Guide Roller
Guide Roller Spacer
103 Tooth Rotor
Rotor Assembly (include. ref. 72, 277-280,
287)
Tubing Tong Housing
Tong Cover
Pinion Shaft
29 Tooth High Speed Pinion

30

WGT.
LBS
10.00
.06
.06
.13
.06
.13
.13
17.00
6.75
1.00
.25
.25
1.00
1.00
.25
.25
.25
.25
.06
.13
.13
5.00
.06
40.00
62.25
140.00
54.00
2.50
1.50

TUBING TONG REPLACEMENT PARTS LIST FOR

45000
REF. NO.
51
52
54
60
61
62
63
64
65
66
67
68
69
70
71
72
76
78
81
89
93
95
96
97
98
99

104
106
115
116
116-1R
116-1
117
119

PART NUMBER
45051
45052
45060
992082-96
940007-304
940048-5205
992134-86
900572-5
992007-05
992007-03
992051-14
992005-03
992051-10
992162-09
992082-95
992073-01
992073-04
992253-200
992011-138
992007-02
940021-206
45095
45096
45097
45098
45099
45099-1
992209-01
45104
45106
45106-200
940007-304
45116-200
45116
45116-250
45116-1
45117
900470-16

NO.
REQD
1
1
1
4
1
1
3
1

2
6
16
2
4
7
2
10
6
1
1
4
1
1
2
1
2
1
4
1
1
1
1
12
1
1
1
1
3
2

DESCRIPTION
14 Tooth Low Speed Pinion
Retaining Ring
Cluster Gear Replaces Items 57-59
Long Dowel
Bearing
Bearing
Set Screw
1/4 Ball
Cap Screw
Cap Screw
Lockwasher
Cap Screw
Lockwasher
Nut
Short Dowel
Grease Fitting
Grease Fitting
Snap Ring
Roll Pin
Cap Screw
Bearing
Bearing Set
Bearing Set
Transmission Spring
Motor Bushing
Caution Plate
Drive Pin
English Caution Plate
Top Cover
Top Cover Hinge
Top Cover Hinge Assy Ref 150, 151, 160
Bearing
Tail Handle Assembly (Ref. 116, 117)
Tail Handle
Throttle Back Guard (For tong w/ relief valve)
(Ref 116-1R, 202, 417, 241)
Tong Handle Back Guard
Shift Bushing
End Yoke

31

WGT.
LBS
2.00
.06
.13
.25
.50
.06
.06
.06
.06
.13
.13
.13
.06
.06
.06
.06
.13
.13
.13
.50
.50
.50
.06
.13
.06
.01
.06
13.00
.06
.07
.25
39.06
36.00
1.5
3.00
.06
.06

TUBING TONG REPLACEMENT PARTS LIST FOR

45000
REF.
NO.
120
121
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
149
150-1
150-2
150-3
151
152
153
154
155
156
157
158
159
160
161
162
162-S
163

PART NUMBER
992107-10
992005-04
45125
992011-138
992012-45
45128
992049-125
992012-34
992049-106
992049-165
45133-200
45134
992082-38
45193
45137-200
992082-97
45139
45140
903317-17
45142
940016-208
45144-200
992005-17
992089-09
992164-05
992155-04
992066-04
992066-03
992005-14
992107-05
992003-10
992004-07
992089-05
992089-07
992003-08
992217-01
992011-102
992017-13
992213-15
992025-07
900706-240
900706-241
992141-S-12-12

163
164

992141-S-12-12
992138-S-12-12

NO.
REQD
2
6
1
4
2
1
2
6
4
2
1
1
2

2
1
3
6
3
1
1
1
1
2
3
2
2
2
2
1
2
1
1
6
1
1
1
1
3
1
4
2
1
2
1

DESCRIPTION
Jam Nut
Cap Screw
Shift Lever
Roll Pin
Cotter Pin
Shift Link
Clevis Pin
Cotter Pin
Clevis Pin
Clevis Pin
Gear Housing Assembly (Ref. 133-135)
Inner Gear
Dowel
Stud
Gear Frame Assembly (Ref. 137-140)
Planet Gear Shaft (WAS 45138)
Bearing
Planet Gear
Bearing
Thrust Washer
Bearing
Back Swivel
Cap Screw
Ny Lok Nut

Hex Nut
Flat Washer
FH Socket Screw
FH Socket Screw
Screw
Heavy Thin Nut
Cap Screw
Cap Screw
Nylon Lock Nut
Nylon Lock Nut
Cap Screw
Shoulder Bolt
Roll Pin
Cap Screw
Hex Nut
Soc Screw
Hydraulic Hose
Hydraulic hose (Short) (For relief valve)
Hydraulic Fitting 90 NPT (For Tong With Relief
Valve)
Hydraulic Fitting 900 NPT X NPT
Hydraulic Fitting
32

WGT.
LBS
.06
.13
1.00
.13
.13
.50
.13
.06
.13
.13
8.00
2.00
.13
.13
3.00
.06
.06
.50
.31
.13
.25
1.00
.25
.06
.06
.06
.13
.13
.5
.06
.06
.13
.06
.06
.13
.06
.06
.06
.06
.06
2.00
1.50
.50
.50
.50

TUBING TONG REPLACEMENT PARTS LIST FOR

45000
REF.
NO.
165
166

992434-S-12-12
46056

NO.
REQD
1
2

166
168

46056
992142-S-12-12

1
2

169
170

992008-19
992338-S-12-12

1
2

171
172
184
185
186
187
188
189
190
191
192
200
201
202
203
221
222
222

992107-08
900470-7
45184
45185
45186
45187
45188
45189
45190
45191
45192
992005-05
45201
992019-06
45203-1
992023-05
45030-100
45023-100
45240
800024
992019-03
45242
45243
970400-5
45245
45277
45278

2
1
1
1
1
1
1
1
1
1
1
2
1
4
1
2
1
1
1
1
4
1
1
1
1
3
2

241
242
243
244
245
277
278

PART NUMBER

DESCRIPTION
Hydraulic Fitting Tee (For Tong With Relief Valve)
Hex Coupling NPT X NPT
(For Tongs Without Relief Valve)
Hex Coupling NPT X NPT (For Tong With Relief Valve)
Adapter 90 elbow .75 NPT X .75 FNPT
(For Tong With Relief Valve)
Cap Screw
Adaptor 90 elbow .75 NPT X .75 NPT
(Tong with relief valve)
Jam Nut
End Yoke
L.H. Door Spring Pin
R.H. Door Spring Pin
Safety Latch Plate
Safety Latch Bar
Control Valve Swivel Yoke
Fixed Control Valve Yoke
Control Valve Pivot Plate
Control Valve Link Assembly (Ref. 130, 131, 190)
Safety Latch Pin
Cap Screw
Motor Adapter
Cap Screw
Rear Shift Lever Handle
Cap Screw
Dual Suspension Hanger Assy (option)
Single Suspension Hanger Assy (option)
Control Valve Assembly (Ref. 241-243, 245)
Control Valve Repair Kit
Control Valve End Cap Bolt
Control Valve End Cap
Control Valve Body
Hydraulic Motor Standard
Control Valve Spool
Large Roller
Small Roller

33

WGT.
LBS
.50
.13
.7
.50
.50
.7
.06
.50
.50
.50
.50
.50
.25
.25
.50
.75
.13
.13
2.00
.13
5.00
.25
10.0
15.0
.20
2.00
11.0
47.0
2.00
1.75
1.00

TUBING TONG REPLACEMENT PARTS LIST FOR

45000
REF. NO.
279
280
287
288
289
290
291
292
293
294
295
300
301
302
303
304
305
312
314
337
401
401
405
406
408

410R
410
411
411R
414
415
416
417
418

PART NUMBER
45279
45280
45287
45288
45289
45290

NO.
REQD
5
5
1
1
2
2

DESCRIPTION
Roller Bushing
Roller Pin
Inner Ring
Brake Band
Brake Band Pin
Jaw Pin

WGT.
LBS
.20
.80
10.00
5.00
.50
.75

See Jaw Assemblies

See Jaw Assemblies
See Jaw Assemblies
See Jaw Assemblies

992015-02
45300
45301
45302
45303
45304
45305
992151-S-12-12
943972-45
900706-241
45403-101

3
1
1
1
1
1
1
1
1
1
1

45403-102
700B-04-024-02
45406
992138-S-4-4
45410-200
45430-200

1
1
1
1
1
1

45430-01
45410
992327-018
992327-019
992453-12
45407-202

1
1
1
1
2
2

992005-03
992116-09
992051-06
992131-S-16-12

1
1
1
1

Socket Screw
Shift Bracket
Throttle Bracket
Shift Rod
Throttle Rod
Shift Handle
Throttle Handle
Hex Nipple (for relief valve assy)
Relief Valve (for relief valve assy)
Hydraulic Jumper Hose
Torque Gauge Assembly Psi/ Ftlbs See ILL175
Torque Gauge Assyembly Bar/ Nm See ILL-145
1/4 Hose Assembly
90 Degree Elbow Adapter
Straight Hydraulic Fitting
Back Guard Assembly (ref. 147, 410, 411)
Back Guard Tong Assy (For Relief Valve
Tong Assy) Ref. 410R, 411R, 415, 416, 147
Back Guard (For Tong With Relief Valve)
Back Guard
U-Clamp
U-Clamp (For Tong With Relief Valve)
Hydraulic Swivel 3/4 NPT
Hydraulic Swivel Assy 3/4 NPT (Ref 414,
418)
Screw (For Tong With Relief Valve)
1/2 Nut (For Tong With Relief Valve)
3/8 Lock Washer (For Tong With Relief Valve)
Hydraulic Fitting 3/4 NPT X 1 NPT

34

.20
3.00
5.00
1.00
.50
1.00
.50
.50
5.00
1.25
2.00
.50
.25
.10
.13
2.50
2.40
2.00
.10
1.00
1.00
1.5
.10
.10
.10
.20

35

=TUBING TONG REPLACEMENT PARTS LIST

FOR 55000/56000/45000
JAW ASSEMBLIES
REF. NO.
291
293
294
291
293
294
291
293
294
291
293
294
291
293
294
291
293
294
291
293
294
291
293
294
291
293
294
291
293
294
291
293
294

PART NUMBER
45291H-100
45291H
45293H
992012-72
45291F-100
45291F
45293F
992012-72
45291G-100
45291G
45293G
992012-72
45291A-100
45291A
45293A
992012-72
45291B-100
45291B
45293B
992012-72
45291C-100
45291C
45293C
992012-72
45291K-100
45291K
45293K
992011-132
45291E-100
45291E
45293C
992012-72
45291L-100
45291L
45293K
992012-72
45291D-100
45291D
45293D
992015-02
45291M-100
45291M
45293D
992015-02

NO.
REQD
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1

DESCRIPTION
1.66 Jaw Assembly (1-1/4 Pipe)
1.66 Jaw
1.66 Die
Cotter Pin
1.900 Jaw Assembly (1-1/2 Pipe)
1.900 Jaw
1.900 Die
Cotter Pin
2.06 Jaw Assembly
2.06 Jaw
2.06 Die
Cotter Pin
2-3/8 Jaw Assembly
2-3/8 Jaw
2-3/8 Die
Cotter Pin
2-7/8 Jaw Assembly
2-7/8 Jaw
2-7/8 Die
Cotter Pin
3-1/2 Jaw Assembly
3-1/2 Jaw
3/8 X 1 X 3 7/8 Die
Cotter Pin
3-3/4 Jaw Assembly
3-3/4 Jaw
3/8 X 1 X 2 1/4 Die
Roller Pin
4 Jaw Assembly
4 Jaw
3/8-1 X 3 7/8 Die
Cotter Pin
4-1/4 Jaw Assembly
4-1/4 Jaw
3/8 X 1 X 2 1/4 Die
Cotter Pin
4-1/2 Jaw Assembly
4-1/2 Jaw
3/8 X 1 X 1 7/16 Die
Screw
4-3/4 Jaw Assembly (Model 56100 only)
4-3/4 Jaw
3/8 X 1 X 1 7/16 Die
Screw
37

WGT.
LBS
8.50
6.50
2.00
.01
7.50
6.50
2.00
.01
6.50
5.50
2.00
.01
5.50
4.50
1.00
.01
5.50
4.50
1.00
.01
4.75
4.50
.25
.01
4.37
4.25
.12
.01
4.75
4.50
.25
.01
4.12
4.00
.12
.01
3.12
3.00
.12
.01
3.12
3.00
.12
.01

TUBING TONG REPLACEMENT PARTS LIST

FOR 55000/56000/45000
BUSHING ASSEMBLIES
REF. NO.
292
293
294
292
293
294
292
293
294
292
293
294
292
293
294
292
293
294
292
293
294
292
293
294
292
293
294
292
293
294
292
293
294

PART NUMBER
45292H-100
45292H
45293H
992012-74
45292F-100
45292F
45293F
992012-74
45292G-100
45292G
45293G
992012-74
45292A-100
45292A
45293A
992012-72
45292B-100
45292B
45293B
992012-72
45292C-100
45292C
45293C
992012-75
45292K-100
45292K
45293K
992011-129
45292E-100
45292E
45293C
992012-72
45292L-100
45292L
45293K
992011-128
45292D-100
45292D
45293D
992015-02
45292M-100
45292M
45293D
992015-02

NO.
REQD
1
1
2
4
1
1
2
4
1
1
2
4
1
1
2
4
1
1
2
4
1
1
2
4
1
1
2
4
1
1
2
4
1
1
2
4
1
1
2
2
1
1
2
2

DESCRIPTION
1.66 Bushing Assembly (1-1/4 Pipe)
1.66 Bushing
1.66 Die
Cotter Pin
1.900 Bushing Assembly (1-1/2 Pipe)
1.900 Bushing
1.900 Die
Cotter Pin
2.06 Bushing Assembly
2.06 Bushing
2.06 Die
Cotter Pin
2-3/8 Bushing Assembly
2-3/8 Bushing
2-3/8 Die
Cotter Pin
2-7/8 Bushing Assembly
2-7/8 Bushing
2-7/8 Die
Cotter Pin
3-1/2 Bushing Assembly
3-1/2 Bushing
3/8 X 1 X 3 7/8 Die
Cotter Pin
3-3/4 Bushing Assembly
3-3/4 Bushing
3/8 X 1 X 2 1/4 Die
Roll Pin
4 Bushing Assembly
4 Bushing
3/8 X 1 X 3 7/8 Die
Cotter Pin
4-1/4 Bushing Assembly
4-1/4 Bushing
3/8 X 1 X 2 -1/4 Die
Roll Pin
4-1/2 Bushing Assembly
4-1/2 Bushing
3/8 X 1 X 1 7/16 Die
Screws
4-3/4 Bushing Assy
4-3/4 Bushing
3/8 X 1 X 1 7/16 Die
Screw
38

WGT.
LBS
20.50
16.00
2.25
.01
17.00
15.00
2.00
.01
15.75
14.00
1.75
.01
15.00
13.00
1.00
.01
11.25
10.25
1.00
.01
9.00
8.50
.25
.01
8.00
7.75
.12
.01
10.75
10.25
.25
.01
11.00
10.50
.12
.01
11.50
11.00
.25
.01
5.25
5.00
.25
.01

TUBING TONG REPLACEMENT PARTS LIST

FOR 55000/56000/45000
2-3/8 BUSHING WITH REDUCING DIE
REF. NO.

PART NUMBER
45296-000

NO.
REQD
1

292
293
294

45292A
45294-00
992012-72
45296-100

1
2
4
1

292
293
294

45292A
45294-01
992012-72
45296-101

1
2
4
1

292
293
294

45292A
45294-02
992012-72
45296-102

1
2
4
1

292
293
294

45292A
45294-03
992012-72
45296-103

1
2
4
1

292
293
294

45292A
45294-04
992012-72

1
2
4

DESCRIPTION
2-3/8 Bushing / 1.06 Reducing Die
Assembly
2-3/8 Bushing
2-3/8 X 1.06 Reducing Die
Cotter Pin
2-3/8 Bushing / 1.31 Reducing Die
Assembly
2-3/8 Bushing
2-3/8 X 1.31 Reducing Die
Cotter Pin
2-3/8 Bushing / 1.66 Reducing Die
Assembly
2-3/8 Bushing
2-3/8 X 1.66 Reducing Die
Cotter Pin
2-3/8 Bushing / 1.90 Reducing Die
Assembly
2-3/8 Bushing
2-3/8 X 1.90 Reducing Die
Cotter Pin
2-3/8 Bushing / 2.06 Reducing Die
Assembly
2-3/8 Bushing
2-3/8 X 2.06 Reducing Die
Cotter Pin

WGT.
LBS
19.00
13.00
3.00
.01
18.00
13.00
2.50
.01
17.00
13.00
2.00
.01
16.50
13.00
1.75
.01
16.00
13.00
1.50
.01

2-3/8 JAW WITH REDUCING DIE

REF. NO.
291
293
294
291
293
294
291
293
294

PART NUMBER
45295-000
45291A
45294-00
992012-72
45295-100
45291A
45294-01
992012-72
45295-101
45291A
45294-02
992012-72

NO.
REQD
1
1
1
2
1
1
1
2
1
1
1
2

DESCRIPTION
2-3/8 Jaw / 1.06 Reducing Die Assembly
2-3/8 Jaw
2-3/8 X 1.06 Reducing Die
Cotter Pin
2-3/8 Jaw / 1.31 Reducing Die Assembly
2-3/8 Jaw
2-3/8 X 1.31 Reducing Die
Cotter Pin
2-3/8 Jaw / 1.66 Reducing Die Assembly
2-3/8 Jaw
2-3/8 X 1.66 Reducing Die
Cotter Pin

39

WGT.
LBS
7.50
4.50
3.00
.01
7.00
4.50
2.50
.01
6.50
4.50
2.00
.01

TUBING TONG REPLACEMENT PARTS LIST

FOR 55000/56000/45000
2-3/8 JAW WITH REDUCING DIE
291
293
294
291
293
294

45295-102
45291A
45294-03
992012-72
45295-103
45291A
45294-04
992012-72

1
1
1
2
1
1
1
2

2-3/8 Jaw / 1.90 Reducing Die Assembly

2-3/8 Jaw
2-3/8 X 1.90 Reducing Die
Cotter Pin
2-3/8 Jaw / 2.06 Reducing Die Assembly
2-3/8 Jaw
2-3/8 X 2.06 Reducing Die
Cotter Pin

6.25
4.50
1.75
.01
6.00
4.50
1.50
.01

2-7/8 JAW WITH REDUCING DIE

REF. NO.
291
293
294

PART NUMBER
45295-104
45291B
45294-10
992012-72

NO.
REQD
1
1
1
2

DESCRIPTION
2-7/8 Jaw / 2-3/8 Reducing Die Assembly
2-7/8 Jaw
2-7/8 X 2-3/8 Reducing Die
Cotter Pin

WGT.
LBS
12.75
10.25
1.25
.01

2-7/8 BUSHING WITH REDUCING DIE

REF. NO.

292
293
294

PART NUMBER
45296-104

NO.
REQD
1

45292B
45294-10
992012-72

1
2
4

DESCRIPTION
2-7/8 Bushing / 2-3/8 Reducing Die
Assembly
2-7/8 Bushing
2-7/8 X 2-3/8 Reducing Die
Cotter Pin

WGT.
LBS
12.75
10.25
1.25
.01

3-3/4 JAW WITH REDUCING DIE

REF. NO.
291
293
294

PART NUMBER
45297-100
45291K
45293-11
992012-72

NO.
REQD
1
1
1
2

DESCRIPTION
3-3/4 Jaw / 3-5/8 Reducing Die Assembly
3-3/4 Jaw
3-3/4 X 3-5/8 Reducing Die
Cotter Pin

WGT.
LBS
12.75
10.25
1.25
.01

3-3/4 BUSHING WITH REDUCING DIE

REF. NO.

292
293
294

PART NUMBER
45298-100

NO.
REQD
1

45292K
45293-11
992012-72

1
2
4

DESCRIPTION
3-3/4 Bushing / 3-5/8 Reducing Die
Assembly
3-3/4 Bushing
3-3/4 X 3-5/8 Reducing Die
Cotter Pin

40

WGT.
LBS
12.75
10.25
1.25
.01

TUBING TONG SPARE PARTS LIST FOR ONE YEARS OPERATION

PART NO.

NO.
REQUIRED

DESCRIPTION

45288
45277
45278
45279
45280
45290
45287
45289
45025
992154-214

2
3
2
5
5
2
1
4
2
4

Brake Band
Large Roller
Small Roller
Bushing
Roller Pin
Jaw Pin
Inner Ring
Brake Band Pin
Door Spring
O-Ring for Spool

41

M/S MANUAL BACK-UP ACCESSORY

ILLUSTRATION-069

Oil Country Manual Back-Up Assembly:

1. Install manual back-up hanger assembly on tong, insuring that leveling adjustment bolt
is to the rear of the tong.
2. Install back-up tool in hanger assembly, place pin and safety clip in lever to secure
assembly.
3. To set manual back-up for break-out, the lug jaw assembly (ref. 422) must be positioned
on right hand side of back-up.
4. To operate back-up, position the tong on pipe so that the lug jaw system is gripping.
Using both hands, install lever latch in lug jaw assembly in a position to grip tubing
coupling. Firmly hold lever latch with one hand, using opposite hand to operate tong
throttle. Break out joint, push on lever latch to release.
5. For make-up of tubing, remove lever latch assembly from hanger assembly. Reposition and install so that lug jaw is on left hand side. Position the tong on tubing and
grip pipe with jaw system. Install lever latch in lug jaw so that back-up will grip on upset
below coupling. This will ensure that the coupling is made-up to proper torque.
a. To prevent injury, always grip lever latch loosely with palm of hand. Lever latch
and lug jaw may become separated if not fully engaged on teeth of lug jaw when
torque is applied to tubing.
b. Oil Country recommends that the back-up tong be used only when necessary.
This will minimize wear and reduce labor.

42

Oil Country Manual back-up Assembly

Continued

Back-up Usage
The Back-Up should be used during the following conditions:
1. When pulling tubing out of the well and the coupling unscrews from pin on tubing in the
well.
2. When weight of pipe becomes light enough to allow pipe to rotate in slips.
3. When running tubing in well until load is significant to prevent tubing from rotating in
the slips. To prevent rotating, secure tubing spider to wellhead.
NOTE: When running tubing in the hole, back-up must be used: (1) on the upset below
the tubing coupling to insure proper make-up of coupling, (2) to prevent string from
turning in the slips, (3) to ensure the make-up of both threaded connections.

43

44

REPLACEMENT PARTS LIST

FOR M/S MANUAL BACK-UP ASSEMBLY
REF.
NO.
127
127
206
206
209
267
267
295
359
360
572
572
421
422
422
422
422
422
494
494
573
574
575
591
622A
622
623
624
643

PART
NUMBER
992012-36
992012-36
45206
45206
45209
45266
45267
45578
992015-02
45359
992047-12
45572
45577
45421
4542045422
45424
45579
45580
45494
45494
45573
45574
45575
992008-18
45622-5

NO.
REQD
4
5
1
2
2
1
1
1
2
3
3
1
1
1
1
1
1
1
1
2
5
1
1
2
7

45622
45623
45624
945031-64
45715-100
45700
45720
45725-100
45745-100
45715-200
45730

1
1
1
2
1
1
1
1
1
1
1

45740

45725-200
45745-200

1
1

DESCRIPTION
COTTER PIN 1.900 - 4-1/2
COTTER PIN 4-1/2 - 6-1/8
LATCH SPRING 1.900 - 4-1/2
LATCH SPRING 4-1/2 - 6-1/8
DIE
LEVER 1-5/16 - 2-1/16
LEVER 1.900 - 4-1/2
LEVER 4-1/2 - 6-1/8
SOCKET SCREW
HANGER PIN ASSY
HAIR PIN
LEVER LATCH
LEVER LATCH, SHORT 4-1/2 - 6-1/8
LONG JAW
1.31 - 2.06 LUG JAW
2-3/8 - 3.668 LUG JAW
3-1/2 - 4-1/2 LUG JAW
4-1/2 - 5-1/4 LUG JAW
5.200 - 6-1/8 LUG JAW
HINGE PIN 1.900 - 4-1/2
HINGE PIN 4-1/2 - 6-1/8
LONG SPRING (LEFT)
SHORT SPRING (RIGHT)
HINGE PIN
SCREW
INNER/OUTER SLEEVE ASSY (Ref. No.
622, 623, 643, 591, 359)
OUTER SLEEVE
INNER SLEEVE
LEVER, BAR
SUSPENSION SPRING
BACK-UP ASSY COMPLETE WITH 1.31 - 2.06 LUG JAW
BACK-UP ASSY COMPLETE WITH 2-3/8 - 2-7/8 LUG JAW
BACK-UP ASSY COMPLETE WITH 3-1/2 - 4-1/2 LUG JAW
BACK-UP ASSY COMPLETE WITH 4-1/2 - 5-1/4 LUG JAW
BACK-UP ASSY COMPLETE WITH 5.200 - 6-1/8 LUG JAW
LEVER LATCH SUB ASSY 1.31 - 2.06
LEVER LATCH ASSY COMPLETE WITH
2-3/8 - 2-7/8 LUG JAW
LEVER LATCH ASSY COMPLETE WITH
3-1/2 - 4-1/2 LUG JAW
LEVER LATCH SUB ASSY WITH 4-1/2 - 5-1/4 LUG JAW
LEVER LATCH SUB ASSY WITH 5.200 - 6-1/8 LUG JAW

45

WGT.
LBS
.10
.10
.13
.13
.20
2.00
2.00
2.00
.20
1.00
.06
35.00
35.00
12.00
6.00
6.00
8.00
7.00
5.00
.13
.13
.13
4.00
.13
.13
10.00
5.00
8.00
.25
53.00
53.00
53.00
53.00
53.00
35.00
35.00
35.00
35.00
35.00

46

HDS BACK-UP
1.05-5 9/16

MODEL 55500
THREE JAW OPEN-MOUTH BACK-UP TONG
1.05 5-9/16
ILLUSTRATION 056-1 PAGE 52

The height of the back-up may be adjusted by placing pins in the desired hole of the front bracket
and back bracket.
BACK-UP accessory is applied to the coupling when coming-out of the hole, assuring that the
pipe joint breaks out at the top of the coupling. Note that proper position of back-up is on
lower half of coupling.
MAKE-UP: When going-into the hole, the BACK-UP may be applied to the body of the pipe,
thus preventing the pipe string from turning in the slips and assuring that the make-up of both
threaded connections is complete.
I.

Selecting the back-up unit to operation needed:

NOTE: Unit is marked (make) on one side and (break) on opposite side.

II. To turn over back-up unit, perform the following procedure:

A. Set tong down.
B. Pull front support pin.
C. Lift tubing tong until back-up unit is in a vertical position.
D. Swivel unit 180 degrees.
E. Set tong back down while guiding back-up unit back to original horizontal
position.
F. Install front support pin back in place and re-install safety hair pin.
III. Operating back-up unit with tubing tong.
A. Open back-up jaw system.
B. Swing tubing tong onto tubing.
C. For air or hydraulic operation on back-up.
1. Actuate handle on valve installed on the tubing tong or rig to close back-up
jaw system onto tubing.
D. Throttle tubing tong to complete operation.
E. Release back-up jaw system.
F. Reverse tong to come off tubing

47

55500
JAW REPLACEMENT AND TIMING

A. Jaw Removal
1. Have Open-Mouth Back-Up Tong with Break side up. Refer to illustration 222,
page 50
2. Use the handles on the Jaw Actuating Ring to rotate it into the clockwise direction until the Jaw Assemblies (ref. 1) are in the closed position.
3. Remove the three Jaw Retainer Pins (ref. 9a)
4. Remove the three Jaw Assemblies (ref. 1).
B. Jaw Insert Replacement
1. Use a 5/16 hex wrench to remove the three Socket Head Cap Screws
and the mating three nuts.
2. Slip the Jaw Insert (ref. 1b) out of the slot in the Jaw Body (ref. 1).
3. Install a new Jaw Insert (ref. 1b) into the slot in the Jaw Body (ref. 1).
There is no orientation required for the Jaw Insert (ref. 1b) to the Jaw Body (ref. 1).
4. Install the three nuts into the mating holes of the Jaw Body.
5. Install the three Socket Head Cap Screws into the mating holes of
the Jaw Body and tighten using a 5/16 hex wrench.
C. Jaw Installation and Timing
1. Have the Open-Mouth Back-Up Tong with the Break side up. Refer to
illustration 222 on page 50.
2. Use the handles on the Jaw Actuation Ring (ref. 4) to rotate it into the counterclockwise direction, until it stops. As shown on ILL-222
3. Grease the gear teeth on the jaw assembly (ref 1).
4. Install the Jaw Assembly (ref. 1) into the positions in the Open-Mouth BackUp Tong as shown.
a. Align the Jaw Pin in the Jaw Assembly (9a) with the
corresponding holes in the Plates of the Back-Up Tong
while engaging the gear teeth of the Jaw Assembly (ref. 1) with the
mating gear teeth of the Jaw Actuating Ring (ref. 4).
b. Use the Timing Pin (ref 15 a) which is stored in extra holes of the
Frame Plates. Locate the timing pin hole in the Plates and mating
hole in the Jaw Assembly (ref. 1). There is a timing pin hole for each
Jaw Assembly location. Each Jaw Assembly (ref. 1) has a timing pin hole.

48

c. Continue to move Jaw Assembly (ref. 1) until Jaw Retainer Pin hole and
timing pin hole is in alignment between Plates and Jaw Assembly (ref. 1).
Note: The gear teeth on the Jaw Assembly (ref. 1) will mesh with the
mating gear teeth on the inside of the Jaw Actuating
Ring (ref. 4).
4. Install Jaw Pin (Ref 9a)
5. With the Timing Pin out of the timing pin holes, use the
handles on the Jaw Actuating Ring (ref. 4) to move the Jaw Assemblies
ref. 1) from the retracted position to engagement position. Move the jaws
several times to check functions and operation.
6. Use the handles of the Jaw Actuating Ring (ref. 4) to move the Jaw
Assemblies (ref. 1) to the fully retracted position, counter-clockwise
until hitting the stop.
7. Use the Timing Pin to re-check the timed position
of each Jaw Assembly (ref. 1) to the Frame Plates.
8. Store the Timing Pin in one of the two storage holes in the Frame Plates
A Bridge Pin (ref 15b) keeps the Timing Pin locked to the Back-Up Tong.
9. Inject grease into grease fittings (ref. 9c) of the Jaw Retainer Pin Assembly
(ref. 9).
10. The Three-Jaw, Open-Mouth, Back-Up is ready for operation.

49

50

MODEL HDS 55500 BACK-UP ASSEMBLIES

WITH DIES, LESS BACK-UP MOUNT
(1.05 - 5-9/16 RANGE)
THREE JAW OPEN-MOUTH BACK-UP
PNEUMATIC STANDARD ASSEMBLIES

PART
NO.
55510-102

55510-101

DESCRIPTION

SIZE OF DIE INSTALLED

AIR OPERATED BACKUP

Fraction
1.900 to 41/2

MM
48.3 mm to
114.3 mm

OPTIONAL
DIE TYPE
Straight
Tooth

AIR OPERATED LESS

VALVE ASSEMBLY,
BRACKET & HOSE ASSY

1.900 to 41/2

48.3 mm to
114.3 mm

Straight
Tooth

48.3 mm to
114.3 mm

Straight
Tooth

WGT
LBS
90

90

HYDRAULIC ASSEMBLIES

55520-202

HYDRAULIC OPERATED
BACK-UP

51

1.900 to 41/2

90

52

MODEL HDS-55500 BACK-UP ASSEMBLY

PNEUMATIC / HYDRAULIC OPERATED
(1.05 5-9/16 RANGE)
THREE JAW OPEN-MOUTH BACK-UP

BACK-UP OPTION ASSEMBLYS

ITEM
NO.
1
a
b
c
d
1
a
b
c
d
1
a
b
c
d
2
3
4
7
8
a
b
c
d
9
a
b
c
10
a
b

QTY
3
1
1
3
3
3
1
1
3
3
3
1
1
3
3
1
1
1
1
1
1
2
2
2
3
1
2
2
8
1
1

PART NO.
55157-100
55101
55157
55140
992116-05
55177-100
55101
55177
55140
992116-05
55152-100
55101
55152
55140
992116-05
55103-01B
55103-300
55105-200
55116-200
55118-100
55118
992073-01
992005-17
992166-09
55126-100
55126
992047-14
992073-01
55141-100
992173-04
992174-03

PNEUMATIC
55510-102

HYDRAULIC
55520-202

(WITH 1.900-4 Jaws)

(WITH 1.900-4 Jaws)

PART DESCRIPTION
2-7/8 - 5-9/16 Straight Tooth Jaw Assembly
Jaw
Insert Straight Tooth
Screw SHC
Nut/Nylock
1.900 - 4-1/2 Straight Tooth Jaw Assembly
Jaw
Insert (1.900 - 4-1/2) Straight Tooth
Screw SHC
Nut/ Nylock
1.05 - 3.69 Diamond Tooth Jaw Assembly
Jaw
Insert (1.05 - 3.69) Diamond Tooth
Screw SHC
Nut/Nylock
Plate, Break (top)
Plate, Make (bottom)
Jaw Actuation Ring
Swivel Stem
Swivel Block Assembly
Swivel Block
Grease Fitting
HHC Screw
Hex Nut with Nylock
Jaw Retainer Pin Assembly
Jaw Retainer Pin
Bridge Pin
Grease Fitting
Wear Bolt Assembly
HHC Screw
Hex Nut with Nylock

53

MODEL HDS-55500 BACK-UP ASSEMBLY

PNEUMATIC / HYDRAULIC OPERATED
(1.05 5-9/16 RANGE)
THREE JAW OPEN-MOUTH BACK-UP

ITEM
NO.
QTY
.
11
11
a
1
b
1
12
1
12
1
a
1
b
1
b
1
b1
1
b1
1
b2
1
b3
1
1
c
c1
2
c2
1
c3
1
d
2
e
1
13
4
a
1
b
1
14
1
15
1
a
1
b
1
16
1
17
1
18
1
19
1
20
4
21
1
a
1
b
1
c
2
d
4
e
4
f
1
g
2
g
2

PART NO.
55142-100
992005-15
992166-09
55145-100
55145-200
55122
55143-100
55143-200
992264P-24-48
992264H-24-48
992264-02
992264-03
55146-100
55121
992049-135
992047-10
992141-S-4-4
992012-35
55147-100
992166-14
992294-13
55178
55179-100
992391-01
992047-12
55181-200
55182-200
55183-200
55186-200
992073-01
55148-200
992277
55150-200
992138-S-4-4
992001-04
992089-01
55180-100
55148-303
55148-403

PART DESCRIPTION
Standoff Bolt Assembly
HHC Screw
Hex Nut with Nylock
Pneumatic Cylinder Assembly
Hydraulic Cylinder Assembly
Yoke Pin
Pneumatic Cylinder Subassembly
Hydraulic Cylinder Subassembly
Pneumatic Cylinder
Hydraulic Cylinder
Mount Clevis
Female Rod Clevis
Cylinder Pivot Pin Assembly
Spacer
Clevis Pin 1/2 X 3-1/2
Bridge Pin
90 Degree Elbow Connector
Cotter Pin
Stem Bolt Assembly
Hex Nut with Nylock
HHC Screw
Tube, Stop
T-Handle, Timing Assembly
T-Handle, Timing
Bridge Pin
Short Front Pad
Long Front Pad
Long Rear Pad
Short Rear Pad
Grease Fitting
Pnuematic Hand Valve Assy
Pneumatic Valve - Hand operated
Valve Mounting Bracket
Straight Connnector
Hex Head Cap Screw 1/4 X 7/8
Nut
Pneumatic 3/8 Supply Hose Assembly: 180 Long
Pneumatic 1/4 Hose Assembly: 52 Long
Hydraulic 1/4 Hose Assembly: 60 Long

54

55

STANDARD BACK-UP MOUNTS

56

57

ITEM

PART NO.

QTY.
I.

DESCRIPTION

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

55138-100
55139-100
55229-100
55237-100
55238-100
55239
55240
55241
55247-100
55248-100
55255-100
55256-100
55127-201
992003-05
992011-144
992007-02 (B1)
992007-04 (B2)
992007-05 (B3)
992007-07 (B4)
992051-14
(a1)

1
1
2
1
1
2
2
2
1
1
1
1
1
12
2
4
2
4
2
12

REAR SUPPORT PIN

FRONT SUPPORT PIN
SPRING HOUSING
SLIDING SLEEVE-LEFT HAND
SLIDING SLEEVE- RIGHT HAND
SPRING PISTON
DIE SPRING
SUPPORT WASHER
LEFT SPRING SUPPORT
RIGHT SPRING SUPPORT
LEFT ALIGNMENT POST
RIGHT ALIGNMENT POST
SWIVEL SUPPORT REAR MOUNT
HEX HEAD CAP SCREW 3/8-16 UNC X 1 LONG
ROLL PIN
HEX HEAD CAP SCREW 5/8-11 UNC X 1 1/4 LONG
HEX HEAD CAP SCREW 5/8-11 UNC X 1 3/4 LONG
HEX HEAD CAP SCREW 5/8-11 UNC X 2 LONG
HEX HEAD CAP SCREW 5/8-11 UNC X 2 1/2 LONG
LOCK WASHER

21

992073-01

GREASE FITTING

22

992089-05

12

NYLOC NUT 3/8-16 UNC

23

992317-100

RETAINER RING

24

55234-02

RIGHT & LEFT SUPPORT STIFFENER

(a2)

(a3)

NOTE: (#1) Reference Drawing:

This document is not to be duplicated without the express written permission of OIL COUNTRY MANUFACTURING, INC.
DRAWN
REVIEWED
APPROVED
REVISION
(A)NND111

TA
TA
KH

08-10-98
08-10-98
08-10-98

TMA

10-16-98

(B)NND111

KEH

09-07-01

REVISION

OIL COUNTRY MFG., INC VENTURA, CA

TITLE::
STANDARD BACK-UP MOUNT
A.
SIZE
A

58

PARTS LIST NO.

ILL-268-1

ASSEMBLY
REV.
B

SHT.
1 OF 1

60

PARTS LIST FOR

HYDRAULIC TUBING TONG
STANDARD M25 MOTOR P/N 970400-5
(ILLUSTRATION 008)
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35

PART NO.

QTY

DESCRIPTION

455031-402
453100-100
458015-116

1
1
1

Housing Shaft
Housing End Cover
Gear Housing

452815-000

Gear (Set)

453784-028
451401-027

4
4

Washer
Cap Screw

451135-048

Shaft

452882-096
453681-001
450384-008

1
2
1

Lip Seal
Check Assembly
Taper Bearing

452581-003
450381-059
452884-021
452882-050
452185-012
452181-999
451432-004
992154-228

1
4
2
12
2
1
2
1

Retainer
Roller Bearing
Seal Gasket
Pocket Seal
Thrust Plate
Name Plate
Drive Screw
O-Ring

450481-002
453581-176

1
1

Bushing (Set)
Spring

61

62

63

64

65