Westco 5500 User manual

Street Address: 1360 N. Olive Street Ventura, CA93001 |Mailing Address: P.O.Box 66 Oak View, CA 93022
PRODUCT MANUAL
MODEL 5500
H
YDRAULIC TUBING TONG
MANUFACTURED IN THE USA
SPECIFICATIONS
MAINTENANCE
OPERATIONS
ASSEMBLY
805-648-5004
805-648-5018
CONTACT:
www.westcointl.com
REV: 1 Date:07/23/2019
Approved by: Bryan Staord

1
WESTCO Manufacturing, LLC
1360 N Olive Street
Ventura, CA 93001 USA
TEL: [phone]
www.westcointl.com
WESTCO Operating Manual
Terms and Conditions of Use
A. The materials contained in this WESTCO operating manual are protected by copyright, trademark,
and other forms of propriety rights. Nothing contained herein shall be construed as conferring any
license or right to use or practice any copyright, trademark, patent or other forms of propriety rights.
This operating manual may not be copied or converted to any mechanical, electronic or machine-
readable form, in whole or in part, without WESTCO’s consent.
B. This operating manual is not intended to address every issue that may arise in the course of
operations of the device described therein or the planning of the same. Each well and each job are
unique and have numerous variables. Experience and other specialized training can complement the
materials used in this manual.
C. WESTCO makes no representation as to the accuracy or completeness of the materials in this
operating manual. All materials are provided “AS IS” WITHOUT WARRANTY OF ANY KIND WHATSOEVER,
EITHER EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR NON-INFRINGEMENT. WESTCO expressly
disclaims all responsibility for the consequences, direct, indirect, consequential or otherwise, of any
inaccuracies or omissions in the materials.
D. This information is confidential and proprietary property of WESTCO. Do not disclose to unauthorized
parties. Do not use except as permitted by WESTCO.

2
TABLE OF CONTENTS
Introduction 3
Safety 3
Tubing Tong Specifications
Torque Chart 7
Fluid Requirements 8
Grease Specification 9
Envelope Dimensions 10
Controls 11
First Time Startup Procedure 12
Installation 13
Operation 18
Tubing Tong Adjustments 18
Gear Train Timing Procedure 19
Preventative Maintenance 20
Troubleshooting 22
Tubing Tong Replacement Parts
Tong Assembly Exploded View 25
Duel Suspension Hanger Assembly 31
Jaw Assemblies 32
Bushing Assemblies 33
Tubing Tong Spare Parts List for one-year operation 36
Tubing Tong Back-up Assemblies 37
MS Back-up 38
Standard Three Jaw Open Mouth Back-up 41
Standard back-up mount assembly 45
Universal Stiff-Arm Assembly 46
Control Valve Assembly 47
Torque Gauge Assemblies 48
Hydraulic Motor Seal Replacement 50

3
INTRODUCTION
This manual contains instructions on the installation, operation, safety, and maintenance of the WESTCO model
5500 hydraulic tubing tong. Illustrations with detailed notes are included in this manual in order to help
assemble, disassemble, and or maintain these tongs. Proper maintenance is highly recommended in order to
maximize the service life of the tong. The operator should thoroughly familiarize himself/herself with the
contents of this manual before operating, making adjustments, or performing any maintenance procedures on
this equipment.
SAFETY
Safety is the highest priority! Use precautions in this section to protect yourself and coworkers from possible
injury or death while using the tubing tong. These precautions reduce the risk of damaging the tong, rig, and
tubular string.
Warnings and Hints:
This manual uses the following symbols:

4
Designated Use
WESTCO model 5500 Hydraulic Tubing Tongs are fast, safe, and accurate tongs for making up and breaking out
1.315” to 4.75” 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.
The simple but rugged gear train consists of a planetary type gearbox mounted directly beneath the motor, and
a gear reduction system which provides the extra torque capacity. The tong is suspended in the derrick or mast
by a wire line and swung onto the tubing. Tong jaws grip automatically and the safety guard door closes.
Operate the throttle in the forward position, and the tubing is automatically made up to the required
specifications as indicated on the torque indicator gauge.
This equipment is NOT designed to be used for drilling operations. Using this equipment for
purposes and/or configurations and/or modifications other than what is expressly mentioned in
this manual is considered contrary to its designated use and is, therefore, prohibited. Operating
this equipment within the limits of its designated use also involves complying with the
operational inspection and maintenance directives contained within this operating manual.
Precautions for Installation
•Connect hydraulic couplings in the following order: 1) return line 2) pressure line. Always disconnect in
the reverse order: 1) pressure line 2) return line.
•Secure hydraulic hoses: do not bend or clamp hoses in a way that might hinder flow of hydraulic fluid.
Hoses should not obstruct workers on the rig floor.
•Use only the original suspension hanger that comes with the tong to suspend it off the rig floor.
•A stiff arm is strongly recommended, but if a flexible line (chain or cable) is used, the line must be
completely horizontal and at a right angle to the longitudinal axis with no slack in the line.
A snub line must be securely attached to the rear of tong and to an anchor point. All slack
must be out of the snub line before the tong is operated. Failure to comply with this
warning may cause serious bodily harm.

5
Precautions for Operation
•Do not operate, adjust, or repair this equipment without proper training.
•Do not operate the tong if the front guard door is open or missing.
•Adhere to all safety warnings
•Keep all body parts and clothing away from moving parts
Keep hands clear of rotating parts. Failure to comply with this warning may cause serious
bodily harm.
Precautions for Maintenance and Troubleshooting
•Before attempting any maintenance or troubleshooting, de-energize the hydraulic power to the tong,
turn off the hydraulic power source, decompress the hydraulic hoses, and then disconnect the hoses.
Ensure jaws cannot move. Make sure to lock/tag out all disabled power sources.
Failure to shut down hydraulic power prior to performing any maintenance, service, and
or troubleshooting may lead to serious bodily injuries.
•Immediately shutdown and repair the hydraulic system if leaking is present.
•Never disconnect any hydraulic hose while it is under pressure.
•Use only spare parts from WESTCO or WESTCO approved vendors.
•Allow only qualified personnel to carry out troubleshooting, service, and maintenance tasks.
•When disposing any tong parts/components, follow appropriate environmental regulations.

6
Precautions for Transportation
The tubing tong must be secured properly to avoid any movements during transportation. Before moving any
components, verify that you have proper lift equipment and space to safely move the tubing tong. The operator
must have adequate training and follow standard safety procedures such as always move a suspended load
slowly and smoothly; keeping it in a horizontal position and balanced. A set of chains or straps may be utilized to
secure the tong to the transport vehicle.
Only use the designated hanger on the tong to lift it off the ground. Failure to do so may
damage the equipment and or cause serious injuries.
Personal Protective Equipment (PPE)
While handling/operating the tubing tong, it is very important to wear the following minimum PPE:
The output noise of a tubing tong during operation exceeds 70 dB (A). The use of ear protection
(i.e. earplugs) is recommended while operating the tubing tong. Failure to do so may lead to
serious hearing injuries.

7
MODEL 5500 TUBING TONG SPECIFICATIONS
•Hydraulic Nominal Requirements: 35-40 GPM @ 2,500 PSI
•Pipe Size Range: 1 ¼” to 4 ½”
•Max Torque in Low Gear: 8,750 ft-lbs.
•Max RPM in High Gear: 100 RPM @ 40 GPM
•Tong Weight: 575 lbs.
0
LOW GEAR
0
HIGH GEAR
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0500 1000 1500 2000 2500 3000
TORQUE [FT-LBS]
PRESSURE [PSI]
5500 TUBING TONG TORQUE CHART

8
Fluid Requirements
To obtain the proper torque during make/break operations, the tubing tong requires a flowrate of
approximately 35 to 40 gallons per minute (132.5 LPM to 151.4 LPM) at 2000 PSI. Every effort should be made to
keep the hydraulic system clean. Whenever the hoses are disconnected, make sure the quick-coupling ends are
capped/plugged to prevent any debris from entering the hydraulic system.
NOTE: Hydraulic power units must provide sufficient hydraulic fluid cooling to prevent the tubing tong from
overheating. The maximum allowed temperature of the hydraulic oil flowing through the tubing tong pressure
inlet line is 158oF (70oC).
Hydraulic Oil Specification
The quality of hydraulic oil used to power the tong affects its performance and service life. The following are key
items to consider when choosing a hydraulic fluid for the power unit:
•The hydraulic oil must contain additives to ensure high anti-wear characteristics. Not all hydraulic
oils contain these in sufficient amounts.
•The hydraulic oil must have the proper viscosity in order to provide adequate lubrication. The oil
must also have a temperature rating that is adequate for this application.
•The hydraulic oil must have good anti-rust and oxidation properties.
Acceptable hydraulic oils for running the tubing tong are as follows:

9
Grease Specification
Tong grease lubrication is very important to ensure optimum performance. In addition, proper lubrication is key
to increase the service life of the tong. WESTCO Int. recommends the following grease:
•Standard Service –Chevron Ultra-Duty Grease EP NLGI 0,1 or 2 (or equivalent)
•Cold Weather Service –Chevron RPM Artic Grease NLGI-1 (or equivalent)
ILL-223: Tubing Tong Lubrication Locations

10

11

12
FIRST TIME STARTUP PROCEDURE
When preparing to operate a new or re-conditioned hydraulic tubing tong or a tong that has been in storage,
perform all of the operations listed below:
Tong:
Clean the tong and remove any packing material. Grease, oil, and lubricate brake band. Function test linkage
and shift mechanism for free operation. Suspend in derrick.
Hydraulic Hoses:
1. Adjust hydraulic system pressure to 500 PSI or less
2. Shift tong to neutral position.
3. Engage hydraulic system clutch.
4. Push throttle lever toward tong.
5. Hold the tong throttle open and allow the hydraulic fluid to circulate for approximately five minutes.
6. Check system for leaks.
7. If operating in cold weather engage tong in high gear and rotate 2-3 minutes for warm up. Check tong
linkage adjustments.

13
INSTALLATION
WESTCO Int. Tubing Tongs are assembled using carefully engineered and machined components. Each tong is
thoroughly tested, inspected, and shipped from the factory after passing quality inspection. The following pages
outline important procedures/requirements that will ensure proper tong operation.
Hose Connections
•Shut down all hydraulic power to the tong
•Connect hydraulic couplings in the following order: 1) return line 2) pressure line. Always disconnect in
the reverse order: 1) pressure line 2) return line (refer to ILL-065 for connection locations).
•Secure hydraulic hoses: do not bend or clamp hoses in a way that might hinder flow of hydraulic fluid.
Hoses should not obstruct workers on the rig floor.
Failure to shut down all hydraulic power prior to making any hose connection may lead to
serious injuries.
Suspending the tong in the derrick
•The tong shall be suspended at a height that allows the tong jaws to grip the tube six inches above the
upset. The angle of the vertical suspension line when the tong is over the tubing MUST NOT be large
enough to cause the tong to come off the tube.
•Connect the tong to the stiff-arm assembly (if a stiff-arm assembly is not in use, continue to next steps).
•Connect a back-up line to the tong. The back-up line (and any accessories used with the back-up line)
must have a load rating of at least 9,000 lbs. The back-up line must be horizontal to the rig floor; it must
not pull up or down while operating the tong. A load cell may be assembled in line with the back-up line
to obtain torque measurements. To ensure accurate torque readings, the back-up line must be
perpendicular to the tong.
oWESTCO International recommends the use of a safety sling to prevent injuries caused by failure
of the main back-up line or stiff-arm assembly. Attach one end of the safety sling to the eyebolt

14
located on the back of the tong. Attach the other end of the sling to the rig. The safety sling
should also be rated for 9,000 lbs.
NOTE: A back-up line must always be used, with or without the coupling back-up assembly
•Connect hydraulic hoses and start power unit.
•Swing the tong onto a tubing joint connection. Throttle the tong slowly until the back-up line’s slack is
removed. Make sure that the tong is now parallel to the rig floor.
If the tong is not parallel with the rig floor, the tong hanger must be adjusted. To level out the
tong, adjust the two bolts located on each side of the hanger.
Inspect the hanger assembly for any excessive wear or damage. The spring hanger should not be
completely bottomed out while the tong is hanging. Replace any worn or damaged parts
immediately.

15
JAW AND BUSHING ORIENTATION
The jaw and bushing are reversible, depending upon the
desired direction of rotation. If the jaw is installed on
the left side (standing in front of the tong, as you look
into the opening of the tong), the tong will rotate the
pipe to the left (Figure 1). When the jaw is installed on
the right side (Figure 2), it will rotate the pipe to the
right (this is the pipe rotation when going into the hole).
Shut down all hydraulic power to the
tong before changing the jaw/bushing
Figure 1: Jaws Installed (Break-out)
Figure 2: Jaws Installed (Make-up)

16
REMOVAL OF JAW AND BUSHING
Position the tong as shown in Figure 3. Throttle the
tong in reverse and position the bushing as shown in
Figure 3. Slightly move the outer ring to eliminate any
force acting on the pivot pin. Remove the pivot pin and
then remove the bushing. Next, remove the jaw pivot
pin and then remove the jaw.
NOTE: It is difficult to remove or install the jaw while
the bushing is still in place.
REVERSAL OF JAW AND BUSHING
Remove the jaw and bushing as outlined above. Move
the outer ring slightly in order to get the lip of the jaw
on the back of the front roller of the outer ring. Make
sure that you are using the correct bushing and jaw
size. Install the jaw as shown in Figure 4. Next, Install
the bushing as shown in Figure 3.
Shut down hydraulic power before
changing the jaw/bushing
Figure 4: Installation/removal of jaw
Figure 3: Installation/removal of bushing

17
JAW AND BUSHING SIZES:
Jaw and bushing sizes are stamped according to the actual O.D. of the tubing that they will fit - not the
“nominal” size of the tubing.
NOMINAL
STAMPED
NOMINAL
STAMPED

"
1.050"

"

"
"
1.315"
"

"

"
1.660"

"
"
--
1.750"
"

"

"
1.99"
--
--
--
 
 "
--
--
"

"
--
--

18
OPERATION
While the tong is suspended, move the gearshift lever (located towards the front of the tong) into high gear.
Open the tong guard door and position the tong onto the pipe (the door spring assembly will close the door
once the pipe is centered on the tong). NOTE: In order to grip the pipe correctly, it is critical that the tong’s jaws
are centered on the pipe. DO NOT SWING THE TONG ONTO THE PIPE TOO HARD AS IT MAY CAUSE THE TONG TO
BOUNCE OFF. Once the tong is centered on the pipe, engage the throttle slowly until the jaws grip and the pipe
rotates.
TONG ADJUSTMENTS
Shift Rod Adjustment
Shift rod adjustment is accomplished with jam nuts located on each end of the rod. Adjust the gearshift handle
in neutral position.
Throttle Adjustment
The throttle rod adjustment is set with the safety arm and the door in the open position. Adjust the safety bar
to match the slot in the safety arm and secure by tightening the jam nut.
NOTE: Proper adjustment allows full throttle in both directions with the door closed and prevents throttling
when door is open.
Gear Shift Tension Adjustment
Adjusting gearshift tension is accomplished by turning the setscrew in until the gears will not shift and then
backing out setscrew until shifting is smooth. There will be approximately three threads of the setscrew
exposed beyond the transmission cover when shifting mechanism is new. Setscrew position is also a wear
indicator for the shift rod fork.

19
GEAR TRAIN TIMING PROCEDURE
The high-speed pinion gear (item 51) must be timed properly to the two cluster gears (item 56/57) in order for
the gear train to rotate properly. Incorrect timing will cause the gear train to bind during operation. NOTE: This
timing procedure must be followed each time the tong’s gears are replaced. STEP 1: Align one tooth of the
pinion gear (item 51) with the centerline of the tong (see above illustration). STEP 2: Install the left and right
cluster gears (item 56/57). Orientate the stamped timing marks on the cluster gears between two of the pinion
gear teeth (see illustration). NOTE: The above illustration is a bottom view of the tong.