OPERATION MANUAL

ZQ203-125 POWER TONGS

 
 
 
 
 
 
 
 
 
 
 
 
Jiangsu Rutong Petro-Machinery Co., Ltd.

Add：No.  33  Huaihe  Road,  New  Economic  Development  Zone,  Rudong 

County, Jiangsu, China. 
Tel：+86 0513 84510292/84129120 
Fax：+86 0513‐84523102                      P.C.：226400 
Http://www.rutong.com                      E‐mail: rdty@rutong.com 
 
 
 
 
 Brief Introduction

ZQ203-125 Drill Pipe Power Tong is a new type of ZQ203-100 Drill Pipe
Power Tong. Open head design allows the tong to come freely away from
drill ~ipe. The tong is a combination of spinning tong and torque tong. Using
'the drill pipe tong to make up or break out drill pipes does not need cathead,
manual tong and rotary wire. It is fit for frequent operating and long-period
drilling with features of easiness, safety and saving labor.
ZQ203-125 shows a more advanced performance than ZQ203-100
with higher torque, elegant figure and added auto-door device. It takes a
combined control over lower-tong gripping, door on and off, and tong body
shifting.
Special Features:
1. Hydraulic and air control system is adopted to e.xert combined
control over gripping operation, door on and off, and cylinder shifting, which
raises reliability of operation.
2. Upper tong and lower tong are as a combined structure, avoiding the
possibility of bending of drill pipe under high torque, and preventing gliding
of drill pipe from spider.
:t Suspending is easier due to the adoption of simple and flexible tong
head floating; automatic ~entering and griping mechanism can guarantee
the reliable gripping of r.ew and old joints.
4. Enhanced tong body and auto door can efficiently limit the
deformation of tong head under high torque.
5. Unique connection structure of cam and plug make its disassembly
and maintenance easier.
6. Air tires clutch is adopted to shift high and low speed without
stopping the tong. Torque and speed can both be controlled, and .maxirnum
torque and speed can come at positive direction and reverse direction.
7. Griping of upper and lower tongs is realized by brake and griping
cylinder respectively. Shifting tong body is conducted by air cylinder instead
of manpower.
 Contents
Sections

1.Functions: .......................................................................... 1

2.Operation Range ............... ........................................................ 3

3. Structure of Main Parts.. ............................................ ... ,;, .... ~ .. ·3

4. Installation and Commission ................................................. .... 6

5. Adjustments of Tor:que and Speed of Tong Head............................ 7

6. Operation Regulations ................................................................. 8

7. Maintenance...........................................................................9

8. Common Troubleshooting ..................... ................................. 10

9. Some Explanations .............................................................12

10. S_election of Hydraulic oil ........................ ......................... ...... 12

Attached Drawings:
1. General View of the tong
2. Transmission Schematic Diagram
3. Hydraulic System
4. Pneumatic System
5. Moving Device
6. Installation Drawing
7. Installation Drawing
8. Installation Drawing
1.Functions
1. 1 Hydraulic System
Rated flow 30gpm
Max. Working pressure 2900psi
1. 2 Pneumatic System
Working pressure 75-135psi
1. 3 The speed of the tongs head at various flows is as follows.

Flow Speed of the Tongs Head r. p. m

gpm High Gear Low Gear
30 40 2.7
26.3 35. 1 2.4
23.7 31.6 2. 1
21 28 1.9
18.4 24.5 1.7
15.8 21 1.4

1.4 The torque of the tongs head at various pressures is as follows.

Pressure of Hydraulic Torque of the Tongs Head
System ft.lbf
psi High Gear Low Gear
2900 9220 92200
2450 7380 73800
2150 6860 66750
1850 6270 59800
1600 5680 48750
1300 4200 39750
1000 2880 30750
725 2260 21750

1 .5 Applicable Pipe OD.

1 .5. 1 There are four sizes of jaws for selection.
Jaws types: 8", 51/2", 5", 41/2", 31/2".
Applicable range: 8" (8-7.6in) drill dollar, 51/2" (7-6.6in) drill pipe joint, 5"(6.3-5.9in)
drill pipe joint, 41/2" (5.75-5.3in) drill pipe joint, 31/2"(4.75-4.3in) drill pipe joint.
 1. 5. 2 Max. Wear allowance is 0.4in for each size of drill pipe joint, eccentric wear
allowance is 0.12in.
1. 5. 3 The total joint length of drill pipe box and pin should not be less than
16.54in.
1.6 Miscellaneous parameters
1.6.1 Shifting distance ~59in
1.6.2 Turning angle door 90°
1.6.3 Turning angle of dial disc ?::-75°
1.6.4 Overall dimensions and weight
Overall size: L x W x H=68x41x69mm
Weight: 58401b

2. Operation Range
2. 1 In Tripping Operation
For drill pipe make up and break out when the torque is less than 92200ff.lbf.
2. 2 For kelly joint make up and break out during drilling.
2. 3 For 8" drill collar make up and break out.
2. 4 For throwing off single.
To throw off single, adjust the suspension device to keep inclination of the tongs
head corresponding to that of the mouse hole' s, vary the direction of the pneumatic
shifting cylinder to make the tongs head align with the mouse hole, then throw off the
single.
2. 5 To keep rotation of drill string (bottom hole assembly) when rig is in trouble, if
transmission system of drilling rig is out of order. Draw works and rotary table will not go
on working, and drill string from sticking, removing the jaws from the low tongs onto well
head, an attached cable to both sides of the tongs end to prevent the tongs from rotating.
Then install the corresponding jaws into the upper tongs according to the size of drill
stem, let the laws engage with kelly joint or drill pipe joint, disengage the pin and clutch
of rotary table and then operate the upper tongs to drive drill stem of drill string rotating.
The time to rotate drill stri'ng is well bore at low speed (2. 7 rpm) should not be too long
(usually less than half hour).

3. Structure of Main Parts

·3. 1 Two-speed planet gearbox
In order to achieve low torque spinning at high speed and high torque make up or

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 break .out at _low speE:d, the tongs is provided with a two-speed planet shift gear and
unique breaking . mechanism ~or sliifting the . !Jear without stopping the tongs. The
efficiency of the t~ngs is th~refore raised (Fig. 1, 2)
See Fig. 2, high speed is obta_iried as hydra1ulic motor drives planet gear(Z3) on the
frame to rotate, power comes from the sum goar (21) when the intemal gear (Z2) is
.brak~d: For low sp~ed, the ~~~u~nce is reversal, hydraulic motor drives the sun gear (26)
·to rotate, power comes from the frame fitted with the planet gear (25) when the Internal
gear (Z4) _is b~ked. . , : · · . ·

3.2 Gear transmiss_ion device

See Fig. 1, transmission box pf reducer gear consists of enhanced lower cover (27)
of the tong, upper cover (22) Qf plan~t gearbox and gland (29). The structure of the three
parts .(upper cover.lower cover,cind gland) combined by idle gear shaft (40) Is reliable
. and securetbe normal running .of.each gear.
, :• Refer to Fig. 2, the outpµ_t shaft or the two-.speed planet gear box is the inpl.!t shaft
of, the two-sp~ed gear reducer ;:issembly, the notched gear (211) is driven to rotate
thrQugh the.first step de~leratlon (27 -28) and the second step deceleration (29- 210-
2:11) . The-functiQn of two, tdle_gea~ (210) is to keep the notched gear (Z11) rotating
continuously by (29). This is necessary for passing the notch.

3. 3 The T•ngs Head (See Fig. 1)

3. 3. 1' Gripping ·mechanis~: The notchEld gear (4) of transmission drives the
· flbating body (5) to rotate ·thro"c.ig h three pins (1.:i!). Brake band (42) stops the brake disc
·ttom rotating 'with about 737.5ft:lbf torque all the time, and the jaw rack (7) with jaws (43)
is ·connected·with the brake disc by screw bolts, when the floating body begins to rotate,
both bra~e disc aHd the jaw rack is braked to sto,p because dies are not In touch with the
joint. But th_
e .cain '( 46) with··a fixed slope rotateis along with the rotation of the floating
body;_the rollers (45) located at the back of the j.;1w will go up along the spiral surface and
comes close to tt.;-e center, and at last grip aga1inst the drill string joint. Meanwhile the
notched ~ear will drive the brake disc, the jaw rack and the jaws on the floating body and
drill string to-rotate for the operation of making up and breaking out.
The lower tong is to drive the jaw rack to rotate in the case body through air gripping
cylinder (49), thus gripping or·loosening the joint beneath.
(:am of the tong is set directly in the groove of floating body and lower cover, and
bolt is not needed. Plug (10) fitted in the dovetail of the jaw rack is to align drill pipe. Plug
is connected through active pin (11 ), and you can take out plug by pressing active pin.

3
 3. 3. 2 Floating mechanism: The floating body seats on the notched gear through
four springs (56) and seat sleeves (55). The springs can secure the floating body enough
vertical shift. For the further tight grip in case of eccentrically wom joint. the floating body
can horizontally move relative to the notched gear. The move is guaranteed through the
clearance between the three pins (12) with square sleeves (13) and the rectangular
holes in the floating body.
3. 3. 3 Brake mechanism: Refer to Fig. 1, the brake mechanism consists of the two
brake bands (42) round the brake discs, connecting rod (39) and adjusting tube (35). The
spring force of the adjusting tube can be adjusted to change the value of braking
moments by rotating the adjusting tube. The brake mechanism can center the floating
body with drill pipe and meet the requirements of eccentric joint.
3. 3. 4 Restoration mechanism: There are three requirements of restorations for
aligning notches to power tongs of open head, that is, the aligning of floating body with
the case body, the aligning of jaws rack of the upper tongs with the floating body, and the
aligr.ing of jaws rack of the low tongs with the case body. First, align approximately with
high speed, then align accurately with low speed, by this way, the floating body can be
aligned exactly with the case body. The aligning of jaw rack of the upper tongs with the
floating body is just the same as the aligning of jaw rack of the lower tongs with the case
body.
Refer to B-B turned of Fig. 1, locating pin (57) is fixed on the floating body, the
locating turning pin ·(58) connected with the locating handle (14) is fixed on the brake
disc. Obviously, the floating body in the position as shown in Fig. 1 is capable of relative
motion to the right with respect to the brake disc, that is, to make counter clockwise
rotation (breaking out position). If the locating handle is inversely turned 180 degree, the
floating body is capable of relative motion to left with respect to the brake disc, that ls, to
make clockwise rotation (making up position). The brake disc will be aligned with the
floating body while the floating body is turned inversely until the locating pin (57) is in
touch with the locating turning pin (58).
In order to observe conveniently, the position of the locating handle of the upper
tongs should conform to rotational working direction of make up (or break out). The
position of the locating handles for the upper tongs and the lower tongs should be the
same. The locating pin of lower tongs and pin-shaft of fork of griping cylinder combine as
dial disc pin (53) and is fixed on the fork. Gripping cylinder is set in the support of the
lowercase.

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 3. 4 Auto-door
Refer to Fig. 1, there is an auto-door beside the opening of the lower case. Door
bolt (30) connects with the tong opening, and gear of the door bolt meshes with rack (:32).
When linkage cylinder ( 1) acts under the function of control system, the long piston (3)
will drive rack to tum door bolt. Rack (32) and sliding device is set in the shell (31 ), a1nd
linkage cylinder is put on the shell. The action of auto-door unites with the griping a:nd
shifting of the power tong. When the tong is not cl2mping the pipe, the door is at open
status under the function of restoration spring (2), and the tong body is free to move.
When the tong is clamping the pipe, linkage cylinder will motivate the auto-door to close,
and the tong is at working status and can't move.

3.5 Suspension device

Suspension device consists of suspension cylinder, balance valve, hand-reversing
valve, air bag support and adjustment device. Suspension cylinder is set in the air bag
support. Air bag support is linked to the gland with ear .a t the shaft end of idle gear.
Suspension cylinder may be up or down or locked. One side of the air bad support is air
reservoir, and hydraulic control components. and pressure-torque gauge are set at the
other side.
Suspension cylinder and the drill pipe tong share the same hydraulic source.
Hand-reversing valve and balance valve work together to keep suspension cylinder
running smoothly and free. Suspension cylinder may be locked at any position during its
stroke. So fine adjusting the height of power tong is available.

3.6 Hydraulic System

In order to simplify hydraulic system, only the hydraulic motor and suspension
cylinder use hydraulic oil as source power. See Fig. 3, hydraulic oil from hydraulic station
(1) goes through M-type hand-reversing valve (2) of suspension device and H-type
hand-reversing valve (3) to suspension cylinder and hydraulic motor. Control M-type
hand-reversing valve and H-type hand-reversing to make hydraulic device rise or fall and
make hydraulic motor run forward or backward.
There is a pressure-torque gauge set at the system. Pressure and torque value can
be directly read from it.
Overflow valve for making up is fitted to control torque for making up. Torque may be
adjusted through the adjusting of overflow valve.
The power tong has its own special power station to be ordered additionally

5
 3.7 Pneumatic System
As shown in Fig. 4, compressed air of drilling rig is used as the air source. In order to
prevent the harmful influence of the long distance airline on the airflow, the tong
preserves compressed air in the suspension device, so the inner cavity of the
suspension device is the reservoir (5) of the pneumatic system.
As shown in Fig. 4, the three three-position four-port hand-reserving valves (4),
which are set at a control panel, contro1 respectively the air tyres (1,2), the air cylinder
for gripping (11) and the air cylinder for shifting (12).
Among the air line to control shifting cylinder (12), there is a two-position three-port
valve. In the air line of gripping cylinder, linkage cylinder (10) is set. Those realize the
linking of the griping, shifting of the tong, and the open/close of door, which enforces the
reliability during working.

3.8 Shifting device

Refer to Fig. 5, shifting cylinder (7) is adopted to move the tong forward and
backward. Use universal coupling (2) and pin-shaft (1) to connect the fork of shifting
cylinder with the ear of the lower case of t,h e tong. The other end is joined with clip 18).
Connect respectively the tail plate and the sleeve of lower case with slipping sleeve (6)
of shifting cylinder through wire rope. Spring (4) secures the stability during shifting. Clip
(8) is attached to the square post fixed on the derrick.

4. Installations and Commission

4.1 Installation of the tongs for a drilling rig (Fig. 6),
4.1.1 Fix the pulley 5.5 US tons on the crown block beam.
4.1.2 One end of wire rope 5/8" to 3/4" is attached to the fork of suspension device
of the tongs, another end of wire rope rewed through the pulley and is connected with
the hook of the hand hoist that infixed on the substructure barn. The level of the tongs
should be 1.8in above the working position of the elevator.
4.1.3 Installation of the fixing post: The fixing post is installed on the substructure.
The top of the fixing post is fixed on the derrick with clip. The wellhead, the tongs and the
fixing post should be in alignment in installation.
4.1.4 The head. of the shifting air cylinder is connected with the tongs. The fork joint
of the piston rod is connected with the fixing post with universal coupling. Cylinder near
the fixing post should be 3. 94-9.84in lower than the end near the tongs.
4.1.5 In order to keep the tongs away from the wellhead automatically (when

6
compressor air isn't available) it is convenient to install a right-hand and left-hand
threaded rod near the racking platform for pulling the tongs backward.

4.2 Installation on another drilling rig (Fig. 7):

This drilling rig has a larger drilling platform, the derrick is type "A", the tong may be
installed near the cathead weld a short sleeve on the substructure instead of original
fixing post. The shifting air cylinder is placed in back end of the tongs, the end of the
shifting air cylinder near the tongs is 3.94-7.87in higher than another end.

4.3 Installation on ZJ45 rig. (Fig. 8)

4.4 Leveling the tongs

Leveling the tongs is very important to its application if the tongs is not level, not only
slip will take place but also damage will occur.
After finishing the connection of pipeline, connect the shifting air cylinder with the tan
of the tongs. Tum on the air valve and shift the tongs to the well head (in the well head
should be a drill pipe for leveling). Adjust the level of the tongs and keep a certain
distance (1.57in) between the tongs and the top surface of the elevator. After the notch of
the tongs goes on to the drill pipe, observe in the front of the tongs head whether the left
or the right sidE' of the tongs is horizontal, if not, adjust the shift screw of suspension
device to achieve leveling through changing tihe right and left IPOSition of suspending wire
rope. After it is nearly leveled, observe whether the two plug screw (serial number is 10
in Fig. 1) of the upper and low tongs contact closely to the pin and box of drill pipe
respectively. If one is not, the tongs is not horizontal. By this way, adjust the adjusting
bolts (serial number is 19 in Fig. 1) of the suspension rod so that the pin and box of drill
pipe can contact closely to the two-plug screw of the upper and low tongs respectively.
Generally, it is all right when the top surface of the tongs is parallel to the surface of
rotary table.

4. 5 Commission,
4.5.1 After finishing the connection of pipe liner, operate the air valves of high and
low speed, the gripping air cylinder of the lower tongs and the shifting air cylinder to see
whether the valves are working well and whether there is any leakage.
4.5.2 Let the tongs run idly for 1-2 minutes with low speed, the pressure for idling at
low speed is within 2.5 Mpa.
4.5.3 Let the tongs run idly for 1-2 minutes with high speed, the pressure for idling
at high speed is within 5 MPa.
4.5.4 R un the motor forward and backward and test the restoration mechanism of

7
the tongs head.
4.5.5 Shift the tongs onto wellhead and grip Ihle joint with the low tongs.
Test the pressure of makir.J up and braking out with high speed (do not test with
low speed to prevent joint from damaging), and adjust the pressure of making up with the
overflow valve for making up and the pressure of breaking out with tnain overflow valve
to meet the requirement of the well.

5. Adjustment of torque and speed of tongs heads.

5.1 The speed of the tongs: the speed of the tongs head is proportional to the flow of
oil pump supply. It is adjusted before delivery.
5.2 The torque of the tongs head: the torque of the tongs head is proportional to the
pressure of hydraulic system. The adjusting way: shift the t·:mgs to well head, make the
tongs grip the drill pipe joint at high gear until tho tongs stop turning, then shut off the
overflow valve for making up. Adjust overflow valve of power station to its prescribed
pressure (i.e. prescribed torque); then turn on the overflow valve for making up until to
prescribed pressure (i.e. prescribed making up torque).
Caution: Do not use low gear to adjust pressure, because the torque at low gear is
too much to destroy joint.

6. Operating Regulations.
6.1 Turn on the valve of airline from drilling rig to the tongs. (Put the valve on driller'
s console if possible)
6.2 Start oil pump and make the oil pump run idly; m'?.anwhile, the reading of the
pressure gauge should not exceed 220psi.
6.3 Check on whether the size of jaw is in correspondence with the size of dril1 pipe
sub. Put the two locating handles (serial numbers are 14, 48 in Fig. 1) to the position
according to making up or brak:ng out.
6.4 Operate slightly the air valve of the shiftin~1 air cylinder to move the tongs to well
head smoothly, do not turn on the air valve compl1~tely, otherwise, the tong:; will quickly
move to wellhead and lead to an impact. If the level of the tongs is wrong, operate the
hand-reversing valve of suspension device to adjust it to a suitable position.
6.5 After the drill pipe goes into the notch of the tongs head, observe whether the
two plug screws of the upper and lower tongs are contacting closely to the pin and box of
drill pipe respectively, then operate the bi-direction,al air valve of the gripping air cylinder
to make the lower tongs to hold the joint, put the handle of the bi-directional air valve to

8
"O" position and release the air.
6.6 According to the need of making up and breaking out, put the handle of the
bi-directional air valve to corresponding position, there is no necessary to shut down the
tongs in changing speed.
6.7 Operate type "H" hand-reversing valve to control the motor running forward and
backward, change the position of hand-reversing valve according to the need of making
up or breaking out.
6.8 Restoration: This is the procedure that the notches of the tongs head are
aligned with each other. Having finished one make up or one break out, it is necessary to
operate the type "H" hand-reversing valve to make the tongs head rotate inversely
against the working direction of the tong head. Operate the bi-directional air valve
according to the distance between each of the notches in restoring; use high or low
speed to bring about restoration. The type "H" hand- reversing valve should be used as
rarely as possible! for high speed to restore but the bi-directional air valve should be used
skillfully to reduce an inertia shock.
6. 9 In breaking out, when pin is spinned out from box completely (i. e. drill pipe
rotates reversely for five and half turns or the sound of drill pipe falling down is heard
after broken out) tum the handle of the bi-directional air valve towards the direction of
making up to restore. When the upper tongs have loosened the drill pipe but the notches
is still not aligned, it is also permitted to hoist a stand when the tong is shut down. After
hoisting, the stand proceeds to restore again, this procedure will save time.
6 .1 o Before the pin has not spinned out of the box completely don 't hoist drill pipe
upward to prevent drill string from falling down to hole bottom. Before the upper tongs
has not loosen the drill pipe, it is not permitted to hoist the drill pipe to prevent the floating
body front bringing out of the tongs or drill pipe from falling down to make damage of the
parts.
6 .11 Operate the handle of the bi-directional air valve of gripping air cylinder to the
position opposite the working position to make the lower tongs restore "O" position and
align the notches.
6.12 Operate the handle of the bi- directional air valve of the shifting air cylinder to
move the tongs out of wellhead smoothly.
6.13 Having finished wlhole trip, put all hydraulic and air valves to "O" position, tum
off one-way valve, oil pump and the valve of air line from drilling rig to the tongs.
6.14 When the drilling rig is moved to other place, all the bare joints of hydraulic and
air lines should be sealed up to prevent dirt from entering into hydraulic and air lines.

9
 6.15 The position of the locating handle of the upper and low tongs should be in
accordance with making up or breaking out. In changing their position, it is not permitted
to operate it until each of the notches of the tongs is aligned, otherwise the mechanism
will be out of order.

7. Maintenance
7.1 Set up a system of personal responsibility.
7.2 According to the working condition of the filter of hydraulic system, it is
necessary to clean or change its core timely to prevent the core from plugging up by dirt
to affect its normal use.
7.3 After a new tongs is used, hydraulic oil should be changed (or settled) within
one month. The oil level of the tank should be kept above the lower limit line; otherwise,
oil should be filled up promptly. When supplying oil to the tank, prevent impurity from
coming into it.
7.4 After finishing every trip, the tongs head should be washed clean with water,
and be blown dry with compressed air. In winter blow with steam. After the cam (serial
number is 46 in Fig. 1) and roller parts (45) are cleaned up, coat their surface with grease.
The cam should be clean and the roller pin and pin-shaft should be able to tum freely.
7.5 After every three wells completed, change the eng1
ine oil in the gearbox and the
molybdenum disulfide lubricant in the transmission box once {well depth is considered as
9840ft).
7.6 Maintenance requirement of the !bearings in transmission system is the same
as bearings in air compressor.
7.7 After every trip, clean the shifting and gripping air cylinders, and suspension
cylinder with clean water, and wipe the piston rod dry with cotton yam and coat its
surface with grease, its extended parts should be drawn in its cylinder completely._
7.8 After every trip, inject 50cc clean engine oil into the air valve to lubricate all parts
of the airline and to prevent rusting.
7.9 Other grease nipples are as follows,

Position Qty Period

Spline shaft 1 Inject grease before every trip
Gripping air cylinder !brace 2 Ditto
The end of idle gear shaft 2 Ditto
Rollers 14 Ditto

10
8 Commonly Troubleshooting
Trouble Probable Cause Correcting Action
per tongs or low 1 . Long time service of the dies, 1. Replace dies.
tongs fail to grip worn and tom, blunt.
in making up or 2. Die groove being filled with dirt. 2. Clean dirt with wire brush.
breaking out 3. Improper heat treatment of dies to 3. Replace dies.
make it so fragile or so soft so as to
be not able to grip.
4. Too loose for large brake band to 4. Fasten the adjusting tube o1
make the upper tongs jaws not able the brake band or replace spring
to follow the cam. of the tube.
5. Dirty brake disc and brake band 5. Clean brake disc and brake
fails to stop the tongs. band.
6. Tongs not leveled. 6. Level the tongs.
7. Tongs not moving exactly to 7. Move tongs to well head
wellhead. exactly and grip drill pipe.
8. Air cylinder or air line leaking to 8. Turn the angle coupling tight,
cause air pressure dropping below check up sealing condition of
72.5psi. gripping air cylinder, replace
sealing ring.
9. Dirty tongs and much filth in jaw 9. Clean jaw rack, jaw and roller,
rack to cause roller difficult to roll, smear grease on their surface.
but slip.
10. When jaws replaced, 10. Replace corresponding plug
corresponding plug screw not screw.
replaced.
11. Drill pipe joint worn badly to 11. Replace under size jaw.
make jaw fail to grip. 12. According to making up and
12. The direction of locating handle breaking out, put the locating
of the upper tongs is not in handle correspond with the
correspondence with the low tongs. nameplate indication.
13. The notches of the upper and 13. The locating handles must be
low tongs are not aligned each other, reversed after the notches have
thE:ir locating handles fail to work. been aligned.
14. Grip the drill pipe before put the 14. Before reverse the direction,
locating handle to working position. be sure whether the locating pin
of moving disc of the low tongs is
in half-ring of locating turning pin,
if not, put back the gripping air
cylinder, repeat the reversing
operation.

11
High speed 1. Air line leaking 1. Replace the airline leaking.
without low 2. Dirty slide of bi-directional or wear 2. Clean and. polish the slide or
speed or low cause air valve leaking. replace valve.
speed without 3. Air clutch leaking or brake band 3. Replace air tyre of clutch or
high speed lining worn excessively. brake band lining.
4. Quick release valve leaking. 4. Replace the core of the valve.
Shift gear slow 1. Quick release valve blocked up. 1.Clean or replace quick release
valve.
2. Too small clearance between ai~2. Adjust the clearance to proper
clutch and internal gear. condition. (Occur at new
installing)
Pressure at low Overflow valve for making-up is not Adjust overflow valve {towards
gear is not high adjusted to prescribed pressure. pressure-rising direction).
enough
Pressure at low 1.Breake band lining v.10m 1. Replace the brake band lining
speed is not excessively not able to hold the of the air clutch (for low speed).
high enough to internal gear of the gearbox, causing
make breaking slipping.
out fail. 2. Hydraulic system break down, 2:
a) Oil level in oil tank is too low. a) Stop to fill it with oil if enough.
b) Oil viscosity is too high. b) Replace it with proper viscosity
c) Oil line is broken. oil or heat oil with preheated.
d) Loose contact between joint and c) Replace oil line.
oil line. d) Tighten up joint.
e) Relief valve stuck. e) Olean relief valve.
f) V belt too loose to work for pump. f) Jack up oil tank to tighten belt
3. Large brake band too loose. 3. Adjust large brake band to
proper condition.
Auto-door fails 1.Airline is broken or seal ring 1.Replace the airline.
to close or open damaged. 2.Repair the gear or replace the
2.Rack and door gear are blocked or rack or door bolt.
damaged.
3.L~aking of quick-releasing valv,e 3.Replace the quick-releasing
4.Restoration spring fails. valve.
4.Replace the spring.
Griping of the 1.Airline is broken. 1.Replace the airline.
tong head, door2.Air1ine's connection 2.Connect the airline correctly
close/open arid according to air control principle.
shifting of tong 3.Quick-releasing valve is blocked. 3.Clear or replace the valve.
body fail to link 4.Shuttle valve or two-posiition 4.Replace the shuttle valve a~d
together. three-oort air valve fails to work. air valve.

12
Hydraulic 1.Motor damaged 1.Repair the motor.
system r.?rmal
but tongs not
rotate
Motor or pump 1.Too long for service continuously. 1.Stop to cool until normal.
overheated 2. Viscosity of oil too high or too low. 2.Replace with proper viscosity
oil.
3. Reservoir oil level too low. 3.Stop to fill with oil.

9. Some Exfjlanations
9.11he tongs have five si7.es jaws for different size of pipe, they are 8", 51/2", 5",
4-1/2" and 31/2" to respectively four kinds of rollers, they are ¢ 80(8"), <t> 90(5-1/2"), cl>

100(5"and 4-1/2") and <I> 120 (3-1/2"). There are !our pieces for each size of jaw.
9.2 The tongs has five of plug screw sizes for different size of drill string. Each size
has a mark •on itself. Don't confuse with them in application.
9.3 If dies of the tongs are not so many. They car. be substituted with the dies of the
Manual Tongs, but only on occasion that the driil string is fitted with rock bit during a trip.
If the string is in combination with a scrapping bit, the slot to fixed die on jaw will be
damaged.
9.4 The torque of breaking out is high, so it cannot be used without the door,
otherwise, it will cause dP.formation of the case body, resulting discard on the t?ngs.
9.5 Max. Pressure of hydraulic system should be below 2900psi, the pressure of the
relief valve for hydraulic system has been adjusted to this value before delivery from
factory, don't adjust the relief valve aimlessly.
9.7 When left hand drill pipe is used, the direction of making up and breaking out
must be opposite to right hand drill pipe's. If use safety valve for making up to control
pressure, loosen the four screws fixed the relief valve onto valve panel of oil motor. Tum
the valve 180° . The relief valve of making up m<1y not be used, L e. tum off the valve, in
order to avoid insufficient pressure of breaking out unable to break out.

10. Selection of Hydraulic Oil

10.1 In hydraulic transmission, viscosity is a primary parameter in selecting
hydraulic oil. The viscosity of hydraulic oil vary as its working temperature, therefore the
working temperature in oil tank should be kept within range between 15 to 70 degree
centigrade. If necessa~, hydraulic oil should be heated or oooled.
10.2 In hydraulic oil there should not be solid impurity bigger than 0.002in.

13
 10.3 Generally, hydraulic oil should be replaced every year. As the working condition
is poor in oilfields, it is necessary to take care of hydraulic oil, and to prevent water and
impurity from going into oil. Check the change of oil quality at regular intervals according
to the change of viscosity and water and impurities contents determine the time to
replace oil.
10.4 30 # antiwar hydraulic oil is recommended for the tongs. When working
temperature is below minus 25 degree centigrade, 30 # cold-proof hydraulic oil is
recommended. It may be substituted temporarily with 30# turbine oil in short-term work.

14
 Parts Details of General View of ZQ203-105 Drill Pipe Power Tong
No. Description No. Description
1 Linkage cylinder 31 Small shell
2 Restoration spring 32 Rack
3 Long piston 33 Universal coupling
4 Notched gear 34 Large gear
5 Floating body 35 Adjustment tube
6 Brake disc 36 Screw bolt
7 Jaw rack 37 Air pressure meter
8 Die 38 Bi·directional air vlave
9 Inserts 39 Connecting rod
10 Plug 40 Idle gear-shaft
11 Active pin 41 Dial disc
12 Pin 42 @rake band
13 Square sleeve 43 Jaw
14 Upper locating 44 Jaw pin
handle
15 Suspension device 45 Jaw roller
16 Hand-reversing valve 46 Cam
,__
17 Overflow valve 47 Elastic pin
18 Oil motor 48 Lower locating handle
19 Adjustment screw 49 Gripping cylinder
rod
20 Idle gear 50 Support for gripping
cylinder
21 Spline gear 51 Oil in and out port
22 Upper case 52 Tail plate
23 High gear tyre 53 Dial disc pin
24 Sun gear 54 Fork for air cylinder
25 Low gear tyre 55 Spring sleeve
26 Central gear 56 Spring
27 Lower case 57 Locating pin
>-
28 Gear shaft 58 Locating turning pin
29 Gland 59 Fork
30 Door bolt 60 Shift screw

15
 • ----
I

-~

15

3
A-A

-
0\ I.O

'"
c.o

""
C'-1
 36
42

c-c
c:I 111 ct V"'"1~ \\ I LA .Ill. £JI /,,·11!.,!1~~ -fr
:; :4
3
3f-2b____ 0-D

-..J

~.
s

'
K

.48 ,~ 67, 7 in
5~
 Hydnuliemotor \

+---- .....

Fig.2 Transmission Schematic Diagram

balance valve

overf Iow va Ive

H-chan in valve

Preasure-tor ue ~eter
11-chan in
1 Hydraulic power station
2 Hydraulic suspender
3 Control system of tong

Fig. 3 Hydraulic System

18
 I2 11

~Ol 110
2
DI ! IOt 7

.9

:0 7

I.high gear air tyre 2.low gear air tyre 3.quick 1eleasc vave 4.two-position four-port vlave
5. air bag 6. air pres.sure meter 7.two-J:X)Slion three-port air valve 8.shuttle valve
9.small quick release air vavc 1OJ inking 1,,-ylind<..'r ! I.griping cylinder 12.shiiling cyli.n<lcr

Fig.4 Pncwnatic System

 ~

C
C
....
....
... -c,,
...,
"'
0
N

I.pinshaft 2.univme coupling 3.m rope 4.spring S.budde 6.sliding sk:eYe 7.shifting cylinder 8.clamp

Fig.5 Moving Device

 crCNt block beam pulley (S.SUS IOCIS)

wire rope (6/8"·718") 262.◄n •

the right-hand and lelt -hand sere~ rod

/
t---c::=--c lo be attached to the beam near raking platform with v.:ire rope

first beam of derrick

/ I.clamp
and hoist (J.JUS tuns)
drin pipe
casing(S 1/2")
ait cylinoer
for moving --- about 26.2n
3.9-Uirl
drm lloo,
----._ ::11• • wood wedge
· to be attached to substrvcture beam · ~
· with w,re rope - - - - ~ t v r e beam

square box in bottom of fixed post

Fig.6 Installation on Drilling Rig

21
 .
\ \·, I

. t
\ l~ I

I .the tong 2.shifting cylinder 3.shifting c;yli:lder brace 4.hydraulic system assy.
5.handhoist(3.3UStons) 6.wireropeclam1p(0.7in) 7.wircrope(S/8" or3/4")
8.derrick pillar 9.pulley (5.5US tons)

Fig.8 Installation Drawing

22