ZQ162-50

DRILL PIPE POWER TONG

OPERATION MANUAL
ZQ162-50 -SM
STANDARD:SY/T5074-2004

API Spec 7K

JOLLY ENGINEERING SERVICES INC.

WWW.JOLLYENERGY.COM
 Contents
I. SUMMARY……………………………………………………..1
II. MAIN PROPERTIES AND PARAMETERS…………………1
III. MAIN STRUCTURE AND WORKING PRINCIPLE………..2
IV. INSTALLATION AND COMMISSION……………………….6
V. SOME EXPLANATIONS………………………………………9
VI. COMMON TROUBLESHOOTING………………………….10
VII. LIST OF SPARE PARTS……………………………………..12

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I. SUMMARY
ZQ162-50 drill pipe power tong is used to make up and break out oil
tubing and small drill pipe in workover job. Open throat design. It is a
combination of spinning tong and torque tong.
ZQ162-50 power tong is a kind of hydraulic air power tong to meet the
need of well servicing equipment in our country. It can substitute physical
labor. Features of design are as follows:
1. Convenient power source. Compressed air is the power source
except for hydraulic motor and lift device.
2. Float body of the tong head makes suspending installation simpler.
3. Adoption of low speed high torque plunger motor, several gear
shifting, and convenient to control.
4. Auto-aligning and clamping mechanism secures reliable clamping
and no sliding even for new and old joints.
5. Advanced notch-restoring mechanism.
6. Easy and convenient replacement of dies.
7.Torque and speed can be controlled. And maximum torque and speed
will be obtained in both forward and reverse direction.

II. MAIN PROPERTIES AND PARAMETERS

1. Hydraulic System
Rated Flow 120L/min(31.7gpm)
Max. Working Pressure 16Mpa(2320.5psi)
2. Pressure System
Working Pressure 0.5-0.9Mpa(72.5-130.5psi)
3. Under different flow, RPM is as follows:
Flow RPM
L/min(gpm) High Gear Low Gear
120(31.7) 60 4.1
110(29) 55 3.8
100(26.4) 50 3.4
90(23.8) 45 3.1
80(21.1) 40 2.7
70(18.5) 35 2.4
60(15.9) 30 2.1

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4. Under different pressure, Torque is as follows:
Hydraulic System Torque (kgf.m)(lbf.ft)
Pressure MPa(psi) High Gear Low Gear
16(2320) 350(2532) 5360(38769)
15(2180) 340(2459) 5030(36382)
14(2034) 320(2315) 4690(33923)
13(1889) 300(2170) 4360(31536)
12(1744) 275(1989) 4020(29077)
11(1598) 250(1808) 3690(26690)
10(1450) 230(1664) 3350(24230)
9(1308) 205(1483) 3020(21844)
8(1162) 180(1302) 2680(19384)
5. Moving distance 1000mm(39.4in)
6. Size range of pipe
Drill pipe: 23/8”(Ф85) 27/8”(Ф105) 31/2”(Ф127) 5” (Ф162)
Casing: 51/2”(Ф138 Ф156)
Tubing: 3”(Ф88.9)
7. Overall Dimensions (mm)
Length X Width X Height 1570x880x1372mm(61.8*31.5*54in)
7. Weight 1700kg(3748lb)

III. MAIN STRUCTURE AND WORKING PRINCIPLE

ZQ162-50Ⅱ power tong mainly consists of tong head, planet gearbox,
speed reduction device, air passage, lift device and hydraulic system, while
the tong head comprises clamping mechanism, floating mechanism, brake
mechanism and position-restoring mechanism.

1. Two-speed planet gearbox

In order to achieve spinning joints at high speed and low torque, and
making up or breaking out joints at low speed and high torque, the tong is
provided with a two-speed planet shift gear and unique braking mechanism
for shifting the gear without stopping the tong. The efficiency of the tongs is

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therefore promoted.
See Fig.1, high speed is obtained as hydraulic motor drives planet gear
Z3 on the frame to rotate, power comes from the sun gear Z1 when internal
gear Z2 is braked. For low speed, the sequence is reverse, hydraulic motor
drives the sun gear Z6 to rotate, power comes from the frame of the planet
gear Z5 when the internal gear Z4 is braked.

2. Reducer Assembly
Refer to Fig. 1, the output shaft of the two-speed planet gear box is the
input shaft of the two-speed gear reducer assembly, the notched gear Z11 is
driven to rotate through the first step deceleration (Z7-Z8) and the second
step deceleration (Z9-Z10-Z11). The function of two idle gears Z10 is to keep
the notched gear Z11 rotation continuously by Z9. This is necessary for
“passing the notch”.

3. Tongs Head
3.1 Gripping mechanism:
The notched gear of transmission drives the floating body to rotate
through three pins. If brake band continuously prevents the brake disc from
rotating with about 1000N·m torque and the jaw rack with jaws is connected
with brake disc by screws, when the floating body begins to rotate, both
brake disc and the jaw rack is braked to stop because disc is not in notch
with the tool joint. But the cam with a fixed slope rotates along with the
rotation of the float body, the rollers located at the back of the jaw will go up
along the spiral surface and comes close to the center along the groove and
at last grip against the drill string joint. Meanwhile, the notched gear will
drive the brake disc, the jaw rack and jaws on the floating body and drill
string to rotate for the operation of making-up and breaking-out.
Griping cylinder of lower tong will drive jaw rack to rotate in the housing,
so the lower joint of drill pipe can be tighten or loosen.
3.2 .The floating body:
Owing to the relative position between the upper tong and lower tong is
variable; it is necessary that upper tong can float relatively to the lower tong.
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 Floating body sits on the notched gear through four springs. Action of
springs will permit enough vertical movement for floating body. Floating
body can shift a little horizontally against notched gear to ensure clamping
when deviating worn of drill pipe joint happens. The shift is guaranteed
through the gap between the three spare sleeves of pins in the notched
gear and the spare holes in the floating body.
3.3 .The brake mechanism:
Two brake bands, connection rod and band adjusting sleeve make up
brake mechanism. Turning the adjusting sleeve will adjust the force of
spring in the sleeve, so as to change the value of brake torque. The brake
mechanism has the function of guide for floating body and fit for joint
deviation as well.
3.4 Restoration mechanism:
There are three restorations for aligning notches to power tongs of
open head: the aligning of floating body with the case body, the aligning of
jaws rack of upper tong with the floating body, and the aligning of jaws rack
of the low tongs with the case body.
First, align approximately with high speed, and 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 tong with floating body is just the
same as the aligning of jaw rack of the lower tongs with case body.
During restoration, use restoring turning pin to align notch. Screw pins
into the floating body, and install restoring turning pin into the brake disc.
There are two limit blocks in the brake disc. Align the floating body with jaw
rack by turning the restoring turning pin. The restoration of the lower tong is
the same as that of the upper tong.
For easy to see, in installation, the point direction of locating handle of
upper tong should be identical to the rotating direction for making-up
(breaking-out). And the direction of locating handle of lower tong keeps the
same with that of upper tong.

4. Pneumatic System
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 As shown in Fig. 2, compressed air from well servicing rig is used as
the air source for the tong. Three-position four-way reversing valves control
high and low gear air tyres, shifting cylinder and gripping cylinder
respectively.

5. Lift Device
Lift device consists of lift cylinder, balance valve, hand-reversing valve,
air bag supporter and adjusting device. Lift cylinder is set inside the air bag
supporter. Air bag supporter is connected with gland with ear of shaft end of
idler gear. Lift cylinder can move upward or downward and lock tight. On the
one side of air bag supporter is air reservoir, and on the other side include
hydraulic control components and pressure-torque gauge.
Lift cylinder and the power tong share the same hydraulic source. Hydraulic
system allows the balance and smooth for upward and downward
movement of lift cylinder through the combined work of hand-reversing
valve and balance valve. Lift cylinder can be locked tight at any position of
stroke. So the height of the tong can be fine set.

6. Hydraulic System
See Fig. 3, hydraulic oil is simple, for only hydraulic motor and lift
cylinder need hydraulic oil. Hydraulic oil goes from hydraulic station (1),
passing through M type hand-reversing valve of lift device (2), to H type
hand-reversing valve of power tong (3), to control lift device and hydraulic
motor. The lift cylinder will go up and down and the hydraulic motor will
rotate forward and backward by controlling the M type and H type
hand-reversing valves.
Pressure gauge is supplied in the hydraulic system. You can read the
pressure directly from it during operation. In order to control torque for
making-up, relief valve is installed to adjust pressure for making up.
The power tong has its special hydraulic power station, need to be
purchased additionally.

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IV. INSTALLATION AND COMMISSION
1. Installation
1) Installation of hydraulic system
Rated pressure of hydraulic system is 16MPa(2320.5psi), rated flow is
120L/min(31.7gpm). On the valve panel of oil motor, M30*1.5 C-type joint of
external thread is for pressure hose, M42*2 D-type joint of external thread is
for return hose, and M18*1.5 C-type joint of internal thread is for leak-off
hose. These three joints are corresponding with joints of power station
respectively. Do not cross-connect the joints. Hydraulic system pressure
has already been set before leaving factory, i.e. 16MPa. Don’t adjust Relief
valve to avoid changing maximum pressure. Oil-in and oil-out holes in lift
device both are M30*1.5 C-type joints.
2) Installation of Pneumatic system
Air source the pneumatic system needed is from well servicing rig. The
working pressure is 0.5-0.9MPa(72.5-130.5psi). Only need to connect
general air-in hose (M22*1.5 C-type joint) with air source.

2. Commission
1) Level the tong
Leveling is essential. If the tong is not level, clamping-slipping and
damage of the tong will happen.
Connect the shifting cylinder with the tong rear and the fixing post
respectively through universal coupling. Shift the tong to well mouth by
controlling the “forward-backward” handle of air valve, and adjust the height
of the tong through lift device, to make the bottom of the tong 40-50mm high
away from the upper surface of Elevator. Open the door and permit the drill
pipe to enter into the notch of the tong. Watch the tong to see if left and right
level has reached. If not, screw the screw rod in the lift device to achieve
level through changing the right and left position of suspension wire rope.
After finishing right and left leveling, watch the two plug screws of upper and
down tongs to see if they contact with drill pipe joint. Adjust four adjusting
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screws under the lift device to drive the two plug screws contact with drill
pipe coupling.
2) Commission
a. After connecting all air lines, handle the double-way air valves to see
if air leaking appears, and see if shifting cylinder and gripping cylinder work
smoothly.
b. Idle run the tong for 1-2min at low gear, with pressure of low gear
being within 2.5MPa.
c. Idle run the tong for 1-2min at high gear, with pressure of low gear
being within 5MPa.
d. Operate H-type hand-reversing valve to test the forward and reverse
run of motor. And test restoration mechanism of tong head.
e. Operate M-type hand-reversing valve to test upward and downward
movement of the lift device.

3. Operation
3.1 Turn on the valve of air line and the oil valve of hydraulic station.
3.2 Check jaws, rollers, dies, plug screws, to see if the size is identical to the
joint size of drill pipe or tubing.
3.3 According to making-up or breaking-out, put the locating handle of tong
head and the locating handle of griping cylinder at corresponding position.
(Attention: the two handles should point to the same direction.)
3.4 Open the door and shift steadily the tong onto well mouth by controlling
double-way air valve of shifting cylinder. Be careful not to make the tong hit
the pipe all of a sudden. Be sure that the two plug screws contact well with
the pipe.
3.5 Making-up: put the two locating handles at making-up position. Operate
the double-way air valve of gripping cylinder to make the lower tong clamp
drill pipe joint. Set the double-way air valve of shifting cylinder at middle
position, releasing the compressed air. Then set the double-way air valve of
high and low gear at low gear position, and push up the H-type

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hand-reversing valve. The tong clamps the drill coupling at low gear, then
set the handle at high gear to make up the joint, not needing to stop the tong.
Choose the torque according to the Pressure-Torque Comparison Table. Do
not tighten the pipe joint at low gear. When making-up is finished, press
down the H-type hand-reversing valve to make the tong run in the reverse
direction and align the notch at low gear. Control the double-way air valve of
gripping cylinder to loosen the lower tong and control the double-way air
valve of shifting cylinder to draw back the power tong away from wellhead
position.
3.6 Breaking-out: put the two locating handles at breaking-out position.
Operate the double-way air valve of gripping cylinder to make the lower tong
clamp drill pipe joint. Set the double-way air valve of shifting cylinder at
middle position, releasing the compressed air. Then set the double-way air
valve of high and low gear at low gear position, and push down the H-type
hand-reversing valve. The tong loosens the drill coupling at low gear, then
set the handle at high gear to break out the joint, not needing to stop the
tong. When breaking-out is finished, push up the H-type hand-reversing
valve to make the tong run in the reverse direction and align the notch at low
gear. Control the double-way air valve of gripping cylinder to loosen the
lower tong and control the double-way air valve of shifting cylinder to draw
back the power tong away from wellhead position.
3.7 When a whole trip is finished, set all handles of valve to neutral position.
Shut off all hydraulic and air lines and wrap the joints to prevent dirties from
entering into the lines.

4.Maintenance
4.1 After finishing every trip, the tongs head should be washed clean with
water, and be blown dry with compressed air. After the cam, roller, and
piston rod are cleaned up, coat their surfaces with grease. Inject 50ml clean
machine oil into the air valve panel to lubricate components.
4.2 For every three wells, replace the machine oil in gearbox and the
molybdenum disulfide grease in speed-changing box (for well of 3000m
deep).

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V. SOME EXPLANATIONS

1. The tong is suitable for drill string of different size. Six sizes for jaws, rollers and plug screws. Jaw, roller, and plug
screw match as follows:

3 7 1
51/2” 3”
Griping 2 /8” 2 /8” 3 /2” 5”
casing and tubing and
Description drill pipe joint drill pipe joint drill pipe joint drill pipe joint
coupling coupling
Griping upper lower upper lower upper lower upper lower upper lower upper lower
Size Ф85 Ф85 Ф105 Ф105 Ф120 Ф120 Ф162 Ф162 Ф138 Ф138 Ф88.9 Ф107

7 7 7 1
Z27/8”
Jaw Z2 /8” Z2 /8” Z2 /8” Z5” Z5” T5 /2 Z27/8”
Y3”
Plug
45 36 30 9 21 12 45 36
Thickness
Roller Size Ф102 Ф102 Ф85 Ф77 Ф77 Ф102
Die Thick Normal Normal Normal Thick Normal Thick Normal
2. Max pressure of hydraulic system should not be more than 16Mpa. The pressure of relief valve has been
adjusted before delivery from factory, so don’t adjust the relief valve freely.

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VI. COMMON TROUBLESHOOTING
Trouble Probable Cause
Lift cylinder fails No pressure oil into the hydraulic cylinder.
to work.
Oil motor is too 1.Too long working time for the motor.
hot. 2.High or low viscosity of hydraulic oil.
3.Hydraulic oil of hydraulic system is few.
Gear changing 1. Quick release valve is blocked up.
is slow. 2. Too small clearance between air clutch and
internal gear.
Upper or lower 1. Long time service of the dies, worn and torn,
tong fails to grip blunt.
in making up or 2. Die groove being filled with dirt.
breaking out 3. Die is too crisp or too soft due to inappropriate
heat treatment.
4. Too loose for brake band to make the upper
tong jaws not able to roll up the cam.
5. Dirty brake disc and brake band fails to stop
the tong.
6. Tong not leveled.
7. Tong is not pushed to its exact position.
8. Air cylinder of griping cylinder or air passage is 8. Check the sealing of gripping cylinder and
leaking to cause air pressure below 0.5 MPa.
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Correcting Action
Check if hose line connected well, and if
reverse valve at right position.
1.Stop the tong until normal.
2.Use hydraulic oil of appropriate viscosity.
3.Stop the tong to fill enough oil.
1. Clean or replace quick release valve.
2. Adjust the clearance to proper position.
(during new assembly)
1. Replace dies.
2. Clean dirt with wire brush.
3. Change the dies.
4. Fasten the adjusting tube of the brake band
or replace springs of the tube.
5. Clean brake disc and brake band.
6. Level the tongs.
7. Move the tongs to its right position and then
grip drill pipe.
seal rings.
 9. Dirty tongs and much filth in jaw rack cause 9. Clean jaw rack, jaws and rollers, and
rollers difficult to roll on the cam but slip. grease their surface.
10. Forget to replace plug screws when replace 10. Replace the right plug screws.
jaws.
11. Jaws fail to grip joint due to its bad worn. 11. Replace jaws of right size.
12. The direction of the locating handles of the 12. According to making up and breaking out,
upper tong and lower tong are not identical. put the locating handles to correspond with
the nameplate indication.
When reversing the direction of locating
handle, be sure the locating pin of dial disc of
the lower tong is in the semi-round of turning
pin of locating handle. If not, draw back griping
cylinder to its original position, and then
reverse the locating handle.
High gear 1. Air passage leaking. 1. Replace air pipeline.
without low gear 2. Dirty or wear of slide disc of bi-directional 2. Disassemble the air valve. Clean and polish
or low gear valve and cause air leaking. the slider disc or replace the valve.
without high 3. Air leaking of Ø300*100 air tyre clutch, or 3. Replace air tyre of clutch or brake band
gear. much wear of brake band lining. lining.
4. Air leaking of quick air release valve. 4. Replace the core of the valve.
Pressure at high The pressure of the relief valve for making up is Adjust the relief valve for making up to proper
gear is not high not high enough. pressure (increase pressure).
enough.

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VII. LIST OF SPARE PARTS
No. Part No. Description Qty.
1 RS17.01-12 Inserts for jaw rack 8
2 RS17.01.02.00 Roller parts 11
3 RS17.01-09 Die 8
4 RS17.01-10 Thick die 8
5 GB879-86 Cylindrical spring pin 10*30 16
6 RS17.01-15 Cam 8
7 RS17.06.01.00 Brake band 2
8 RS17.01-17 Jaw rack 2

General View of ZQ162-50 Drill Pipe Power Tong

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Fig.1 Transmission Drawing for ZQ162-50 Power Tong

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 air source from rig

Pneumatic System
1.high gear tyre 2.low gear tyre 3.quick release valve
4.shifting cylinder 5.griping cylinder 6.air bag
7.high-low gear reverse valve 8.reverse valve of shifting cylinder
9.reverse valve of griping cylinder 10 air control valve panel
11.pressure gauge

Fig.2 Air Line System

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Fig.3 Hydraulic System of ZQ162-50 Drill Pipe Power Tong

1.Pump 2.Fuel filter 3. Pressure gauge

4.H-type hand-reversing valve 5.Relief valve for making-up
6.Hydraulic motor 7.Relief valve 8.Pressure gauge
9.Lift cylinder 10.Balance valve 11.M-type hand-reversing valve

Ⅰ.Hydraulic station Ⅱ.Lift cylinder Ⅲ.Hydraulic system

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