K-SERIES MANUAL TUBING TONG

OPERATING PROCEDURE MANUAL

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K Series Manual Tubing Tong Operating Procedure Manual
 TABLE OF CONTENTS

Section Page

1 - Introduction 2
1.1 General Information
1.2 Description
1.3 Technical Data

2 - Operation 3-5
2.1 Preparation
2.2 Installation
2.3 Operation

3 - Maintenance & Inspection 6-7

3.1 Inspection
3.2 Lubrication

4 - Size Change and Repairs 8

5 - Replacement Parts 9-10

6 - Accessories 11-12

7 - K Series Tong Die Chart 13

Certificate of Warranty and Guarantee to Quality 14

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1 - INTRODUCTION

1.1 PURPOSE

The technical manual contains operation and maintenance instructions for AOT K Series
Manual Tubing Tongs with complete parts breakdown. It provides a guide for proper field
use, disassembly and repair.

1.2 DESCRIPTION

The K Series consists of five models of manual tubing tongs. The five models handle a wide
range of tubing diameters with the simplistic installation of appropriately sized dies.

1.3 TECHNICAL DATA

MODEL MAXIMUM TORQUE RATING RANGE

K-25 2,000 FT. LBS. 1.050” - 2 7/8”
K-30 5,000 FT. LBS. 1.050“ - 4 1/8”
K-50 7,500 FT. LBS. 2 7/8” - 5 1/2”
K-50 HT 15,000 FT. LBS. 2 3/8” - 5 1/2”
K-70 12,500 FT. LBS. 3 1/2” - 7”

ANY OVERLOADING OF THE RECOMMENDED RATING OR MISUSE OF THIS

EQUIPMENT CAN CAUSE SERIOUS INJURY OR DEATH.

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2 - OPERATION

2.1 PREPARATION

In order for the K Series tongs to operate properly, it is necessary to install the proper size
die. The proper size of die corresponds to the tubing diameter on which the tong will be
used. Proper die installation procedures may be found in Section 4 of this manual.

2.2 INSTALLATION

As with any tong, the K Series are easily installed on the rig floor. All K Series tongs can be
used with or without a hanger. The hanger is recommended as an aid to tool handling for the
K-30, K-50 and K-70 tongs (See Figure 1a).

Hanger
Rollover Block

Tong

FIGURE 1A

Hangers as seen in Figure 1a can be used in tandem with an optional Rollover Block allowing
for ease in change of K-Series Tong direction of action. Additional information on this and
other user enhancing options is discussed in Section 6 of this manual.

Once attached to the tong, the hanger is affixed and suspended via wire rope made vertically
adjustable die to its attachment to a rig air tugger or similar mechanism.

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The K-25 Series tong utilizes a hanger similar in function to that of the larger K-Series Tongs
(See Figure 1b). The K-25 Hanger has the integrated ability to be utilized in either direction
of tong action.

K-25 Rollover Hanger

K-25 Tong

FIGURE 1B

2.3 OPERATION

After installation of the proper size dies, the “K” Series Tong is ready for Service. The jaws of
the tong should be properly latched around the pipe on an even surface so that the end of the
Tong Handle catches on the Head Pin of the Latch Jaw. Use the handle provided on the
Latch Jaw when latching or unlatching the tong (See Figure 2).

Head Pin

Tong Handle

Latch Jaw

FIGURE 2

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 KEEP HANDS AND FINGERS AWAY FROM ALL OTHER AREAS WHEN
HANDLING THE TONG. FAILURE TO FOLLOW THIS PROCEDURE COULD
RESULT IN INJURY OR LOSS OF LIMB.

The force used to apply torque should be at a 90 degree angle and parallel to the horizontal,
or torque direction, or rotational direction to the Tong Handle (See Figure 3).

Applied Force
Line of Action

FIGURE 3

• Check the Latch Jaw and Tong Handle for full engagement when latched around the
pipe.
• Insure that the tongs are used with proper size tubular and torque gauge.
• DO NOT EXCEED MAXIMUM TORQUE RATING FOR THE TONG THAT IS BEING
USED.

Failure to follow this procedure voids all warranty and could cause serious injury or
death.

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3 - MAINTENANCE

PRACTICE SAFETY AT ALL TIMES WHEN SERVICING AND DURING DAILY

USE OF AOT EQUIPMENT. ALWAYS USE PROPER SAFETY METHODS,
MATERIALS AND TOOLS. ALWAYS WEAR PROTECTIVE GEAR FOR EYES,
HEAD AND HANDS.

3.1 INSPECTION

To insure optimum performance from the K Series Tong, the following weekly inspections
should be performed (See Figures 5 & 6):

1. Check for worn handle and head pins and replace as necessary.
2. Check Tong Die Bushing, Screws and Washers for proper torque and condition.
3. Tongs should undergo a Magnetic Particle Examination conforming to API
specification 7K or equivalent at a minimum of once a week when in use. This can be
performed at any AOT approved facility in order to avoid possible warranty
nullification.

Inspect face for excessive wear

FIGURE 5

IF PIN HOLES IN JAWS OR HANDLE SHOW EXCESSIVE WEAR, DISCARD AND

REPLACE. DO NOT USE OVERSIZE PINS OR ATTEMPT TO WELD. IF CRACKS
ARE FOUND, DISCARD & REPLACE.

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3.2 LUBRICATIONS

Lubricate the tong regularly during times of usage and storage in order to prevent corrosion.
Use an extreme pressure, multipurpose, Lithium base grease of # 1 or # 2 consistencies.
When the tool is in use, lubricate the tong according to the following schedule or annually
while in storage (See Figure 6).

DAILY:

1. Remove, grease and reinstall Handle and Head Pins.

2. Remove, grease and reinstall Tong Die Bushings and Screws.
3. Grease both faces of Tong Handle where contact is made by the Handle Jaw.

Handle Pin Head Pins

Handle Jaw

Tong Handle
Tong Die Screw
Tong Die Bushing

FIGURE 6

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4 - SIZE CHANGE AND REPAIRS

ALWAYS WEAR EYE PROTECTION WHEN REMOVING OR REPLACING

INSERTS TO PROTECT AGAINST CHIP FRAGMENTS.

Changing Dies to replace worn Dies or change sizes (See Figure 7)

1. Remove Tong Die Screws and Bushings.

2. Clean and grease Button Pockets and backs of Dies prior to installation of new Dies.

3. Important: Always install the proper size die for the tubular to be used on. Make sure
the side of the die closest to the button pockets is facing towards the end of the latch
jaw or away from the handle when the tong is opened.

4. Grease the Tong Die Bushing and Screw, Install Tong Die Bushings into the Dies and
insert into Jaws. Install Screws with Lockwashers and Hand tighten. Using a 3/16”
Allen wrench, apply approximately 8-10 ft. lbs. of torque to each screw.

DO NOT OVER TORQUE SCREWS BECAUSE THIS WILL CAUSE THE BUTTON LIPS
TO SHEAR WHEN TORQUE IS APPLIED TO THE TONG.

Tong Die Screw

Tong Die Bushing

Die

FIGURE 7

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5 - REPLACEMENT COMPONENTS (SEE FIGURE 8 AND TABLE 1)

2 1

9
8
7

6 4

FIGURE 8

TABLE 1

05-101 K-25 COMPONENTS

Item # Part # Description Qty. *
1 05-103 TONG HEAD PIN 3 3
2 05-104 TONG HANDLE PIN 1 1
3 05-105 TONG DIE BUSHING (AS ASSY.) 6 24
4 05-105 TONG DIE SCREW & WASHER 6 24
5 05-106 K-25 HANDLE JAW 1
6 05-107 K-25 LATCH JAW 1
7 05-108 K-25 CENTER JAW 1
8 05-114 K-25 TONG HANDLE 1
9 05-117 SPRING LOCK (ALL PINS) 8 8
(* SUGGESTED SPARE QUANTITY)

06-101 K-30 COMPONENTS

Item # Part # Description Qty. *
1 06-109 TONG HEAD PIN 3 3
2 06-108 TONG HANDLE PIN 1 1
3 06-110 TONG DIE BUSHING 6 24
4 06-111 TONG DIE SCREW & WASHER 6 24
5 06-105 K-30 HANDLE JAW 1
6 06-107 K-30 LATCH JAW 1
7 06-106 K-30 CENTER JAW 1
8 06-104 K-30 TONG HANDLE 1
9 06-157 SPRING LOCK (ALL PINS) 8 8
(* SUGGESTED SPARE QUANTITY)
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 TABLE1 (CONT.)

06-501 K-50 COMPONENTS

Item # Part # Description Qty. *
1 06-509 TONG HEAD PIN 3 3
2 06-508 TONG HANDLE PIN 1 1
3 06-510 TONG DIE BUSHING 6 24
4 06-511 TONG DIE SCREW & WASHER 6 24
5 06-505 K-50 HANDLE JAW 1
6 06-507 K-50 LATCH JAW 1
7 06-506 K-50 CENTER JAW 1
8 06-504 K-50 TONG HANDLE 1
9 06-516 SPRING LOCK (ALL PINS) 8 8
(* SUGGESTED SPARE QUANTITY)

06-605 K-50 HT COMPONENTS

Item # Part # Description Qty. *
1 06-508 TONG HEAD PIN 3 3
2 06-708 TONG HANDLE PIN 1 1
3 06-510 TONG DIE BUSHING 6 24
4 06-511 TONG DIE SCREW & WASHER 6 24
5 06-601 K-50 HT HANDLE JAW 1
6 06-603 K-50 HT LATCH JAW 1
7 06-602 K-50 HT CENTER JAW 1
8 06-704 K-50 HT TONG HANDLE 1
9 06-516 SPRING LOCK (ALL PINS) 8 8
(* SUGGESTED SPARE QUANTITY)

06-701 K-70 COMPONENTS

Item # Part # Description Qty. *
1 06-508 TONG HEAD PIN 3 3
2 06-708 TONG HANDLE PIN 1 1
3 06-510 TONG DIE BUSHING 6 24
4 06-511 TONG DIE SCREW & WASHER 6 24
5 06-705 K-70 HANDLE JAW 1
6 06-707 K-70 LATCH JAW 1
7 06-706 K-70 CENTER JAW 1
8 06-704 K-70 TONG HANDLE 1
9 06-516 SPRING LOCK (ALL PINS) 8 8
(* SUGGESTED SPARE QUANTITY)

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6 - ACCESSORIES (SEE FIGURES AS DEPICTED BELOW AND TABLE 2)

K-25 Rope Guide FIGURE 9

K-25 Rollover Hanger FIGURE 10
K-30, 50, 50 HT, 70 Standard Hanger FIGURE 11
K-30, 50, 50 HT, 70 Rollover Hanger FIGURE 12
K-30, 50, 50 HT, 70 Tong Handler FIGURE 13
K-30, 50, 50 HT, 70 Tong Handler (installed) FIGURE 14

AOT PART # 05-109 AOT PART # 05-113

Figure 9 Figure 10

AOT PART # 06-113 AOT PART # 06-112

FIGURE 11 FIGURE 12

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 K-30 AOT PART # 06-199
K-50 AOT PART # 06-599
K-50 HT & K-70 AOT PART # 06-799

Figure 13

FIGURE 14

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7 - K-SERIES TONG DIE CHART

K-20 K-50 & 50 HT

Part # Description Qty/Reqd. Part # Description Qty/Reqd.
04-119 3/4" (1.050") 3 06-575 2 7/8" 3
04-120 1" (1.315") 3 06-576 3 1/2" 3
04-121 1 1/4" (1.660") 3 06-577 3 3/4" 3
04-122 1 1/2" (1.900") 3 06-578 4" 3
04-123 2 1/16" 3 06-579 4 1/8" 3
04-124 2 3/8" 3 06-580 4 1/2" 3
06-581 4 3/4" 3
K-25 06-582 5" 3
Part # Description Qty/Reqd. 06-583 5 1/2" 3
05-129 3/4" (1.050") 3
05-120 1" (1.315") 3 K-70
05-121 1 1/4" (1.660") 3 Part # Description Qty/Reqd.
05-122 1 1/2" (1.900") 3 06-758 3 1/2" 3
05-123 2 1/16" 3 06-757 4" 3
05-124 2 3/8" 3 06-756 4 1/2" 3
05-125 2 1/2" 3 06-755 4 3/4" 3
05-126 2.697" 3 06-754 5" 3
05-127 2.776" 3 06-753 5 1/2" 3
05-128 2 7/8" 3 06-759 5 3/4" 3
06-752 6" 3
K-30 06-751 6 5/8" 3
Part # Description Qty/Reqd. 06-750 7" 3
06-132 3/4" (1.050") 3
06-136 1" (1.315") 3
06-133 1 1/4" (1.660") 3
06-134 1 1/2" (1.900") 3
06-119 2 1/16" 3
06-120 2 3/8" 3
06-121 2 7/8" 3
06-135 3" 3
06-122 3 1/16" 3
06-123 3 1/8" 3
06-124 3 1/4" 3
06-130 3 3/8" 3
06-125 3 1/2" 3
06-126 3.668" 3
06-127 3 3/4" 3
06-131 3 7/8" 3
06-128 4 1/8" 3

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 CERTIFICATE OF WARRANTY AND GUARANTEE TO QUALITY

Seller warrants all materials, products and supplies manufactured or furnished by it to be free
from defects in material and workmanship, under normal use and service, when installed,
used and serviced in the manner provided and intended by seller for a period of twelve (12)
months after installation or delivery, whichever shall occur first. Seller’s obligations under this
warranty are expressly limited to repair or replacement, at its option, of any materials,
products or supplies returned to seller’s plant, Broussard, Louisiana, and which are
determined by seller to be defective. All freight charges for return and reshipment shall be
paid by customer. A new warranty period shall not be established for repaired or replaced
materials, products or supplies; such items shall remain under warranty only for the
remainder of the warranty period on the original materials, products or supplies. This is the
sole warranty of seller and no other warranty is applicable, either express or implied, in fact or
by law, including any warranty as to merchantability or fitness for a particular use or purpose.

In case of goods or parts not wholly of seller’s manufacture, seller shall make available to the
customer whatever warranty or guaranty is extended to seller for such goods or parts by the
supplier or manufacturer thereof.

Seller will not assume responsibility or liability for any repairs, rebuilding, welding or heat
treating done to its material, products or supplies outside of seller’s plants, such work shall
void any all warranties. All parts used in the manufacture and/or final assembly of seller’s
materials, products and supplies are necessary for both safety and operational performance.
Omission of any part or failure to replace any part may result in a malfunction and a
consequent safety hazard for which seller disclaims any responsibility or liability for injuries or
damage as a result thereof.

Buyer’s sole and only remedy in regard to any defective materials, products or supplies shall
be the repair or replacement thereof as herein provided, and seller shall not be liable for any
consequential, special, incidental or punitive damages resulting from or caused by any
defective materials, products or supplies.

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