GEARENCH ZB1260U User Manual

Petol Friction Breakout Unit

ZB1260U

Operating Manual

Gearench

P.O. Box 192

4450 Highway 6 South

Clifton, Texas 76634

Phone: [phone]

Fax: [phone]

© 2008 by GEARENCH. All rights reserved

Form ZB1260U revision 06/30/08

Table of Contents

Petol ZB1260U Unit Description ................................................................................................................... 3

Warranty ......................................................................................................................................................... 4

Safe Practices and Procedures ....................................................................................................................... 6

Responsibility .......................................................................................................................................................... 6

Replacement Parts ................................................................................................................................................... 6

Safety ...................................................................................................................................................................... 6

Safe Practices .......................................................................................................................................................... 7

Safety Sources and Publications .............................................................................................................................. 8

Responsibility of Distributors ................................................................................................................................. 8

Installation.................................................................................................................................................... 10

Location ................................................................................................................................................................ 10

Setup ..................................................................................................................................................................... 10

Recommended Equipment .................................................................................................................................... 10

Operation ..................................................................................................................................................... 11

Torque – Pressure Conversion Chart ..................................................................................................................... 11

Loading ................................................................................................................................................................. 12

Breaking Out ......................................................................................................................................................... 12

Making Up ............................................................................................................................................................ 12

Safe Operating Area .............................................................................................................................................. 13

Parts List ...................................................................................................................................................... 14

Final Assembly ...................................................................................................................................................... 16

Cylinder Assembly ................................................................................................................................................ 18

2

Petol ZB1260U Unit Description

The ZB1260U Petol Friction Breakout Unit was designed for making up and breaking out
downhole pumps and specialty downhole tools requiring accurate torque and no marking.
The unit is equipped with a hydraulic cylinder, which may be powered by any hydraulic
power source capable of producing up to 5000 psi.

The unit may be used with any pump shop equipment manufactured by Gearench. The unit
may be configured in any fashion using floor plates, pump stands, and extension stands for
working on tools of any length.

Warning:

The unit should not be operated at a pressure above 5000 psi. The tong or wrench
being used with the cylinder may have a torque rating lower than 5000 foot-pounds in
which case the maximum operating pressure will be less. Applying too much pressure
for the tong or wrench may result in damage to the tong or wrench and possibly in
injury to personnel.

3

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 warranties, express or implied, verbal
or written. To the maximum extent allowed by law GEARENCH disclaims all implied warranties, 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 not 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, someone working for you, or any other person sustain a personal injury as a result of 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/or 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.

4

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 of this warranty, except in such forum. Purchase and/or use of the
GEARENCH 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 or federal court or other
country, 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 required to accomplish the purpose of 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 or 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

5

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: National
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 & TITAN 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.

6

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

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

Never apply excess leverage to a wrench or tool by means of a "Cheater Bar". Never strike

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 firmly 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 PROCEDURES 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.

7

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]

Responsibility of Distributors

IT IS THE RESPONSIBILITY OF THE PURCHASERS OF GEARENCH PRODUCTS 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.

8

Safety Precautions

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.

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

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

9

Installation

Location

The Petol Friction Breakout Unit should be located in an area with adequate room to work
the tools. The unit should be located indoors mounted on a finished shop floor. No special
foundation is required.

Setup

Locate the hydraulic power unit in a convenient location and connect the hoses to the
hydraulic cylinder. Cycle the cylinder several times to clear the system of any entrapped air.

Recommended Equipment

The following equipment is recommended for installation and operation. Only one pump is
required. The recommended pumps are of minimum capacity. A larger or more elaborate
pump or power unit may be used.

Installation kit Petol ZI1260-7

Hand pump Enerpac P-84

Power Team P159-D

Electric pump (110V) Enerpac WEM1304B

Power Team PE104

Air pump Enerpac PAM-1402N

Power Team PA6D

Hoses (2 each) Enerpac HC-913 (6 feet long)

10

Operation

The hydraulic pressure gauge is used to indicate the current system pressure in psi. See the
torque-pressure conversion chart below.

WARNING:
Never operate the tong with a pressure higher than required to perform the make up or
break out operation. Operation at excessive pressure may damage the downhole tool
and/or injure personnel.

Torque – Pressure Conversion Chart

PRESSURE - TORQUE CONVERSION

Pressure Torque Pressure Torque

300 360 2300 2730

400 470 2400 2850

500 590 2500 2970

600 710 2600 3090

700 830 2700 3200

800 950 2800 3320

900 1070 2900 3440

1000 1190 3000 3560

1100 1310 3100 3680

1200 1420 3200 3800

1300 1540 3300 3920

1400 1660 3400 4030

1500 1780 3500 4150

1600 1900 3600 4270

1700 2020 3700 4390

1800 2140 3800 4510

1900 2250 3900 4630

2000 2370 4000 4750

2100 2490 4100 4870

2200 2610 4200 4980

11

Loading

To load the tool in the unit set the tool into the vise or benchrench as needed. Adjust the vee­saddle or pump support to support the tool. Position the tong for make up or break out as
needed and set the tong onto the tool. Attach the tong to the cylinder with the quick release
pin.

CAUTION:
The vee-saddle or pump support must be used to support the tool while torquing.

Breaking Out

Load the tool and adjust the tong and vise as described above. Fully ratchet the tong. Slowly

increase the system pressure until the connection is broken loose or the working load of the

tong is reached. Do not exceed the rating of the tong. Consult with GEARENCH as
needed for help with the toughest break out jobs. After the initial breakout, the tong may

be unpinned from the cylinder and operated by hand until the connection is fully loosened.

Making Up

Load the tool and adjust the tong and vise as described above. Make up the connection hand
tight using the tong. Pin the tong to the cylinder. Fully extend the cylinder. Retract the
cylinder increasing the pressure on the cylinder until the desired torque is reached.

12

Safe Operating Area

For safe operation, it is recommended that the operator and other personnel not stand in the
areas shown in the figure below during operation.

13 14

Parts List

The following drawings, diagrams, and parts lists describe all parts, which may be needed as
replacement items. Where appropriate, standard industrial 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.

All tong, vise, and chain components are manufactured only by
GEARENCH. DO NOT ATTEMPT TO SUBSTITUTE THESE
COMPONENTS. The unit will not work properly unless these components
are matched to the specific application. Consult our factory as your
requirements change. Any non-GEARENCH substitutions of these
components void all warranties and subject the user to assumption of
liabilities resulting from subsequent use.

Final Assembly Parts List

15 16

Final Assembly

Item Qty Part Number Description Make/Model Notes

1 1 ZB1260 Bench assembly

2 1 ZB1260U-1 Rail

3 1 UHCY-ZB Cylinder assembly See pages 13-14

4 8 HXS007 Hex bolt ½-13UNC x 1-3/4 Gr. 5

5 8 HXN043 Hex nut ½-13UNC

6 8 HXW005 Lock washer ½

7 1 ZI1260-7 Installation kit

Cylinder Assembly

17 18

Cylinder Assembly

Item Qty. Part Number Description Make/Model Notes

1 1 UHCY-ZB-EB Eye bracket

2 1 UHCY-ZB-C Cylinder Vickers/Aeroquip

TG10CAGA1AA07000

3 1 UHCY-ZB-RC Rod clevis Vickers/Aeroquip

S-462-10

4 1 HP374 Pin McMaster-Carr

98325A498

5 1 HP375 Pin McMaster-Carr

98325A745

6 2 UHCH-F45 Reducer bushing Weatherhead

C3109X8X6

7 1 UHCH-F43 Male run tee Weatherhead

C3759X6

8 1 UHCH-F42 Reducer bushing Weatherhead

C3109X6X4

9 1 UHCH-G06 Pressure gauge Wika

213.40 4” LM 5000psi

With custom face

10 2 UHCH-Q05 Quick Connect Enerpac

CR-400

Or equal

Or equal

Or equal

Or equal

Or equal

Or equal