Shanghai Happies Industrial Co., Ltd.

Model: XYQ89-3YC Hydraulic Power Tong

PARTS OPERATION AND MAINTENANCE MANUAL

Contents

1.Summary 2.Specifications 3.Installation 4.The explanation of hydraulic circuit 5.Operation and Lubrication 6.Maintenance and Lubrication 7.Troubles and Trouble Shooting 8.Figures and Table of parts a. General Figure of Model XYQ3C Hydraulic Power Tong b. General Figure of 3c-1 Master Tong and table of parts. c. General Figure of 3c-2 Master Tong and table of parts. d. General Figure of Fore guide arm assembly and table of parts. e. General Figure of back guide arm assembly and table of parts. f. General Figure of lifter assembly and table of parts.

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1.Summary

Model XYQ3C Hydraulic Power Tong is a special device for Well Service, which is used to make up and break out tubing thread. It is a improved new product based on Model XYQ3B hydraulic power tong. Driving by hydraulic motor with low speed and large torque, model“H”

manual control valve simply matching with oil motor. It’s a lighter hydraulic power tong for well service .

This product has the following features.

1) The tong head uses inner curved roller climbing and cliping mechanism and needn’t to change any part during making up or breaking out the tubing thread which diameter is “27/8″”

or “31/2″”.

2) Two shifts provides high speed at the high gear and large torque at the low gear.

3) The brake mechanism is on the upper and so it is easy to adjust and repair.

4) The new type hydraulic Backup tong and master tong form a combined tong . Operating the manual control valve of master tong, the combined tong clipping and unloosing simultaneously.

5) The adequate torque will be gained during making up and breaking out the various steel tube by adjusting pressure of oil .

6) This product has owned several patent of China.

2.specifications

A. Master tong

a)Application Range 23/8″、27/8″、31/2″

tubing

b)High Gear Rated Torque 1.6－1.1 kN.m

c)Low Gear Rated Torque 1.8－3.0 kN.m

d)Max. torque 4.0 kN.m

e)High Gear Rated Rotation Speed 100r/min

f)Low Gear Rated Rotation Speed 30r/min

g)Opening 95mm

h)Weight 105kg

B. Backup tong

a)Application Range 23/8″、27/8″、31/2″body of upset

b)Opening 116mm

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c)Weight 53kg

C. Overall dimension of Combined tong 650×430×350mm

D. Rated hydraulic system pressure 6－10MPa

E. The max. oil supply pressure 12.5MPa

F. Oil supply 80L/min

3.Installation

A. Connect mechanical lift(3c-5)with tong hanger of mater tong(3c1-45) and hang the lifter on the derrick of work over rig. The hanging point is 15m above ground and the hanging should be in free condition. The distance between the tong center and the center of the well is recommended to be 0.5m(Fig1).

B. Adjust the screw on the tong hanger (3c1-45) to lever the tong. If it is not leveled. It will cause malfunction of the tong.

C. Tie one and of back guy on derrick and the other end on back guide seat (3c1-34) of power tong. Back guy should be capable of bearing a load of 20kN. When power tong is in make up position, the back guy should of the operator. Who operates the control handles this insures a safe operation (Fig2).

D. Connect hoses from the hydraulic power source the control valve of the power tong. The pressure oil hose should be connected to the upper port of the control valve. The return oil hose connects to the lower port of the valve. Be sure they are connected correctly.

4 Explanation of hydraulic circuit.

Fig3 is the hydraulic circuit of power tong.

Manual control valve (3) controls power tong motor (1) and hydraulic cylinder(2)on the backup tong. Connect hydraulic hoses of backup tong to master tong. The pressure gauge (4)displays both system pressure and torque. The relationship between pressure on the gauge and torque is shown in the figure(4): line 1 is low gear rated torque and line 2 is high gear rated torque.

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5.Operation

A. Shifting

Operation the manual control valve (3c1-74). High gear is available when push down the shifting handle (3c1-135).Low gear is available when uplift the shifting handle (3c1-135). The shifting should be done at low speed in order to avoid damaging of the gears.

B. Operation of make up and break out.

Make-up.

After aligning the openings of the master and backup tong head turn the rest knob (3c1-54)(3c2-2) and make the arrow point the direction for makeup. Move the tong to pipe string. Operate the control valve (3c1-74) to make the tong heads rotate along the direction for makeup. After the pipe is made up. Reversely rotate the tong heads by operating the control valve (3c1-74) to align the openings. Then move the tong off the pipe string.

Break-out

After aligning the opening of the tong heads with the opening of the housing. Turn the reset knob (3c1-54)(3c2-2) and make the arrow point the direction for beak out move the tong to the pipe sting. Operate the control valve (3c1-74) to make the tong heads rotate along the direction for backing off and the pipe is backed off. Align the openings by rotating reversely the tong heads. Then, move the tong off the pipe string.

C. Change Tong Dies

Pushing screw driver into tong-die retaining pins (3c1-109)(3c2-44) of jaw sets can take out tong dies.

6.Maintenance and lubrication

A. Check out the fastening crew and make sure it is fastened before operating the power tong.

B. Grease every moving parts before operating the power tong.

C. If the jaws do not come out due to insufficient braking force, adjust the braking adjust bolts (3c1-61), slightly to increase the braking force. Be sure not to screw too hard, otherwise

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discs will be over heated.

D. After every trip, If water or dirt is present, clear at once.

E. After every trip cleaning at once by diesel oil, then grease every moving parts.

F. Don't use steam to clean tong. If steam is used, the bearing will be damaged because of loosing oil or entering water.

G. Temperature of hydraulic oil cannot exceed 65℃. If the temperature is too high, the sealing will cease to be effective.

H. Hydraulic oil should be clean and replaced when it becomes dirty. Keep filter screen clean.

J. Selection of Hydraulic oil.

a.Yc-N46 low Freezing Hydraulic oil, suitable for the Ambient Temperature -20℃－+40℃.

b.YB-N46 wear Resistant Hydraulic oil, suitable for the Ambient Temperature -10℃－+40℃.

c.YA-N46 Common Hydraulic oil, suitable for the Ambient Temperature 0℃－+40℃.

7.Troubles and Trouble shooting.

Ordinary Troubles Cause Remedy

1.Solid dirt fills die groove Clean the dirt

2.Tong dies are much worn Change dies

3.The brake moment of tong bead is a little smell.

Tighten spring propely

(3c1-33) Tong dies slippage

4.The Tong body is not level. Level tong body (master tong backup tong)

Tong head of master tong or backup tong does not align with the opening of housing

Retaining pins (3-c1-93)(3c2-5)

are not wrapped by reset knob.

Turn reset knobs

(3-c1-54)(3c2-2)180°,then reset.

The clipping of master tong is normal but backup tong slippage

The rotation direction of jaw set shelf of backup tong and maker tong are reverse.

Exchange the position of the hoses (3c2-40)of backup tong.

Engaging a gear is not firm and it disengage easily

Locking force is a little small. Add adjusting slim and increase the pressure of spring-(3c1-33)

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Model XYQ3C Hydraulic Power Tong Part number

Drawing number PART NAME

QTY.

Remark

3C－1 XYQ3C.Z Master tong 1

3C－2 XYQ3C.B Backup tong 1

3C－3 XYQ3C.QD Fore guide arm assembly 2

3C－4 XYQ3C.HD Back guide arm assembly 1

3C－5 XYQ3C.DT Mechanical lifter assembly 1

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-7-

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3C1-141 The assembly of safety door

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Model XYQ3C Hydraulic Power Tong Master Tong－3C.Z

Part number

Drawing number PART NAME

QTY.

Remark

3C1－1 GB5782-86 Hexagon head bolt 10 3C1－2 XYQ3C.Z.1 Assembly of tong head 1 3C1－3 XYQ3C.Z-1 Case 1 3C1－4 XYQ3C.Z-2 Roller 22 3C1－5 XYQ3C.Z-3 Lower bearing 1 3C1－6 GB819-85 Cross recessed head screw M5×10-4.8 33 3C1－7 XYQ3C.Z-4 Roller shaft 22 3C1－8 GB92-86 Retainer of bolt fasten shaft end B18 11 3C1－9 GB70-85 Hexagon socket head cap screw M5×16-8.8 11 3C1－10 XYQ3C.Z-5 Locating disc. 1 3C1－11 XYQ3C.Z-6 Duplex gear 1 3C1－12 XYQ3C.Z-7 Liner 1 3C1－13 XYQ3C.Z-8 Shaft liner 1 3C1－14 GB276-82 Deep grooved ball bearing 105 4 3C1－15 XYQ3C.Z-9 Bearing disc (1) 1 3C1－16 XYQ3C.Z-10 Bearing disc (2) 1 3C1－17 GB893.1-86 Circlip of hole 47 2 3C1－18 GB1152-89 Oil cup M8×1 3 3C1－19 XYQ3C.Z-11 Duplex gear shaft 1 3C1－20 XYQ3C.Z-12 Motor liner 1 3C1－21 XYQ3C.Z-13 Internal gear 1 3C1－22 XYQ3C.Z-14 Shift gear 1 3C1－23 XYQ3C.Z-15 Spline gear 1 3C1－24 XYQ3C.Z.2 Assembly of clutch gear 1 3C1－25 XYQ3C.Z-16 Bearing disc (3) 1 3C1－26 XYQ3C.Z-17 Power input shaft 1 3C1－27 XYQ3C.Z-18 Bearing corer 1 3C1－28 GB276-82 Deep grooved bearing 205 1 3C1－29 GB70-85 Hexagon socket head cap screw M6×16-8.8 6 3C1－30 XYQ3C.Z-19 Lower cower 1 3C1－31 GB70-85 Hexagon socket head cap screw M8×20-8.8 14 3C1－32 XYQ3C.Z-20 Slip 1 3C1－33 XYQ3C.Z-21 Spring 11 3C1－34 XYQ3C.Z-22 Back guide arm seat 1 3C1－35 XYQ3C.Z-23 Guy pin 1 3C1－36 GB91-86 Cotter 4×30 1 3C1－37 GB70-85 Hexagon socket head cap screw M12 × 4 3C1－38 GB93-87 Washer 12 8 3C1－39 GB309-84 Roller 3×19.8 68

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3C1－40 GB276-82 Deep grooved ball bearing 208 1 3C1－41 XYQ3C.Z—24 Adapter (1) or (2) 2 3C1－42 GB1235-76 “O”sealing ring 2 3C1－43 Pressure gauge 0－16MPa 1 3C1－44 Pendular line motor BMD－400 1 3C1－45 XYQ3C.Z-25 Hanger 1

3C1－46 GB70-85 Hexagon socket head cap screw M10 ×

20-8.8 13

3C1－47 XYQ3C.Z-26 Tong cover 1 3C1－48 XYQ3C.Z-27 Upper bearing disc 1 3C1－49 XYQ3C.Z-28 Brake disc 1 3C1－50 XYQ3C.Z-29 Friction plate 2 3C1－51 GB68-85 Recessed head screw M5×8-4.8 11 3C1－52 XYQ3C.Z-30 Joint board 1 3C1－53 XYQ3C.Z-31 Braking steel disc 1 3C1－54 XYQ3C.Z-32 Reset knob 1 3C1－55 GB119-86 Cylindrical pin 5×18 1 3C1－56 XYQ3C.Z-33 Reset knob shaft 1 3C1－57 XYQ3C.Z-34 Locating seat 1 3C1－58 GB308-89 Ball Ф5 2 3C1－59 XYQ3C.Z-35 Spring 2 3C1－60 GB65-85 Grooved cylindrical head screw 2 3C1－61 GB32.1-88 Hexagon head screw with hole M10×40-4.8 10 3C1－62 XYQ3C.Z.3 Right handle (RH) 1 3C1－63 XYQ3C.Z.4 Left handle (RH) 1 3C1－64 XYQ3C.Z-36 Locating disc 2 3C1－65 XYQ3C.Z-37 Back handle 2 3C1－66 XYQ3C.Z-38 Hanger seat 1 3C1－67 XYQ3C.Z-39 Hanger pin shaft 1 3C1－68 GB91-86 Cotter 2.5×20 1 3C1－69 XYQ3C.Z-40 Cover 2 3C1－70 GB70-85 Hexagon socket head cap screw M8×25-8.8 4 3C1－71 GB93-87 Spring washer 8 4 3C1－72 GB65-85 Grooved cylindrical head screw M6×10-4.8 8

3C1－73 GB70-85 Hexagon socket head cap screw M12×35-8.8

4

3C1－74 XYQ3C.Z.5 Manual control valve 1 3C1－75 XYQ3C.Z-41 Plug 2 3C1－76 XYQ3C.Z-42 Idler shaft liner 2

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3C1－77 XYQ3C.Z-43 Idler shaft 2 3C1－78 XYQ3C.Z-44 Waterproof guard 4 3C1－79 GB893.1-86 Circlip of hole 62 4 3C1－80 GB283-87 Single cylindrical roller bearing 42206E 4 3C1－81 XYQ3C.Z-45 Idler gear 2 3C1－82 XYQ3C.Z-46 Sleeve 2 3C1－83 GB1235-76 “O”sealing ring 2 3C1－84 XYQ3C.Z-47 Joint board 1 3C1－85 GB1235-76 “O”sealing ring 2 3C1－86 XYQ3C.Z-48 Bolt 2 3C1－87 XYQ3C.Z-49 Name plate 1 3C1－88 XYQ3C.Z.6 Assembly of shifting mechanism 1 3C1－89 XYQ3C.Z-50 Screw 2 3C1－90 Steel wire Ф2×700 1 3C1－91 XYQ3C.Z.1-1 Open gear cover 1 3C1－92 GB70-85 Hexagon screw head with hole M10×40-4.8 13 3C1－93 XYQ3C.Z.1-2 Cylindrical pin 1 3C1－94 XYQ3C.Z.1-3 Open gear 1 3C1－95 XYQ3C.Z.1-4 Ramp 4 3C1－96 GB70-85 Hexagon screw head with hole M10×20-8.8 4 3C1－97 GB70-85 Hexagon screw head with hole M10×16-8.8 4 3C1－98 XYQ3C.Z.1-5 Jaw bracket 1 3C1－99 XYQ3C.Z.1-6 Spring shaft 4 3C1－100 XYQ3C.Z.1-7 Spring (left) 4 3C1－101 XYQ3C.Z.1-8 Spring (right) 4 3C1－102 XYQ3C.Z.1-9 Die 2 3C1－103 XYQ3C.Z.1-10 Pin shaft 4 3C1－104 XYQ3C.Z.1-11 Jaw set 2 3C1－105 XYQ3C.Z.1-12 Jaw roller 2 3C1－106 XYQ3C.Z.1-13 Roller shaft 2 3C1－107 GB78-85 Hexagon socket head fasten screw 2 3C1－108 XYQ3C.Z.1-14 Spring 4 3C1－109 XYQ3C.Z.1-15 Cylindrical pin 4 3C1－110 XYQ3C.Z.5-1 Valve body 1 3C1－111 GB70-85 Hexagon screw head with hole M12×35-8.8 4 3C1－112 XYQ3C.Z.5-1 Combined vale spindle 1 3C1－113 GB1235-76 “O”sealing ring 36×3.5 2 3C1－114 XYQ3C.Z.5-2 Valve end cover 1 3C1－115 XYQ3C.Z.5-3 Spring seat (1) 1

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3C1－116 XYQ3C.Z.5-4 Spring 1 3C1－117 XYQ3C.Z.5-5 Spring seat (2) 1 3C1－118 XYQ3C.Z.5-6 Plate 1 3C1－119 XYQ3C.Z.5-7 Bearing seat 1 3C1－120 GB70-85 Hexagon screw head with hole M6×16-8.8 4 3C1－121 GB882-86 Pin shaft 1 3C1－122 XYQ3C.Z.5-8 Shaft fork 1 3C1－123 GB882-86 Pin shaft B12×45 1 3C1－124 GB93-87 Spring washer 1 3C1－125 GB6170-86 Hex mat M12 1 3C1－126 XYQ3C.Z.5-9 Operating handle 1 3C1－127 XYQ3C.Z.5-10 Ball shaped handle 1 3C1－128 XYQ3C.Z.6-1 Sleeve 2 3C1－129 XYQ3C.Z.6-2 Shift fork 1 3C1－130 XYQ3C.Z.6-3 Roller 1 3C1－131 XYQ3C.Z.6-4 Roller shaft 1 3C1－132 GB91-86 Cotter 2×10 1 3C1－133 XYQ3C.Z.6-5 Roller sub seat 1 3C1－134 XYQ3C.Z.6-6 Parallel key 1 3C1－135 XYQ3C.Z.6-7 Shift fork shaft 1 3C1－136 XYQ3C.Z.6-10 Ball shaped handle M6 1 3C1－137 GB6170-86 Hex nut M6 2 3C1－138 GB93-86 Spring washer 6 2 3C1－139 XYQ3C.Z.6-8 Roller 2 3C1－140 XYQ3C.Z.6-9 Bolt shaft 2 3C1－141 XYQ3C.Z.7（2A） The assembly of safety door 3C1－142 GB93-87 Spring washer 14 1 3C1－143 XYQ3C.Z.7（2A）-2 Lower door pin 1

3C1－144 XYQ3C.Z.7（2A）-1 Washer 1

Have board 3C1－145 XYQ3C.Z.7（2A）.1-2 The body of safety door 1

3C1－146 XYQ3C.Z.7-1 Under door pin 1 3C1－147 GB97.2-85 Flat washer 12 1 3C1－148 Model 28 bike pull

spring Pull spring（Φ 2.5×Φ 15×65）

1

3C1－149 GB71-85 Coniform Fastening Screw M6×10-14H 1

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Model XYQ3C Hydraulic Power Tong Backup Tong－3C.B

Part number

Drawing number PART NAME

QTY. Remark

3C2－1 XYQ3C.B-1 Backup tong head cover 1 3C2－2 XYQ3C.B-2 Backup tong reset knob 1

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3C2－3 GB119-86 Cylindrical pin 5×20 1 3C2－4 XYQ3C.B-3 Backup tong reset knob shaft 1 3C2－5 XYQ3C.B-4 Retainer 1 3C2－6 XYQ3C.B-5 Duplex gear 1 3C2－7 XYQ3C.B-6 Backup tong jaw set bracket 1 3C2－8 GB1096-76 Ordinary parallel key 16×56 1 3C2－9 XYQ6B.B-7 Rotation shaft 1 3C2－10 XYQ3C.Z-36 Locating disc 1 3C2－11 GB70-85 Hexagon screw head with hole M6×16-8.8 6 3C2－12 XYQ3C.B-7 Gear cover 1 3C2－13 XYQ3C.B-8 Liner 1 3C2－14 XYQ3C.B-9 Rack plunger 1 3C2－15 XYQ3C.B-10 Spring 2 3C2－16 GB308-89 Ball Ф5 2 3C2－17 XYQ3C.B-11 Stop screw 1 3C2－18 GB93-87 Washer 10 5 3C2－19 XYQ3C.B-12 Cylinder 1 3C2－20 XYQ3C.B-13 Tong end seat 1 3C2－21 XYQ3C.B-14 Body of backup tong head 1 3C2－22 XYQ3C.B-15 Fore seat of backup tong 2 3C2－23 GB70-85 Hexagon screw head with hole M10×25-8.8 12 3C2－24 GB70-85 Hexagon screw head with hole M10×16-8.8 4 3C2－25 XYQ3C.Z.1-6 Twist spring shaft 4 3C2－26 XYQ3C.B-16 Twist spring shaft (left) 4 3C2－27 XYQ3C.Z.1-10 Pin shaft 4 3C2－28 XYQ3C.Z.1-11 Jaw set 2 3C2－29 XYQ3C.B-17 Die 2 3C2－30 XYQ3C.Z.1-12 Roller of jaw set 2 3C2－31 XYQ3C.Z.1-13 Roller shaft 2 3C2－32 XYQ3C.B-18 Twist spring (right) 4 3C2－33 XYQ3C.B-19 Ramp of backup tong 4 3C2－34 GB70-85 Hexagon screw head with hole M12×30-8.8 4 3C2－35 GB93-87 Spring washer 12 4 3C2－36 GB70-85 Hexagon screw head with hole M10×30-8.8 20 3C2－37 GB1235-76 “O”sealing ring 54×3.5 2 3C2－38 XYQ3C.B-20 Cylinder cover 2 3C2－39 Gland ring 45×4.2 2 3C2－40 JB/ZQ4427-86 Adapter of hose 8Ⅱ-500 2 3C2－41 XYQ3C.B-21 Oil passing bolt 4

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3C2－42 XYQ3C.B-22 Longer adapter 1 3C2－43 GB1235-76 “O”sealing ring 22×2.4 6 3C2－44 XYQ3C.Z.1-15 Retainer pin 4 3C2－45 XYQ3C.Z.1-16 Spring 4 3C2－46 GB78-85 Hexagon socket head screw M10×10-33H 2 3C2－47 XYQ3C.B-37 Back handle 2 3C2－48 XYQ3C.B-10 Adapter (1) 1 3C2－49 XYQ3C.B-11 Adapter (2) 1 3C2－50 GB70-85 Hexagon screw head with hole M6×15-8.8 2 3C2－51 XYQ12.B-15 Cover 2

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Model XYQ3C Hydraulic Power

Tong Fore guide arm assembly－3C.QD

Part number

Drawing number

PART NAME

QTY.

Remark

3C3－1 XYQ3C.QD-1 Fore guide arm seat 2 3C3－2 XYQ3C.QD-2.0 Assembly of fore guide arm casing 2 3C3－3 XYQ3C.QD-3 Spring 2 3C3－4 XYQ3C.QD-4 Fore guide arm 2 3C3－5 XYQ3C.QD-5 Pin shaft 2 3C3－6 GB91-86 Cotter 2.5×30 2 3C3－7 XYQ3C.QD-6 Fore sub seat of master tong 2 3C3－8 GB70-85 Hexagon screw head with hole M10

×20-8.8 4

3C3－9 GB93-87 Spring washer 10 4

Model XYQ3C Hydraulic Power Tong

Back guide arm assembly－3C.HD Part

number Drawing number

PART NAME

QTY.

Remark

3C4－1 XYQ3C.HD-1 Back guide arm seat 1 3C4－2 XYQ3C.HD-2.0 Assembly of back guide arm casing 1 3C4－3 XYQ3C.HD-3 Spring 1 3C4－4 XYQ3C.HD-4 Back guide arm 1 3C4－5 XYQ3C.HD-5 Pin shaft 1 3C4－6 GB91-86 Cotter 2.5×20 1

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wer Tong rical lifter－3C.DT

Model XYQ3C Hydraulic PoAssembly of cylind

Part number

Drawing number

PART NAME

QTYmark

. Re

3C5－1 GB882-86 Pin shaft B16×55 1 3C5－2 GB91-86 Cotter 3.2×26 1 3C5－3 XYQ3C. DT-1 Hanger bar 1 3C5－4 GB91-86 Cotter 5×50 1 3C5－5 XYQ3C. DT-2 Cylinder end cover 1 3C5－6 XYQ3C. DT.1 Assembly of lifter 1 3C5－7 XYQ3C. DT-3 Big spring of cylinder 1 3C5－8 XYQ3C. DT.2 Assembly of cylinder body 1 3C5－9 GB882-86 Pin shaft B20×60 1 3C5－10 GB91-86 Cotter 4×30 1

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