GEARENCH TJA35 User Manual

PETOL™ Tong Jack

TJA35

Operating Manual

GEARENCH™

P.O. Box 192

4450 South Highway 6

Clifton, Texas 76634

Phone: [phone]

Fax: [phone]

© 2014 by GEARENCH. All rights reserved

Form TJA35 revision 07/15/14

Table of Contents

PETOL™ Tong Jack Description ......................................................................................... 1

Warranty ................................................................................................................................. 2

Safe Practices and Procedures ............................................................................................... 4

Responsibility ..................................................................................................................................................... 4

Replacement Parts .............................................................................................................................................. 4

Safety .................................................................................................................................................................. 4

Safe Practices...................................................................................................................................................... 4

Safety Sources and Publications ......................................................................................................................... 5

Responsibility of Distributors ............................................................................................................................. 6

Safety Precautions .............................................................................................................................................. 6

Operation ................................................................................................................................. 7

Pressure to Force Conversion Chart ................................................................................................................... 8

Making-Up a Connection.................................................................................................................................... 9

Breaking-Out a Connection ................................................................................................................................ 9

Parts List ................................................................................................................................ 10

ii

PETOL™ Tong Jack Description

The TJA35 PETOL™ Tong Jack is a portable pneumatic powered actuator designed to
provide the operating force on a tong handle. It was designed to eliminate the use of
“cheaters” and overhead hoists on connections unable to be made up or broken out by hand.

The Tong Jack can produce up to 3500 pounds of force lifting on a tong handle. It is
intended for use in a shop with a floor of adequate strength to support 3500 pounds.

The TJA35 offers the following features:

Tilting the unit back, and engaging the wheels allows the unit to be easily maneuvered
around the workshop.

The applied force is controlled by adjusting an hydraulic relief valve on the side of the
unit. A pressure gauge and pressure to force conversion chart are mounted to the unit
to indicate the applied force produced.

The machine is operated by using minimum 40 psi regulated compressed air.

Tongs can be easily changed to accommodate different diameter ranges and torque
requirements.

1

Warranty

What Is Covered

GEARENCH™ tools are expressly warranted to you, the purchaser, to be free of defects in material and
workmanship.

How Long Coverage Lasts

This express warranty lasts for the lifetime of the GEARENCH tool. Warranty coverage ends when the tool
becomes unusable for reasons other than defects in workmanship or material.

How Can You Get Warranty Service

To obtain the benefit of this warranty, contact a GEARENCH sales representative in Clifton, Texas.

GEARENCH · 4450 South Highway 6 · P.O. Box 192 · Clifton, TX 76634

What Will We Do To Correct Problems

Warranted products will be repaired or replaced, at GEARENCH’s option, and returned at no charge to you, the
original purchaser; or, if after three attempts at repair or replacement during the warranty period, the product
defect in material or workmanship persists, you can elect to receive a full refund of your original purchase price
for the product.

What Is Not Covered

Defects, failures or conditions that are due to normal wear and tear, abuse or misuse, are not covered by this
limited warranty. In addition, this limited warranty is in lieu of all other war ranties, express or implied, verbal
or written. To the maximum extent allowed by law GEARENCH disclaims all imp lied wa rranties, including
implied warranties of merchantability and/or fitness for a particular purpose. GEARENCH also specifically
denies any liability for any incidental damages and/or consequential damages, including but not limited to
property damage to property other than the product itself, loss of sales profits, down time, costs or any other
damages measurable in money, whether or not included in the foregoing enumeration.

Please be advised that some states do not allow the exclusion or limitation of incidental or consequential
damages, so this limitation or exclusion may no t apply to you. This warranty gives you specific rights, and you
may also have other rights, which vary from state to state, province to province, or country to country.

Are Personal Injuries Covered

In the event you, s omeone working for you, or any othe r pe rso n sustain a pe rsona l inj ury as a r esult o f using the
GEARENCH tool, GEARENCH limits its potential liability for such a claim or injury to the fullest extent
allowed by law, and disclaims and denies any liability for such personal injury.

Please be advised that some states do not allow the exclusion or limitation of liability for personal injuries, so
the above limitation or exclusion may not apply to you, or the individual claiming injury.

No Other Express Warranty Applies

This GEARENCH LIMITED WARRANTY is the sole and exclusive warranty, express or implied for
GEARENCH products. No employee, agent, dealer or other person is authorized to alter, modify, expand or
reduce the terms of this warranty or to make any other warranty on behalf of GEARENCH.

Law Applicable

All matters related to the sale and/o r use of the GEARENCH tool that is the subject of this limited warranty,
along with the construction and enforcement of the terms of this limited warranty itself, shall be subject to the
substantive and procedural laws of the state of Texas, not the conflicts of laws provisions of Texas, but rather
the laws of Texas themselves.

2

Forum Selection Clause

Any dispute arising out of the sale and/or use of the GEARENCH tool that is the subject of this limited warranty
shall be presented in the form of a claim or lawsuit to the offices of GEARENCH in Clifton, Bosque County,
Texas. No claim or suit may be brought against GEARENCH, arising out of the sale and/or use of the tool, or
arising out of the terms o f this warranty, except in suc h forum. Purchase and /or use of the GEAREN CH tool
makes you subject to the benefits and limitations of this limited warranty. Accordingly, any writ, judgment or
other enforcement, obtained from a jurisdiction, county, parish, state o r fede ral co urt or other co untry, other that
from the forum identified above, shall be void and unenforceable against GEARENCH.

Arbitration Clause

In the event of dispute or claim arises out of the sale and/or use of the GEARENCH tool that is the subject of
this limited warranty, or arises out of the interpretation or enforcement of the terms and conditions of this
limited warranty, such dispute shall be submitted to binding arbitration pursuant to the rules of the American
Arbitration Association. If r equired to accomplish the purpose o f this Arbitration clause, the purchaser hereby
expressly waives any right to demand trial by jury.

Complete Agreement

This express limited warranty contains the entire agreement regarding express or implied warranties related to
the GEARENCH tool that is the subject of it. No writing or language contained in the purchase order o r any
other document of the purchaser, or invoice of GEARENCH or any intermediate seller, shall be construed as
modifying, in any way, the rights and liabilities contained in this limited warranty. GEARENCH expressly
disclaims any obligations expressed in any customer purchase order or document that are contrary to the terms
and limitations of this warranty.

Severability

If any term or limitation contained in this limited warranty is deemed unenforceable by law, then the term shall
be severed from the remaining portions of the limited warranty which shall remain enforceable.

All communications to GEARENCH regarding the use of the tool and any aspect of the sale of the tool of this
limited warranty should be addressed to GEARENCH.

GEARENCH · 4450 South Highway 6 · P.O. Box 192 · Clifton, TX 76634

3

Safe Practices and Procedures

Responsibility

"It is the responsibility of the employer to train the employee in the proper selection and
usage of tools, chains, etc., and to ensure that they are selected and used in that manner. In
many instances, injury results because it is assumed that anybody knows how to use common
hand tools. Observations and the record show that this is not the case. A part of every job
instruction program should therefore be detailed training in the proper use of hand tools (and
of all other special tools and equipment needed to accomplish the job)." - (Source: Natio nal
Safety Council)

"Employers are responsible for the safe condition of tools and equipment used by employees,
including tools and equipment which may be furnished by employees." - (Source: OSHA

1910.242A)

Replacement Parts

Use only PETOL™ replacement parts - no other parts are of comparable strength, quality and
interchangeability.

Safety

While we pride ourselves on the quality and dependability we build into GEARENCH™
tools and products, we caution users that it is only prudent to know and follow the simple
rules of safety when using our products, or anyone else's.

Always follow safe practices and procedures in accordance with the recommendations of
OSHA, The National Safety Council (NSC), The Hand Tools Institute (HTI), The National
Association of Chain Manufacturers (NACM), The International Association of Drilling
Contractors (IADC), Etc. All applicable Governmental rules, regulations or restrictions, now
in effect or which may be promulgated, take precedence over the suggestions in this
publication. The information in this publication is designed to supplement standard safe
practices and procedures, not in lieu of, or replacement thereof.

Safe Practices
(Source: The National Safety Council)

Failure to observe one or more of the following five safe practices accounts for most hand
and powered tool accidents:

1. ALWAYS WEAR SAFETY GOGGLES TO PROTECT EYES

2. SELECT THE RIGHT TOOL FOR THE JOB

3. KEEP TOOLS IN GOOD CONDITION

4. USE TOOLS CORRECTLY

5. KEEP TOOLS IN A SAFE PLACE

4

Safety Goggles must always be worn by persons in any area where hand and powered tools
are being used.

Never apply excess lev erage to a wrench o r tool by means of a "Cheater Bar". Never st rike
wrenches and tools with hammers or other objects.

All tools should be kept clean, inspected on a regular basis, and replaced when they show
signs of wear.

Be especially careful not to place yourself in a position that could result in bodily injury in
the event of a failure. Brace yourself firm ly and pull rather than push when wrenching. (If
necessary to push, do so with the flat of the hand rather than gripping around the wrench.)

Never stand under or near loads being hoisted off the ground.

READ SAFE PRACTICES AND PR OCEDURES MANUAL, CATALOG INFORMATION
AND PRODUCT LABELING PRIOR TO OPERATION.

Spinning and drill pipe chain, cathead chain, and the PETOL™ Connecting Link attachment
are designed for the specific purpose for which the name indicates. Chains and attachments
that are to be used for any other purpose should be selected in accordance with the
recommendations of ASTM, NACM, Rigger's Handbook, and the commercial chain
manufacturer's technical manuals.

Safety Sources and Publications

In the interest of Safety the following sources of Safety information is furnished:

The Hand Tools Institute (HTI)
25 North Broadway
Tarrytown, New York 10591
[phone]
www.hti.org

The National Safety Council (NSC)
1121 Spring Lake Drive
Itasca, Illinois 60143-3201
[phone]
www.nsc.org

International Safety Council
1121 Spring Lake Drive
Itasca, Illinois 60143-3201
[phone]

5

Responsibility of Distributors

IT IS THE RESPONSIBILITY OF THE PURC HASERS OF GEARENCH PR ODUCTS TO
CONVEY THE INFORMATION IN THIS PUBLICATION AND ANY OTHER
INFORMATION RELATING TO THE INDIVIDUAL PRODUCT, THROUGH THE
CHANNELS OF DISTRIBUTION, DOWN TO AND INCLUDING THE INDIVIDUAL
USING THE PRODUCT

NOTE:
In view of the fact that the actual use determines whether safety requirements have
been met, the ultimate responsibility to comply rests with the end user.

Safety Precautions

1. Select the right tool for the job.

2. Keep tools in good condition.

3. Use tools correctly.

4. Keep tools in a safe place.

5. Wear protective clothing, gloves and safety shoes as appropriate.

6. Use only PETOL™ & TITAN™ replacement parts to ensure proper strength.

7. Do not exceed limitations of machine.

8. Do not use machine for unintended purposes.

9. Inspect machine prior to use.

10. Use pressure control to regulate force.

11. Place machine close to vise.

12. Review operating manual and procedures prior to use.

13. Do not place tong on non-uniform surfaces.

14. Do not place tong on thin sections.

15. Insure all dies and inserts are in good working condition on tong and vise

16. Remove any unserviceable equipment from service.

17. If equipment slips in vise, stop and reset vise.

18. Insure proper body placement during operation.

19. Insure proper hand placement.

20. Remove trip hazards and unnecessary objects from area.

21. Wear appropriate personal protection equipment.

6

Operation

The operating controls of the PETOL™ Tong Jack are shown in the figure below. The
pressure gauge is used to monitor and adjust the operating pressure. The pressure to force
conversion chart is used to determine the actual force in pounds being applied to the tong.
The air connection supplies the compressed air to the unit. The pressure control regulates the
output pressure and adjusts the force produced. Turning the knob clockwise increases the
pressure. Turning the knob counter-clockwise reduces the pressure. The direction control
causes the arm to raise or lower. Lift the control to raise the arm, lower the control to lower
the arm. The tong connection pin connects to the tong handle. If the tong has a clevis on the
handle, use the “y” shaped link shown in the diagram. If the tong has a single handle loop,
use two flat plate links in place of the “y” link.

7

Pressure to Force Conversion Chart

Pressure - Force Conversion Chart

(psi)

(lbs)

(psi)

(lbs)

170

200

1630

1900

260

300

1710

2000

340

400

1800

2100

430

500

1890

2200

510

600

1970

2300

600

700

2060

2400

690

800

2140

2500

770

900

2230

2600

860

1000

2310

2700

940

1100

2400

2800

1030

1200

2490

2900

1110

1300

2570

3000

1200

1400

2660

3100

1290

1500

2740

3200

1370

1600

2830

3300

1460

1700

2910

3400

1540

1800

3000

3500

The chart below is in “force”. Torque is typically measured in foot-pounds. In order to
calculate the torque, the length from the load pin to the pipe center must be known in inches.
The torque in food pounds can then be calculated by the formula:

Torque (foot-pounds) = Force (lbs) x Length (inches) / 12

Pressure

Force

Pressure

Force

8

Making-Up a Connection

Place the tool into a suitable vise with the connection as close to the vise as possible. Make
up the tool by hand as tight as possible. Place the tong as close to the connection as possible.
Move the Tong Jack into position and connect the tong to the Tong Jack. Connect the air
supply to the Tong Jack. Lower the arm as far as possible. With the arm fully lowered,
adjust the pressure control to provide the required torque.

WARNING: Under no circumstances should the maximum working load of the
tong or vise be exceeded. The tong jack may be capable of providing more force
than the tong is rated for.

Lift the arm to apply force to the tong. If the tong arm reaches the end of its travel, lower the
arm, insure that the tong is still properly latched, and raise the arm again. Continue raising
the arm until the arm stops moving. The tool will then be full made up. Lower the arm and
unlatch the tong.

Breaking-Out a Connection

Place the tool into a suitable vise with the connection as close to the vise as possible. Place
the tong as close to the connection as possible. Move the Tong Jack into position and
connect the tong to the Tong Jack. Connect the air supply to the Tong Jack. Lower the arm
as far as possible. With the arm fully lowered, adjust the pressure control fully counter­clockwise to achieve the minimum pressure possible. Raise the tong until the arm stops
moving. Continue lifting on the tong handle while SLOWLY increasing the pressure until
the connection breaks. Do not adjust the pressure higher than the rating of the tong or vise.
If the connection does not break before reaching the rating of the tong, vise, or maximum
pressure of the Tong Jack, stop the operation and use a safe method of producing higher
torque. Should you need assistance, please contact GEARENCH™ for help in selecting
appropriate equipment.

WARNING: Under no circumstances should the maximum working load of the
tong or vis e be exceed ed. Th e to ng jack may be cap abl e of p rovi din g more force
than the tong is rated for.

Lower the arm and unlatch the tong.

9

Parts List

The following d rawing and p arts list d escribe all parts , which may be needed as replacem ent
items. Where appropriate, standard industrial, electrical, and hydraulic components have
been used. Should a standard industrial item need replacing, the item may be purchased
locally. To assist you in obtaining parts, the OEM component manufacturer and model
numbers are shown on the parts list. Of course, all replacement parts will be supplied by
GEARENCH™ if you prefer to order from us.

10

Parts List

Item

Qty.

Part Number

Description

Notes

1 1 TJB35

Base 2 1 TJL35

Left plate

3 1

TJR35

Right plate

4 1

TJC35

Control panel

5 2 TJW35-1

Wheel

McMaster-Carr
22245T17 (or equal)

6 1 TJW35-2

Axle 7 1 TJG35

Guard

8 1 TJY35

Hydraulic cylinder

Vickers (or equal)
NZ16EE5N5KA04000

9 1 TJM35

Arm 10 4 TJT35

Trunion mount

11 1 TJH35

Handle 12 1 TJS35-1

Tong support arm

13 1 TJS35-2

Tong support leg

14 1 TJN35

Nameplate

15 1 HP375

Quick release pin

Carr-Lane
CL-12-BLPT-3.00 (or equal)

16 2 HXC002

Cotter pin

1/8 x 1

17 2 HXN010

Locknut

5/16-18UNC nylon insert

18 4 HXN016

Locknut

1/2-13UNC heavy flexlock

19

16

HXS003

Hex bolt

3/8-16UNC x 1-1/4

20

16

HXS006

Hex bolt

3/8-16UNC x 1

21 4 HXS007

Hex bolt

1/2-13UNC x 2

22 6 HXS029

Hex bolt

5/8-11unc x 1-1/2

23 6 HXS069

Hex bolt

5/16-18UNC x 1-1/4

24 4 HXS072

Hex bolt

1/2-20UNF x 1

25 4 HXW003

Flat washer

5/8

26 6 HXW004

Spring lock washer

5/8

27 8 HXW005

Spring lock washer

1/2

28

32

HXW006

Spring lock washer

3/8

29 6 HXW008

Spring lock washer

5/16

30 2 UHCH-F97

Male connector

Swagelok S-600-1-6 (or equal)

31 2 UHCH-F15

Male elbow

Swagelok
S-600-2-6ST (or equal)

32 1 UHCH-F95

Female elbow

Swagelok S-400-8-4 (or equal)

33 1 UHCH-F71

Male connector

Swagelok S-400-1-4 (or equal)

34 1 UHCH-F88

Female bulkhead

Weatherhead
C5275X6 (or equal)

35 1 UHCH-F89

Male elbow

Weatherhead
C5405X6X6 (or equal)

11

Item

Qty.

Part Number

Description

Notes

36 2 UHCH-F91

Male elbow

Weatherhead
C5515X6X8 (or equal)

37 1 UHCH-F96

Male connector

Parker 6-6FFTX-S (or equal)

38 3 UHCH-F94

Male connector

Weatherhead
C5205X6X6 (or equal)

39 1 UHCH-F45

Reducer bushi ng

Weatherhead
C31095X8X6 (or equal)

40 1 UHCH-G08

Pressure gauge

Wika
9318275-UC (or equal)

41 1 UHCH-G10

Gauge mount

42 3 UHCH-H12

Hydraulic hose

Gates (or equal)
6C2AT-6FJX90M-6FJX-23

43 1 UHCH-H13

Hydraulic hose

Gates (or equal)
6C2AT-6FJX90M-6FJX-37

44 1 UHCH-H14

Hydraulic hose

Gates (or equal)
6C2AT-6FJX90M-6FJX-29

45 1 UHCH-P21

Hydraulic pump

Power Team
PA55A-B-A-A-A-A-A-B-D-BB-A-G

46 1 UHCH-T014

Hydraulic tube

47 1 UHCH-T015

Hydraulic tube

48 1 UHCH-T016

Hydraulic tube

49 1 UHCH-V45

Directional valve

Barksdale 6942S23H03-MC

50 1 UHCH-V46

Relief valve cartridge

Sun RPEE-OAN

51 1 UHCH-V48

Relief valve body

52 1 UHCH-V49

Ball valve (brass)

McMaster –Carr
47865K41 (or equal)

53

1

UHCY-ZB-RC

Cylinder rod clevis

Vickers S-462-10 (or equal)

54 1 TMW35

Master link

54A 2 18-1-A

Chain link

Not shown, use in pla ce of master link
for single to ng handle loop

55 1 HP009

Master link – arm pin

56 1 HXKR075

Klipring

Rotor-clip PO-75 STPA (or equal)

57 4 HXBR001

Blind rivet

3/16 X 1/4

58 2 UHCH-F92

Male connector

Weatherhead
C5315X6 (or equal)

12