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VARCO TDS-11SA-Service-Manual PDF
VARCO TDS-11SA-Service-Manual PDF
SM00856
Revision B
Counterbalance
System
Motor Cooling
System
AC Drilling
Motors (2)
Transmission/
Motor Housing
Hydraulic
System
Rotating Link
Adapter
Guide Beam
and Carriage
Pipehandler
Specifications 2
Lubrication 3
Installation, Commissioning 4
and Decommissioning
Motor Housing, 6
Transmission
PH-75 Pipehandler 7
PH-50 Pipehandler 8
Hydraulic System 9
TDS-11SA Rev. B
1 General Information
2 Specifications
3 Lubrication
4 Installation, Commissioning
and Decommissioning
6 Motor Housing,
Transmission
7 PH-75 Pipehandler
8 PH-50 Pipehandler
9 Hydraulic System
Varco Systems
General Information
Preface ...................................................1-3
Manual conventions ........................................... 1-3 1
Note ............................................................................... 1-3
Caution .......................................................................... 1-3
Warning ......................................................................... 1-3
2
Overall equipment safety requirements ............ 1-3
Personnel training ......................................................... 1-3
Systems safety practices ............................................... 1-4
Electrical systems and components .................................. 1-4
Hydraulic systems and components .................................. 1-4 3
Pneumatic systems and components ................................ 1-5
General safety ............................................................... 1-5
Equipment motion hazards ................................................ 1-5
When replacing components ............................................. 1-6
4
During routine maintenance .............................................. 1-6
Visibility of equipment operation ........................................ 1-6
Proper use of equipment ................................................... 1-6
Varco Service Centers .................................................. 1-6
5
Identification numbers ....................................... 1-7
Lifting points ....................................................... 1-8
Safety wiring ....................................................... 1-9
Torque values ..................................................... 1-10 6
Basic useage ...................................................... 1-11
Drilling ahead with singles ............................................. 1-11
Drilling ahead with triples............................................... 1-12
Backreaming ................................................................. 1-13 7
TDS-11SA Rev. B
General Information
1 Counterbalance
System
Motor Cooling
System
AC Drilling
Motors (2)
Transmission/
Motor Housing
Hydraulic
System
Rotating Link
Adapter
Guide Beam
and Carriage
Pipehandler
Preface
Manual conventions 1
This Preface contains the conventions used throughout this manual.
Avoid injury to personnel and/or equipment damage by reading this
manual and related documents before operating, inspecting, or
servicing the equipment.
The following examples explain the symbols for notes, cautions, and
warnings. Please pay close attention to these important advisories.
Note
Caution
Warning
Personnel training
All personnel installing, operating, repairing, or maintaining
equipment, or those in the vicinity of this equipment, should be
trained in rig safety, tool operation, and maintenance as applicable.
❏ Isolate, lock out, and tag the hydraulic and electrical power and
controls. 1
❏ Isolate, lock out, and tag the pneumatic, electrical power and
controls.
General safety
Equipment motion hazards
Some Varco equipment can travel horizontally, vertically or both.
Identification numbers
1
i Trace code identifies the
configuration of your equipment
Encoder
Instruction Label
Located on the righthand
brake cover
SALES ORDER NO.
ASSY NO. REV
TRACE CODE
DATE OF MANUFACTURE
AC Motor
Identification Label Top Drive
Located on the side Identification Plate
of each AC motor Located on the front
of the motor housing
Warning Labels
Located on the side
of each AC motor
Warning Label
Located on the
side of the bonnet
Lifting points
1
Lifting Point
For lowering/hoisting the
Top Drive and
Guide Beam/Skid
Tag Line
Attachment Points
For the Guide
Beam/Skid with
Top Drive attached
Block
Lifting Points
For the Guide
Beam/Skid with
Top Drive attached
Crane
Lifting Points
Crane For the Guide
Lifting Points Beam/Skid with
For the Guide Top Drive attached
Beam/Skid with (1 each side)
Top Drive attached
Safety wiring
1
1 2
3 4 5
i
Refer to ASP00019
Procedure for Safety Wiring
Torque values
(Unless otherwise specified)
Basic useage
Drilling ahead with singles
1
Makeup
Open
IBOP
Link Tilt
Close IBOP
Stab Makeup
Basic useage
Drilling ahead with triples
1 Step 1 Step 2 Step 3 Step 4 Step 5
Set slips on string Raise block Pickup stand Lower block to Pull slips
with elevator stab motor into
Stop circulation Tilt link tilt to top of stand Start circulation
derrickman Stab bottom of
Breakout connection stand onto string Spin in motor Begin drilling
using pipehandler and stand
and drilling motor
(in reverse) Makeup both
connections
with motor
Start
Circulation
Stop
Circulation
Stab Makeup
Basic useage
Backreaming
Step 1 Step 2 Step 3 Step 4 Step 5 1
Hoist while Set slips on string Hoist free stand Setback stand Lower block, stab
circulating and with elevator using link tilt motor into string
rotating Breakout
connection using Spin in motor
When 3-rd pipehandler and and makeup
connection drilling motor connection with
surfaces, stop (reverse) motor
rotation and
circulation Breakout and Start circulation,
spinout stand pull slips, hoist
at floor and rotate
Hoist and
Rotate
Breakout
Consumables
Consumable Part Quantity Part Number
Brake
Pads
Wash
Pipe
Hydraulic
Oil Filter
Gear
Oil Filter
Stabilizers
Tong Dies
Stabbing
Guide
Size specifications
Bail
120 in.
31.0 in.
Bail
88 in.
260.0 in.
230.0 in.
To Center
of Gravity
160.0 in.
To Center
of Gravity To Center
25.0 in. of Gravity
50.0 in. 41.5 in.
Size specifications
Rear
35.9 in.
2
34.0 in.
C
L
Well
21.1 in.
C
L
Well
Front
General specifications
Components Items Description
Drill Pipe Sizes 3-1/2 in. to 5 in. (4 in. to 6-5/8 in. OD tool joint)
Variable Frequency Drive Type IDM Yaskowa Drive (800 hp, 575 VAC) or
Siemens (800 hp, 600 VAC)
Electrical House Size 125.4 in. x 84.0 in., 91.2 in. height (Siemens)
Type 140.0 in. x 90.0 in., 91.0 in. height (IDM)
Weight 9,500 lb
Input requirement 600 VAC(50/60 Hz), or 750 VDC, or 690 VDC(50/60 Hz)
Mud Hose
75 ft. (22.9 m)* Drill Stand
Connected to Standpipe Made-up at
at 73 ft. (22.3 m) Level 4 ft. (1,2 m)
Level
93 ft. (28.3 m)
Service Loop
AC Power and
AC Cables Control Cables
Performance curve
55,000
50,000
45,000
800 HP
40,000
Drill Pipe Torque (ft-lbs)
2 35,000
Dual AC Motor Top Drive TDS-11SA
2 x 400 = 800 HP, 500 Ton System
30,000 10.5:1 Transmission
25,000
20,000
15,000
10,000
5,000
0
0 25 50 75 100 125 150 175 200 225 250
Drill Pipe RPM
TDS-11SA Rev. B
Lubrication
Transmission
Selecting the proper gearbox oil
TDS transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of the
gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA “extra pressure” rating (EP), and a
minimum viscosity of 100 SUS at internal operating temperature.
Lubrication schedule
Description Frequency
Replace the Gearbox Oil Following Intial Break-in Following first month of operation
Replace the Gearbox Oil and Perform an Oil Analysis Every 6 Months
Oil viscosity should be adjusted based on expected ambient conditions for next six months
Replace the Gearbox Oil Filter (P/N 30111013-1) Every 3 Months
Remove, clean and replace the Magnetic Drain Plug Yearly
The first oil change should be performed after the first month of
operation since new units often contain metal contaminates and
contaminates caused by initial break-in.
Transmission
Recommended gear oils
Ambient Temperature Range
-6˚ to 16˚ C 7˚ to 30˚ C Above 21˚ C
(20˚ to 60˚ F) (45˚ to 85˚ F) (Above 70˚ F)
Manufacturer
Castrol Alpha LS-68 Alpha LS-150 Alpha LS-320
Chevron NL Gear 68 NL Gear 150 NL Gear 320
Exxon Spartan EP68 Spartan EP150 Spartan EP320
Gulf EP Lube HD68 EP Lube HD150 EP Lube HD320
Mobil MobilGear 626 MobilGear 629 MobilGear 632
Shell Omala 150 or Omala 150 Omala 320 or
Spirax 80W-90 GL5 Spirax 85W-140 GL5
3
Statoil Loadway EP68 Loadway EP150 Loadway EP320
Texaco Meropa 68 Meropa 150 Meropa 320
Total Carter EP 68 Carter EP 150 Carter EP 320
Union Extra Duty NL4EP Extra Duty NL4EP Extra Duty NL6EP
76 MP Gear Lube 76 MP Gear Lube
80W-90 GL5 85W-140 GL5
Viscosity Index
AGMA 4EP 5EP 6EP
ISO Viscosity Grade 150 220 320
Gearbox lubrication
3
Cork Ball
(Level Sight
Indicator) Glass
Gearbox
Oil Drain
i
Gear Oil
Sight Gauge
Check with Top Drive
“OFF” Replace gear oil every
6 Months
Gearbox Oil Fill
Clean area before
i
removing plug, then
use a 1 3/8 inch, 12 point
socket to remove plug
“Pop-up”
Dirt
Alarm Procedure
Check oil level, prior to adding oil
(do not mistake the tan colored
foam for the dark brown oil)
Ensure that the unit is turned OFF
Gear Oil Filter
Replace every The area must be wiped clean
prior to adding gearbox oil
3 Months
Recheck oil level and replace the
plug after adding oil
Yearly Run the unit and recheck the oil
level (not foam level), after the unit
Magnetic Drain Plug has been running and the
Remove and clean contamination transmission oil is warm
Hydraulic system
Precautions
Lubrication schedule
Description Frequency
Hydraulic system
Recommended hydraulic fluid
Oil Temperature Range
-15˚ to 75˚ C -10˚ to 85˚ C
(5˚ to 167˚ F) (14˚ to 185˚ F)
Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
3 Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
Viscosity Index
ISO Viscosity Grade 32 46
Hydraulic system
Hydraulic lubrication
Procedure
The area must be clean prior to adding hydraulic fluid
Remove dust plug from the male quick disconnect at
the TDS hydraulic oil fill
Remove dust plug from the female quick disconnect
on the lubrication kit and connect it to the male fitting
Pump fluid until the level reaches the middle of the
Cork Ball sight glass as shown
(Level Indicator) After adding fluid, replace the dust plugs
Sight
Glass
Replace
hydraulic fluid
3
Yearly
Sight Hydraulic or earlier based
Glass Oil Sight on oil analysis
Gauge Red
“Pop-up”
Hydraulic
Dirt Alarm
Oil Fill
Male Quick
Disconnect
Replace every
3 Months
Hydraulic
Oil Filter Dust Plug
Female
Quick
Disconnect
Hydraulic
Lubrication Kit
55 gal Drum
Varco P/N 92643
Hydraulic
Oil Drain
Motors
Lubrication schedule
Description No. of Points Frequency Type
Manufacturer
Chevron Black Pearl EP2 (Do Not Substitute)
Motors
Motor lubrication
i Grease Fittings
Apply motor grease
to designated Grease
grease fittings Fitting
with hand grease gun 1/8 inch
Varco P/N
53201
3 Months
!
Pipe Plug 3
AC Blower 1/8 inch
Motor (2) (remove and
3 pumps reinstall after
(2 grease fittings lubricating)
each motor)
3 Months
AC Drilling
Motor (2)
5 pumps
(2 grease fittings
each motor) 3 Months
Hydraulic Pump AC Motor
3 pumps
(2 grease fittings)
Procedure
Lubrication schedule
Description No. of Points Frequency Type
Washpipe Assembly 1 Twice Daily General Purpose Grease
IBOP Actuator Yoke, Cylinder Pins 5 Daily General Purpose Grease
IBOP Actuator Cranks 2 Daily General Purpose Grease
Stabilizer Bushing 4 Daily General Purpose Grease
Clamp Cylinder Gate 2 Daily General Purpose Grease
Upper Bonnet Seal 1 Weekly General Purpose Grease
Bail Pins 2 Weekly General Purpose Grease
Rotating Link Adapter Gear – Weekly General Purpose Grease
Rotating Link Adapter 2 Weekly General Purpose Grease
Shot Pin Assembly 1 Weekly General Purpose Grease
Upper IBOP Valve 1 Weekly General Purpose Grease
Torque Arrestor at Clamp Cylinder – Weekly General Purpose Grease
Wireline Adapter 2 Weekly General Purpose Grease
Elevator Link Eyes 4 Weekly Pipe Dope
Traveling Block Sheaves 3 Monthly General Purpose Grease
Guide Dolly Runner Shaft 12 Every 6 mos. General Purpose Grease
Manufacturer
Castrol N/R MP Grease
Chevron Avi-Motive W Avi-Motive
Exxon Lidok EP1 Lidok EP2
Gulf Gulf Crown EP31 Gulf Crown EP32
Mobil Mobilux EP1 Mobilux EP2
Shell Alvania EP1 Alvania EP2
Statoil Uniway EP1N Uniway EP2N 3
Texaco Multifak EP1 Multifak EP2
Total Multis EP1 Multis EP2
Union Unoba EP1 Unoba EP2
Viscosity Index
NGLI 1 2
i
Apply general purpose
grease to designated
grease fittings with
grease gun. Use a brush
when greasing other parts.
Daily
Wash Pipe
Assembly
Apply one pump
twice daily
Weekly Weekly
Bail Pins (2) Upper Bonnet Seal
Two pumps each side One pump
Use Hand Pump Only
Weekly
Weekly
Rotating Link
Rotating Link Adapter
Adapter Gear
Three pumps each
Brush with grease
i
Apply general purpose grease to
designated grease fittings with
grease gun. Use a brush when
greasing other parts.
Daily
IBOP Actuator Yoke
One pump each side
3
Daily
IBOP Actuator Cranks
One pump each side
Daily
Weekly Stabilizer Liner
One pump each side
Upper IBOP Valve
Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps Weekly
Replace Clamp Cylinder Gate
! plug before
operating
One pump each side
Daily Weekly
Stabilizer Liner Elevator Link Eyes
One pump each side (4)
Pipe Dope
i
Apply general purpose grease
to designated grease fittings
with grease gun
Weekly
Guide Rollers
4 Places
One pump each
(if equipped)
Weekly
Guide Rollers
16 Places
One pump each
(if equipped)
Weekly
Bogies
4 Places
One pump each
(if equipped)
TDS-11SA Rev. B
Installation, Commissioning
and Decommissioning
Installation, Commissioning
and Decommissioning
4-2 Varco
Varco Systems
Systems
Installation, Commissioning
and Decommissioning
Illustrated index
Counterbalance
Page 4-34
Rotary Hose
Service Loop
Page 4-29
Intermediate
Varco Tieback
Driller’s Console Page 4-6
(VDC)
Page 4-30
Control Cable
with Connectors
Page 4-31 Main Tieback
Page 4-7
Unitized Variable
Frequency Inverter and
Varco Control Panel (House)
Page 4-8
AC Cables
Page 4-9
AC Power and
Control Cables
Page 4-9
Preinstallation
Preparation
The TDS interfaces with the rig’s hoisting system and electrical
power system. Derrick and electrical system modifications are
required when installing the TDS on existing rigs.
For derricks that handle triples, the required top drive travel is
about 100 ft. compared to about 75 ft. when using a Kelly. It is
generally necessary to replace the regular rotary hose (which is
normally 60 ft. long) with a 75 ft. hose, and extend the standpipe
height to approximately 73 ft.
Although many rig floor layouts are possible, installing the guide
beam on the drawworks side of the derrick, or mast, and opposite
the V-door is an ideal arrangement for handling tubulars from the V-
door.
❏ Drawworks fastline
Preinstallation
Installing the crown padeye and hang-off link
Crown Padeye
■ Weld at 30 inches
from well center
■ Padeye to be suitable
for 25 ton load
Crown
30 inches
25 Ton
Shackle
i
For land rig applications,
when possible, install crown
padeye, hang-off link and
tieback with mast layed down.
Hang-off Link
■ Adjust length per
General Arrangement
Drawing
Hang-off
Tieback
Drill Typical
Floor Cross Girt
Below Crown
C
L
Well
Preinstallation
Installing the intermediate tieback
Locking
4 Bolt
Pivot
Point
Drill i
Floor
Refer to General Arrangement
30.0 inches Drawing for installation heigth.
C
L
Well
Preinstallation
Installing the main tieback
Procedure
■ Install the main spreader beam at the
appropriate distance from well center
■ Install the tieback plate and tieback link
■ Torque and lock wire all bolts
i
Typical (depending Tieback Link
on block and hook
configuration.
Tieback
Plate
4
Main
Spreader
Beam
Apply Anti-seize
Compound
Typical
Auxiliary
Spreader Beam
Optional
Main Tieback and
Spreader Beam
Adjust after
installation
of TDS and
guide beams
Mast Leg
Drill
Floor
30.0 inches
C
L
Well
Preinstallation
Locating the control house
Drawworks
V-Door
Ramp
4 C
L
Well
TDS
Varco
Driller s
9,500 lb Console
(4300 kg)
Control House
C
L
Well
Control
House
i
Typical installation
Recommendations
Position the control house off-driller s side or
91 in. behind the drawworks
(2310 mm)
Position as close to derrick plate as possible
to minimize cable lengths
Ensure a safe distance from direct sources of
heat (i.e. diesel engines, general exhausts)
140 in. 90 in. Location of the control house must ensure
(3560 mm) (2290 mm) accessibility from all sides
Do not expose the control house to H2S
Preinstallation
Installing power cables
COM
POS
ITE
CON
NEC
TOR
AUX
. PO
WE
RC
ON
N ECT
OR
SER
IAL
Ground Lug CON
NEC
TOR
to Top Drive
Plug Panel
i
Typical installation
UI
NC
OM
ING
575
VA
C
V IN
CO
MIN
G5
75V
AC
WI
NC
OM
Incoming Power Cables
ING
575
VA
575VAC to main circuit breaker
C
(3 Places)
UO
4
UT
GO
ING
575
VA
C
VO
UT
GO
ING
575
VA
Outgoing Power Cables
C
WO to Top Drive
UT
GO
ING
575
(3 or 6 Places)
VA
C
Varco
Rain Cover Control House
Typical
Plug Panel
Procedure
Clean all connector contacts
Connect the power cables with the isolation
circuit breaker turned OFF
Connect cables in accordance with the
electrical schematic provided in the Technical
Drawings book
Lockwire all connector nuts
Earth the control house with the Varco
Ground Rod Kit (See page 4-10)
Preinstallation
Earthing the control house (land rigs)
Copper Plated
Steel Rod
Cable Clamp
Cable Lug
Copper Wire
10 ft
Procedure
Insert the grounding rod into the soil (the rod
Ground Rod Kit
must be in contact with ground water) Grounding Points
P/N 116004
Connect the rod to the control house Located at opposite
(connection must be clean) corners of the house floor
For offshore installations the control house
i must be grounded to the ground point on the
rig structure
Preinstallation
Checklist
The following assumes that all pre-installation planning and rig-up is
complete prior to installation of the guide beam assembly and TDS.
This includes:
❏ Make sure the derrick/mast is vertical, with the block over the
center of the rotary table.
Installation
Raising the top guide beam section to the drill floor
Procedure
Locate the top guide beam section near the
V-Door
Ensure the hoist carriage is free to slide the
entire length of the guide beam
Ensure the latch moves freely
Attach lifting slings to the lifting eyes of the
hoist carriage
Eusure the transport shipping pins are in
place and secure
Hoist the guide beam section to the drill floor
using a tugger line with a backup line to tail
Remove tugger line after top guide beam is in Hoist
position on drill floor Carriage
Tugger Line
Attachment
Points
4 (Rig UP)
RIG DOWN UP
Tugger Line
3,0000 Lbs Attachment
Tugger Pull Points
(Rig DOWN)
Top Guide
Beam
Shipping
Latch Pins
2 places
Drill
Floor
Backup
Line
Installation
Attaching the carriage sling to the hook
Hoist
Carriage
Cable Sling
Attachment
Points
(RIG UP)
RIG DOWN UP
Cable Sling
Attachment
Points 4
(RIG DOWN)
Top Guide
Beam
Disengage
Shipping Pins
Hoist
Procedure
Cable Sling Attach a short cable sling from the hook/block
to the hoist carriage at the RIG UP
attachment points
Disengage the shipping pins
Hoist the top guide beam using the
drawworks
Installation
Moving guide beam sections
Procedure
Locate the remaining guide beam sections
near the V-Door
Attach tugger lines to the lifting eyes of the
first guide beam section to be hoisted
Hoist the guide beam section to the drill floor
using the rear tugger line or tailing line to
stabilize and balance the guide beam
Tugger
3,200 lb Line
(1450 kg)
24 ft. Guide Beam Section
Tugger
4 Line
3
Guide Beam Section Guide Beam
Hoist to the drill floor Section
Tugger
Line
Tugger
Line
2
Lifting Eyes
Attach tugger lines
for hoisting
Drill
Floor
1
Guide Beam Sections
Prior to Installation
Installation
Hooking the first guide beam section
Guide Beam
Top Section
1 2
Present Match
Grease
the bores on
both joint halves
Guide
Surface
4
3 4
Engage Hook
Hook Pin
In fully engaged
position
Present
and Hook
the first guide
beam section Hook Pin
Saddle
Procedure
Tugger Line
Guide Beam Leave attached Locate the guide beam to be hooked
Section to stabilize the under the top guide beam section
Hooked back end of Grease the bores on both joint halves
the guide beam
Align the guide surface with the hook pin as
shown
Lower the top guide beam to match and
engage the hook pin to the hook pin saddle
Hoist the top guide beam to fully engage the
hook pin
Manually stabilize the back end of
the guide beam
Installation
Hoisting the first guide beam section
Guide Beam
Top Section
Hoist
Hook Pin
4 First Guide
Beam Section
Initially hoisted
by the hook pin
Installation
Stabbing and pinning the first guide beam section
Guide Beam 1
Top Section Stab
the guide beam
joints together
Lynch Pin
2
Joint Pin
Install after stabbing 4
4 3
Secure Retainer Pin
with the Apply grease
lynch pin and insert
Stab
and Pin
the guide
beam joint
Block as Procedure
Required Lower the guide beam to drill floor and stab
the guide beam joints together
Secure the guide beam in a vertical position if
required
Install the cleaned and greased joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown
Installation
Completing guide beam installation
Tugger
Line Tugger
Line
Procedure
Move the next guide beam section to the drill floor
Present the end of the guide beam to be hooked
Ensure that the bores on both joint halves have
been greased
Drill Engage the hook pin saddle around the hook pin
Floor
Hoist the guide beam with the drawwork
Lower the guide beam to the drill floor and stab
the guide beam joints together
Install the joint pin
Install the retainer pin
Secure the pins with the lynch pin
Installation
Hoisting and attaching the guide beam
Diverter To Protect
Against Accidental
Unlatching
Procedure 4
Hoist Carriage
Attach guide beam Extension
assembly to hangoff link
Procedure Tieback
Handle
Rotate intermediate
tieback handle UP 90
degrees
Insert the intermediate
tieback into the slot
located on the lower
guide beam
Rotate intermediate
tieback handle DOWN 90
degrees to lock the guide
beam in place
Adjust the tieback bracket
so the center of the guide Guide
beam is 30 inches from Beam
well center Slot
Intermediate
Tieback
Attach Intermediate
Tieback into Lower
Guide Beam Slot
Installation
Removing the hoist carriage
Hoist
Carriage
Drill
Floor Procedure
Lower hoist carriage to drill floor
Remove hoist carriage from drill floor and
store (to be used again for rig down and
transport)
Installation
Moving the top drive to the drill floor
Procedure
Ensure the safety of all personnel
■ Locate the Top Drive at the bottom of the
V-Door ramp
■ Attach a lifting sling to the bail
■ Attach backup lines to the skid
■ Hoist the Top Drive and skid to the drill floor
30,000 lb
(13600 kg) 4
TDS-11SA
on the skid
Lifting
Block
Hoist using
the drawwork
Side Bracket
(2 Places)
TDS
2 hoisted up
V-Door Ramp
Drill Bail
Floor 60 ft Slings Lifting Detail
(2 Places
Typical)
1 TDS Backup
on skid Line
Installation
Attaching the top drive to the hook
i There are two basic methods for installing the TDS-11SA top drive, depending on the travelling equipment
configuration. Follow the installation procedures for option 1 or option 2 as appropriate for the rig.
V-Door
Ramp
Procedure
Remove hoist cable slings
Attach bail to block or hook
Secure lower end of skid to prevent
movement toward or down V-door
ramp
Hoist using drawworks
Installation
Lifting the top drive to the rig floor
Hook open
towards
drawworks
i
Hook open
towards Depending on the
v-door traveling equipment and
bail length, variations of
this procedure may be
required
Installation
Hoisting and connecting the top drive to the guide beam
Guide 1 2
Beam Present Hook
Lower Insert hook pin Lower TDS/Skid
Section into hook pin saddle until it makes
contact with Lower
Tieback
Hook Pin
Grease
the bores on Hook Pin
both joint In fully engaged
halves position
Grease
the bores on Hook Pin
both joint Saddle
halves
Guide Beam
/Skid Section
Skid not shown
4 3
Attach
Lower
Tieback
OPTION
2
Lower
Tieback
Present
and Hook
TDS to the guide
beam section Guide Beam
Hook /Skid Section
Joint Skid not shown
OPTION
1
Procedure
Lower
Tieback Backup Locate the TDS skid to be hooked
Line under the bottom guide beam section
Grease the bores on both joint halves
Align the guide surface with the hook pin as
shown
Lower the TDS skid to match and engage the
hook pin to the hook pin saddle
The lower guide beam section and skid will
contact the lower tieback
Installation
Attaching the torque tieback
Tieback
Retainer
Pins
Tieback
Tieback Hook
Pivot Pin
OPTION
2
Tieback
Pivot Pin
OPTION Tieback
1 Hook
Procedure
Engage tieback hooks to secure the
lower guide beam/skid
Insert retainer pins
Installation
Pinning the top drive to the guide beam
Guide Beam
Bottom Section
4
Secure
with the Lynch
Pin Seating
lynch pin Surfaces
2 3
Lower
Joint Pin Retainer Pin
Tieback
Install Apply grease
and insert
4
OPTION
2
1
Guide Beam
/Skid Section
Hoist until it seats
Hoist Skid not shown
Using the
drawwork
OPTION i
1 The bottom end of guide
beam/skid should be
approxmently 7 ft plus
or minus 6 inches above
Drill the drill floor
Floor Procedure
Hoist guide beam/skid section until it seats
Install the joint pin
Grease and install the retainer pin
Secure the retainer pin with the lynch pin as
shown
Installation
Releasing the top drive from the skid
Pin
View of 1
Carriage Upper
from Rear Latch
Engaged
Lower
Latch
Pin Disengaged 4
Pin
Latches
OPTION Both sides
engaged
2
Pin
Pin 2
Upper
Latch
Disengaged
Lower
Latch
Lower the TDS, disengage the
Disengaged
OPTION Upper Carriage Latch
1 and pin it as shown.
Pin
Drill
Floor Option 2 Procedure
Lower the blocks
Remove the slings
Connect the hook/block to the bail
Disengage the carriage latches
Installation
Installing derrick termination
Hoist Line Derrick/
Attachment Point Mast Leg
Derrick
Leg Plate
Hoist Line Service Loop
Attachment Brackets
Points
Mount the
Derrick
Termination
Plate
as recommended
83 ft
from drill floor
Recommendations
Mount on the side of the derrick adjacent to the
service loop brackets on the Top Drive
Installation
Installing the service loop to the derrick
Hoist
Derrick
Termination Plate
1,000 lb
(450 kg)
Each
Service Loop
Sling
!
Avoid damage to
the service loops
by using care when
dragging it near TDS
sharp edges and Service Loop
allow room for
passing under the
V-door
Lifting Eyes
Do not remove
Derrick
Service Loop
! Recommendations
Avoid damage to the
service loops by maintaining a Do not unpack the service loops until they are
40 inch minimum ready to hang
bend radius Use a sling attached to the lifting eyes to hoist
each service loop
Service Loop Use the swivel at the tugger line attachment to
and Storage Tub allow each service loop to uncoil without
3,600 lb twisting
(1600 kg)
Installation
Installing the driller’s console
Drawworks
V-Door
TDS Ramp
Recommended Area
for Varco Driller’s
Console Location
!
UE
RQ
TO
P
IBO
Y
NC
Customers who choose to use control BR
AK
E
EM ST
GE
ER OP
Recommendations
Mount within easy reach and in plain view of the
driller while the drawworks brake and clutches
are being operated
Pigtail Cable Location must ensure that the gauges are easily
Connect to seen by the driller during drilling operations
control house Location must be visible and readable at night
Installation
Installing the driller’s console cabling
COM
POS
ITE
CON
NEC
TOR
AUX
. PO
WE
RC
ON
NEC
TOR
SER
IAL Profibus Serial Link
CON
NEC
TOR to Driller’s Console
UI
NC
OM
ING
575
VA
C
V IN
CO
MIN
G5
75V
AC
Plug Panel
WI
NC
OM
ING
575
VA
C
UO
4
UT
GO
ING
5 75V
AC
VO
UT
GO
ING
575
VA
C
WO
UT
GO
ING
575
VA
C
Varco
Rain Cover Control House
Plug Panel
Recommendations
Ensure that the Varco Driller’s Console is
properly located
Connect the power cables with the isolation
circuit breaker turned OFF
Connect cables in accordance with the
electrical schematic provided in the Technical
Drawings book
Tighten connector nuts
Lockwire connector nuts to prevent loosening
Installation
Motor rotation checkout procedure
Direction
of Rotation
Counterclockwise
Procedure
Assign the Top Drive and inverter by selecting Direction
FORWARD or REVERSE on the driller’s console of Rotation
Clockwise
Check the rotation direction of the cooling and oil
pump motors
Rotate the drill stem using the THROTTLE on the
driller’s console and observe proper operation
Cooling Motors
2 Places
UE
RQ
TO
RQ
TO
X
MA
OP
IB P
IBOSED Y
CL
O NC
GE
MER OP RQ
UE
E ST 0 TO
ILL
DR
D
SE AR
P LO RW
IBO C F
OF FO
X
MA
EN E
OP RS
VE
IVE RE 0
DRULT
FA Throttle Direction
of Rotation
Counterclockwise
Forward/Reverse
Control
Varco
Driller’s
Oil Pump
Console
TO
RQ
UE
Motor
OP
IB
Y
NC
E GE
AK ER OP
BR EM ST
ER
DL
AN
EH
PIP
Drill Stem
Direction Reverse
of Rotation
Forward
Installation
Installing the pipe elevator and links
Catch
Link Bolt
Rear Motor
Guard
Pipehandler
Rotate Switch
Link Tilt
Varco
Driller’s
Console
OP
TO
RQ
UE
Link
IB
Y
NC
E GE
AK ER OP
BR EM ST
ER
DL
AN
EH
PIP
Clevis
Pin
Procedure
Using the Varco Driller’s Console, rotate the
pipehandler 90˚ (positioning the catch link under
the front of the motor guard)
Lubricate the elevator link eyes with pipe dope
Hoist the elevator link onto the rotating link adapter
(the small link eye at the bottom)
Secure the catch link with the pin and bolt
Secure the elevator link to the link tilt
Rotate the pipehandler 180˚ and install the other
elevator link
Install the pipe elevator in accordance with the pipe
elevator manual
Installation
Installing the counterbalance
Procedure
Refer to Setting up the circuits in the
Hydraulic section of this manual for initial
system set up Hook
Install the pear links to the ears on the hook
Turn on the Top Drive power
Rotate the counterbalance mode valve from Pear Link
the RUN position to the RIG-UP position 2 Places
When the cylinders reach the end of stroke,
slide the cylinder clevis over the pear link
and install the cylinder clevis pin
Cylinder
After securing the counterbalance cylinder to Clevis
the pear link, rotate the counterbalance 2 Places
mode valve to the RUN position
Adjust PCC clockwise to raise the pressure
at test port CB until the bail just begins to lift
off of the block
Reduce the pressure slowly (25 psi) to allow
pressure to stabilize
4
Cylinder
Clevis Pin
2 Places
Rig-up/Run/ Counterbalance
Shutdown Valve Cylinder
Shown in RIG-UP 2 Places
position (switch to RUN (8.5 inch stroke)
after the counterbalance
is installed) Bail
RUN
SHUTDOWN
RIG-UP
COUNTERBALANCE MODE
WN
DO
R
UT
U
N
SH
CO
UN
TE
RB
ALA
NC
EM
OD
E
RIG
-U
P Hydraulic
Manifold
Commissioning
Checkout procedure
Initial Rig-Up
Pre-charge all accumulators (See the
Hydraulics System section of this manual)
Adjust the hydraulic system
Bleed the air from the hydraulic system Cork Ball
(Level Indicator)
Constantly monitor the hydraulic fluid level, and
never allow the level to fall below the middle of
the sight glass (system power OFF)
Checkout Procedure
Lubricate all grease points (See Lubrication)
Check for loose or missing connectors Sight
Glass
Lockwire all connector nuts
Check for interference along entire mast Hydraulic
Remove exhaust covers from AC drilling motors Oil Sight
Gauge
Check blower inlets and outlets for blockage
Set the air conditioner to 75˚F (27˚C)
4
Turn on the main breaker
Air Inlet
Between motor
and brake housing,
2 Places
Exhaust Cover
4 Places
TOP DRIVE
INS
T
WH ALL
UN EN
ST IT IS
VARCO
OR
ED
Exhaust Outlet
Through louvers at
bottom of AC drilling motors,
6 Places
Commissioning
Hydraulic system checkout procedure
Checking hydraulic fluid level
Cork Ball
(Level Indicator)
Red
“Pop-up”
Dirt Alarm
Sight
Glass
4 Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter
Procedure
Ensure that the pipehandler clamp cylinder is
unclamped, the counterbalance cylinders are
connected to the hook, the bail is resting in the
hook, and the system power is OFF
Check to see that the hydrulic fluid level is at
the middle of the sight glass
If the fluid is low, add hydraulic fluid (see the
Lubrication and Maintenance section of this
manual
Check the red “pop-up” alarm on the hydraulic
filter for contamination
Replace the filter (P/N 114416-1) if the
indicator has popped up
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
Commissioning
Electrical system checkout procedure
Emergency Stop
Latch
9 Places
M
RP
UE
RQ
TO
UE
RQ RPM Meter
TO
X
MA
P
IBOOP
IB SED Y
CL
O NC
GE
AK
E ER OP RQ
UE
BRRAKE EM ST 0 TO
T
B N
O
SE AR
D
DR
ILL
Torque Meter 4
ER LOA P LO RW
DL T F IBO C F
OF FO
AN K TIL MA
X
EH LIN EN E
PIP OP
VE
RS
HT E E
IVE
TE IG AK AK RE 0
TA R BR TO BRON DRULT
RO AU FA
FT F
S LE ILT OF
OILLOS
S KT T
ES LINOFF TIL
PR
P CH
-U IT EN ILL
KE LIM WR LD DR
MAENT UE HO
RR RQ H &
CU TOPUS
OR
OT P R
L M EM WE
X RIL RT PO N
MA DOVE UL
IC O
RA
YD
MP H
0 LA ECK UTO
A
AR /
M CH
AL NCE
E
SIL
O SS
E RL
OW
BL
UE
RQ
SP
IN TO
ILL
DR
Procedure
All personnel must stand clear
All personnel operating the Top Drive should be
trained in rig safety and tool operation
Operate each control on the Varco driller’s console
(See Varco FIP00003)
Check for alarm conditions and resolve any alarms
at this time (See Varco FIP00003)
Check all connectors for tightness and lockwire
Check operation of meters
Check operation of emergency stop
Check the latches on the driller’s console for
tightness
Pigtail Cable
Connected to
control house
Commissioning
Mechanical checkout procedure
Checking gearbox oil level
Procedure
With the drive motors and hydraulic
system off, check to see that the oil level
(identified by a floating cork ball) is at the
middle of the glass located on the lube
pump adapter plate mounted on the side
of the gearbox
Always check the oil level, not foam level
(oil is dark brown, foam is tan) after the
unit has been running and the
transmission oil is warm
If the oil level is low, add gear oil (see the
Lubrication and Maintenance section of
this manual
Check the red “pop-up” alarm on the gear
oil filter for contamination
Replace the filter (P/N 111013-1) if the
4 indicator has popped up
Cork Ball
(Level Sight
Indicator) Glass
i i
Gear Oil Gearbox Oil Fill
Sight Gauge Clean area before removing plug,
Check with Top Drive then use a 1 3/8 inch, 12 point
“OFF” socket to remove plug
“Pop-up”
Dirt Alarm
Commissioning
Adjusting the link tilt
i
Jam Nut
Adjust the derrickman position
with the adjusting screw and
lock in position with the jam nut
Link Tilt
Crank
Assembly
Pin
26 inches
(660 mm) 4
Typical
Clamp
i
Mousehole
Position Cable 3-4 inches
Pull “up” or “down” (76-102 mm)
to set mousehole
position
i
Drill Down
Position
Bottom of elevator
should be above
Link the bottom of the
Mousehole stabbing guide
Position
Derrickman’s Position
Link clamps should be adjusted
so that the elevator does not Elevator
hit the diving board in this position Well Center
Float Position
Commissioning
Breaking out the saver sub
During normal operation, the torque backup clamp cylinder is
sitting on the springs, which are supported by the bottom plate of
the torque arrestor.
1. Loosen the tool joint lock between the saver sub and the lower
IBOP valve by unscrewing the ten bolts. Refer to the tool joint
lock assembly and disassembly procedures in the
Maintenance section. Slide the tool joint lock down until it
rests on the clamp cylinder body.
Commissioning
V1 V1
CB1 CB1
CB2 V2 CB2 V2
Upper IBOP
Valve
Clamp
Lower IBOP
Valve
Body 4
Positioning
1 Holes
Tool Joint Lock
Torque
Loosen Screws Arrestor Clamp
Cylinder
Safety
Pin
2
Tool Joint Lock
Rest on Clamp
Cylinder
Positioning
Slot
Saver Sub
3
Clamp Cylinder Raise to Next Hole
Using VDC: In Torque Arrestor
Commissioning
Making up the saver sub
1. Manually screw in the replacement saver sub into the lower
IBOP valve.
5. Position the tool joint lock correctly and follow the proper
assembly procedure described in the Tool joint locks section.
Commissioning
Breaking out the lower IBOP
Remove the saver sub first as described in the previous section.
1. Loosen the tool joint lock between the lower IBOP valve and the
upper IBOP valve by unscrewing the bolts. Slide it down and
rest it on the tool joint lock sitting on the clamp cylinder.
2. Raise the clamp cylinder with the two tool joint locks until the
clamp cylinder slot lines up with the second hole on the torque
arrestor. Insert the pin.
4. Once the connection is broken out, switch to SPIN and allow the
motor to spin until the upper IBOP valve and the lower IBOP
valve separate.
4
5. Remove the safety pin. Lower the clamp cylinder with the lower
IBOP. The lower IBOP is ready for removal.
Stand clear. The lower IBOP valve and saver sub must
be supported before unclamping them. They will fall
through the bottom of the stabbing guide if not
supported.
Commissioning
V1 V1
CB1 CB1
CB2 V2 CB2 V2
Torque
Arrestor
Upper IBOP
Valve
Lower IBOP
4 Valve 7
Loosen Screws Clamp
Cylinder
8 Safety
1 Rest on Pin
Tool Joint Lock Clamp Cylinder
Loosen Screws
9
Raise
2 Clamp
Tool Joint Lock Cylinder
Rest on Clamp to Next Hole
Cylinder
3
Clamp
Cylinder Raise to Next Hole
In Torque Arrestor
Using VDC: (Saver Stub Breakout) Using VDC:
4 Select TORQUE mode. 10 Select TORQUE mode.
5 TORQUE WRENCH PUSH & HOLD. 11 TORQUE WRENCH PUSH & HOLD.
Commissioning
Making up the lower IBOP
1. Screw in the replacement saver sub and the lower IBOP valve
together manually and stand them under the clamp cylinder (a
pup joint may be used to support it). Position the clamp cylinder
by stabbing over the lower IBOP valve. Make sure the lower
IBOP valve comes up through both tool joint locks sitting on the
clamp cylinder body. Tighten four alternate screws on the top
tool joint lock to secure it to the lower IBOP valve to provide a
temporary shoulder to support the weight of the lower IBOP
valve and the saver sub.
4. Lower the clamp cylinder and line up the first slot and hole on
the clamp cylinder and the torque arrestor. The clamp cylinder
jaws line up with the saver sub.
Commissioning
Breaking out the upper IBOP
Refer to the illustration on the next page. Remove the saver sub
and the lower IBOP first, as described in the previous section.
i The saver sub and the lower IBOP can be removed as one unit by
breaking the connection between the upper and lower IBOPs.
1. Lower the clamp cylinder with the broken out lower IBOP
valve and the saver sub.
2. Unclamp the lower IBOP valve/saver sub assembly by
releasing the TORQUE WRENCH PRESS AND HOLD button.
3. Remove the two tool joint locks sitting on the clamp cylinder.
Stand clear. The lower IBOP valve and saver sub must
be supported before unclamping them. They will fall
through the bottom of the stabbing guide if not
supported.
4
4. Remove the IBOP actuator yoke by unpinning it at three
places.
5. Remove the two upper IBOP cranks by unscrewing the 2 sets
of screws.
6. The IBOP actuator shell stays on the upper IBOP valve
assembly.
7. Loosen the top tool joint lock and rest it on the actuator shell.
8. Raise the clamp cylinder with the actuator shell and the tool
joint lock until the third slot and hole line up. Insert the pin.
11. Once the connection is broken out, switch to SPIN and allow
the motor to spin until the upper IBOP valve and drive stem
separate.
12. Remove the safety pin. Lower the clamp cylinder with the
upper IBOP. The upper IBOP is ready for removal from the
clamp cylinder.
14. Remove the tool joint lock and the actuator shell.
Commissioning
V1 V1
CB1 CB1
CB2 V2 CB2 V2
10
Tool Joint
Lock
Loosen
Upper IBOP 9 Screws
Valve Remove Clamp
Actuator Cylinder
1 Yoke Safety
Tool Joint Pin
Lock
Loosen
Screws 4
2
Tool Joint
Lock
Rest on
Clamp
Cylinder
11
Raise to Next Hole
Clamp
Cylinder
8 In Torque Arrestor
Support Saver Sub/
Lower IBOP Valve
and release from
Clamp Cylinder.
3 Remove Lower
Raise to Next Hole Tool Joint Locks.
In Torque Arrestor
5 TORQUE WRENCH PUSH & HOLD. 12 TORQUE WRENCH PUSH & HOLD.
Commissioning
Making up the upper IBOP
1. Place the upper IBOP valve on the floor under the clamp
cylinder so that the clamp cylinder can be stabbed over it (a
pup joint may be used to support it). Lower the clamp cylinder
so that the upper IBOP comes up through the clamp cylinder.
Place the actuator shell and tool joint lock over the upper
IBOP and tighten four alternate locking screws to secure it to
the upper IBOP, providing a temporary shoulder to support its
weight.
3. Raise the clamp cylinder with the upper IBOP valve while
rotating the drive stem clockwise to engage the threads. Once
the drive stem and upper IBOP valve start to spin together,
stop the motor, switch to FORWARD and SPIN and press and
hold the TORQUE WRENCH PRESS AND HOLD button to
4 spin in.
4. Spin the lower IBOP and saver sub into position (refer to the
appropriate procedures in the previous sections). Make sure
that the two tool joint locks are properly installed on the clamp
cylinder and in the correct sequence.
7. Place the three tool joint locks at their respective joints. Install
the three tool joint locks by using the proper assembly
procedure described in the Tool joint locks section.
Decommissioning
Securing the TDS for rig-down
Procedure
Lower the Top Drive to the drill floor
Remove the mud hose, drill pipe elevator
and links
Power may be needed to turn rotating head
into position for removing the links
Locate the RIG-UP/RUN/SHUTDOWN valve
on the hydraulic manifold
With the hydraulic power ON select the
“RIG-UP” position and remove the extended
counterbalance cylinders from the hook ears
Select the “SHUTDOWN” position and turn
off the Top Drive
Isolate and lock out ALL power to the Varco
control house
Hydraulic
Manifold
N
W
O
R
D
U
T
N
U
H
S
Lower CO
UN
TE
RB
R
IG
ALA
-U
N CE
P
the TDS to
MO
DE
RUN
Drill
SHUTDOWN
Floor
RIG-UP
COUNTERBALANCE MODE
Decommissioning
Removing and storing the electrical cables
and service loops
Derrick
Termination Lower
Plate
1,000 lb
(450 kg)
Each
Service Loop
Sling
!
4 Avoid damage
to the service
loops by using
care when
dragging it near
sharp edges
and allow room
for passing under Derrick
the V-door Service
TDS Loop
Service
Loop
! Lifting Eyes
Avoid damage to Do not remove
the service loops by
maintaining a Procedure
36 inch minimum
bend radius Position the service loop tubs for convenient
loading of the service loops
Disconnect the derrick service loop from the
An electrical short can occur if quick
derrick termination plate and the control house
connectors are not kept clean and dry.
Whenever separating quick Disconnect jumper cables (if installed)
connector(s), immediately install Cap all connectors and lower the derrick service
the weather plugs to prevent loop into a service loop tub
connectors from becoming Use a sling attached to the lifting eyes to lower
contaminated with water or debris. each service loop and a swivel at the tugger line
When the connector is not in use attachment to allow each service loop to coil
secure/locate the connector so that is without twisting
Service
does not lie on the ground and make
sure to minimize any exposure to water,
Loop and Disconnect the Top Drive service loop and repeat
Storage Tub the above procedure
mud, etc. Prior to re-connecting, inspect
3,600 lb
the inside of the connectors to make Remove the service loop tubs from the area
(1600 kg)
sure they are clean and dry. Remove the derrick termination plate if necessary
Decommissioning
Setting the latches and locking the bail
Counterbalance
View of Cylinders
Carriage Disconnect
from Rear from the hook
Exhaust
Cover
TOP DRIVE
INST
WH ALL
UN EN
4 Places
VARCO
ST IT IS
OR
ED
Pin
Latches
Both sides
Lower engaged
the TDS to
the drill floor
Pin
Procedure
Lower the Top Drive to the Drill Floor
Drill It is NOT necessary to drain gear oil or
Floor hydraulic fluid for rig down
Disconnect the counterbalance cylinders
from the hook
Install exhaust covers
Engage the upper and lower carriage
latches as shown
Remove TDS using the reverse of
installation procedure
Decommissioning
Long term storage procedures
Top Drive Long Term Storage Procedures
For indoor storage, cover the Top Drive in its shipping and handling skid. A cargo
container is appropriate for outdoor storage.
Avoid wide variations in temperature and high humidity. The preferred environment is
clean and dry at 60-̊80F̊ ambient.
All exposed unpainted metal surfaces are coated with a rust preventive prior to
shipment;however, check these surfaces periodically to be sure that no corrosion is
taking place. The recommended rust preventive (slushing compound) for bare metal
surfaces is e
Kndall Grade 5 (GE-D6C6A1) or equivalent. Make sure that the gearbox
and hydraulic systems are properly filled. Use rust inhibitors where appropriate.
Cover all openings to prevent water or dust from entering. Leave enough space
around the drilling motors for ventilation. Do not use silica gel or a dehydrating agent.
During storage, rotate the motors and gear train periodically to distribute lubricant.
Perform this at three month intervals if stored indoors, and at one month intervals if
stored outdoors.
For long term storage recommendations dealing with the AC drilling motors, see the
motor manufacturer’s manual.
TDS-11SA Rev. B
Guide Beams
and Carriage
Monthly
Crown Padeye
Visually inspect
weld for cracks
Shackle
2.0"
(50 mm)
minimum
Monthly
Shackle
Inspect and
replace if worn
Monthly
5 1.5" Hang-off Link Bores
(37 mm) Inspect and
minimum repair if worn
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
!
Verify that the joint pins,
retainer pins and lynch pins are
in place and secure. Replace
any missing or damaged pins.
Secure
Daily
Lynch Pin
Weekly
Joint Pin
Yearly
Typical Guide
Beam Joint
Daily
Retainer Pin
Monthly
Inspect welds
for cracks
Main
Spreader Beam
Tieback Plate
Yearly
Tieback Link
Inspect retainer pins,
tieback hooks, and
5 pivot pins for wear.
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
Mast Leg
Locking
Bolt
Pivot
Point
Weekly
Typical all welds
and connections
Inspect clamped connections
for tightness and double nuts.
Inspect welds for cracks.
Weekly
Typical
all rollers
Inspect for uneven
wear, damage and
looseness, replace
as required
Yearly
5
Bogey (16)
Disassemble,
inspect for wear,
and relubricate
Daily
Typical all
detent pins
Verify that pins
are in place
and secure
TDS-11SA Rev. B
Motor Housing
and Transmission
Illustrated index
AC Motor
Bail
Blower
Page 6-10
Assembly (2)
Page 6-19
S-Pipe
Page 6-11
AC Motor
Brakes (2)
Page 6-20
AC Drilling Washpipe
Motors (2) Assembly
Page 6-21 Page 6-13
6 Gearbox
Gearbox
Lubrication
Assembly
Pump Assembly
Page 6-4, 6-7
Page 6-7
Inspection schedules
Daily Page Number
Check for missing lockwire and cotter pins
Check the wash pipe assembly for leaks See page 6-13
Weekly
Check the AC motor louvers for damage See page 6-21
Monthly
Check the flow of oil throughout the main body while the lube pump is running See page 6-4
Check the blower motor assemblies for loose bolts See page 6-19
6 Months
Check the gear teeth for pitting and corrosive wear See page 6-9
Check for primary and secondary gear set backlash See page 6-9
Check the S-pipe for pitting, corrosion, or erosion See page 6-11
Check the upper mainshaft liner for erosion caused by leaking wash pipe packing See page 6-12
Yearly
Check the gearbox lubrication pump assembly for wear or damage See page 6-8 6
Check bail, bushings and bail pins for wear See page 6-10
Check the upper bearing retainer o-ring, bearing isolator, and oil seal for wear See page 6-16
Check the radial grooves on the stem and the load collar for wear See page 6-17
Megger motors
5 Years
Magnetic particle inspection (MPI) See page 6-24
Pipe Plug
Pipe Plugs
Monthly
Upper
Compound
Gear Drain Hole
Check flow
Monthly
Body Spray
Nozzles
Cover spray Monthly
6 nozzles not shown
Spillway
Check flow
Pipe Plug
Remove using a
2 inch, 12 point socket
Main Body
4. Allow the sled to move freely, allowing the belt tension spring to
apply the proper tension to the belt.
Sled
Hold-down
Screws
Belt Tension
4 Places
Spring
View from Side
6 Electrical
Connector
Sled
Encoder Belt
Encoder
1. Drain the gearbox oil and disconnect the hydraulic lines from the
pump assembly
6
i When reinstalling the pump assembly into the main body, inspect
the O-ring for damage and replace the O-ring if any flat spots, nicks,
or other damage is found.
6. Install the pump assembly into the main body. Torque the
fasteners in accordance with DS00008, and reconnect the
hydraulic and electrical connections.
Thrust Plate
Yearly 2 Places
Ring Seal
Gearbox Lubrication
Body Seal
Pump Assembly
2 Places
Check parts for wear or damage
Gear
Housing
Gear Set
Roller Bearing
4 Places
Pump
Adapter Plate
Capscrew
10 Places
6
Hydraulic Motor
Low-Speed/High-Torque
O-ring Main Body
Procedure
Drain the gearbox oil and disconnect the
hydraulic lines from the pump assembly
Remove the pump assembly by removing the
ten lockwired capscrews that attach the pump
adapter plate to the main body
Disassemble using the drawings in the
Technical Drawing Package as well as the
pump vender service instruction
Inspect and relace any parts that are worn or
damaged
A 6 Months
Gear Teeth
Check for wear, pitting,
and gear set backlash
A B
Procedure
Inspect the pump adapter plate at the same
i time the gear backlash is checked
Wear allowances
Component Replace when
Bail
Yearly
Bushing
2 Places
Yearly
Main Body
5 Years
Bail Pin
2 Places
Yearly
Clamp
Bolts
6
Seal Ring
6 Months
Upper
Mainshaft Liner
Replace ONLY if
erosion is found
during inspection
Polypack
Seal
6 Polypack Seal
Replace the Polypack
Seal when the upper
mainshaft liner is replaced
Main Shaft
Remove any
corrosion found on
bore of mainshaft
Upper
Mainshaft Liner
Washpipe assembly
Assembling the washpipe assembly
1. With the packing box upside down, assemble the packing seals
and spacers into the packing box using care to line up the upper
spacer slot with the dowel pin.
3. Install the socket head dog nose screw, ensuring that the screw
nose is fully engaged in the groove of the lower spacer.
4. Install the grease fitting and turn the packing box upright.
5. Install the wash pipe into the packing box assembly (slotted end
up).
7. Grease the packing seal and install into the holding ring using
care not to grease the outside diameter of the holding ring.
8. Install the packing seal and holding ring over the slotted end of
the wash pipe.
10. Install the upper and lower o-rings using grease to hold them in
place.
Washpipe assembly
Inspecting the washpipe assembly
!
The wash pipe nut and
the packing box have
left-handed threads
6
Ensure that the nose of the
socket head dog nose screw
is fully engaged in the groove of
the lower spacer
Special Tools
3" Bore
Wash Pipe Wrench
30150084
Washpipe assembly
Inspecting the washpipe assembly
O-Ring
Snap Ring
Holding Ring
Upper Spacer
Packing Seal
Daily 5 per set
Wash Pipe
Assembly Wash Pipe
Inspect for leaks Nut
Middle Spacer
Wash Pipe
Middle Spacer
Packing
Assembly Box 6
Socket Head
Dog Nose Screw
O-Ring
Procedure
Visually inspect the wash pipe assembly for leaks
Replace any worn or damaged parts
Apply pipe dope to the threads before installing in
the Top Drive
Bearing
Retainer
Lube Tube
Bearing
Oil Isolator Bearing
Seal Retainer Lube Tube O-Ring
Cap Screw 2 Places
Bearing 6 Places
Shield
Bearing
Retainer
Retainer Yearly
O-Ring Retainer O-Ring
Yearly
Bearing Isolator
Yearly
Oil Seal
6 Lube Tube
Shims
Mainshaft
Inspecting the mainshaft
Wear allowances
Component Replace when
Stem
5 Years
Split Load Collar
Yearly
Radial Grooves
Inspect for groove
wear and pitting Radial Grooves
0.650 Inspect for groove
Yearly wear and pitting
max
Yearly
0.620
min
Retainer Ring
Mainshaft
Inspecting mainshaft end play
Dial
Indicator
Shims
Bearing
Retainer
Procedure
6 Check mainshaft endplay with every washpipe
changeout
Remove the washpipe assembly
Check the mainshaft axial movement by
applying an upward force to the mainshaft and
measuring the amount of axial movement with a
dial indicator
If axial shaft movement is not .001 in. to .002 in.,
remove the bearing retainer and adjust the
number of shims under the bearing retainer as
required to allow .001 in. to .002 in. of axial
Motor
Fan Cover
Bolts
4 Places,
lock wire
in pairs
Motor Fan
Bolts
6 Places
Top Bearing
Housing
Monthly
Check for
loose bolts
6
Procedure
Check bolts for tightness
Tighten as needed
Check motor cables for damage
Megger motors yearly
Caliper
Mounting Steel
Bolts Plate
6 0.09 in.
Min.
Adjust
Weekly
Motor Leads
Check for damage
6
Weekly
Louvers
Check for damage
Weekly
Screen
Check for contamination
Taper Roller
Main Body Cover Bearing
Internal
Retaining Ring
Upper Stem
Compound Gear Liner
Internal
Retaining Ring Poly Pack
Seal
Oil
Spacer Ring Gallery
O-Ring
Lower Compound
Roller Bearing
Tapered Roller
6 Thrust Bearing
Main Body
Main Shaft
Sleeve
Wear Sleeve
Lube Plate
Oil Assembly Bearing
Lock Washer Retainer
Cap Screw
❏ Bail
❏ Link adapter
❏ Power subs
❏ Power swivels
❏ Elevator links
ASTM A-275 Std. Method for Magnetic Particle Inspection of Steel Forgings
TDS-11SA
TDS-11SA Rev.
Rev. B
B 7-1
PH-75 Pipehandler
Rotating Link
Adapter
Page 7-24
Link Tilt
Page 7-8
IBOP Actuator
Yoke and Cylinder
Page 7-17
Stabilizer
Page 7-15
Clamp Cylinder
Body
Well Control System Page 7-10
Page 7-19
Stabbing Guide
Page 7-13
7
Weekly
Check link tilt clamps for position and tightness See page 7-6
Check stabbing guide and flippers for damage and wear See page 7-14
Check clamp cylinder gate hinge pin for wear See page 7-14
Check IBOP actuator cylinder for leaks See page 7-17
Check IBOP actuator cam followers for wear or excessive play See page 7-19
Check upper and lower IBOPs and IBOP crank for damage (if equipped) See page 7-21
Check shot pin assembly for leaks See page 7-23
Monthly
Check elevator link eyes for wear See page 7-8
Check link tilt bushings for wear See page 7-9
Check link tilt actuator cylinders for leaks See page 7-9
Check link tilt actuator cylinder pins for wear See page 7-9
Check clamp cylinder body wear bushings for wear See page 7-14
Check stabilizer springs for damage See page 7-16
Check front and rear stabilizers for wear See page 7-16
Check pins and bushings on IBOP actuator cylinder and yoke for wear See page 7-17
Check shot pin assembly for wear or damage See page 7-23
Yearly 7
Check piston ring for pitting and chipping See page 7-25
Check stem for pitting, grooves and chipping See page 7-25
Replace GLYD rings, o-rings and bushings on rotating link adapter See page 7-25
5 Years
MPI Inspection See page 7-31
Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:
Rig-up/Run/
Shutdown Valve
Shown in RIG-UP
position (switch to RUN
i
after the counterbalance Typical location for
is installed) Rig-up/Run/
Shutdown Valve.
RUN This valve may be in
a different location
on your TDS.
SHUTDOWN
RIG-UP
COUNTERBALANCE MODE
WN
DO
R
UT
U
N
SH
CO
UN
TE
RB
AL A
NC
EM
OD
E
RIG
-U
P Hydraulic
Manifold
4. Remove the clevis pin from the link, which connects the link tilt
to the elevator link.
5. Using the sling, hoist the elevator link away from the
pipehandler.
Elevator links
Inspecting the elevator links
Recess in
Motor Guard
950 lb
(431 kg)
Elevator Link
2
Lift and
Link Tilt remove
Pipehandler
Rotate Switch Weekly
Front Link Tilt Clamps
Inspect for position
and tightness
1 7
PIP
EH
AN
DL
ER
Rotate
BR
AK
E
IB
OP
EM
ER TO
G
ST EN RQ
U
OP CY E
Monthly
Elevator
Varco TO
RQ
UE Link Eyes
Driller’s Console Inspect for wear
RP
M
(see table)
Elevator links
Inspecting the links (Varco links only)
Wear Chart - Forged Links
Upper C
Upper Eye Lower Eye Capacity (per set) C
Eye
Dimension (C) Dimension (A) in Tons (Hook)
B = 2 7/8 in., 250-Ton
4 7/8 inches 2 3/16 inches 225
2. Disconnect the hydraulic lines from the link tilt cylinders and cap
all connections.
Link tilt
Inspecting the link tilt
Wear allowances
Component Replace when
Pins Wear exceeds .06 in. on diameter as measured by
comparing worn surfaces to un-worn surfaces
Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear
Pins
Inspect for wear
replace as needed
Monthly
Monthly
Bushings
Inspect for
wear replace
as needed
Monthly
Link Tilt
Actuator
Cylinders
Inspect the
hydraulic Link Tilt
connections
for leaks
7
Monthly
Bushings
Inspect for wear
replace as needed
Yearly Monthly
Pipehandler Moving Components
Dissassemble and Observe operation and
inspect per illustration look for excessive wear
and replace as needed
5. Remove the end cap, spring spacer, spring sleeve, and spring.
6. Slowly lower the clamp cylinder body off the torque wrench
frame and move it to a suitable work area.
8. Remove the four wear bushings, and replace the wear bushings
as necessary.
12. Remove the gate, front jaw, front stabilizer, and front stabbing
guide.
18. Carefully push the piston out of the body. Remove and discard
the piston seal.
19. Remove the wiper rod and rod seal from the body. Discard the
seals.
20. Clean the piston, cylinder head, and the body. Clean and
lightly lubricate the new seals and seal surfaces prior to
reassembly.
Clamp Cylinder
Safety Pin
Store Position
Torque
Arrestor
Clamp Cylinder
Safety Pin
Clamp Cylinder
Hanger
Clamp
Cylinder
Assembly
Spring
7
Spring
Post Support clamp
cylinder body
before removing
Bottom Bottom Plate.
Plate
Stabilizer
Liner
Jaw
Retainer
Hex-head
Screw Hi-collar
Washers
Hinge Pin
Retainer
Rod
Seal
Wiper
Rod Stabilizer
Liner
Rear
Jaw
Screw
Front
Stabilizer
Washer
Hinge
Pin Front
Jaw
Gate
Nut
Spring
Front
Stabbing Front
Guide Stabbing
Retainer Guide
7
Cylinder
Head
Ring Arm Guide
Cylinder
Spring
Head
Piston
Seal Piston
Seal Piston
V1
CB1
CB2 V2
Clamp Cylinder
Front and Gate Hinge Pin
Rear Stabilizers Check for pin wear,
Inspect for wear replace as necessary
Weekly 6 Months
Tong Dies
Inspect for
excessive wear Daily
Daily
Clamp Cylinder 7
Check for leaks,
replace seals
as necessary
Swing Clear
Weekly
Clamp Weekly Stabbing Guide
Cylinder Gate Inspect for damage
Flippers
Shown open
Inspect for damage
and excessive wear
Screw
7 Washer
Nut
6 Month
Cotter
Stabilizer Springs Pin
Check for damage,
replace as necessary
Weekly
IBOP
Actuator Cylinder
Check for leaks,
tighten fittings
Monthly
Pins and Bushings
Check for wear
or excessive play
Monthly Weekly
IBOP IBOP
Actuator Yoke Actuator Yoke
Check pins and Check cam followers for wear
bushings for wear or excessive play
or excessive play
7
Wear allowances
Component Replace when
2. Remove one gate hinge pin, open the gate, and pull back the
torque wrench assembly.
2. Make sure the save sub, IBOPs, and main shaft are free of “high
spots”, such as tong marks. If high spots exist, remove with file
or light grinding.
3. Slide the tool joint lock over the main shaft, IBOP valves, and
saver sub.
4. Clean the IBOP valves, main shaft, and saver sub surfaces
thoroughly. Make sure these surfaces are smooth and free of
grease, oil, and pipe dope.
! Never tighten locking screws before the tool joint lock is at the
correct location, otherwise it will not slide freely.
8. Make sure no screw turns any more. The gap between the tool
joint collars should be as equal as possible all the way around.
1.4"
Tapered
Inner Ring
Remove O-Ring
and Look through
this Space and
Split on Inner Ring Tool Joint Lock to
be Offset on Upper
and Lower IBOP
Joint Connection
Tool Joint
1.0" Shoulder
I.D. Groove
First Line Up this Point with the
Tool Joint Shoulder. Then Move
Inner Ring Down 3/8" with the
Outer Assembly. Replace O-Ring
Daily
Tool Joint
Locks
1.4" Tool Joint Inspect for loose bolts.
7 Shoulder Repair or replace if necessary.
Torque to 185±5 ft lb.
1.4"
Weekly Daily
Upper IBOP Valve
(Remote) Check for
Open Inspect for damage proper operation
and pressure test
for leaks
Weekly
Weekly Daily
Lower IBOP
7
Valve
(Manual) Check for
(Optional) proper operation
Inspect for damage and pressure test
for leaks
5 Years
Upper and Lower IBOP
5. Inspect the shot pin bearing and press the bearing out of the
shot pin mounting bracket if the bearing is scored or
damaged.
Drive
Gear
Bearing
Shot Pin
Housing
Assembly
Rod Seal
Assembly
Monthly Bearing
Shot Pin Retainer 7
Check for wear,
remove burrs
Rod Seal
Assembly
Monthly O-ring
Shot Pin Sleeve
Check for wear Retaining
Ring
Shot Pin
Flange Bushing
2. Disconnect and cap all tubing, remove the shot pin assembly
and the landing collar.
5. Remove the bolts that attach the load stem to the main body.
6. Raise the top drive slowly to separate the link adapter from
the main body.
8. Orient the assembly with the stem flange up and block the
entire assembly so that it is secure in this position.
! Protect the internal surfaces of the rotating link adapter and the
surfaces of the drive stem when separating the two components.
When removing the rotating link adapter from the stem, carefully
tap with a mallet. There can be misalignment between the two
bores when raising the drive stem and gear assembly.
7
3. Remove and discard all rotary seals, O-rings, thrust ring, and
the wear bushings from inside the rotating link adapter and
gear inside dimension.
4. Remove and discard the stem flange O-rings and stem bore
shaft seals.
Eye Bolts
Rotary GLYD Ring
(10 Places)
Remove, discard and replace
Yearly
Thrust Ring
Retainer Ring Remove, discard and replace
Yearly
Turcite Bushing
Remove, discard and replace
O-Ring
Yearly
Rotary GLYD Ring
Wiper Seal
Yearly
Piston Ring
Inspect for pitting
Rotating Link and chipped plating
Adapter Gear
7
Wear allowances
Component Replace when Yearly
2. Install the gear with its rotating seal and wiper in place.
6. Install all of the rotary seals on the rotating link adapter, and
an O-ring on the top surface.
7. Install the two wear bushings and the thrust ring in the rotating
link adapter.
11. Install the gear onto the link adapter and install the bolts.
7
12. Pressure test each port at 1,000 psi and inspect for leaks at
the adjacent ports.
14. Inspect the lower gearbox seal (located inside the stem
flange), and replace as necessary.
6. Install the link tilt crank and pin, and secure in place.
8. Install tubing.
12. Turn on the top drive and perform all pipehandler functions
several times, checking for proper function and any leaks.
! Always install a new mainshaft seal and use care not to damage the
seal or the case. 7
! Always install a new drive stem O-ring and use care not to damage
the O-ring or the case.
❏ Bail
❏ Link adapter
❏ Power subs
❏ Power swivels
❏ Elevator links
7
Details on MPI procedures are in the following publications:
Rotating Link
Adapter
Page 8-24
Link Tilt
Page 8-8
IBOP Actuator
Yoke and Cylinder
Page 8-17
Stabilizer
Page 8-15
Stabbing Guide
Page 8-13
8
Drill Pipe Elevator
For pipehandler lubrication and Elevator Links
see Page 3-13 Page 8-5
Inspection schedule
Each Use Page Reference
Check wireline adapter sheaves for excessive wear or damage See page 8-28
Daily
Check for missing lockwire and cotter pins
Check for loose or broken parts and leaks
Check for damaged hoses and fittings
Check tong dies for wear See page 8-14
Check clamp cylinder for leaks See page 8-14
Check hoses for wear or damage See page 8-17
Check tool joint locks for tightness See page 8-20
Check upper and lower IBOP valves for proper operation See page 8-21
Weekly
Check link tilt clamps for position and tightness See page 8-6
Check stabbing guide and flippers for damage and wear See page 8-14
Check clamp cylinder gate hinge pin for wear See page 8-14
Check IBOP actuator cylinder for leaks See page 8-17
Check IBOP actuator cam followers for wear or excessive play See page 8-19
Check upper and lower IBOPs and IBOP crank for damage (if equipped) See page 8-21
Check shot pin assembly for leaks See page 8-23
Monthly
Check elevator link eyes for wear See page 8-8
Check link tilt bushings for wear See page 8-9
Check link tilt actuator cylinders for leaks See page 8-9
Check link tilt actuator cylinder pins for wear See page 8-9
Check clamp cylinder body wear bushings for wear See page 8-14
Check stabilizer springs for damage See page 8-16
Check front and rear stabilizers for wear See page 8-16
Check pins and bushings on IBOP actuator cylinder and yoke for wear See page 8-17
Check shot pin assembly for wear or damage See page 8-23
Yearly
Check piston ring for pitting and chipping See page 8-25
Check stem for pitting, grooves and chipping See page 8-25 8
Replace GLYD rings, o-rings and bushings on rotating link adapter See page 8-25
5 Years
MPI Inspection See page 8-31
Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:
Elevator links
Disassembly/assembly
1. Disconnect and remove the drill pipe elevator from the
elevator links.
4. Remove the clevis pin from the link, which connects the link tilt
to the elevator link.
5. Using the sling, hoist the elevator link away from the
pipehandler.
Elevator links
Inspection
Recess in
Motor Guard
950 lb
(431 kg)
Elevator Link
2
Lift and
Link Tilt remove
Pipehandler
Rotate Switch Weekly
Front Link Tilt Clamps
Inspect for position
and tightness
1
PIP
EH
AN
DLE
R
Rotate
BR
AK
E
IBO
P
EM
ER TO
STGOENC RQ
UE
P Y
8 Monthly
Elevator
Varco TO
Link Eyes
DrillerÕs Console
RQ
UE
Elevator links
Inspection (Varco links only)
Wear Chart - Forged Links
Upper C
Upper Eye Lower Eye Capacity (per set) C
Eye
Dimension (C) Dimension (A) in Tons (Hook)
B = 2 7/8 in., 250-Ton
4 7/8 inches 2 3/16 inches 225
Link tilt
Disassembly/assembly
1. Shutdown the power and bleed the system (turn the valve on
the bottom of the gearcase to the SHUT DOWN position).
2. Disconnect the hydraulic lines from the link tilt cylinders and
cap all connections.
Link tilt
Inspection
Pins
Inspect for wear
replace as needed
Monthly
Monthly
Bushings
Inspect for wear
replace as needed
Monthly
Link Tilt
Actuator Cylinders
Inspect the hydraulic
connections for leaks
Link Tilt
Monthly
Bushings
Inspect for wear
replace as needed
Wear allowances
Component Replace when
Pins Wear exceeds .06 in. on diameter 8
Bushings Metal backing is visible through the lining
End cap of the metal backing exceeds .04 in. wear
5. Remove the end cap, spring spacer, spring sleeve, and spring.
6. Slowly lower the clamp cylinder body off the torque wrench
frame and move it to a suitable work area.
12. Remove the gate, front jaw, front stabilizer, and front stabbing
guide.
16. Push the cylinder head in enough to relieve the load on the
cylinder head ring. Remove the cylinder head ring. Use care in
this operation.
8
18. Carefully push the piston out of the body. Remove and discard
the piston seal.
19. Remove the wiper rod and rod seal from the body. Discard the
seals.
20. Clean the piston, cylinder head, and the body. Clean and lightly
lubricate the new seals and seal surfaces prior to reassembly.
RUN
SHUTDOWN
RIG-UP
Hydraulic
COUNTERBALANCE MODE
Manifold
Rig-up/Run/
Shutdown Valve
Shown in SHUTDOWN
position
(Shown with
link tilt removed)
Torque Arrestor
Spring
Spring Spacer
Spring Shims
Adjust to ensure
the torque wrench
clamps fully onto
the saver sub Support clamp
cylinder body
before removing
end cap.
End Cap
Clamp Cylinder
8 Body
Rear
Stabilizer
Front
Stabilizer
Hinge Pin
Retainer Spring
Hex Head
Screws
Cylinder Clamp
Head Ring Cylinder
Body
Cylinder
Head Body
Piston Seals
Seals
Jaw
Piston Assembly
Tong
Dies
Gate
Wear
Bushing Socket
Head Cap
Screws
Hinge
Pin
Front
Rear Stabbing
Stabbing Guide
Guide
Flippers
8
Spring Retaining
Plate
Tugger
Line
V
A
R
C
O
P
H
5
0
Front and
Wear Bushings
Rear Stabilizers
Check for wear,
Inspect for wear
replace as necessary
Weekly Monthly
Tong Dies
Inspect for
excessive wear O Daily
RC
Daily VA Clamp Cylinder
Check for leaks,
replace seals
as necessary
Swing Clear
Weekly
Clamp Stabbing Guide
Cylinder Gate Inspect for damage
Shown open
Weekly
8
Weekly Clamp Cylinder
Flippers Gate Hinge Pin
Inspect for damage Check for pin wear,
and excessive wear replace as necessary
Cotter Pin
Weekly
IBOP
Actuator Cylinder
Check for leaks,
tighten fittings
Daily Monthly
Hoses Pins and Bushings
Replace if worn Check for wear
or damaged or excessive play
Monthly
IBOP Weekly
Actuator Yoke IBOP
Check pins and Actuator Yoke
bushings for wear Check cam followers for wear
or excessive play or excessive play
Wear allowances
Component Replace when
2. Remove one gate hinge pin, open the gate, and pull back the
torque wrench assembly.
2. Make sure the save sub, IBOPs, and main shaft are free of “high
spots”, such as tong marks. If high spots exist, remove with file
or light grinding.
3. Slide the tool joint lock over the main shaft, IBOP valves, and
saver sub.
4. Clean the IBOP valves, main shaft, and saver sub surfaces
thoroughly. Make sure these surfaces are smooth and free of
grease, oil, and pipe dope.
! Never tighten locking screws before the tool joint lock is at the
correct location, otherwise it will not slide freely.
8. Make sure no screw turns any more. The gap between the tool
joint collars should be as equal as possible all the way around.
8
9. Safety wire all screws.
1.4"
Tool Joint
1.0" Shoulder
I.D. Groove
First Line Up this Point with the
Tool Joint Shoulder. Then Move
Inner Ring Down 3/8" with the
Outer Assembly. Replace O-Ring
Daily
Tool Joint
Locks
1.4" Tool Joint Inspect for loose bolts.
Shoulder Repair or replace if necessary.
Torque to 185±5 ft lb.
1.4"
Tool Joint Lock to be Equally
Spaced on Lower IBOP and
Saver Sub Joint Connection
8
Removing the Tool Joint Locks
Gradually release the locking screws all the way around. Initially release each screw
about a quarter of a turn, avoid tilting and jamming the collars. Do not remove the
screws completely at this time, otherwise the collars may spring off.
Remove any rust formed or dirt collected adjacent to the tool joint lock. Once the screws
are loose, remove the tool joint lock from the saver sub, IBOP valves, and main shaft.
Wear allowances
Component Replace when
Weekly Daily
Upper IBOP Valve
(Remote) Check for
Open Inspect for damage proper operation
and pressure test
for leaks
Weekly
Close IBOP Crank
(Remote)
Inspect for damage
Weekly Daily
Lower IBOP Valve
(Manual) Check for
(Optional) proper operation
Inspect for damage and pressure test
for leaks
8
5 Years
Upper and Lower IBOP
5. Inspect the shot pin bearing and press the bearing out of the
shot pin mounting bracket if the bearing is scored or
damaged.
Weekly
Shot Pin Assembly
Check for leaks,
Shot Pin tighten fittings
Base
Dowel Pin
Rod Seal
Assembly Monthly Dual Port
Manifold
Shot Pin
Check for wear,
remove buurrs
Rod Seal
Assembly
Monthly
Shot Pin Sleeve
Check for wear
Hydraulic
Motor
O-ring
Monthly
Shot Pin Bushing
Check for wear
Shot Pin
Cap
Pinion Gear
Wear allowances
8
Component Replace when
Shot Pin
Shot Pin Outer diameter is less than 1.375 in. Cover
Shot Pin Sleeve Inner diameter is greater than 1.510 in.
Shot Pin Bushing Inner diameter is greater than 1.475 in.
2. Disconnect and cap all tubing, remove the shot pin assembly
and the landing collar.
5. Remove the bolts that attach the load stem to the main body.
6. Raise the top drive slowly to separate the link adapter from
the main body.
8. Orient the assembly with the stem flange up and block the
entire assembly so that it is secure in this position.
Disassembling the link tilt assembly
1. Attach a 3-point sling to the stem and pull the stem out of the
link adapter.
! Protect the internal surfaces of the rotating link adapter and the
surfaces of the drive stem when separating the two components.
When removing the rotating link adapter from the stem, carefully
tap with a mallet. There can be misalignment between the two
bores when raising the drive stem and gear assembly.
3. Remove and discard all rotary seals, O-rings, thrust ring, and
8 the wear bushings from inside the rotating link adapter and
gear inside dimension.
4. Remove and discard the stem flange O-rings and stem bore
shaft seals.
Thrust Ring
Retainer Ring Remove, discard and replace
Yearly
Turcite Bushing
Remove, discard and replace
O-Ring
Yearly
Rotary GLYD Ring
Wiper Seal
Yearly
Piston Ring
Inspect for pitting
Rotating Link and chipped plating
Adapter Gear (Heat to 175-200° F
to install)
Wear allowances
Component Replace when Yearly
2. Install the gear with its rotating seal and wiper in place.
6. Install all of the rotary seals on the rotating link adapter, and
an O-ring on the top surface.
7. Install the two wear bushings and the thrust ring in the rotating
link adapter.
11. Install the gear onto the link adapter and install the bolts.
12. Pressure test each port at 1,000 psi and inspect for leaks at
the adjacent ports.
14. Inspect the lower gearbox seal (located inside the stem
flange), and replace as necessary.
8
6. Install the link tilt crank and pin, and secure in place.
8. Install tubing.
12. Turn on the top drive and perform all pipehandler functions
several times, checking for proper function and any leaks.
! Always install a new mainshaft seal and use care not to damage the
seal or the case.
! Always install a new drive stem O-ring and use care not to damage
the O-ring or the case.
Wireline adapter
Inspection
i
Inspect the condition of the
sheaves before and after each use
8 Each Use
Sheaves
Replace or repair damaged
parts as necessary
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes. Compare the measurements with the Wear
Chart to determine the current strength of the elevator links. The
capacity of the links equals the capacity of the weakest link.
❏ Bail
❏ Link adapter
❏ Power subs
❏ Power swivels
❏ Elevator links
TDS-11SA Rev. B
Hydraulic System
Hydraulic system
The hydraulic control system is a completely self-contained,
onboard system. A 10-horse power, 1800 rpm, AC motor, drives
two hydraulic pumps and powers the hydraulic system. A fixed
displacement pump drives the lube oil system motor. A variable
displacement pump provides hydraulic power for the AC motor
brakes, powered rotating head, remote actuated IBOP, pipe backup
clamp cylinder, link tilt, and counterbalance system. Three hydro-
pneumatic accumulators are located on the main body.
Illustrated index
Specifications
10 HP AC
Motor and
Front
Pump Assembly
Page 8-17
Rear
Link Tilt
Counterbalance Manifold
Accumulator
Rotating Head
(Elevator Positioner)
Rotating
Head Gearbox Lube
Motor Oil Distribution
Pre-Fill Valve
Manifold
M
Variable Fixed
10 HP A.C. Displacement Displacement
Motor Pump Pump (Mtr. Lube) Hydraulic
Reservoir
Inspection
Precautions
To avoid serious injury or death, read and understand the following
warnings before performing inspection and maintenance
procedures:
Inspection
Inspection
Maintenance schedule
Hydraulic system oil lubrication schedule
Description Frequency
Replace hydraulic system filter (P/N 114416-1) Every 3 months
Perform hydraulic system oil analysis Every 6 months
Replace hydraulic fluid Yearly, or earlier based on oil analysis
Inspect hydraulic reservior bladder Yearly
Replace hydraulic reservior bladder Every 2 years
Daily inspections
Description
Check the condition of the hydraulic filter indicator
Check hydraulic fluid levels
Check for hydraulic fluid leaks
Check the condition of hydraulic hoses
Manufacturer
Castrol Hyspin AWS-32 Hyspin AWS-46
Chevron AW Hyd oil 32 AW Hyd oil 46
Exxon Nuto H32 Nuto H46
Gulf Harmony 32AW Harmony 46AW
Mobil DTE 24 DTE 25
Shell Tellus 32 Tellus 46
Statoil Hydraway HMA 32 Hydraway HMA 46
Texaco Rando oil HD32 Rando oil HD46
Total Azolla ZS 32 Azolla ZS 46
Union Unax AW32 Unax AW46
Viscosity Index
ISO Viscosity Grade 32 46
Inspection
Inspecting the hydraulic fluid level and filter
Cork Ball
(Level Indicator)
Daily
Red
Pop-up Sight
Dirt Alarm Glass
Hydraulic
Oil Sight
Gauge
Hydraulic
Oil Filter
Procedure
Check the red “pop-up” alarm on the hydraulic
filter daily
Replace the filter (Varco P/N 114416-1) if the
indicator has popped up or as recommended
Use care to prevent contamination from
entering the hydraulic system during
maintenance activities
Inspection
Adding the hydraulic fluid
Specifications
Reservoir Capacity 25 gal
Procedure
Cork Ball
Turn the Top Drive OFF (Level Indicator)
Ensure that the area is clean prior to adding
hydraulic fluid
Remove dust plug from the male quick
disconnect at the Top Drive hydraulic oil fill
Remove dust plug from the female quick
disconnect on the lubrication kit
Connect the two fittings and pump fluid until
the level reaches the middle of the sight Sight
glass as showm Glass
See Lube Schedule for specifications
Hydraulic
After adding fluid, replace the dust plugs Oil Sight
Gauge
Hydraulic
Oil Fill
Female
Quick
Disconnect
Hydraulic
Lubrication Kit
55 gal Drum
Varco P/N 92643
Inspection
Draining the hydraulic fluid
Precautions
Hydraulic fluid may be hot
Use care when opening the valve
Avoid spills
Holds 25 gallons
Pump
Valve
Inlet/Drain
Handle
Adapter
10 HP AC
Pump Motor
Procedure
Isolate power to the pump motor Fixed
Ensure that the valve is closed Displacement
Pump
Remove the plug and attach a hose
Open the valve and drain the fluid
Close the valve and remove the hose Variable
Displacement
Replace the plug Pump
Inspection
Inspecting the hydraulic reservoir bladder (yearly)
Hydraulic Oil
Reservoir
Between AC
Drilling Motors
Reservoir Never put oil in the reservoir
Breather bladder. Add oil at the
hydraulic oil fill only,
Reservoir as described on page 8-9.
Cover
Apply gasket
sealing compound
to prevent leaks
Yearly
Reservoir Bladder
Varco P/N 110191-501
Check for wear and damage
Gasket Front
Varco P/N 110132
Rear
Apply gasket
sealing compound
to prevent leaks
Hydraulic Oil
Reservoir
Procedure
Drain hydraulic fluid and clean area before
inspecting the reservoir bladder
Remove the 10 cap screws and lock washers
from the cover
Remove cover with bladder attached
Check the bladder yearly for wear or damage
Replace the bladder every two years
Replace the bladder if fluid is found inside or
if fluid escapes the reservoir breather when
the Top Drive is on its back 9
Inspection
Inspecting the heat exchanger
Blower and
Brake Covers
Monthly
Oil Heat
Exchanger
Remove any dirt
and inspect for leaks,
corrosion, and cleanliness
Drill Motor
Assembly
Left side
Inspection
Using the hydraulic system test ports
* SA
* P
* T1
C4
A6
SV2
C5
Rotating B6
Link B5
Adapter
B9 * These test ports are on sides
Z1 B1 or bottom of manifold.
Inspection
Precharging the accumulators
Accumulator Setting Port
Accumulator
Counterbalance
Charging Assembly
Accumulator
Varco P/N 114446-1
Upper IBOP
Time- Delay
Accumulator
Hydraulic
System Manifold
Accumulator (Reference)
Front
Procedure
Disconnect the hydraulic lines to the accumulators
and drain them of all hydraulic fluid Rear
With the hydraulic system shut down, and the
counterbalance mode valve in the “shut down”
position, test the hydraulic pressure at CB, SA and
C4 on the hydraulic manifold, mounted to the
transmission housing
Verify that all three points measure 0 psi
Inspection
Inspecting the IBOP timing circuit
IBOP Actuator Cylinder
2.500" Dia. Bore X 2.00" Stroke
1.750" Dia. Rod Hydraulic
Cylinder
Open
Close
Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge
Gas Charged
Accumulator
(Small)
Rotating
Link Adapter
-6
-6
A4 B4
A4 B4
-6
-6
Cable ID
A B
Number
b
C04
P T
-6
-6
-6
D03
2 3
PC4
System
Tank
Pressure
Inspection
Inspecting the IBOP and oil pressure switch
Hoses
Inspect for wear
or damage.
Replace yearly
or as required.
Yearly
Pressure
Adjusting Screw
Yearly
Wires
Inspect for wear
Switch Pressure Settings or lose connections.
Component Setting
IBOP Pressure Switch Factory preset at 1500 psi (102.0 BAR) rising
+0
Oil Pressure Switch Factory preset at 10.0 -1.0 psi decreasing
Pump Pressure
Compensator
Adjustment Point
Variable Fixed 10 HP AC
Displacement Displacement Pump Motor
Pump Pump
! Make sure the Top Drive is properly filled with hydraulic fluid and
lube oil before performing this procedure. Also make sure the Rig-
Up/Shutdown valve is in the SHUTDOWN position.
2. Set the relief valve RV1 for the variable displacement pump to
a minimum setting, fully counterclockwise, which allows the
hydraulic system to operate without building up pressure, and
turn the motor off.
13. Raise the setting of relief valve RV1 from 0 psi to 1,500 psi at a
steady rate. During the pressure rise, observe the ammeter. The
motor current should rise to a maximum value at 800 psi, then
drop off and begin to rise again. The point where the current
drops is the pump pressure compensator setpoint.
14. Adjust relief valve RV1 to its minimum setting. If maximum motor
current does not occur at 800 psi, adjust the pump pressure
compensator as required.
15. Adjust relief valve RV1 again from 0 psi to 1,500 psi, and back
to 0 psi to verify maximum motor current at 800 psi.
16. Connect a gauge to test point SA, and leave the gauge on PV.
17. Adjust relief valve RV1 to 2,200 psi and secure the jam nut.
3000 Pressure at PV
Pressure at SA
2000
Pressure 1700
(psi)
1000
800
150
0 10 20 30 40 50 60
9
Approximate Time
(seconds)
23. Observe the cycle of loading and unloading of the relief valve.
To verify the setting of UV1, note the difference in pump noise
level between the loaded and unloaded condition.
RV2 RV1
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
Manifold End View
Bottom View B6 A6 DR Z1
P
TF
B5 B4
B5 C5 B9
TR
T1
SA
SA
CTR
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
C4
B8
PF
CB
SA
RIG-UP
UV1
G5 SV4 PF
COUNTERB NCE MODE
RUN
P/N 0181
PV
XC
MV
SHUTDOWN
DF
UV1
PF
9
Manifold Assembly
RV1
PV PF
800 PSIG
Variable Displacement
Pump-Motor Assembly
B
Fixed
1.10 IN^ 3/REV. MAX. Displacement
.50 IN^ 3/REV. MIN. Pump
L1
S
2. To set the relief valve, make sure the pumps are operating.
12. Prepare the hardware to attach the cylinder pear links to the
hook.
13. Rotate the counterbalance mode valve from the RUN position
to RIG-UP position. This causes the counterbalance cylinders
to slowly extend.
! Cylinders stroke to the end of stroke with the mode valve in the
RUN position.
17. Reduce the pressure slowly (25 psi) to allow the pressure to
stabilize.
21. Connect a gauge to test point B9. Activate the STAND JUMP
mode on the drilling console. Adjust relief valve SJR until the
bail lifts off the hook. The gauge at B9 should read about 190
psi.
23. Switch back to STAND JUMP mode and observe the pressure
CB increase by 200 psi.
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
RIG-UP/SHUTDOWN
Manifold Valve
Bottom View B6 A6 DR Z1
Manifold
P
TF
B5
End View
B5 C5 B4
B9
CTR
SA
TR
T1
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
CB
SA
C4
B8
PF
UV1
RIG-UP
G5 SV4 PF
COUNTERB NCE MODE
1
RUN
P/N 0181
XC
PV MV
SHUTDOWN
DF
CB
Manifold
Side View SJR
D4 A4 PC5 AR5
CV3 PC4 D1
SJR P1
PF
A8
PV
A4 A5
D5
C4
CB G5 DF
2
-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø
75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
4.000" Dia. Bore X 8.50" Stroke
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T
-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16
5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø
SA To Tank 9
To test the system, turn the auto brakes switch on the driller’s
console to the ON position. Attach a pressure gauge to B1 in the
manifold. The pressure reading should be 1,500 psi. If the reading
is not 1,500 psi, adjust the pressure control reducing valve PC 1 to
1,500. Turn the auto brakes switch to the OFF position. The
pressure reading should be very low.
PC1
CB6 CA6 CV5
CV4
A2
B2 CDR CV1
PC1 RV1
LC5 RV2 PCC
LB6 LA6 T1
T1
B1
C5 A2 B2
Manifold
Side View
Manifold
Bottom View B6 A6 DR Z1
TF
B5 B4
B5 C5 B9
TR
T1
SV5
B1
B4 SV2 SV1 SV9 CV2
G6 E6 E5 PV
P5
C4
B8
PF
RIG-UP
G5 SV4 PF
COUNTERB NCE MODE
RUN
P/N 0181
PV MV
SHUTDOWN
DF
B1
i The electrical system jogs the rotating head until the pin engages a
hole.
3. When the pin stalls out, measure the pressure at B5. Set the
relief valve pressure to 400 psi.
6. Test the pressure at C5. Adjust reducing valve AR5 to 1,000 psi.
Hydraulic
Drive Motor
SV5
C5
Link Adapter
Rotation Gear
Hydraulic Manifold
10 HP AC Motor
and Pump Assembly
Motor
A
Relief Valve
B
Rotating Motor
Link Shot Pin Relief Valve
B5
Adapter Relief Valve
C5
Link Adapter
A5
Rotation Gear
Shot Pin
2. Adjust the four load holding valves in pairs – the upper pair and
lower pair. Adjust all four counterbalance valves fully clockwise,
then one turn counterclockwise.
i If the valves are not adjusted correctly, link tilt operation is not
synchronized.
4. There are two test points on the link tilt cylinder manifold.
7. Command the link tilt to the OFF position and observe the
pressure decay at C1. This decayed pressure is the setpoint of
the counterbalance valve.
8. Raise the valve setpoint by turning the adjusting screw 1/4 turn
counterclockwise.
10. Command the link tilt to the DRILL position and repeat the
procedure above, using test port C2 to set the counterbalance
valve on the DRILL side.
2. Operate the clamp. The shot pin must go through the hole,
which locks up the gear.
Hydraulic
Drive Motor
Test Points
(3)
Motor
Relief
Valve
(2)
Link Adapter
Rotation Gear
Troubleshooting
Troubleshooting the HPU and reservoir bladder
Problem Probable cause Remedy
Hydraulic system Relief valves RV1 and RV2 out of adjustment. Test pressures and adjust relief valves.
overheating
Unloading valve is not working. Test and adjust UV1 or replace unloading valve.
Hydraulic components System pressure is down. First make sure RIG-UP/SHUTDOWN valve is in
do not operate. the correct position. Test pumps and motors.
Test relief valve pressures. Adjust as required.
Check for leaks, loose fittings, loose cylinders,
worn hoses, fluid levels and seals.
Pumps are rotating in the wrong direction. Inspect hydraulic connections and
correct rotation.
Troubleshooting
HPU and reservoir bladder schematic diagram
PV PF TR DR Manifold Assembly
Hydraulic Fill
Disconnect
System
Pressure
6µm
50 PSID
Prefill Valve
Pressure -12
Compensator T
Filter with
Control Bypass
T -16
800 PSIG Valve
-6
XC
B
1.00 In^ 3/Rev.
L
10 HP
1800 RPM 4 PSI
L1 Filter Vent
S
(Strainer)
Variable Fixed
Displacement Displacement
Pump Pump
Reservoir Assembly
Troubleshooting
Troubleshooting the counterbalance and stand jump
The accumulator, with precharge pressure of 900 psi, along with
check valve CV3, maintains a hydraulic pressure.
Counterbalance testing
For the counterbalance operation, a lift of approximately 30,000 lb is
achieved with a pressure of 1600 psi at CB. Perform the following
steps to adjust the force:
3. Test the pressure at port CB. Observe the position of the top
drive on the hook.
Troubleshooting
Stand jump testing
For the optional stand jump feature, a lift of about 33,000 lb is
achieved with a pressure of approximately 1800 psi at CB. The
additional 300 psi pressure over the normal counterbalance
pressure is provided by energizing the stand jump solenoid valve
SV9. Perform the following steps to adjust the pressure:
Troubleshooting
Problem Probable cause Remedy
Counterbalance does not Cylinder damaged. Seal leaks. Inspect cylinder and repair or replace seal.
function.
No hydraulic pressure. Test pressure and ajust pressure reducing valve.
Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.
Solenoid valve SV9 is not operating. Test electrical and hydraulic operation.
Replace or repair as applicable.
Troubleshooting
Counterbalance and stand jump schematic diagram
-4 2
ZC CP
OR1 OR2
CP -12
.075ø .075ø
75 PSI 75 PSI
1 2 1 2 CP -12 Counterbalance Cylinders
4.000" Dia. Bore X 8.50" Stroke
T-13A T-13A 2.000" Dia. Rod
CV1 CV2 -12
T
-12 Counterbalance
Normally-Open Accumulator
T
.010ø Logic Cartridge 728 Cubic Inches
Metering 900 PSI Precharge
T -16
5 PSI
-6
XC 90 PSI
25mm
Prefill Cable ID Stand Jump Solenoid
Valve Number (Solenoid Valve 9)
.047ø
SA To Tank
9
Troubleshooting
Troubleshooting the brakes
Problem Probable cause Remedy
Brake does not release. Directional valve is stuck. Test the valve and replace if necessary.
Brake releases but still drags. Check valve is blocked or tube is pinched. Replace the check valve or tube as required.
Brakes do not engage or slip. Hydraulic oil on brake pads. Check for hydraulic leaks and repair.
Pressure is not 1,500 psi or does not rise Reducing valve is plugged or needs to be
crisply to 1,500 psi. adjusted or replaced.
2 Position
Solenoid Valve
Brakes On
Cable ID
Number
A B
b
C01
P T -4
P1
Test Point
1500 PSI
PC1 1 T-11A
Reducing 2 3
Valve
Troubleshooting
Troubleshooting the shot pin cylinder and clamp
cylinder
Problem Probable cause Remedy
Shot pin does not engage. Solenoid valve is not operating or relief valve Check electrical actuation and test pressure.
is not adjusted. Adjust as required.
Normal pressure change indicates plumbing Repair plumbing or shot pin cylinder.
or shot pin cylinder are faulty.
Shot pin applies Relief valve is not operating or Test pressures and adjust as required.
excessive force to out of adjustment.
rotating head gear.
Clamp cylinder does No pressure or reduced pressure at the cylinder. Test pressures and adjust and repair as required.
not actuate.
Cylinder is damaged. Inspect cylinder and repair or replace.
To provide high pressure to the clamp circuit, Repair plumbing, rotating head, or clamp cylinder.
i pressure at C5 must be 2,000 psi and G5 must
be less than 100 psi. If this condition is met,
pressure at CP should increase from less than
100 psi to higher than 2,000 psi. If not, check
the plumbing, rotating link adapter, and
clamp cylinder.
Shot pin engages Control valve not operating. Check pressure at C5. Replace valve CV5
but clamp cylinder if required or the regenerate manifold.
does not activate.
Troubleshooting
Shot pin cylinder and clamp cylinder schematic diagram
Clamp Cylinder
10.000" Dia. Bore X 2.0" Stroke
8.000" Dia. Rod
Hydraulic Cylinder
Cavity Plug CP CR
1 3
Pilot-to-Close CKEB
T-2A
Check Valve 2
30 PSID
2 1
CNEC
Shot-Pin Cylinder 3 T-2A
2.000" Dia. Bore X 2.31" Stroke 1 T-5A
Relief Valve 1.500" Dia. Rod COFA
.047ø
1
2 Position
T-10A Non-Adjustable
Solenoid
B5 C5 Flow Control
Valve 5
Clamp/Shot Pin
-8
-8
Clamp
E5 G5
-8
P T
-6
-6
A5 SV5 B5 C5 E5 G5
D03
Pressure
.159ø T-11A 1
50 PSI .031ø Reducing
3 AR5 Valve
3
1 2
LC5 2
Logic .031ø 1000 PSI
T-11A
Cartridge
Externally-Drained
Pilot-to-Open
3 2 Valve
T-21A
4 75 PSI
CV5 1
P5
Drain 1
T-11A 3
System Pressure
PC5 2
Tank Drain
System Pressure
Tank
T1 T1 D5 Manifold Assembly
9
Troubleshooting
Troubleshooting the link tilt cylinders
Problem Probable cause Remedy
Links drift when Pressure at B8 does not decay to Replace the pilot to open check valve.
valve is released. less than 100 psi.
Pilot to open check valve is stuck open Replace the pilot to open check valve.
or contaminated.
Load holding relief valves are out of Adjust or replace the load holding relief valve.
adjustment, stuck open, or contaminated.
Drill pipe elevator Use manual override. If the link tilts, the Test the solenoid and connectors.
does not float back problem is electrical. If the links do not tilt, Test the hydraulic system.
to center position. the problem is hydraulic.
Link tilt does not tilt. Solenoid valve is not shifting. Check electrical continuity.
Troubleshooting
Link tilt cylinders schematic diagram
Mousehole
Drill Down
C1 C1 C1 X1 C2 C2 C2
V1 V2
FL
-6
-6
-8
-8
-8
-8
X -8
X -8
X
X
B8 B8 E6 E6 G6 G6 H J
B8 E6 G6 H J
-8 X
-8 X
-8
-8
Rotating Link -8
Adapter Assembly
-8
-8
9
A8 D1 Manifold Assembly
X
Troubleshooting
Troubleshooting the gearbox lubrication hydraulic
system
Problem Probable cause Remedy
Oil leaking from lower seal. Worn oil seals. Replace seals.
Gearbox oil temperature Oil level too low or too high. Adjust oil level to middle of sight glass.
(less than 230˚F).
Incorrect lubricant used. Check recommended lubricants chart
and replace as needed.
Oil pump loss alarm is on. Oil level is too low. Oil overheated. Add oil.
Broken lube pump adapter plate spline. Replace adapter plate spline.
Restricted oil flow. Foreign particles blocking orifice or nozzle. Clean orifice or nozzle.
Troubleshooting
Gearbox lubrication hydraulic system schematic
diagram
Pressure Spray
Switch Nozzles (4) Orifices (6)
S04 10 PSI
Decreasing
-16
1.0 1.5 .062ø .205ø .059ø .059ø .047ø .047ø L4
GPM GPM
Ea. Ea.
Upper Lower Upper Lower Upper Lower
Compound Compound Mainshaft Radial/Main Compound Compound
Gear Gear Bearing Thrust Bearing Bearing
Bearings
Lube-Oil
Filter
Lube Pump 5.10 In.^ 3/Rev. 60µm
L1 -16
Lube-Oil Pump
-10
A B
Tank
-10
3.0 In.^ 3/Rev.
Hydraulic Hydraulic
Motor Heat Exchanger
Tank
2 T-10A
RV2
400 PSI
Manifold PF
Part of
Pump Motor
Assembly Reservoir
Assembly
Troubleshooting
Problem Probable cause Remedy
Tool does not rotate. Direct control valve or relief valve is sticking. Inspect, repair or replace the valve.
Solenoid valve is not electrically operating. Check electrical connections and valve functions.
Motor is worn out or gear teeth are broken. Replace the motor.
Directional valve does not shift. Test pressure left and right. Replace the valve.
Tool does not return Valve is sticking or relief valve is Test pressures and inspect valves.
to home position. out of adjustment. Adjust the relief valve as required.
If the motor will drive normally, but not drive Checkout control system.
to the home position, the cause could be
the control system.
Links are not Counterbalance valves are out of adjustment. Adjust valves together-pressure is the same
synchronized. for all four valves.
Troubleshooting
Rotating link adapter motor schematic diagram
A B
Fixed
Displacement
Motor
1 2
Pressure
Relief Valves
T-10A 1700 PSI
2 1
A B
Cable ID A B Cable ID
Number Number
b a
C03 C02
Left P T Right
-6
-6
A2 SV2 B2 Manifold
.071¿
Assembly
D03
Troubleshooting
Troubleshooting the IBOP actuator schematic diagram
IBOP Actuator Cylinder
2.500" Dia. Bore X 2.00" Stroke
1.750" Dia. Rod Hydraulic
Cylinder
Open
Close
Time-Delay
Accumulator
30 Cubic Inches
800 PSI Precharge
Gas Charged
Accumulator
(Small)
Rotating
Link Adapter
-6
-6
A4 B4
A4 B4
-6
-6
Cable ID
A B
Number
b
C04
P T
-6
-6
-6
D03
2 3
PC4
System
Tank
Pressure
33-2
Manual
Valve 3 Position 4 Way Valve MV
(Rotary)
33-3
Fixed Displacement
33-4
Pumps
Variable Displacement
33-5
33-6
Pressure
Relief Ventable Relief Valve RV1
Valves
33-7
33-8
33-9
33-10
1
3
Cavity Plug PC5
2
33-14
Internal Plug
33-15
33-16
33-17
33-19
Logic 33-20
Cartridge
33-21
33-22
33-23
33-24
33-25
33-26
33-27
33-29
Hydro-Pneumatic Accumulator
33-30
33-31
Hydraulic Cylinder
33-32
Tank (Reservoir)
33-33
Test Point
33-34