CAVINS/BJ POWER SUCKER ROD TONG

MODELS MARK II THROUGH MARK VI

OPERATING, SERVICE AND REPLACEMENT

PARTS MANUAL
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

TABLE OF CONTENTS

SUBJECT PAGE

1. INTRODUCTION 3

2. SPECIFICATIONS 6

3. INSTALLATION 7

4. OPERATION 8

5. MAINTENANCE 12

6. TROUBLESHOOTING 13

7. SHOP REPAIRS 16

8. REPLACEMENT PARTS 21

9. INNER RING ASSEMBLIES AND BACKUP WRENCHES 29

10. OVERALL DIMENSIONS 33

11. MOTOR AND CONTROL VALVE PARTS 36

12. TORQUE CHARTS 38

Cavins Oil Well Tools, 2853 Cherry Avenue, Signal Hill, CA 90755, U.S.A.
Phone: +1 (562) 424-8564 Fax: +1 (562) 595-6174
Email: sales@cavins.com
Revised 8-9-06

Page 2 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

INTRODUCTION

This manual contains important instructions on
the maintenance and safe operation of the
Cavins-BJ Power Sucker Rod Tong, Models II
through VI. An illustrated presentation with
detailed explanation is included for
maintenance, assembly and disassembly of
these tongs.
Full benefit of the long life, performance and
reliability 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 running, making
adjustments or carrying out maintenance
procedures on the tong.
SAFETY PRECAUTIONS
Safety based on technical skill and years of
experience has been carefully built into your
Cavins/BJ Power Rod Tong. Time, money and
effort have been invested in making your tong a
safe product. The dividend you realize from this
investment is your own personal safety.
It should be remembered, however, that power
driven equipment is only as safe as the person
who is at the controls. You are urged, as the
operator of the equipment, to observe the
following rules:
When operating the tong from the side,
using the side positioned control handle,
a back-up (snub) line or stiff arm must
be secured to the tong.
Never put hands within the rotating parts
of the tong while the tong is running or
the hydraulic system is connected. The
hydraulic hoses should be disconnected
from the tong before proceeding with
any activity that would require a person
to place their hand through the front
opening or the top or bottom openings
of the tong.
Never operate the tong without the
guard doors in place and operating
properly.
Never operate the tong without the
spring hanger and the safety sling
installed. Ropes, chain or other devices
in place of the spring hanger should
NOT be used .
Do not exceed the maximum pressure
for which the system is rated.
Always use a back-up (snub) line or stiff
arm for all tong operations.
Keep loose fitting clothing away from the
rotating parts of the tong.
WARNINGS PERSONAL INJURY
Failure to comply with the following warnings
could result in serious bodily injury or loss of life.
Read and clearly understand all
operating and maintenance instructions.
Contact the Cavins BJ customer service
department if additional information or
instruction is required.
Do not operate tong with the doors
open, loose or missing.
Keep hands, clothing and foreign
objects clear of rotating parts.
Shut off power unit and disconnect
supply hoses to tong before removing
the inner ring/jaw assembly or
performing any type of maintenance or
adjustments to the tong.
A stiff arm or a back-up (snub) line must
be installed and used at all times when
operating the tong.
The stiff arm or snub line must be kept
level with the attachment point on the
tong, tight and at a right angle (90
degree) to the tong when the jaws are
engaged.
Apply the load slowly against the snub
lines. DO NOT JERK SNUB LINES.
The working strength of the snub line
must have a minimum load rating of
2500 LBS (1134 Kgs). A minimum
diameter of 1/2 inch (12.7 mm) wire
rope is recommended.
All hardware used to suspend the tong ;
bolts, nuts, pins, safety line and snub
line or stiff arm must be inspected for
tightness, wear and/or damage before
each job or trip.
Read and comply with all warnings
placed on the tong.

Page 3 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

WARNINGS EQUIPMENT OR PROPERTY

DAMAGE

Failure to comply with the following warnings

could result in equipment or property damage.

The tong must be level and a stiff arm or

snub line installed at right (90 degree)
angle to the centerline of the tong.
A spring hanger, with a safety line, must
be installed for the free movement of the
tong up and down on the hanging line.
The power unit must be the correct size
for the tong.
All relief valves must be checked and
set as specified before running any job.
API or manufacturers recommended
torque values for the given sucker rod or
tubing must not be exceeded.
Do not operate the tong with incorrect or
mismatched jaw sizes installed.
Do not operate the tong unless all parts
are functioning properly and all safety
devices are correctly installed.

Page 4 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI
CAVINS/BJ Power Sucker Rod Tongs are
available in both hydraulic and air powered
models. They provide faster, more uniform
make-up and break-out of sucker rods and
macaroni tubing, without damage to thread
couplings, while delivering up to 1,850 foot-
pounds of torque.
This tong has a clean, functional design for
balanced weight distribution and easy handling
by one person. A single master control handles
both speed and direction of rotation. The tandem
control feature allows operation from the front or
either side. The swinging door gate provides
quick on-off action while eliminating hand
latching.
Page 5 of 38
A single unitized jaw assembly fits 5/8, 3/4 and
7/8 rod sizes without change and a fast jaw
change will adapt the tong to 1/2", 1 and 1-1/8
rod sizes. The tool is equipped with a torque
gage for safe, uniform make-up.
The rod tong is easily converted to macaroni
tubing by replacing the rotating jaw assembly
with CAVINS/BJ macaroni tubing jaws. Jaws are
available for API 1.050 O.D. (3/4 nominal) ;
1.315 O.D. (1 nominal) ; 1.660 O.D. (1-1/4
nominal) and 1.900 O.D. (1-1/2 nominal) tubing
sizes.
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

HYDRAULIC

PUMP SIZE. A hydraulic power unit/source that
will deliver 20 to 30 gallons per minute and 2000
psi maximum pressure is recommended.
However, a dual pump and unloading valve that
will return one half the hydraulic oil flow to the
tank when pressure exceeds 1,000 psi may be
used. Any hydraulic system suitable for the
CAVINS/BJ Power Tubing Tong will be
satisfactory for the CAVINS/BJ Power Rod
Tong.
OIL TANK. A 50-gallon oil tank containing at
least 35 gallons of specified hydraulic oil should
be used. An important part of the hydraulic
system, the oil tank must be properly designed
to dissipate heat, prevent foaming and deliver
clean oil to the pump suction without undue
friction loss caused by an inadequate oil filter.
POWER FLUID SPECIFICATIONS: Viscosity
Range 150 to 300 S.S.U. @ 100 deg. F. (Max
@starting temperature 3000 S.S.U.) ; Viscosity
index 80 or above.

HYDRAULIC DRIVE/TORQUE OPTIONS

AIR Model Torque Hydraulic Motor Cluster Gear Pinion Gear Assy.
Assy. Assy.
Mark II 1180 ft.-lbs Max 31908 27847 27850
Mark IV 1370 ft.-lbs Max 31909 27847 27850
Mark V 1850 ft.-lbs Max 31908 28613 28614

AIR

AIR COMPRESSOR AND HOSE. An air

compressor with a capacity of at least 100 c.f.m.
is recommended for speed operations. The
receiver volume should be at least 150 gallons
(approximately 20 cu. Ft.). The maximum
pressure needed at the tong is 120 psi. A 1 air
hose is used.

Page 6 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI
HANGING TONGS
Hang the tong on a suitable line (usually a 9/16
wire rope) from a point high enough to allow the
tong to swing easily. The tong may be hung over
a sheave either on a fixed line or a counter-
weighted line. There is a spring in the
suspension assembly that will allow the tong to
move vertically while the joint is being made up
or broken out, even if the tong is suspended on
a fixed line.
BALANCE ADJUSTMENT
With the tong on the rod, adjust the leveling
screw at the top of the hanger so the tong hangs
perfectly level while threading rods. Adjust the
height of the tong so the jaws in the inner ring
are the same height as the top square of the
rods.
INNER RING
Check the inner ring (jaw assembly) for size and
rotation. Instructions for removal and installation
of the inner ring are in Section IV, Operation.
BACK-UP WRENCH
Check the back-up wrench for size. One back-
up wrench fits both 3/4 and 7/8 rods. All other
back-up wrenches fit only one specific rod size.
Install the back-up wrench so it hangs on the
back-up wrench support spring. Make sure the
load cell piston of the torque indicator protrudes
enough to hold the back-up wrench away from
the case at least 3/8. If necessary, add oil to the
system according to instructions in Section V,
Troubleshooting, under Torque Indicator
Malfunction.
Page 7 of 38
HOSES
Connect the hoses with the power hose on the
right, as viewed from the back of the tong. The
hoses should be 1 x 50 when used on a
portable power unit and 1 x 15 when used on a
well service rig power source.
SELF SEALING COUPLINGS
IMPORTANT: Check all hoses to make certain
that the self-sealing couplings are completely
engaged and the hydraulic system is not
blocked in anyway.
HYDRAULIC OIL
Check the oil tank level to ensure that there is
plenty of oil in the system. With the hoses
properly hooked up to the tong, engage the
pump and allow the oil to circulate for a few
minutes to warm up the tong before full
operation. In cold weather, allow time for warm-
up as you would for an internal combustion
engine.
CAUTION: As with any tool, the CAVINS/BJ
Power Sucker Rod Tong must be handled
with care. Make no adjustments while
hydraulic power is connected. Keep fingers
and hands out of rotating jaw areas.
WARNING: This product could be hazardous
if improperly used. Misuse of this tool could
cause serious injury to personnel. This tool
must be properly installed and maintained.
Do not remove or alter any parts. Do not
weld or alter without factory authorization.
All replacement parts must be of Cavins Oil
Well Tools manufacture.
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI
OPERATING THE TONG
The tong can be operated from the front or
either side. It is ordinarily operated from the
front. All functions of the tong including
engaging the rotation jaws and releasing them
are controlled by the operator through the
tandem throttle handle. The swinging door
safety gates are opened and closed
automatically by sucker rod contact when the
tong is swung on or off the rod string. These
gates are a safety guard. They should be in
place and operable whenever the tong is in use.
With the jaws open, position the tong so the
back-up wrench lines up with the bottom square.
Then guide the tong onto the rod so the back-up
wrench easily slides onto the bottom square.
This may require lifting the tong slightly at the
front to get the back-up wrench over the lower
rod elevator and/or turning the tong to one side.
If the tong is hung at the correct height, the jaws
in the inner ring will automatically position
themselves to the top square.
NOTE: Keep fingers and hands away from
rotating jaws.
SETTING THE RELIEF VALVE
When breaking out rods, the relief valve setting
on the hydraulic power system is not critical. Set
it high enough to break the rods but not more
than 2000 psi.
The relief valve setting is critical when starting in
the hole. To avoid over-torquing a rod before the
correct torque setting is obtained, back off on
the relief valve until the pressure is low enough
to slowly turn the tong. Then make up the rod
and adjust the pressure upward until the correct
torque setting is obtained. API recommended
torque values are marked on the torque gage.
Because of the inherent characteristics of the
hydraulic motor, its rotating torque is 15-20%
higher than the stalled torque. It is suggested
that the relief valve be reduced this amount
before rotating a rod in at full speed. Again, note
the torque gage and adjust accordingly.
Page 8 of 38
CALCULATING PRELOAD VALUES FOR
SUCKER ROD PIN AND COUPLING JOINT
For optimum performance, the sucker rod pin
and coupling joint must be made up to achieve
the desired preload. Because of the many
variables involved machine asperities,
differences in materials, variations in lubricants
employed, cleanliness of connections and
condition of power tong equipment torque
does not provide an accurate measurement of
the repeatable desired preload value in the
sucker rod pin joint.
Calculations and test data show that a more
accurate measurement is provided by the
angular or circumferential displacement of a
coupling and pin after shouldering from a hand-
tight position. This method is preferred in the
field to achieve the desired preload in a sucker
rod pin and coupling joint. It is also a method of
calibrating power sucker rod tongs.
CIRCUMFERENTIAL DISPLACEMENT VALUE
Table 1 tabulates the circumferential
displacement values necessary to achieve an
optimum preload in coupling and pin joint under
various field conditions. Note the three
categories and choose the correct column to
meet local field conditions. Use Column 1 when
installing a new string of API Class D rods. Use
Column 2 when installing a new string of API
Grade C and K rods (see footnote). Use Column
3 when reinstalling used rods with old or new
couplings.
JOINT CONDITION. To achieve satisfactory
preload results for sucker rod joints, the joint
must be perfectly clean, undamaged, well-
lubricated and have a free-running fit to shoulder
contact. Applied displacement will then
efficiently preload the joint to prevent shoulder-
face separation during pumping.
CALIBRATION OF POWER TONG. The rod
tong must be calibrated to produce the
recommended circumferential displacement
make-up values shown in Table I. After initial
calibration, check the power tong calibration
each 1000 feet and recalibrate for each change
in rod size.
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

TABLE 1 7. Repeat Steps 4, 5 and 6 until proper

SUCKER ROD JOINTS CIRCUMFERENTIAL displacement is achieved. Check
DISPLACEMENT VALUES calibration of tong for a minimum of 4
joints, for each 1000 feet there after,
1 2 3 and for each change in rod size.
Rod Size New String *New String Subsequent
of API of API Installation
Grade Grade C & K of API Class
D Rods Rods C,K & D
1/2" 6/32 4/32 4/32
5/8 8/32 6/32 6/32
3/4" 9/32 7/32 7/32
7/8 11/32 9/32 9/32
1 14/32 12/32 12/32
1-1/8 18/32 16/32 16/32

*For the initial run of API Class C and K rods, a

set correction factor cannot be recommended
because of variance shown by test results. To
minimize these variables, API Class C and K rod
joints should be made up once and broken out
before marking and final make-up.

PROCEDURE:
1. Check condition of power tong. If
hydraulic-powered, circulate hydraulic
power oil system to warm up tong.
2. Set the tongs operating pressure on the
low side of the estimated value required
to produce prescribed circumferential
displacement value shown in Table 1.
3. Screw the first joint together hand-tight.
Scribe a fine vertical line across the pin
and coupling shoulder to establish hand-
tight reference (Figure 1).
4. Make up joint with power tong operating
and the tong throttle depressed to the
fully open position. Do not hit the throttle
a second time after joint shoulder and
tong have stalled.
5. Remove the tong and measure the
circumferential displacement of the
scribed, hand-tight vertical line (Figure
2).
6. Increase or decrease the tong operating
pressure to achieve the selected
prescribed circumferential displacement,
as shown in Table 1.
FIGURES 1 and 2. Scribing line across pin
and coupling shoulder.
CHANGING DIRECTION OF ROTATION
DETERMINING DIRECTION OF ROTATION.
The inner ring rotates a rod in the direction
indicated on top and bottom of the assembly,
just opposite the opening. The side marked
MAKE is for making up rods. The side marked
BREAK is for breaking out rods.
A simpler and quicker way to determine the
direction the jaws will turn a rod is to note the
jaw in the inner ring opening. This jaw points like
an arrow in the direction the rods will turn
(Figures 3 and 4).
INNER RINGS WITH INDEXING KNOBS. Rod
tong inner rings have an indexing knob on the
side (Figure 5). Its purpose is to prevent
installing the inner ring upside down or out of
phase with the outer ring. The knob makes it
necessary to line up the opening of the inner
ring with the opening in the frame, as described
above.

Page 9 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

FIGURE 3. Making up rods. FIGURE 4. Breaking out rods.

REMOVING THE INNER RING. Rotate the tong

to close the jaws and stop the rotation when the
opening of the inner ring lines up with the
opening in the frame (Figures 3 and 4). Next,
reverse the rotation enough to free the inner ring
from the resisting force of the brake. The
amount of travel is equivalent to about one tooth
on the outer ring. The inner ring is then free to
be lifted out (Figures 6 and 7).**

NOTE: Disconnect hydraulic hoses before

removing inner ring.

REPOSITIONING INNER AND OUTER RINGS:

1. After removing the inner ring, turn it FIGURE 5. Inner ring assembly.
over. Do not rotate it.

2. Rotate the outer ring half way around.

Carefully line up the outer ring roller in
the middle of the brake drum opening
(Figures 6 and 7). Note that outer ring
roller is in the middle of both brake drum
and frame openings.
** An optional tool, the CAVINS Fingersaver, is
recommended for removal of the inner ring. (See
separate manual)

3. Replace the inner ring. Line up the

opening of the inner ring with the brake
drum opening.

4. When the inner ring is in place and has

dropped down over the brake drum pins,
the top of the inner ring will be about
1/2" below the top of the outer ring. This
will verify correct installation of inner
ring.

Page 10 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

FIGURE 6. Inner ring removed outer ring roller FIGURE 7. Inner ring removed outer ring roller
in middle of brake drum opening. in middle of brake drum opening.

INSTALLING INNER RING FOR MACARONI

TUBING. Macaroni inner rings are made in four
sizes: 1.050, 1.315, 1.660 and 1.900 (3/4, 1,
1-1/4 and 1-1/2 nominal, respectively).

The macaroni inner rings are installed in the

same manner as the inner rings for sucker rods.

Page 11 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

MAINTENANCE CHECK LIST LUBRICATION

Check all throttle control linkage for loose pins. If
oversize pins are needed but are not available, a
new hole can be drilled with a 3/16 drill bit to
accommodate a standard pin.
Remove the inner ring and check the two outer
ring rollers for wear.
There are no grease fittings on the CAVINS/BJ
Power Rod Tong because all bearings are
grease-packed and sealed. Normally, the jaw
pins, wear rings, outer ring gear and idler gears
receive sufficient lubrication from the rods. If not,
oil or brush grease on these points.

With the inner ring removed, rotate the outer ring

and check the fourteen outer ring frame rollers.

Check the torque gage by prying against one

side of the back-up wrench.

Test the spring tension on each of the gate

doors with the tong in an upright position. If the
spring tension is uneven, loosen the gate spring
capscrew and slide the spring to one side until
the spring tension is the same on both gates.
The gate spring is shown in FIGURE 14.

Page 12 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI
TONG OUT OF TIME
A tong is out of time when the brake drum does
not line up with the opening of the frame (Figure
8). With the brake drum in this position, the
indexing knob (Figure 5) may not allow the inner
ring to go into place correctly.
Align the brake drum with the frame opening by
using a backup wrench and a pipe wrench as
shown (Figures 8 & 9).
FIGURE 8. Tong out of time brake drum not
aligned.
Page 13 of 38
NOTE: Before making any adjustments,
disconnect hydraulic hoses.
TORQUE INDICATOR MALFUNCTION
Like all gages, the torque gage should be tested
periodically. The torque indicator is a closed
system and occasionally must be recharged with
oil. Oil is needed when the load cell piston will
not hold the back-up wrench away from the case
when under load. When the load cell cylinder is
filled with oil, the piston should protrude about
3/8 form the case (FIGURE 10).
FIGURE 9. Tong in time brake drum aligned
using a crescent wrench and the back-up
wrench.
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

To add oil, turn the tong on its side with the fill
hole on the high side. Remove the filler plug
(FIGURE 11). With the long end of an Allen
wrench, push the load cell piston back until it
bottoms against the seal (FIGURE 12). Add
hydraulic oil (FIGURE 13) and replace the plug.

Compress the torque indicator load cell piston

by prying to one side on the back-up wrench. If it
feels spongy, work the air out of the system by
turning the tong right side up and partially
unscrewing the gage. Again pry against the load
cell piston. When all the air is expelled at the
gage, retighten it and refill the load cell cylinder.
If necessary, repeat the process two or three
times to expel all air. It is very important that all FIGURE 11. Removing torque indicator fill plug.
air is out of the system.

JUMPING OUT OF TIME

The tong can jump out of time if the brake cover

plate becomes loose, allowing the brake drum to
disengage from the inner ring. This problem can
also occur if the brake drum pins have worn
down or moved down until they are too short.
Turn the pins end for end and drive them back
into place, or replace them with new pins. The
pins should extend 1/2" above the brake drum.

FIGURE 12. Pushing back load cell piston.

FIGURE 13. Filling load cell cylinder with

hydraulic oil.

FIGURE 10. Torque Indicator load cell piston

protrudes 3/8 when cylinder filled with oil.

Page 14 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI
JAWS FAIL TO ACTUATE
This is caused by a worn out brake band, by
interference between the jaws and the inner or
outer ring, or both.
If there is interference between the jaws and the
outer ring, something is probably holding the
inner ring too high, causing the jaws to hit or
drag the inside top of the outer ring. This can be
caused by:
1. The brake drum not being down against
the brake cover plate
2. A brake drum pin sticking up too high, or
3. A jaw pin not evenly spaced in the inner
ring, causing the brake drum pin to
contact it.
Page 15 of 38
Foreign matter between the brake drum and the
inner ring can also cause jaw failure. A loose
brake cover plate could also prevent proper
actuation of the jaws, by letting the inner ring set
too low.
OIL LEAKING FROM WEEP HOLE UNDER
MOTOR
An oil weep hole is provided in the frame, under
the motor. It prevents the case from filling up
with hydraulic oil if the motor shaft seal leaks or
blows out. Should this happen, remove the
motor from the tong and replace the seal.
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

CHANGING BRAKE BAND

NOTE: Disconnect hydraulic hoses before

disassembly.

1. Remove the small gate spring capscrew

and pry the gate spring out of the slot in
the brake cover plate (FIGURE 14).

2. Remove the two 1/4 x 3/4" capscrews

in the back of the brake cover plate and
the two 3/8 x 1-3/4 bottom gate
capscrews in the front of the plate.

3. Remove the brake cover plate (FIGURE

15).
FIGURE 15. Removing brake cover plate.
4. Turn brake drum to remove left anchor
pin (FIGURE 16).

5. Remove anchor pin (FIGURE 17).

6. Turn brake drum to remove right anchor

pin.

7. Remove brake drum and brake band as

an assembly (FIGURE 18).

8. Remove old brake band from brake

drum (FIGURE 19).

9. Install new brake band on brake drum

(FIGURE 20) and reassemble tong by
reversing disassembly procedure. FIGURE 16. Turning brake drum to remove left
anchor pin.

FIGURE 14. Removing gate spring.

FIGURE 17. Removing anchor pin.

Page 16 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REPLACING OUTER RING ROLLER PINS

AND BUSHINGS

It is not often necessary to replace the outer ring

roller pins and bushings. But, if badly worn, they
can cause a slipping or jumping problem.

NOTE: Disconnect hydraulic hoses before

disassembly.

To remove the roller from the tong, take out the

outer ring roller pin retaining snap ring. Then lay
the tong on its side and drive the pin out the top
(FIGURE 21).

If necessary, force the little snap ring out with FIGURE 18. Removing brake drum and brake
the roller pin. This usually destroys the snap as an assembly.
ring. Unless a bushing tool is available, it may
be necessary to cut part way through the
bushing with a hacksaw blade to remove it.

If a press is not available to press in the new

bushing, press it in with a vise, or drive it in,
using the outer ring roller pin to support the
bushing. After installing the bushing, it may be
necessary to ream the bushing hole to make it
free on the pin.

REPLACING OUTER RING WEAR RINGS

NOTE: Disconnect hydraulic hoses before

disassembly.
FIGURE 19. Removing old brake band from
Remove the hanger and gate assemblies brake drum.
(FIGURE 22).

Remove the frame cover by prying up evenly

(FIGURE 23). The main points of interference
will be at the three dowel pins.

After removing the frame cover (FIGURE 24),

remove the two 1/4" x 1 wear ring screws and
as many outer ring frame rollers as necessary to
lift out the top outer wear ring (FIGURE 25).

To replace the bottom outer ring wear ring, lift

out the outer ring and remove the two 1/4" x 1-
3/4 wear ring screws that hold the brake cover
plate.
FIGURE 20. Installing new brake band on brake
Then remove as many of the outer ring frame drum.
rollers as necessary to lift out the wear ring
(FIGURE 26).

Page 17 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

TONG DISASSEMBLY

NOTE: Disconnect all power before

disassembly

1. Disconnect the throttle linkage at the

throttle valve.

2. Remove the hanger assembly, motor,

gate assembly, throttle controls, frame
handle and frame cover cap screws.

3. Remove frame cover. In removing the

frame cover, the main points of
interference will be at the three dowel
FIGURE 21. Removing outer ring roller pin. pins.

FIGURE 23. Removing frame cover.

FIGURE 22. Hanger and gate assemblies
removed.

FIGURE 24. Frame cover removed.

Page 18 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

With frame cover removed, note that the

opening of the outer ring is lined up with one of
the idler gears (FIGURE 27). If this line-up is
repeated during reassembly, it will be easier to
get the frame cover back on the tong.

Lift out the outer ring and idler gears.

Turn the tong over and remove the gear case

cover.

Carefully remove the gear case cover gasket

and the small O-ring over the torque indicator
load cell.
FIGURE 26. removing outer ring frame rollers.
Remove the brake assembly as described on
page 17 under Changing Brake Band.

Lift out the second reduction gear (FIGURE 28).

Remove the cluster gear shaft from the tong.

Jack it out of the case with a 3/8 16NC bolt 6
long (extra long threads), inserting this shaft
puller in the tapped bore of the shaft (FIGURE
29).

Remove cluster gear (FIGURE 30).

Remove the snap ring and drive out the motor

pinion assembly (Figures 31 and 32).

NOTE: Remove the motor pinion assembly

out the top of the case. FIGURE 27. Outer ring opening lined up with
one of the idler gears.

FIGURE 25. Removing outer ring wear ring. FIGURE 28. Removing second reduction gear.

Page 19 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

FIGURE 29. Removing cluster gear shaft. FIGURE 32. Removing pinion gear assembly.

FIGURE 30. Removing cluster gear.

FIGURE 31. Removing snap ring.

Page 20 of 38
POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REPLACEMENT PARTS AND DIAGRAMS

POWER SUCKER ROD TONGS

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POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

Page 22 of 38
POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

Page 23 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

- 27842 - Frame Assembly (Mark II,III and IV)

- 27842-5 - Frame Assembly (Mark V and VI)
1 27862 1 Frame
2 27868 1 Outer Ring Wear Ring
3 27869 2 Idler Gear Thrust Washer
4 27870 1 Cluster Gear Shaft
5 27871 2 2nd Reduction Gear Thrust Washer
6 27872 1 Cluster Gear Thrust Washer

7 27873 7 Thrust Washer Retainer Pin

8 942453-11 7 Outer Ring Frame Roller
9 942392-112 1 2nd Reduction Gear Lower Needle Bearing
10 27851 1 2nd Reduction Gear
11 942392-53 2 Idler Gear Shaft Needle Bearing
12 29888 2 Idler Gear Shaft Retaining Disc
13 941156-137 2 Idler Gear Shaft Retaining Disc Snap Ring
14 940287-819 1 2nd Reduction Gear Shaft Seal
15 940287-12 2 Idler Gear Shaft Lower Seal
16 944524-244 1 Motor Pinion Lower Retaining Ring
17 941068-116 3 Frame To Cover Dowel
18 944422-8 7 Outer Ring Frame Roller Nut

19 944524-295 1 Motor Pinion Upper Retaining Ring

- 27850 1 Motor Pinion Assembly (Mark II,III and IV)

20 27921 1 Motor Pinion Gear
21 979384-8 1 Motor Pinion Lower Bearing
22 979384-10 1 Motor Pinion Upper Bearing

- 28614 1 Motor Pinion Assembly (Mark V and VI)

20 29197 1 Motor Pinion Gear
21 979384-8 2 Motor Pinion Lower Bearing
22 28610 1 Motor Pinion Bearing Adapter Ring

Page 24 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

- 27847 1 Cluster Gear Assembly (Mark II, III and IV)

23 27922 1 Cluster Gear
24 942392-72 1 Cluster Gear Bearing

- 28613 1 Cluster Gear Assembly (Mark V and VI)

23 29196 1 Cluster Gear
24 942392-72 1 Cluster Gear Bearing

- 27846 2 Idler Gear Assembly

25 27866 1 Idler Gear
26 27867 1 Idler Gear Shaft

- 27845 1 Outer Ring Assembly

27 27865 1 Outer Ring Gear
28 29173 2 Outer Ring Roller Assembly
28A 29173-1 1 Outer Ring Roller
28B 29173-2 1 Roller Bushing
29 943631-91 2 Outer Ring Roller Pin
30 944524-50 2 Outer Ring Roller Pin Retainer Ring

- 27843 1 Frame Cover Assembly

31 27874 1 Frame Cover
32 27868 1 Outer Ring Wear Ring
33 942453-11 7 Outer Ring Frame Roller
34 944422-8 7 Outer Ring Frame Roller Nut
35 942392-53 2 Idler Gear Shaft Needle Bearing
36 940287-12 2 Idler Gear Shaft Seal
37 27869 2 Idler Gear Shaft Thrust Washer
38 27873 4 Thrust Washer Retainer Pin
39 942393-84 1 2nd Reducing Gear Shaft Bearing
40 940286-318 1 2nd Reducing Gear Shaft Upper Seal
41 944047-8 2 Frame Cover Snap-In Seal
42 944047-15 1 Frame Cover Snap-In Seal
43 941286-69 2 Frame Cover Wear Ring Cap Screw

44 941286-126 2 Frame Cover Cap Screw

45 941286-218 3 Frame Cover Cap Screw
46 941286-203 3 Frame Cover Cap Screw

- 27844 1 Gear Case Cover Assembly

47 27875 1 Gear Case Cover
48 27876 1 set Back-up wrench Support Spring
49 28007 1 Support Spring Plate
50 939100-3 2 Support Spring Cap Screw
51 27877 1 Back-up Wrench Pivot Spring
52 27878 1 Pivot Pin
53 941286-93 1 Pivot Spring Cap Screw
54 939212-4 1 Nut
55 904993-7 1 Hair Pin
56 939352-3 1 Lock Washer
57 27909 1 Pivot Spring Retainer Plate

Page 25 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

58 27908 1 Torque Indicator Load Cell Piston

59 27871 1 2nd Reducing Gear Thrust Washer
60 27872 1 Cluster Gear Thrust Washer
61 27873 3 Thrust Washer Retainer Pin
62 942271-17 1 Load Cell Piston O-Ring
63 945509-212 2 Piston O-Ring Back-up Ring
64 940288-471 1 Piston Seal
65 940968-1 1 Load Cell Pipe Plug
66 27918 1 Gasket Gear Box Cover
67 941286-71 11 Gear Case Cover Cap Screw
68 939354-3 11 Lock Washer

- 16377 1 Suspension Spring Assembly

69 16378 1 Shank
70 939484-8 1 Shank Nut
71 939672-28 1 Shank Cotter Pin
72 16682 1 Washer
73 16380 1 Lower Cap
74 16683 1 Housing
75 27955 1 Inner Spring
76 16379-1 1 Upper Cap Assembly
77 16446 1 Outer Spring

- 27852 1 Hanger Assembly

78 27852-1 1 Hanger
79 15532 1 Hanger Balancing Screw
80 940918-240 1 Hanger Balancing Screw Bolt
81 939484-8 1 Hanger Balancing Screw Nut
83 939097-23 4 Hanger Cap Screw
84 939672-28 1 Hanger Cotter

- 27848 1 Brake Drum Assembly

85 27879 1 Brake Drum
86 943733-208 2 Brake Drum Pin

Page 26 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

87 27849 1 Brake Band

88 939502-30 2 Brake Band Anchor Pin
89 939370-7 3 Brake Band Anchor Pin Washer
90 943733-17 2 Brake Band Anchor Pin Retainer

91 27855 1 Brake Cover Plate

92 941286-102 2 Brake Cover Plate Cap Screw
93 942271-9 1 Torque Indicator O-Ring
94 27860 1 Frame Handle

95 941442-3 6 Frame Cover Nut

95A 939354-3 2 HI-Collar Lock Washer
96 29783 1 Control Valve Shaft
97 29143 1 Torque Indictor Gage

- 29192 1 Front End Control Assembly

98 27853 2 Front End Control Valve Lever Left
99 29188 1 Front End Control Valve Lever Right
100 943733-58 8 Control Valve Lever Pin
101 940072-14 1 Elbow
102 940225-47 1 Nipple
103 29189 1 Front End Control Connecting Bar
104 29190 1 Front End Control Bracket
105 940585-39 1 Front End Control Shoulder Screw

106 27856 1 Right Gate

107 27857 1 Left Gate
108 27858 1 Gate Spring
109 32984 2 Gate Bolt, Top
110 32985 2 Gate Bolt, Bottom
111 941286-47 1 Gate Spring Cap Screw
112 939363-23 2 Gate Washer
113 943733-36 2 Gate Roll Pin

- 31908 1 Hydraulic Drive Group (Mark II and V)

114 970400-8 1 Motor and Valve Assembly
115 900115-33 4 Cap Screw
116 31101 4 Bushing
117 31783 2 Valve Link
118 31784 1 Valve Crank
119 31785 2 Link Pin
121 939672-16 4 Cotter Pin
122 942841-44 2 Swivel Joint

Page 27 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

- 31909 1 Hydraulic Drive Group (Mark IV)

114 970400-7 1 Motor and Valve Assembly
115 900115-33 4 Cap Screw
116 31101 4 Bushing
117 31783 2 Valve Link
118 31784 1 Valve Crank
119 31785 2 Link Pin
120 939370-9 8 Washer
121 939672-16 4 Cotter Pin
122 942841-44 2 Swivel Joint

123 24927 1 Motor Gasket

Page 28 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

INNER RING ASSEMBLIES AND BACKUP

WRENCHES

125

130

128
127

129
126

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 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

- 27899-2 1 Inner Ring Assembly 1/2 Rod

125 27894 1 Inner Ring
126 27895 1 Plain Jaw
127 27896 1 Jaw 1/2" With Lug
128 27897 2 Jaw Spring
129 27722 2 Jaw Hinge Pin
130 27898 1 Back-up Wrench 1/2" Rod

- 27899 1 Inner Ring Assembly 5/8, 3/4" & 7/8 Rod

125 27894 1 Inner Ring
126 27900 1 Jaw 5/8, 3/4 & 7/8 Plain
127 27901 1 Jaw 5/8, 3/4" & 7/8 With Lug
128 27897 2 Jaw Spring
129 27722 2 Jaw Hinge Pin
130 27902 1 Back-up Wrench 5/8 Rod
130 27903 1 Back-up Wrench 3/4 & 7/8 Rod

- 27899-3 1 Inner Ring Assembly 7/8 Rod with 1-1/8 Flats

125 27894 1 Inner Ring
126 27900-1 1 Plain Jaw 7/8 Rod with 1-1/8 Flats
127 27901-1 1 Jaw With Lug 7/8 Rod with 1-1/8 Flats
128 27897 2 Jaw Spring
129 27722 2 Jaw Hinge Pin
130 27903-1 1 Back-up Wrench 7/8 Rod with 1-1/8 Flats

- 27899-4 1 Inner Ring Assembly 1 Rod

125 27894 1 Inner Ring
126 32967 2 Jaw 1
128 27897 2 Jaw Spring
129 27722 2 Jaw Hinge Pin
130 27906 1 Back-up Wrench 1 Rod

- 27899-1 1 Inner Ring Assembly 1-1/8 Rod

125 27894 1 Inner Ring
126 27905 2 Jaw 1-1/8
128 27897 2 Jaw Spring
129 27722 2 Jaw Hinge Pin
130 27907 1 Back-up Wrench 1-1/8 Rod

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 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

INNER RING ASSEMBLIES FOR MACARONI

TUBING

131

132
132

133

135

134
136

Page 31 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

- 30712 1 Inner Ring Assembly For 1.900 Tubing

131 28686 1 Inner Ring
- 30713 2 Jaw Assembly
132 30694-3 1 Jaw 1.900 Tubing
133 30721 1 Die
134 947129-170 1 Die Pin
135 28729 2 Jaw Spring
136 941072-157 2 Jaw Hinge Pin

- 30714 1 Inner Ring Assembly For 1.660 Tubing

131 28686-1 1 Inner Ring
- 30715 2 Jaw Assembly
132 30694-2 1 Jaw 1.660 Tubing
133 30723 1 Die
134 947129-170 1 Die Pin
135 28729 2 Jaw Spring
136 941072-157 2 Jaw Hinge Pin

- 30716 1 Inner Ring Assembly For 1.315 Tubing

131 28686-2 1 Inner Ring
- 30717 2 Jaw Assembly
132 30694-1 1 Jaw 1.315 Tubing
133 30724 1 Die
134 947129-170 1 Die Pin
135 28729 2 Jaw Spring
136 941072-157 2 Jaw Hinge Pin

- 30718 1 Inner Ring Assembly For 1.050 Tubing

131 28686-2 1 Inner Ring
- 30719 2 Jaw Assembly
132 30694 1 Jaw 1.050 Tubing
133 30726 1 Die
134 947129-170 1 Die Pin
135 28729 2 Jaw Spring
136 941072-157 2 Jaw Hinge Pin

Page 32 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

OVERALL DIMENSIONS

34 In
86.4 cms

15-1/2 In
39.4 cms

Page 33 of 38
POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

34 In
86.4 cms

15-1/2 In
39.4 cms

Page 34 of 38
POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

34 In
86.4 cms

17 In
43 cms

Page 35 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

HYD MOTOR (REF 137) & VALVE (REF 19)

9
8

7
6

4 5

18
19
3 To Valve
17
16
2

15
1
13 12
12 13
16
11 14
10

14
17

20
23
22 28 21

25

26
31
24 27
29 31 30 30

Control Valve

Page 36 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

REF. PART NUMBER QTY DESCRIPTION

NUMBER REQD

137 970400-8 1 Motor, Mark II and V

1 971499-1012 1 Retainer
2 971499-1011 1 Lip Seal
3 971499-1004 1 O Ring
4 1 Bearing Cup (Comes with 971499-1006)
5 971499-1006 1 Taper Bearing
6 970499-1247 1 Key
7 971499-1254 1 Shaft
8 971499-1056 1 Housing, Shaft End Cover
9 971499-1010 2 Check Assembly
10 971499-1036 1 Shaft Bushing
11 971499-1037 1 Spring
12 971499-1038 4 Roller Bearing
13 971499-1040 2 Thrust Plate
14 971499-1041 2 Gasket Seal
15 971499-1255 1 Gear Housing
16 971499-1256 1 Gear Set
17 971499-1039 12 Pocket Seal
18 971499-1257 1 Housing, Port End Cover
- 971499-1258 4 Washer
- 971499-1259 4 Stud
- 971499-1260 4 Nut

19 971499-1241 1 Control Valve Assembly

20 971499-1242 1 Housing
21 971499-1243 1 Spool
22 971499-1244 1 Snap Ring
23 971499-1245 1 Spring
24 971499-1246 1 Spacer
25 971499-1247 1 End Cover
26 971499-1248 1 Spring Guide
27 971499-1249 1 Retaining Ring
28 971499-1250 1 Spring Retaining Seat
29 971499-1251 1 Washer
30 971499-1252 2 O-Ring Gasket
31 971499-1253 2 O-Ring Seal

Page 37 of 38
 POWER SUCKER ROD TONG, MODELS MARK II THROUGH MARK VI

TORQUE CHART

2000
1900
1800
1700
1600
1500
1400
1300
1200
Torque - Foot Lbs

1100 1-1/8 ROD

Mrk V
1000 Mrk IV
900 Mrk II
1 ROD
800
700
600
7/8 ROD
500
400
3/4 ROD
300
5/8 ROD
200
1/2 ROD
100
0
0 2 4 6 8 10 12 14 16 18 20
Hundreds

Oil Pressure PSI - X100

Page 38 of 38