Table of Contents
Summary of Contents for Westco 4500
- Page 1 MODEL 4500 HYDRAULIC TUBING TONG OPERATIONS AND SERVICE MANUAL Westco Manufacturing, LLC 1360 N. Olive Street Ventura, CA 93001 Phone: (805) 648-5004 Fax: (805) 648-5018 www.westcointl.com WI-4500 Rev.0 Approved by Vern Olson...
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Page 2: Table Of Contents
19-25 PHOTO OF “BULL GEAR ASSEMBLY” TUBING TONG REPLACEMENT PARTS LIST FOR THE MODELS 5500, 5600, 4500 JAW ASSEMBLIES TUBING TONG REPLACEMENT PARTS LIST FOR THE MODELS 5500, 5600, 4500 BUSHING ASSEMBLIES TUBING TONG REPLACEMENT PARTS LIST FOR THE MODELS 5500, 5600, 4500 2-3/8”... -
Page 3: Warning
WARNING DO NOT OPERATE, ADJUST, OR REPAIR THIS EQUIPMENT WITHOUT PROPER TRAINING. ADHERE TO ALL SAFETY WARNINGS. DO NOT REMOVE GUARD DOORS. 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. -
Page 4: General Description
GENERAL DESCRIPTION The Westco Models 4500 Hydraulic Tubing Tongs are fast, safe, and accurate tongs for making up and breaking out 1.315” to 4.75” (Model 4500) 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 tong’s gear train. -
Page 5: First Time Start-Up Procedure
FIRST TIME START-UP PROCEDURE The operator should read and follow these instructions before attempting to operate the tongs for 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”... -
Page 6: Operating Instructions
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. -
Page 7: Installation And Maintenance Of Tong
TONG WHILE IN OPERATION. For correct torque readings, the Back-up line MUST BE ON A 90 ANGLE WITH THE TONG. b. Westco International recommends the use of a safety sling to prevent injury of personnel caused by failure of the main Back-up line or stiff-arm assembly. The safety sling attached to the safety eye on the back of the tong and fastened to the rig or to a secure tie down. -
Page 8: Tong Fails To Go On Tubing
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. -
Page 9: Changing The Tubing Tong Brake Band
CHANGING THE TUBING TONG BRAKE BAND Align the opening of the inner and outer rings with the opening in the tong frame. Remove the two cap screws from the brake band 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. -
Page 10: Running The Tong
RUNNING THE TONG *Before operating the tong for the first time, refer to “First Time Start-Up Procedure” MAKING UP THE TUBING With the tong suspended, position gearshift lever (located towards the front of the tong) in high gear. 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). -
Page 12: Tong Linkage Adjustment
TONG LINKAGE ADJUSTMENT SHIFT ROD ADJUSTMENT Shift rod adjustment is accomplished with jam nuts located on each end of the rod. Adjust gearshift handle in neutral position. THROTTLE ADJUSTMENT The throttle rod adjustment is set with the safety arm and with the door in open position. Adjust safety bar to match the slot in the safety arm and secure by tightening jam nut. -
Page 13: Grease Specifications
GREASE SPECIFICATIONS Due to the operating environment of the tong, water insoluble grease is required. The grease should have high pump ability 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. -
Page 14: Important Lubrication And Preventive Maintenance
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. -
Page 15: Troubleshooting
TROUBLESHOOTING TONG RUNNING TOO SLOWLY Pump intake line plugged Clean intake line and filter. Reservoir oil lever too low Add oil. Air leak in pump intake line Identify source of leak and make necessary (Oil in reservoir may be too foamy) repairs. - Page 16 B. TONG WILL NOT DEVELOP SUFFICIENT TORQUE Tong valve or relief valve on tong not working: a. Valve stuck Check for dirty or gummy sludge. Check for contamination of oil. Check for broken spring valve. b. Valve leaking Check valve seat for scouring. Check oil seals. Check for particles stuck under valve stem.
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Page 17: Storage
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. -
Page 18: How To Order Parts
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... -
Page 19: For The Model 4500
TUBING TONG REPLACEMENT PARTS LIST FOR THE MODEL 4500... - Page 21 Ref. # Part Number Description Weight/ Req’d Lbs. 55011-100 Bottom transmission Assembly (Ref. 11, 12, 17, 48, 50-52, 61-64, 72, 78, 97) 45011 Bottom Transmission Cover 10.00 45012 Bushing 45015 Bearing Spacer 45016 Thrust Washer 45017 Shift Fork 45018 Gear Shaft Bushing 45022-100 Hanger Assembly (Ref.
- Page 22 Ref. # Part Number Description Weight/ Req’d Lbs. 992007-05 Cap Screw 992007-03 Cap Screw 992051-14 Lock washer 992005-03 Cap Screw 992051-10 Lock washer 992162-09 992082-95 Short Dowel 992073-01 Grease Fitting 992073-04 Grease Fitting 992253-200 Snap Ring 992011-138 Roll Pin 992007-02 Cap Screw 940021-206 Bearing...
- Page 23 45140 Thrust Washer Ref. # Part Number Description Weight/ Req’d Lbs. 903317-17 Bearing 45142 Thrust Washer 940016-208 Bearing 45144-200 Back Swivel 1.00 992005-17 Cap Screw 992089-09 Nylon Lock Nut 992164-05 Hex Nut 992155-04 Flat Washer 150-1 992066-04 FH Socket Screw 150-2 992066-03 FH Socket Screw...
- Page 24 45190 Control Valve Pivot Plate Ref. # Part Number Description Weight/ Req’d Lbs. 45191 Control Valve Link Assembly (Ref. 130, 131, 190) 45192 Safety Latch Pin 992005-05 Cap Screw 45201 Motor Adapter 2.00 992019-06 Cap Screw 45203-1 Rear Shift Lever Handle 5.00 992023-05 Cap Screw...
- Page 25 992138-S-4-4 Straight Hydraulic Fitting 45410-200 Back Guard Assembly (Ref. 147, 410, 411) 45430-200 Back Guard Tong Assy (For Relief Valve 2.50 Tong Assy) (Ref. 410R, 411R, 415, 416, 147) 410R 45430-01 Back Guard (For Tong With Relief Valve) 2.40 45410 Back Guard 2.00 Ref.
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Page 27: Tubing Tong Replacement Parts List For The Models 5500, 5600, 4500 Jaw Assemblies
TUBING TONG REPLACEMENT PARTS LIST FOR THE MODELS 5500, 5600, 4500 JAW ASSEMBLIES Ref. # Part Number Description Weight/ Req’d Lbs. 1.66” Jaw Assembly (1- ¼” Pipe) 45291H-100 8.50 45291H 1.66 Jaw 6.50 45293H 1.66 Die 2.00 992012-72 Cotter Pin 1.900”... - Page 28 3/8” x 1” x 1- 7/16” Die 45293D 992015-02 Screw TUBING TONG REPLACEMENT PARTS LIST FOR 5500/5600/4500 BUSHING ASSEMBLIES Ref. # Part Number Description Weight/ Req’d Lbs. 1.66” Bushing Assembly (1-1/4” Pipe) 45292H-100 20.50 45292H 1.66 Bushing 16.00 45293H 1.66 Die 2.25...
- Page 29 3/8” x 1” x1-7/16” Die 45293D 992015-02 Screw TUBING TONG REPLACEMENT PARTS LIST FOR 5500/5600/4500 2-3/8” BUSHING WITH REDUCING DIE Ref. # Part Number Description Weight/ Req’d Lbs. 2-3/8” Bushing/1.06” Reducing Die Assembly 45296-000 19.00 2-3/8” Bushing 45292A 13.00 2-3/8” x 1.06” Reducing Die 45294-00 3.00...
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Page 30: 2-3/8" Jaw With Reducing Die
TUBING TONG REPLACEMENT PARTS LIST FOR MODEL 5500/5600/4500 2-3/8” JAW WITH REDUCING DIE Ref. # Part Number Description Weight/ Req’d Lbs. 2-3/8” Jaw/1.90” Reducing Die Assembly 45295-102 6.25 2-3/8” Jaw 45291A 4.50 2-3/8” x 1.90” Reducing Die 45294-03 1.75 992012-72 Cotter Pin 2-3/8”... -
Page 31: Tubing Tong Spare Parts List For One Year's Operation
3-3/4” BUSHING WITH REDUCING DIE Ref. # Part Number Description Weight/ Req’d Lbs. 3-3/4” Bushing/3-5/8” Reducing Die Assembly 45298-100 12.75 3-3/4” Bushing 45292K 10.25 3-3/4” x 3-5/8” Reducing Die 45293-11 1.25 992012-72 Cotter Pin TUBING TONG SPARE PARTS LIST FOR ONE YEAR’S OPERATION Part Number No. -
Page 32: M/S Manual Back-Up Accessory Illustration-069 Westco Manual Back-Up Assembly
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. Westco recommends that the back-up tong be used only when necessary. This will minimize wear and reduce labor. BACK-UP USAGE The back up should be used during the following conditions: 1. -
Page 33: Replacement Parts List For M/S Manual Back-Up Assembly
REPLACEMENT PARTS LIST FOR M/S MANUAL BACK-UP ASSEMBLY Ref. # Part Number Description Req’d Cotter Pin 1.900 – 4 ½” 992012-36 Cotter Pin 4 ½” – 6 1/8” 992012-36 Latch Spring 1.900 – 4 ½” 45206 Latch Spring 4 ½” – 6 1/8” 45206 45209 Lever 1 5/16”... -
Page 34: Parts List For Hydraulic Tubing Tong Standard M25 Motor P/N 970400-5 (Illustration 008)
PARTS LIST FOR HYDRAULIC TUBING TONG STANDARD M25 MOTOR P/N 970400-5 (ILLUSTRATION 008) Item No. Part No. Qty. Description 455031-402 Housing Shaft 453100-100 Housing End Cover 458015-116 Gear Housing 452815-000 Gear (Set) 453784-028 Washer 451401-027 Cap Screw 451135-048 Shaft 452882-096 Lip Seal 453681-001 Check Assembly...
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