250-HXI-700 - Oct 13 2010

TESCO Corporation
Service Guide
250 HXI 700 Top Drive System
PLC System
250 Ton HXI 700 HP with D4P-700 Power Unit
Tesco Corporation (“TESCO”) has made every effort to ensure that this document contains accurate and current
documentation for the TESCO top drive, however, the document is intended to be used in conjunction with a complete
training program and on-site supervision and TESCO does not warrant or guarantee that the information contained herein
is either complete or accurate in every respect, and the reader hereby protects, indemnifies and holds harmless Tesco
Corporation together with its directors, officers, employees and agents from and against all liability for personal injury,
death or property damage to any person arising directly or indirectly from the use by the reader of the information
contained in the document.
This equipment was filled at the factory with TESCO ULTREX™ brand fluids and greases. To ensure maximum
performance and to avoid cross-contamination, we strongly recommend the continued usage of TESCO ULTREX™
lubricants, unless otherwise specified.
TESCO ULTREX™ is a trademark and TESCO® is a registered trademark of Tesco Corporation.
Tesco Corporation © 2010
Contact Information
Corporate Head Office
3993 W. Sam Houston Parkway No., Suite 100
Houston, Texas, 77043
USA
www.tescocorp.com
www.tescoparts.com
Telephone: (713) 359-7000
Fax: (713) 359-7001
After Market Sales and Service Contact
Toll Free North America: 1-877-TESCO-77
International: 713-359-7295
ii 250 HXI 700 Top Drive System

Revision Information
Version Date Description of Changes
Rev 0 October 2010 First release of document
TESCO Corporation iii

iv 250 HXI 700 Top Drive System
TABLE OF CONTENTS
Chapter 1: General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Chapter 2: Top Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Load Collar and Load Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mudsaver Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pipe Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Counter Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Top Drive Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Handling Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Chapter 3: Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gearbox Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gearbox Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Expansion Bottle View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Expansion Bottle Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Extend Frame Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Extend Frame parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove the Lower Quill Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove the Lube Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove the Expansion Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remove the Gearbox Assembly from the Travel Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove the Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove the Quill Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove the Extend Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove the Bonnet and Washpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove the Pinion Gear Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove the Upper Quill Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Remove the Gearbox Lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Remove and Disassemble the Quill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remove and Disassemble the Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Service Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Assemble the Gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Set the Pre-load and Check the Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Continue Gearbox Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TESCO Corporation v
Install the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install the Extend Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install the Assembly on the Travel Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install the Expansion Bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install the Lube Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install the Quill Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install the Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Install the Lower Quill Bearing Retainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 4: Bonnet, Gooseneck, and Washpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove the Gooseneck from the Bonnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassemble the Gooseneck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Remove the Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Remove the Washpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Install the Washpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Install the Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assemble the Gooseneck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Install the Gooseneck on the Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chapter 5: Motor Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Motor Manifold Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Motor Manifold Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Remove the Ball Valves and Lower Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Remove the Upper Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remove the Motor Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Remove the Motor Manifold Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Disassemble the Motor Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assemble the Motor Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Install the Motor Manifold Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install the Motor Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install the Upper Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Install the Ball Valves and Lower Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 6: Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pipe handler Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pipe Handler Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
load Collar Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Load Collar Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
vi 250 HXI 700 Top Drive System

TABLE OF CONTENTS
Load Nut Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Load Nut Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Remove the Elevator Link Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Disassemble and Remove the Load Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Disassemble the Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassemble the Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assemble the Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assemble the Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Install the Load Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Install the Elevator Link Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Chapter 7: Pipe Handler Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Service Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Chapter 8: Pipe Handler Rotate Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Service Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
ReAssembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Chapter 9: Grabber Leg Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Grabber Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Grabber Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Grabber Cylinder
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Grabber Cylinder Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Lower Grabber Leg Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Lower Grabber Leg Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Upper Leg Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Upper Leg Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Upper Grabber Leg Hydraulics Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Upper Grabber Leg Hydraulics Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Grabber lift Manifold Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Grabber Lift Manifold
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Link Tilt Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Link Tilt Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
TESCO Corporation vii

Remove the Split Pipe Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Remove the Link Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Remove the Grabber Leg Assembly from the Pipe Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Remove the Upper Leg from the Lower Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Remove the Manifolds from the Upper Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Disassemble the Upper Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Disassemble the Lower Grabber Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Disassemble the Grabber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Disassemble the Grabber Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Assemble the Grabber Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Assemble the Grabber Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Assemble the Lower Grabber Leg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Assemble the Upper Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Install the Manifolds on the Upper Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Install the Upper Leg on the Lower Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Install the Grabber Leg Assembly onto the Pipe Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Install the Link Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Install the Split Pipe Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Chapter 10: 12-Station Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Manifold Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Manifold Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Transducer Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Transducer parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
12-Station Manifold Installation Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
12-Station Manifold Installation Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Remove the 12-Station Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Remove the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Remove the 12-Station Manifold Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Remove the Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Disassemble the Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Disassemble the 12-Station Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Assemble the 12-Station Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Assemble the Transducer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Install the Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Install the 12-Station Manifold Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Install the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Install the 12-Station Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Chapter 11: Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
viii 250 HXI 700 Top Drive System

TABLE OF CONTENTS
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Assembly Preparation and Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Pipe Handler Rotate Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Pipe Handler Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Grabber Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Link Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Mudsaver Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Grabber Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Capped Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Motor Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Chapter 12: Mudsaver VAlve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Remove the Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Disassemble the Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Assemble the Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Install the Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Chapter 13: Swivel Yoke and Counter Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Uninstall the Swivel Yoke and Counter Balance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Disassemble the Swivel Yoke and Counter Balance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Assemble the Swivel Yoke and Counter Balance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Install the Swivel Yoke and Counter
Balance Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Chapter 14: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Remove the Front Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Remove the Swivel Link Stop Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Remove the Side Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Remove the Front Guard Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Remove the Gearbox Assembly from the Travel Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
TESCO Corporation ix
Install the Gearbox Assembly on the Travel Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Install the Front Guard Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Install the Side Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Install the Swivel Link Stop Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Install the Front Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Appendix A: Torque Standards for High Strength Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Appendix B: Maintenance and Service Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Lock-Out Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Daily Top Drive Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Weekly Top Drive Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Monthly (Periodic) Top Drive Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Six-Month Top Drive Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1,000 Operating Day Top Drive Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
TESCO UltrexTM Lubricants Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Check and Adjust Preload for the Quill Upper Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Check for Quill End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Calculate the Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Adjust the Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
x 250 HXI 700 Top Drive System

GENERAL INFORMATION CHAPTER
1
SAFETY INSTRUCTIONS
Warning! Before operating or servicing this Caution: Only trained personnel must
top drive system, always read and perform inspections and related
follow all safety instructions such activities.
as the warnings and cautions
mentioned below and throughout
the manual. Caution: Safe access must be provided to all
areas where adjustments and
Top Drive System users risk injury to themselves and to maintenance are necessary.
others if the top drive is used improperly and/or safety
precautions are not followed. TESCO advises personnel
who work with or near the equipment to always wear Caution: This equipment can generate noise
proper personal protective equipment (PPE). Proper PPE up to 106 decibels at the prime
consists of, but is not limited to, the following: mover and 86 decibels at the top
drive. Hearing protection suitable
• Hearing protection (ear defenders) for this noise level must be worn
• Hard hat when operating this equipment.
• Safety glasses
• Steel toe shoes Warning! Electrical voltages of different
• Fall protection when working above 6.5 ft (2 m), or potentials are used throughout the
the minimum height requirement as directed by TESCO top drive components (480
local jurisdiction. VAC, 380 VAC, 208 VAC, 120 VAC).
It is imperative that only qualified
personnel install, maintain, and/or
Caution: This equipment is designed and troubleshoot the electrical
certified for use in a hazardous systems. A severe hazard exists to
environment. When maintenance personnel not accustomed to, nor
requires replacement of parts, only familiar with, electrical hazards
identical parts can be used. Using and procedures.
alternate, non-identical parts as a
substitution may void compliance
and certification. Warning! Accumulators used in the auxiliary
hydraulic system are under
pressure from gas. Release this
Caution: Always perform the correct lock- pressure before any maintenance
out procedures as recommended is done on the auxiliary hydraulic
by the Safety or Loss Prevention system.
department before implementing
maintenance.
Caution: Only authorized personnel can

install and operate the top drive
system.
TESCO Corporation 1
CHAPTER 1
Warning! Temperature of equipment can

cause injury if touched. The
operator must take steps to
eliminate any risk of injury that
may result from being in contact
with or in proximity to machinery
parts at high or low temperature.
Equipment temperature should be
checked before any adjustments or
maintenance work is done and
appropriate personel protective
equipment is worn.
GENERAL SPECIFICATIONS
The 250 HXI 700 Top Drive System is designed for use on prime movers, hydraulic pump drives, pumps, and filtration
land-based drilling rigs and workover rigs. The top drive is equipment.
powered using an independent hydraulic power unit.
The 250 HXI 700 Top Drive is powered using a 700 hp
To create the optimum power supply system required for (522kW) Caterpillar C18 prime mover with a four-pump
each of its top drives, TESCO combines industry proven drive.
Top Drive Specifications Imperial Metric*

Rated capacity through load collar 250 ton 227 tonne
Rated horsepower 700 hp 522 kW
Maximum continuous drill torque 24,000 ft-lbs 3,254.5 daN-m
Make-up/breakout torque 32,000 ft-lbs 4,339.4 daN-m
Maximum speed 200 rpm
Weight of the top drive plus: 14,000 lbs** 6350 kg**
• Elevators
• Elevator links
• Yoke + links (counter-balance system)
Length (250T, with 9 ft. links 17.5 ft. 5.3 m
Width 4 ft. 1.2 m
Quill connection NC50
Hazardous area certification
CSA Class 1 Div II or II 2 G
*Metric unit conversions have been provided for convenience only. All product specifications
use the original Imperial units unless indicated otherwise.
**Note: All weight values are approximate.
2 250 HXI 700 Top Drive System

GENERAL INFORMATION
REQUIRED TOOLS
This list includes tools and materials that are likely to be • Center punch
needed for disassembly and reassembly of the top drive • Utility knife with blades
components.
• Machinist file set
• Rubber mallet
• Combination wrenches, range of sizes
• Aligning pry bar
• Drive socket sets, range of sizes
• Crowbar pinch point
• Drive adapter
• Half-moon obstruction wrench
• Impact wrench
• Outside caliper
• Adjustable wrenches, range of sizes
• Inside caliper
• Pipe wrenches, range of sizes
• Vernier caliper with depth gauge
• Chain tong wrench with chain and pin
• Caulking gun
• Ball peen hammer
• Grease gun with flexible hose
• Sledge hammer
• Flashlight with extra batteries and bulbs
• Screw driver set
• Strip and cut tool – all-purpose electrical
• Torque wrench
• Solderless terminal and tool
• Chain pullers
• Allen socket set
• Offset wrenches, range of sizes
• Hammer wrench
• Taper taps, range of sizes
• Hex key – long arm
• Blow gun, for air hose
• Magnetic retriever – telescopic
• Pyropen, cordless, with solder and butane
• Hacksaw and blades
• Pressure tool
• Tape measure
• Snipe
• Wire brush
• Setter snipe with 1-1/8” pressed wrench
• Impact socket – deep
• Dial gauge with magnetic base
• Cold chisel set
• Elevator spring installation tool
• Punch set
• Step bit
• Hex key set
• Air hose assembly
• Ball driver T-handle set
• Pliers, retaining ring
• Hex key set – T-handle
• Silicone, high temperature
• Easy out set
• Loctite, red
• Vise grip
• Loctite, blue
• Die grinder with emery wheels
• Anti-seize compound
• Mini grinder with disks
• WD-40
• Drill, reversible with drill bits
• Isopropanol alcohol
• Pliers, side cutting
• Mechanics wire
• Pliers, tongue and groove
• Slings, endless web
• Pliers, diagonal cut
TESCO Corporation 3
CHAPTER 1
• Tape, Teflon
• Tape, electrical
• Tape, duct
• O-ring kits
• Stainless steel wire with pliers
• Oil sample bottles with envelopes
• Pipe dope
• Lockout cards, padlock/key
• Full body harness
• Lanyard – absorption

TOP DRIVE COMPONENTS CHAPTER
2
EXPLODED VIEW
1
13
Safety wire
typ. 4 plcs. 13
2
13
9
4,5,6
11
13
7 13
10
12
13
8
Figure 2.1: 250 HXI Top Drive general assembly
TESCO Corporation 5
CHAPTER 2
PARTS LIST
Item Qty Description Item Qty Description
1 1 Swivel yoke and counter balance 8 1 Grabber leg assembly
2 1 Bonnet, gooseneck, washpipe 9 1 Extend frame, torque arrest
3 1 Motor manifold 10 1 Link tilt
4 1 Gearbox assembly 11 1 Auxiliary hydraulics
5 1 Pipe handler lock 12 1 Mudsaver valve
6 1 Pipe handler rotate motor 13 1 Accessories
7 1 Pipe handler assembly
GEARBOX
• The gearbox is an integrated gearbox and swivel containing the main swivel bearing and gear train to drive the quill.
• Single reduction helical gears (2.28:1) are utilized for high capacity, extended service life, and maximum efficiency.
• The gear train is driven with a single bi-directional, hydraulic vane type motor. It has a pressure rating of 4,500 psi
(31,026 kPa) continuous, and 5,000 psi (34,474 kPa) intermittent.
• The gearbox is flooded with oil for maximum gear and bearing lubrication and reliability.
LOAD COLLAR AND LOAD NUT

The load collar and load nut transfer loads from the elevator links to the quill.
MUDSAVER VALVE
The mudsaver valve is a double-ball crank valve that acts as a mudsaver. It replaces the upper and lower kelly cock. The
valve does not descend below the rotary table, except in emergency situations, and it is always easily accessible. The
mudsaver valve actuator can be operated remotely from the driller’s panel.
Caution: The actuated upper ball valve is not for well control; it functions solely as a mudsaver. The
manual operating lower valve is for well control. Ensure that the valve selected can fit into the
existing casing.
PIPE HANDLING
The pipe handling abilities of the 250 HXI 700 Top Drive include the following:
• Pipe Handler Rotation: The HXI pipe handler rotate mechanism, powered by a single hydraulic motor, provides
360° rotation and can be locked into any orientation. This feature is used to resolve grabber torque when making or
breaking connections.
• Elevator Link Tilt Cylinders: These allow extension and retraction of the elevators 35° forward from the vertical
position and 55° backward from the vertical position.

TOP DRIVE COMPONENTS
• Grabber (back-up wrench): The grabber acts as a back-up tong for making or breaking connections at any point in
the mast. The grabber will accommodate tool joints from 3-1/8 in. (8 cm) to 8-3/4 in. (22 cm) OD.
Important: For tool joints smaller than 4-3/4 in. (12 cm) OD, non-standard dies or a shim kit must be installed. Grabber
intensifier pressures must also be adjusted when smaller OD pipe is used.
COUNTER BALANCE
The top drive features an automatic thread feed compensation for make up and break out operations.
TOP DRIVE POWER

The top drive main motor is powered by four axial piston pumps, which are driven by a 700 hp (522 kW) diesel prime
mover. All top drive robotic functions are powered by an auxiliary power hydraulic system. Both the prime mover and
auxiliary power hydraulic system are located on the power unit skid.
HANDLING FRAME
The top drive is shipped in its own handling frame. This frame allows the top drive to be transported and handled using
standard rig moving equipment.
TESCO Corporation 7
CHAPTER 2

GEARBOX CHAPTER
3
GEARBOX EXPLODED VIEW
15 38
17 15
18
16 Typ 14 plcs. 39 40 Typ 6 plcs.
19 Typ 3 plcs. Typ 4 plcs.
Typ 4 plcs. 3 3 37
. 1 3
13 Typ 31 plcs.
14 2
35
16 Typ 5 plcs.
12 37
11 19
10 36
34
33
8 32
7 9
Typ 14 plcs.
6
5 1
4 31
Dowels
Typ 3 plcs.
43
46
45 Typ 4 plcs.
44 30
54
18
55 29
57
18 47
18 5
56 50 42
51
52 48 41
53 49
58
20
27 22
21
18
26
25 23
Typ 8 plcs.24
28
28
28
Figure 3.1: Gearbox assembly with gear motor
TESCO Corporation 9
CHAPTER 3
GEARBOX PARTS LIST

1 1 Gearbox 30 1 Pinion gear, input
2 31 Hex head flange-lock screw, 1/2"-13UNCx2" 31 1 Bearing
3 11 Socket drive setscrew, 1/2"-13UNCx0.5" 32 5 Shim 0.010”
4 1 Thrust bearing 33 2 Shim 0.005”
5 1 Quill 34 2 Shim 0.002”
6 1 Bull gear, quill 35 1 Bearing retainer, upper motor
7 20 Lockwasher, 5/8" 36 1 O-ring
8 20 Socket head capscrew, 5/8"-11UNCx2-3/4" 37 11 Flat washer, 5/8"
9 1 Bearing 38 1 Motor, hydraulic
10 5 Shim 0.010” 39 1 O-ring
11 2 Shim 0.005” 40 6 Hex head capscrew, 5/8"-11UNCx5"
12 2 Shim 0.002” 41 1 Thermowell
13 1 Bearing retainer, upper quill 42 1 Thermometer
14 1 O-ring 43 1 Expansion bottle assembly
15 2 Oil seal 44 1 O-ring
16 19 Hex head capscrew, 5/8"-11UNCx2-1/4" 45 4 Lockwasher, 3/8"
17 1 Mud shield 46 4 Hex head capscrew, 3/8"-16UNCx1-1/2"
18 8 Fitting, grease, 1/8" MNPT 47 1 Plug, magnetic, 3/4"MNPT
19 2 Plug, hydraulic fitting, #4MORB 48 1 Fitting, 90° elbow, #8MJICx#8MORB
20 1 Bearing 49 1 Fitting, straight, #8MJICx#8MORB
21 1 Bearing retainer, lower quill 50 1 Fitting, straight, #12MORBx#12MNPT
22 1 O-ring 51 1 Ball valve, 2-way
23 8 Lockwasher, 1/2" 52 1 Fitting, straight, #12MJICx#12MNPT
24 8 Socket head capscrew, 1/2"-13UNCx1-1/2" 53 1 Cap, fitting, #12FJIC
25 1 Nipple, fitting, 1/8"MNPTx3" 54 2 Swivel link pin
26 1 Coupling, fitting, 1/8"FNPT 55 2 Retainer, swivel link pin
27 1 Wear-seal sleeve, lower quill 56 4 Lockwasher, 1/2"
28 3 Oil seal 57 4 Hex head capscrew, 1/2"-13UNC x 1-1/2"
29 1 Bearing 58 1 Hose, #8x15"

GEARBOX
EXPANSION BOTTLE VIEW EXTEND FRAME EXPLODED VIEW

2 1
Typ. 16 plcs.
3
10 2
7
Figure 3.3: Extend frame installation
EXTEND FRAME PARTS LIST

3
1 Item Qty Description
1 1 Extend frame mount
2 16 Lockwasher, 3/4"
3 16 Socket head capscrew, 3/4"-10UNCx1-3/4"
Figure 3.2: Expansion bottle assembly
EXPANSION BOTTLE PARTS LIST

Item Qty Description
1 1 Expansion bottle
2 1 Cap, fitting, 2"FNPT
3 1 Fitting, 90° elbow, #8MNPTx#10Barb
4 1 Fitting, tee, 8FNPTx#8FNPTx#8MNPT-Br
5 1 Coupling, straight, 5/8hose X1/2MPT
6 1 Hose, 5/8"IDx7/8"ODx5.4"
7 2 Clamp, worm gear, 3/8" to 3/4"
8 1 Fitting, straight, #8MNPTx#6MNPT
9 1 Ball valve, 3/8FNPT
10 1 Breather, 3/8"MNPT
TESCO Corporation 11
CHAPTER 3
DISASSEMBLY
Drain all fluid from the gearbox before you begin
disassembly. Reserve some of the fluid to examine for
contaminants. B
Remove the Lower Quill Bearing Retainer

1. Remove the grease nipple (A) from the grease port in A
the bearing retainer (B).
2. Slide the retainer (C) off the quill (D).

C D
3. Remove and discard the O-ring and seals.
Remove the Lube Line

1. Disconnect the hose.
2. Remove the fittings.
3. Cover the bores to prevent contamination.
Remove the Expansion Bottle

1. Cut and remove the safety wire on the bolts (H).
2. Remove the bolts and lockwashers.
3. Remove the expansion bottle.
H
4. Remove the O-ring from the flange and discard.

GEARBOX
Remove the Gearbox Assembly from the

Travel Stand K
1. Remove the bolts and locknuts ( J) from the pins (K)

that hold the extend frame (L) to the travel stand.
J
L
2. Place slings around the swivel link pins in the gearbox

and around the quill and lift off from the travel stand.
3. Raise the slings on the gearbox and lower the sling on

the quill until the assembly is vertical.
CHAPTER 3
Remove the Sleeve

D
While the gearbox is suspended, remove the sleeve.
E
1. Heat the sleeve (E) with a blow torch to approximately
250°F (121°C).
2. Carefully remove the sleeve off the quill (D).
Caution: Wear insulated gloves when

handling heated or chilled
components.
Remove the Quill Bearing

G
1. Slide the outer race (F) of the quill bearing off the quill
(D). F
D
2. Heat the inner race (G) of the bearing with a blow
torch to approximately 200°F (93°C).
3. Carefully slide the bearing off the quill.

components.
4. Move the gearbox assembly to a work table above a

hole and lower the quill into the hole until the gearbox
rests on the table.
Remove the Extend Frame

1. Cut and remove the safety wire on the 16 bolts (M)
that hold the extend frame to the gearbox.
2. Place a sling through the top pin bores to support the M
frame.
4. Lift and remove the extend frame from the gearbox.
Remove the Bonnet and Washpipe

See chapter 4 “Bonnet, Gooseneck, and Washpipe” on
page 33 for instructions.

GEARBOX
Remove the Motor

P
Remove the bonnet and washpipe before proceeding. N
1. Cut and remove the safety wire on the 6 bolts (N) that
hold the motor (P) to the gearbox.
2. Remove the bolts and flat washers.
3. Lift the motor from the gearbox.
4. Remove and discard the O-ring from the bottom of the
motor.
Q R
Remove the Pinion Gear Retainer

R
1. Cut and remove the safety wire on the 5 bolts (Q) that
hold the retainer (R) to the gearbox.
2. Remove the bolts and flatwashers.
3. Remove the retainer (R). Q
4. Remove the shims.
Remove the Upper Quill Bearing Retainer V

W
1. Remove the mud shield (S) from the quill. S
2. Cut and remove the safety wire on the 14 bolts (T) that
hold the upper retainer (U) to the gearbox.
3. Remove the #4 ORB plug (V) and the 1/8" NPT
grease nipple (W).
4. Remove the bolts that hold the retainer to the gearbox.
5. Use setscrews to jack the retainer past the O-ring.
T
6. Remove the retainer (U).
CHAPTER 3
7. Remove and discard the O-ring and the two seals.

8. Remove the shims (X). X
Remove the Gearbox Lid

1. Cut and remove the safety wire on the 31 bolts that
hold the lid to the gearbox.
2. Remove the bolts that hold the lid to the gearbox.
3. Use setscrews as jacking scores.
4. Pry the lid at intervals around the perimeter to release
the sealant.
5. Lift the lid from the gearbox.

GEARBOX
Remove and Disassemble the Quill

1. Remove the temperature gauge and the thermowell.
2. Remove the tapered roller bearing (Y):
Y
a. Heat the tapered roller bearing (Y) to approxi-
mately 230°F (110°C).
b. Cut the cage of the roller bearing and make two
cuts in the inner race at 180° from each other,
almost through the race.
c. Split the race with a hammer and chisel.
d. Remove from the quill.
3. Push the pinion gear (Z) to the side.

4. Attach a lifting device to the quill (D) and lift it out of
the gearbox.
5. Move the quill to a stand.
D
Z
6. Remove the 14 bolts and lockwashers that hold the bull

gear (AA) to the quill.
7. Use jacking screws to raise the bull gear. If this is not
possible, then go to the next step.
8. Heat the bull gear to approximately 170°F (77°C) and
lift the gear off the quill. AA
CHAPTER 3
9. Heat the thrust bearing plate (BB) with a torch and

allow gravity to drop the plate.
Caution: Place a piece of wood underneath

to catch the plate.
BB
10. Remove the thrust bearing plate, cage, and rollers from
the gearbox.
Remove and Disassemble the Pinion Gear

1. Lift the pinion gear from the gearbox and move to a
work table.
2. Heat the bearings and pull them off both ends of the
pinion gear.

GEARBOX
INSPECTION
Clean the inside of the gearbox, checking for contaminants
and metal shavings from moving parts. Also examine the
fluid that was drained from the gearbox.
Perform a magnetic particle inspection (MPI) on the gears
and the gearbox.
Clean and inspect all parts for wear, deformation, cracks,
grooves, and pitting. Check cables and hoses for tears and
breaks.
Replace damaged parts.
Service Limits
No cracks are allowed.
Gears should have an even wear pattern with no pitting.
CHAPTER 3
REASSEMBLY
Assemble the Gearbox
1. Clean all bores and tap holes in the gearbox.
2. Buff all bearing bores so that the bearings go in with a
light slide fit. Be sure that all oil galleries are clean of
sand and debris.
3. Record all gear serial numbers, all serial numbers on
the quill and gearbox. (Serial number sheet is provided
in the build book.)
4. If you are replacing the bottom retainer, pre-fit the

retainer onto the gearbox to make sure that the grease
port aligns to the hole in the gearbox with the bolts in
place. Do not leave the retainer on the gearbox for
assembly at this time.
5. Turn over the gearbox with the open side up to begin
installing parts.
6. If you are replacing the thrust bearing, remove the

thrust bearing from the crate and clean all the grease
off the rollers, plate, and cage.

GEARBOX
7. Put the cleaned thrust plate, cage, and rollers into the
gearbox and lightly lubricate with assembly oil or
assembly grease.
8. Place the quill upside down on an assembly stand.

Clean the quill of any oil or residue, or chemical
plating, if applicable.
9. Place the other half of the cleaned thrust bearing onto

the quill. BB
10. Heat the plate with a torch until the plate slides onto
the bottom step in the quill.
11. Check with a feeler gauge to make sure that there is no
gap between the plate and the quill (zero tolerance).
CHAPTER 3
12. After the thrust plate has cooled, turn the quill right
side up on the assembly stand.
Caution: Use appropriate rigging equipment

to safely lift the quill.
13. Clean the bull gear. Suspend the gear from a crane and
heat with a torch to approximately 170°F (77°C) so
that it can slide easily onto the quill.
14. Before setting the gear on the quill, smear Loctite 620
onto the mating surfaces.

GEARBOX
15. After the heated gear is put onto the quill, bolt it down
with the 14 required bolts and lockwashers, using
Loctite 277 on the threads. Torque the bolts to
approximately 200 ft-lbs, using an alternating cross
bolt pattern (12 o’clock to 6 o’clock to 3 o’clock to 9
o’clock).
16. Clean the input pinion gear.

17. Heat the bearings for the pinion gear to approximately
230°F (110°C) and install on the pinion gear shaft.

components.
18. When the pinion gear and bearings have cooled, apply
blueing on the teeth of the gear.
19. Oil the bores of the gearbox for an easier slide fit.
20. Lower the gear into the base of the gearbox.
CHAPTER 3
21. With the pinion gear in place and pushed off to the
side, slowly lower the quill and bull gear into the
gearbox until seated on the thrust bearing plate and
rollers.
22. Heat the tapered roller bearing (Y) to approximately

230°F (110°C) and slide onto the quill.
23. Set the lid on the gearbox and bolt down using half the
bolts. Insert the cone for the tapered bearing and then
Y
roll the gear set in both directions in order to achieve a
distinct blue pattern on both sets of gears. Remove the
lid to check the pattern.
24. With the lid still off, install the thermowell and
temperature gauge into the side of the gearbox. Make
sure that the thermowell does not contact the gears.

GEARBOX
25. Evenly spread Loctite 515 on the surface of the

gearbox where the lid bolts down.
Caution: Do not touch the bare metal or

the Loctite with bare hands. Oils
from skin can cause failure of the
seal.
26. Place the lid on the gearbox and fasten with 31 bolts,
using Loctite 243 on the threads. Torque to 75 ft-lbs.
27. Safety-wire the bolts.
Set the Pre-load and Check the Backlash

1. To set pre-load on the quill, install the entire shim pack X
(X) around the quill. (Use two dowels in opposite holes
to aid in alignment.)
CHAPTER 3
2. Then bolt on the upper retainer (U) without the

O-ring or seals.
3. Lift the quill with a crane to check for end play. Use a
dial indicator to get your reading.
Important: For more details, see “Check for Quill End

Play” on page 171.
4. Adjust the shim pack by subtracting shims in 3 separate U

steps until you achieve 0.005–0.007 in. preload.
5. After the correct setting is achieved, bolt on the
retainer with the seals and O-ring installed. Torque the
bolts to approx 150 ft-lbs using Loctite 243 on the
threads.
6. After pre-load is set, check the backlash between the

gear sets. From the center of the pinion gear, measure
outward 4 in., set up the dial indicator, and turn the
pinion gear to determine the amount of backlash. Refer
to the photo for setup.
Backlash limits = 0.017–0.022 in.
7. After backlash is checked, set the float on the pinion

gear by shimming (CC) the retainer to achieve proper CC
clearance: approximately 0.005–0.010 in. float.

GEARBOX
Continue Gearbox Assembly

R
1. Install the pinion gear retainer (R) with 5 bolts (Q) and
flat washers. Do not safety-wire until after the motor is
installed.
2. Safety-wire the bolts (T) on the quill bearing top

retainer (U). V
W
S
3. Install the #4 ORB plug (V) and the 1/8" NPT grease
nipple (W). Install the dust cover (S) onto the quill.
4. Install the grease nipples in the swivel link pins and

install the pins into the gearbox with the retaining
straps. Do not safety-wire at this time.
CHAPTER 3
Install the Motor

P
1. Seat the O-ring in the groove on the bottom of the N
motor.
2. Lower the motor (P) into position on the gearbox.
3. Bolt the motor to the gearbox with 6 bolts and flat
washers (N), using Loctite 243 on the threads. Torque
the bolts to 150 ft-lbs.
4. You can now safety-wire the bolts (Q) on the pinion
retainer (R).
5. Safety-wire the bolts (N) on the motor.
Q R
Install the Extend Frame

After the washpipe and bonnet are installed (See chapter 4
“Bonnet, Gooseneck, and Washpipe” on page 33 for
instructions.), install the extend frame.
1. Lift the extend frame into position against the gearbox.
Important: You can use dowels inserted in the bolt holes M

to guide the frame into position.
2. Insert 16 socket head bolts (M) with lockwashers and

torque the bolts to 250 ft-lbs.
Install the Assembly on the Travel Stand

1. Lift the gearbox assembly straight up until the quill is
completely clear of the work stand.
2. Attach a sling to the quill and lift the quill to a
horizontal position with the extend frame pointing
down.
3. Lower the assembly into position on the travel stand.

GEARBOX
4. Apply anti-seize compound to the 4 pins (K) and insert

the pins to hold the extend frame (L) to the travel K
stand.
5. Insert a bolt ( J) through the hole in each pin and secure
with a locknut.
J
L
Install the Expansion Bottle

1. Make sure the inside of the expansion bottle is
thoroughly clean with no sand or debris.
2. Grease the O-ring and insert in the flange (H) of the
bottle. H
3. Attach the expansion chamber to the gearbox with 4
bolts and lockwashers, using Loctite 243 on the
threads.
Install the Lube Line

1. Install the fittings into the gearbox.
2. Install the hose into the fittings.
CHAPTER 3
Install the Quill Bearing

1. Heat the inner race of the bearing to 200°F (93°C). G
D
Warning! Wear heat-protective gloves when

handling hot bearings.
2. Slide the heated inner race (G) over the quill (D) and
press it into the bore of the gearbox. Make sure that it
is seated.
Important: Move quickly so that the race does not cool

and prematurely bind to the quill.
3. Slide the outer race (F) of the bearing onto the quill
(D) and tap gently into place with a ball peen hammer
until the outer race is fully seated.
F
D
Install the Sleeve

1. Wipe the quill clean and coat the area where the sleeve
will fit with Loctite 620 (green).

GEARBOX
2. Heat the sleeve to 250°F (121°C).

3. Slide the sleeve (E) onto the quill (D) and press into D
place against the bearing.
E
Important: Move very quickly to get the sleeve in place

before it can cool and tighten prematurely on the quill.
4. When the sleeve is cool to the touch, wipe off all excess
Loctite 620.
Install the Lower Quill Bearing Retainer

DD
1. Thoroughly wipe the retainer to make sure it is clean of
all grease and debris.
2. Tap the first of three oil seals (DD) into the inner bore
of the retainer with a dead blow hammer.
3. Use a seal driver to drive the seal into the bore.
4. Repeat for the second and third seal. Make sure that
the third seal sits a little bit below flush with the surface
of the retainer.
5. Turn the retainer over. DD
6. Insert the O-ring (EE) on the bottom of the retainer.
7. Apply blue grease to the seals (DD) and the O-ring.
EE
8. Insert two dowel pins (FF) into the gearbox bolt bores
to help guide the retainer (C) into position. C D
FF
CHAPTER 3
9. Slide the retainer (C) onto the quill (D) with the
24
O-ring side first. Make sure that the grease ports align. 23
See Figure 3.4.
Important: When installing the retainer, make sure that

the tapped hole is aligned with the grease nipple and 21
coupling assembly. Tapped hole
25
26
18
Figure 3.4: Proper alignment of tapped hole
10. Bolt the retainer to the gearbox with bolts and

lockwashers, using Loctite 243 on the threads. Torque
to 75 ft-lbs.
11. Insert the 3 in. grease nipple into the grease port, using
Loctite 567. Turn until snug.

BONNET, GOOSENECK, AND CHAPTER
WASHPIPE 4
EXPLODED VIEW
10
Typ 10 plcs. 2
9
6
5
4
5
Typ 12 plcs. 7
8
1 12
Typ 10 plcs.
11
Figure 4.1: Bonnet, gooseneck, and washpipe
CHAPTER 4
PARTS LIST
1 1 Bonnet 7 12 Lockwasher, 3/8"
2 1 Gooseneck 8 12 Socket head capscrew, 3/8"-16UNCx1-1/4"
3 1 Hammer union, 4" 9 10 Flat washer, 3/4"
4 1 Nipple, gland nut 10 10 Hex capscrew, 3/4"-10x3"
5 1 Washpipe assembly 11 10 Flat washer, 5/8"
6 1 O-ring 12 10 Hex head capscrew, 5/8"-11UNCx3-1/2"
DISASSEMBLY
Remove the Gooseneck from the Bonnet
1. Unscrew the washpipe from the gooseneck.
2. Cut and remove the safety wire from the bolts (A) that
hold the gooseneck (B) to the bonnet (C).
3. Support the gooseneck (B) with a hook on a crane.
4. Remove the bolts and flat washers that hold the
gooseneck to the bonnet. A
B
5. Lift the gooseneck away from the bonnet.
C
Disassemble the Gooseneck

1. Remove the 12 bolts (D) and lockwashers that hold the B
nipple in the bore of the gooseneck. E
2. Tap lightly on either side of the nipple with a dead

blow hammer and remove the nipple (E) from the D
gooseneck.
3. Remove and discard the O-ring from the nipple.

BONNET, GOOSENECK, AND WASHPIPE
Remove the Bonnet

This procedure is performed after the gearbox assembly has
been removed from the travel stand and is in a vertical
position.
1. Cut and remove the safety wire on the bolts (F) that
hold the bonnet to the gearbox.
C
2. Remove the 10 bolts and flat washers that hold the
bonnet to the gearbox.
3. Lift the bonnet off the gearbox.
Remove the Washpipe

1. Turn the washpipe to release it from the quill.
2. Lift the washpipe off the quill.
3. Remove the O-rings from the washpipe.
CHAPTER 4
INSPECTION
grooves, and pitting.
REASSEMBLY
Install the Washpipe
4. Grease the upper quill threads with anti-seize
compound.
5. Install the O-rings in the washpipe.
6. Lower the washpipe into position over the quill.

7. Tap the side of the protrusions on the base of the
washpipe to snug up the fit (left-hand threaded).

BONNET, GOOSENECK, AND WASHPIPE
Install the Bonnet

1. Make sure that all machined surfaces are clean and free
of dust and debris.
2. Lower the bonnet over the washpipe. Use dowels to aid
in positioning.
3. Bolt the bonnet to the gearbox with 10 bolts (F) and

flat washers, using Loctite 243 on the threads. Torque
to 150 ft-lbs.
4. Safety-wire the bolts (F).
Assemble the Gooseneck

1. Seat the O-ring into the nipple. Apply grease to the B
O-ring. E
2. Fit the nipple (E) into the bore of the gooseneck (B).
D
3. Tap gently into place with a soft hammer.
4. Bolt the nipple to the gooseneck with 12 bolts (D) and
to 35 ft-lbs.
5. Apply anti-seize compound to the threads on the
nipple.
CHAPTER 4
Install the Gooseneck on the Bonnet

This procedure is performed after the extend frame is
attached and the gearbox assembly is moved to the travel
stand. (See “Install the Assembly on the Travel Stand” on
page 28.)
1. Lift the gooseneck (B) and move into position at the
top of the bonnet (C).
2. Using a dowel (G) for positioning, rotate the
A
gooseneck counter-clockwise into position.
3. Attach the gooseneck to the bonnet with 10 bolts (A) B
and flatwashers, using Loctite 243 on the threads.
C
Torque to 250 ft-lbs.
4. Safety-wire the bolts. H G
5. Screw the top of the washpipe into the gooseneck.
Important: Before shipping make sure that the washpipe

is not tightened fully. Make sure that the customer is aware
that the washpipe connection is not torqued.
6. Screw in the top hammer union (H).

MOTOR MANIFOLD CHAPTER
5
MOTOR MANIFOLD EXPLODED VIEW
2 8
7 Typ. 4 plcs.
1
6
15
Typ. 4 plcs.
2 16 17
9 18
12
10 11
3 5
12
13
Typ. 2 plcs. 5 14
7 Typ. 4 plcs.
8 Typ. 6 plcs.
Figure 5.1: Motor manifold assembly
MOTOR MANIFOLD PARTS LIST

1 1 Motor manifold 11 1 Cover
2 2 Poppet valve 12 2 O-ring
3 1 Poppet relief valve 13 4 Lockwasher, 1/2"
4 1 Shuttle valve 14 4 Socket head capscrew, 1/2"-13UNCx2"
5 2 Relief valve 15 1 Cover
6 1 Cover 1 16 1 O-ring
7 10 Lockwasher, 3/4" 17 4 Lockwasher, 3/4"
8 10 Socket head capscrew, 3/4"-10UNCx3" 18 4 Hex head capscrew, 3/4"-10UNCx3"
9 1 Cover 2
10 1 O-ring
CHAPTER 5
INSTALLATION EXPLODED VIEW
Motor
ref only
13
13 10
13 18 17
13
Typ 3 plcs. 17 19 18 19
18 18 Typ 4 plcs.
Typ 12 plcs. 19
19
1 11
2 Typ 6 plcs. 9 16 Typ 4 plcs.
3 15
14
8
14 Typ 4
plcs.
Typ 12 plcs.16
15
12 Typ 4 plcs.
5
4 6 Typ 3 plcs.
Typ 6 plcs.
7
14 12 12 12
12
14
14
20
15 14
Typ 8 plcs.
20
22
23
21
Figure 5.2: Motor manifold installation

MOTOR MANIFOLD
INSTALLATION PARTS LIST

1 1 Mount, motor manifold 13 4 O-ring
2 6 Flat washer, 3/4" 14 6 Split flange
3 6 Hex head capscrew, 3/4"-10UNCx1-1/2" 15 24 Lockwasher, 3/4"
4 6 Anchor shackle 16 16 Hex head capscrew, 3/4"-10UNCx3"
5 1 Motor manifold 17 4 Split flange
6 3 Lockwasher, 7/8" 18 16 Lockwasher, 5/8"
7 3 Socket head capscrew, 7/8"-9UNCx10" 19 16 Hex head capscrew, 5/8"-11UNCx2-1/2"
8 1 Pipe route A1 20 2 Ball valve
9 1 Pipe route A2 21 1 Pipe route, forward
10 1 Pipe route B1 22 8 Hex head capscrew, 3/4"-10UNCx6-1/2"
11 1 pipe route B2 23 1 Pipe route, reverse
12 8 O-ring
DISASSEMBLY
Remove the Ball Valves and Lower Pipes
A
1. Cut and remove the safety wire on the bolts (A) that
hold the split flanges (B) and ball valves (C) to the
motor manifold.
2. Remove the bolts and lockwashers with one half of
D
each split flange.
B
3. Loosen the bolts on the other half of the split flanges C
and remove the pipes (D).
A
4. Remove the remaining bolts, lockwashers, split flange

halves, and the ball valves. C
5. Remove the O-rings from the ball valves and the ends B
of the pipes. A
CHAPTER 5
Remove the Upper Pipes

Use the following procedure to remove each of the four
upper pipes from the motor and motor manifold.
1. Cut and remove the safety wire from the bolts that
hold the split flanges to the motor and motor manifold.
2. Remove the bolts and lockwashers with one half of
each split flange.
3. Loosen the bolts on the other half of the split flanges
and remove the pipes.
4. Remove the remaining bolts, lockwashers, and split
flange halves.
5. Remove and discard the O-rings from the ends of the
pipes.
Remove the Motor Manifold

1. Cut and remove the safety wire from the 3 bolts (D)
that hold the motor manifold to the mounting bracket.
2. With the manifold supported by a crane, remove the
bolts (D) that hold the manifold to the bracket.
3. Lift the manifold away from the bracket and place on a

work table for disassembly.

MOTOR MANIFOLD
Remove the Motor Manifold Mounting

Bracket
1. With the mounting bracket supported by a crane,
remove the 6 bolts (E) and flat washers that hold the
mounting bracket to the gearbox.
2. Remove the bracket from the gearbox.
E
3. Remove the anchor shackles.
4. Remove the fittings.
Disassemble the Motor Manifold G

F
1. Cut and remove the safety wire on the bolts that hold
F
the covers on the manifold block.
3. Remove the covers.
4. Remove and discard the O-rings.
5. Remove the two relief valves (F) from the cover (G).
6. Remove the two poppet valves (H) using a slide
hammer. J
7. Remove the shuttle valve ( J) from the block.

8. Remove the poppet relief valve.
H
INSPECTION
Clean the inside of the manifold block, checking for
contaminants. Also examine the fluid that was drained
from the block.
breaks.
Check the poppet bores for excessive wear.
CHAPTER 5
REASSEMBLY
Assemble the Motor Manifold
Refer to the assembly drawing for ease of assembly. (See
Figure 5.1: Motor manifold assembly.)
Important: Make sure that the block is thoroughly

G
cleaned. Oil all O-rings and bores before installing so that F
F
the O-rings do not tear or break. Oil each cover with
assembly oil before attaching to the block.
1. Install O-rings in the block where necessary before

attaching the covers.
2. Install two new relief valves (F) on the cover (G).
Torque to 30-35 ft-lbs.
3. Install a new shuttle valve ( J) in the block. Torque to

30-35 ft-lbs. J
4. Install the poppet valve. Tap in gently, making sure that
the rings do not bunch up.
H
Caution: Take care when installing the
poppet valves so that the O-rings
do not tear. Use plenty of oil.
5. Attach cover 1 over the poppet valve with 4 bolts and

lockwashers.
6. Install the other poppet valve (H).
7. Insert the oiled O-ring. Apply oil to the surface.
8. Bolt on cover 2 with 6 bolts and lockwashers.
9. Bolt all covers to the block, following these guidelines:
a. Apply Loctite 243 to the threads of all bolts.
b. Insert the bolts with lockwashers.
c. Torque 1/2" bolts to 75 ft-lbs. Torque 3/4" bolts to
250 ft-lbs.
d. Safety-wire all bolts.
10. Cover any remaining open ports to keep out
contaminants.

MOTOR MANIFOLD
Install the Motor Manifold Mounting Bracket

1. Install all required fittings in the ports of the mounting
bracket prior to installation. (See Figure 11.5 on
page 119 in the Auxiliary Hydraulics chapter.)
2. Install all anchor shackles.
3. Attach the mounting bracket to the side of the gearbox

with 6 bolts (E) and flat washers, using Loctite 243 on
the threads. Torque to 250 ft-lbs.
Install the Motor Manifold

1. Lift the manifold into position against the mounting
bracket.
CHAPTER 5
2. Bolt the manifold to the bracket with 3 bolts (D) and

to 440 ft-lbs.
3. Safety-wire all bolts.
Install the Upper Pipes

1. Clean all machined surfaces on the motor.
2. Lubricate the O-rings and install on both ends of the
pipes.
3. Apply Loctite 243 to the threads on the bolts.
4. Loosely bolt, with lockwashers, one half of the split
flange on the motor.
5. Loosely bolt, with lockwasher, one half of the split
flange on the manifold.
6. Position the pipe in the flanges.
7. Bolt on the second half of the flanges. Torque the bolts

on the motor to 150 ft-lbs. Torque the bolts on the
manifold to 250 ft-lbs.
9. Repeat this procedure for each pipe.

MOTOR MANIFOLD
Install the Ball Valves and Lower Pipes

1. Grease the O-rings and insert into the ball valves.
2. Position the ball valves on the motor manifold using
dowels as guides.
3. Loosely bolt one half of the split flange onto the
manifold. Insert the bolts with lockwashers, using
Loctite 243 on the threads, through the split flange and
ball valve and into the manifold.
4. Lubricate the O-rings and install on both ends of the

pipes.
5. Insert the pipe and attach the second half of the flange.
6. Tighten bolts to snug only and turn the pipe so that it
is parallel.
7. Torque the bolts to 250 ft-lbs.
9. Repeat this procedure for the upper pipe.
10. Install a new hammer union seal.
CHAPTER 5

PIPE HANDLER CHAPTER
6
PIPE HANDLER EXPLODED VIEW
19
1 18
41 Typ 10 plcs. 17
16
39 15
41
23 Typ 4 plcs.
40 22
Typ 23 plcs.
2
Typ 14 places.
33
34 Typ 2 places.
36 3 21
34 20
35 4
37
Typ 20 plcs. 5 18
Typ 3 plcs. 6
7
18 38
38
Typ 12 plcs.11 14
10
8
28
29 Typ 4 plcs.
30
9
34
25
25
13 26 34
27
34 27
24
34
26
Figure 6.1: Pipe handler assembly with upper grabber leg
CHAPTER 6
PIPE HANDLER PARTS LIST

1 1 Rotary seal assembly 21 2 Pin, coiled spring, 3/16"ODx1"
2 23 Socket head capscrew, 3/4"-10UNCx5-1/2" 22 1 Nameplate
3 1 Pipe handler adapter 23 4 Socket head capscrew, 1/4"-20UNCx1"
4 20 Flat washer, 3/4" 24 2 Retainer, elevator link
5 20 Hex head capscrew, 3/4"-10UNCx4" 25 4 Hex head capscrew, 1"-8UNCx7"
6 3 Socket head capscrew, 1"-8UNCx2-3/8" 26 4 Hex nut, slotted, 1"-8UNC
7 3 Internal retaining ring 27 4 Safety pin, 1/8"wireODx3-1/8"
8 1 Flange, load collar adapter 28 1 Stop bracket, actuator
9 1 Load collar assembly 29 4 Lockwasher, 1/2"
10 12 Lockwasher, 1/2" 30 4 Hex head capscrew, 1/2"-13UNCx1-1/4"
11 12 Socket head capscrew, 1/2"-13UNCx1-3/4" 33 14 Shoulder bolt
13 1 Load nut assembly 34 36 Flat washer, 1"
14 1 Upper grabber leg 35 14 U-cup seal, 1.000"IDx1.500"OD
15 10 Lockwasher, 1" 36 14 Spring, 2.0"ODx3.5"
16 10 Socket head capscrew, 1"-8UNCx9" 37 1 Hose guard, grabber leg
17 1 Grabber lift pin 38 2 Hex head capscrew, 3/8"-16UNCx3/4"
18 3 Lockwasher, 3/8" 39 1 Slewing bearing
19 1 Hex head capscrew, 3/8"-16UNCx1" 40 1 Plug, fitting, 1/8"MNPT, short
20 2 Breakaway stem, cylinder mount 41 2 Fitting, grease, 1/8" MNPT, long
Important: Instructions for the disassembly and assembly

of the upper grabber leg are included in the Grabber Leg
Assembly chapter.

PIPE HANDLER
LOAD COLLAR EXPLODED VIEW LOAD NUT EXPLODED VIEW
1
7
Quill Load Collar
1
8
4 8
1
2
3
3
2
4
5
3
5
Figure 6.2: Load collar assembly
LOAD COLLAR PARTS LIST

Item Qty Description 6
1 1 Bushing Figure 6.3: Load nut assembly
2 1 Load collar
LOAD NUT PARTS LIST
3 1 Fitting, grease, 1/4”NPT
4 2 Hex jam nut, 1/2”-13UNC Item Qty Description
5 2 Hex head capscrew, 1/2”-13UNCx1-1/2” 1 2 Socket drive setscrew, 7/8"-9UNCx1.72"
2 1 Sleeve
3 1 Split collar
4 1 Retainer, upper
5 1 Retainer, lower
6 12 Socket head capscrew, 1/2"-13UNCx6"
7 1 O-ring
8 2 Retaining ring
CHAPTER 6
DISASSEMBLY
Remove the Elevator Link Retainers BB
1. Remove the safety pins (AA) from the bolt ends.
AA
2. Remove the nuts (Y), bolts (X), and washers (Z).
3. Remove the retainers (W) from the load collar (BB). W
Y
Z
Disassemble and Remove the Load Nut C A

4. Cut and remove the safety wires on the bolts (A) that E
hold the lower retainer (B) of the load nut to the upper
retainer (C). B
5. Remove the bolts and slide the lower retainer off the
quill.
6. Carefully slide the sleeve (E) off the split collar and be
prepared to support the split collar when the sleeve is
fully retracted.
7. Remove the split collar (F).

PIPE HANDLER
8. Remove the snap rings (G) that secure the two

setscrews (H) in the upper retainer (C) of the load nut. C G
9. Loosen the setscrews and slide the upper retainer (C)

off the quill ( J). C
K J
10. Discard the O-ring (K).
Disassemble the Pipe Handler O P

L
1. Support the lower end assembly of the pipe handler N M
with a sling and crane.
2. Disconnect the hoses and remove the fittings on the
rotary seal (L). Cover the holes with tape to keep out
debris.
3. Cut and remove the safety wires (M) on the 20 bolts
that hold the pipe handler adapter (N) to the slewing
gear (P).
4. Remove the bolts and flat washers.
5. Remove the 3 snap rings and setscrews (O) in the pipe
handler adapter.
6. Pull the lower end assembly (pipe handler adapter (N)
and load collar) off the quill ( J).
J N
CHAPTER 6
7. Remove the 23 bolts (Q) that hold the slewing gear (P) L
and the rotary seal (L) to the gearbox.
P
8. Remove the slewing gear. Q
9. Slide the rotary seal off the quill ( J).
Disassemble the Load Collar

A
1. Cut and remove the safety wires on the bolts that hold
the load collar adapter flange (A) to the load collar (B).
3. Lift the adapter flange from the load collar.
4. Remove the anti-rotation bolts (C) and jam nuts from
the side of the load collar.
5. Remove the grease nipple (D). D
B
C
6. Remove the bushing (E) from the load collar (B):
a. Heat a 1-1/2 in. wide strip down the length of the E
bushing to red hot.
b. When cooled, turn the load collar over and ham-
mer the bushing out with a drift.
INSPECTION
Clean and inspect all parts for wear, cracks, grooves, and
pitting. Check cables and hoses for tears and breaks.
Review the seal of the slewing bearing. Make sure that all
shoulder bolts and springs are intact and functional.

PIPE HANDLER
REASSEMBLY
Assemble the Load Collar
1. Place the bushing in the freezer for 24 hours prior to
assembly.
2. Buff the load collar inner bore to remove any burrs or
high spots.
3. Spray the inner bore with oil to ease the bushing

installation.
4. Heat the outer surface of the load collar to achieve

approximately 150°F (66°C) at the inner bore in order
to expand the inner bore.

components.
CHAPTER 6
5. Remove the bushing (E) from the freezer (after 24

hours) and insert into the heated load collar (B).
E
6. Install the anti-rotation bolts (C) with jam nuts in the

side of the load collar. A
7. Install the grease nipple (D).
8. Fit the load collar adaptor flange (A) over the load
collar (B). Fasten with bolts and lockwashers, using
Loctite 243. Torque to 75 ft-lbs.
10. If the adapter flange is a replacement, then tap the
outer holes on the adaptor flange. D
B
Assemble the Pipe Handler

1. Rest the pipe handler adapter on the load collar.

PIPE HANDLER
2. Assemble the springs and flat washers on the shoulder

bolts.
3. Insert the U-cup seals in the bolt bores in the pipe

handler adapter. Coat with white grease.
4. Install the shoulder bolt assemblies, using Loctite 243

on the bolt threads. Torque to 150 ft-lbs.
6. Tap all holes in the pipe handler adapter. Clean all

threads.
CHAPTER 6
7. Slide the rotary seal (F) onto the quill (G).

8. Fit the slewing bearing (H) to the rotary seal, making
sure that the grease-fitting holes align.
9. Bolt the rotary seal and inner race of the slewing gear
to the gearbox, using Loctite 243. Torque to 250 ft-lbs.
Important: When bolting the top flange of the rotary seal

to the gearbox, the bolt hole between ports 7 and 8
should be on the same centerline as the front of the
gearbox. H
F G
10. If you are installing a new rotary seal, remove the

fittings to facilitate installation of the load collar
assembly. Seal the holes with tape to keep out debris.
11. Grease the quill where the lower end assembly will
seat.
12. Lift the lower end assembly (load collar and pipe
handler adapter) and slide onto the quill.

PIPE HANDLER
13. Attach the pipe handler adapter ( J) to the slewing gear

(H) with bolts and flat washers, using Loctite 243.
H
15. Apply anti-seize compound to the tips of the 3

setscrews and apply Loctite 243 on the threads.
16. Insert the setscrews (K) into the pipe handler adapter
K
( J). Torque to 200 ft-lbs. J
17. Secure each setscrew with a snap ring (L) seated into
the groove in the bore with the square shoulder of the
snap ring facing out.
Install the Load Nut

The load nut is assembled as it is installed on the quill.
N
1. Oil a new O-ring (M) and install on the quill. Position
the O-ring over the bore (N) in the quill.
CHAPTER 6
2. Buff the bore of the upper retainer (P).

P
3. Slide the upper retainer (P) onto the quill and work the
O-ring (Q) into the groove in the retainer.
4. Apply anti-seize compound to the inside of the split

P
collar.
5. Buff the inside of the sleeve and apply anti-seize
compound.
6. Holding the split collar (R) on the quill, slide the sleeve
(S) over the collar and snug against the upper retainer. R
7. Install the two setscrews (T) in the upper retainer.

S
8. Install snap rings (U) over the setscrews, making sure U
that they seat in the groove in the bore of the retainer.
9. Slide the lower retainer (V) onto the quill.

V

PIPE HANDLER
10. Bolt the lower retainer (V) through the sleeve (S) to
the top retainer (P), using Loctite 243. Torque to P
75 ft-lbs. S
V
Install the Elevator Link Retainers

1. Install the two elevator link retainers (W) on the “ears”
of the load collar (BB).
BB
2. Fasten with bolts (X), split nuts (Y), and flat washers
(Z).
3. Insert a safety pin (AA) through each bolt.
AA
Y
Z
CHAPTER 6

PIPE HANDLER LOCK CHAPTER
7
EXPLODED VIEWS
9
1
8 16
15
14 13
2
4
3
7
5 3
6
2
Assembled Loctite 243 1

position 6 Gearbox
ref only
11
12
10
4
7
8
9
15
16
14 13
Figure 7.1: Pipe handler lock assembly Figure 7.2: Pipe handler lock installation
CHAPTER 7
PARTS LIST
1 1 Lock cylinder 9 6 Socket head capscrew, 3/4"-10UNCx7-1/2"
2 1 Cylinder retainer 10 1 Retainer, proximity switch
3 1 Snap ring, internal 11 1 Snap ring, internal
4 1 Lock body 12 1 Proximity switch
5 1 Back shim 13 2 Pipe bushing
6 2 Side shim 14 2 Pipe fitting, nipple, 1/4"MNPTx4-1/2"
7 1 Gear segment 15 1 Guard, gear segment
8 6 Lockwasher, 3/4" 16 2 Hex head capscrew, 3/8"-16UNCx3/4"
DISASSEMBLY
Important: The accumulator on the grabber leg may
block access to the lock. Either rotate the pipe handler
adapter or remove the accumulator and bracket. They can
hang down still attached at other end.
A
Warning! Accumulators used in the auxiliary
pressure before any maintenance is
done on the auxiliary hydraulic
system.
the cover plate (A) to the body.
2. Unbolt and remove the cover plate.
3. Remove the snap ring (B) that holds the sensor in
B
place.

PIPE HANDLER LOCK
4. Remove the sensor (C).

5. Cut and remove the safety wire (D) on the bolts that
hold the body on the gearbox.
D C
6. Remove the 6 bolts from the body (E).

7. Slide the body with the shims (F) off the gear segment. F
8. Disconnect the hoses and remove the two pipe fittings

with bushings that are connected to the cylinder
through the back of the gearbox.
CHAPTER 7
9. Remove the snap ring (G) that holds the cylinder in

place.
10. Slide the cylinder (H) and gear segment out of the
gearbox.
11. Unscrew the gear segment ( J) from the cylinder shaft. H
12. Remove the retainer (K).
INSPECTION
breaks.
Service Limits
Check the flat surfaces of the shims where they contact the
lock body. Standard clearance is 0.010 in. Maximum wear
is 0.030–0.040 in.
Check the lock for smooth movement.

PIPE HANDLER LOCK
REASSEMBLY
Important: The accumulator on the grabber leg may
block access to the lock. Either rotate the pipe handler
H
adapter or remove the accumulator and bracket. They can
hang down still attached at other end.

pressure before any maintenance is J
system.
1. Install the lock cylinder on the gear segment.

a. First install the retainer (K) on the cylinder (H).
b. Insert the end of the shaft into the gear segment K
( J), using Loctite 243 on the threads. Torque to 80
ft-lbs.
2. Slide the cylinder into the gearbox with the ports
aligned with the bores in the gearbox.
3. Install the snap ring (G).
4. Slide the bushings onto the pipe fitting nipples.

5. Coat the threads with Loctite 587 thread sealant.
CHAPTER 7
6. Install the two pipe fittings with bushings through the

back of the gearbox into the cylinder.
7. Install the body with the back shim.

8. If replacing the shims, center the leg and measure the F
side shims with a feeler gauge. Check for proper fit,
allowing 0.007 in. clearance on each shim.
9. Machine the shims to fit.
10. After machining the shims, coat both sides with anti-
seize compound and install in the body.
11. Push the body (E) with the shims (F) into the gearbox.
Test the movement of the lock by forcing air into the
fittings, alternating between lock and unlock.
12. Attach with 6 bolts and lockwashers, using Loctite
243. Torque to 250 ft-lbs.
E
13. Safety-wire (D) the bolts.
14. Install the sensor (C) in the body, leaving

approximately 1/8" clearance between the sensor and
the surface of the gear segment. Use the two adjusting
nuts (L), with Loctite 243, to adjust the clearance.
L D C

PIPE HANDLER LOCK
15. Secure in place with the snap ring (B).
16. Install the cover plate (A) with bolts, using Loctite
243.
A
18. Rotate the pipe handler adapter assembly back into

position.
CHAPTER 7

PIPE HANDLER ROTATE MOTOR CHAPTER
8
EXPLODED VIEWS
1 8
6
6
8
1
Gearbox
ref only
5
3
6
4
Figure 8.1: Pipe handler rotate motor assembly Figure 8.2: Pipe handler rotate motor installation
PARTS LIST
1 1 Adapter, rotate motor 5 1 Pinion guard
2 1 Motor, hydraulic 6 9 Lockwasher, 1/2"
3 1 Pinion gear 7 4 Hex head capscrew, 1/2"x2-1/2"
4 1 Cotter pin, 1/8"ODx2" 8 5 Hex head capscrew, 1/2"-13UNCx1-1/2"
CHAPTER 8
DISASSEMBLY
1. Disconnect the hoses from the fittings (A).
A
2. Cut and remove the safety wires (B) from the bolts.
3. Remove the 5 bolts and lockwashers that hold the

motor adapter (C) on the gearbox (D).
Important: You may need to remove the fittings from the

motor for easier access to the bolts.
C D
4. Remove the pinion guard (E), motor (F), and motor

E F C
adapter (C) from the gearbox.

PIPE HANDLER ROTATE MOTOR
5. Remove the bolts that hold the pinion guard (E),

motor (F), and motor adapter (C) together.
6. Remove the pinion guard from the motor.
E
7. Remove the motor adapter from the motor.
8. Remove the cotter pin (G) from the motor shaft.

9. Remove the split nut (H) from the shaft.
10. Remove the pinion gear ( J) from the motor shaft.
CHAPTER 8
INSPECTION
Clean and inspect all parts for wear, deformation, cracks, Service Limits
breaks. After reassembly, perform the following checks:
Replace damaged parts. • Review the gear contact pattern for even contact
across the gear surface.
• Review the gear alignment with the slewing gear.
• Make sure all safety wire is present and intact.
REASSEMBLY
1. Apply Loctite 243 to the threads of the motor shaft.
2. Apply anti-seize compound to the inside bore of the
pinion gear. M
Important: Make sure that the shaft key (M) is not

pushed out during assembly.
3. Slide the pinion gear ( J) onto the motor shaft.

PIPE HANDLER ROTATE MOTOR
4. Secure with the split nut (H) and torque to 80-120 ft-
lb.
5. Insert the cotter pin (G) in the motor shaft.
6. Slide the motor adapter (C) onto the motor (F).

7. Fit the pinion guard (E) onto the motor.
8. Bolt all three parts together loosely with bolts and
lockwashers, using Loctite 243. Keep loose until E
installed on the gearbox.
9. Install the motor adapter (C) on the gearbox (D) with

5 bolts and lockwashers, using Loctite 243. Torque to
75 ft-lbs. C
10. Safety-wire (B) the bolts.
B
CHAPTER 8
11. Attach the two fittings (A) to the motor.
12. Tighten the 4 bolts (K) that hold the pinion guard,
motor, and motor adapter together. Torque to 75 ft-lbs.
Important: Before torquing, make sure that the motor

pinion gear aligns properly with the slewing gear (L).
13. Safety-wire the bolts. L K

GRABBER LEG ASSEMBLY CHAPTER
9
GRABBER EXPLODED VIEW

1
2
Typ. 4 plcs.
17 4
9
Typ. 4 plcs.
7 8 4
Grabber Grabber
Close Open 9
16 13
9
3
9 14
18 13 5
11
14
10
18 5
19 22
Typ. 4 plcs.
21
12
15
23
6
Typ. 4 plcs.
20
Figure 9.1: Grabber assembly
CHAPTER 9
GRABBER PARTS LIST

1 1 Cap, fitting, #4FJIC 13 2 Die holder
2 1 Cap, fitting, #6 JIC 14 2 Keeper plate
3 2 O-ring 15 1 Retraction cap
4 8 Socket head capscrew, 1/2"-13UNCx1-1/2" 16 2 Port extension
5 4 Socket head capscrew, 1/2"-13UNCx1" 17 1 Dirt cover
6 4 Lockwasher, 1/2" 18 2 Cylinder shoe
7 1 Fitting, straight, #4MORBx#4MJIC 19 4 Hex head capscrew, 3/8"-16UNCx1"
8 1 Fitting, straight, #6MJICx#4MORB 20 4 Socket head capscrew, 1/2"-13UNCx1-1/4"
9 4 Die tong 21 1 Torquing box
10 1 Grabber cylinder 22 4 Lockwasher, 3/8"
11 1 Hose guard 23 1 Clamping box
12 2 Retraction pin
GRABBER CYLINDER GRABBER CYLINDER PARTS LIST

EXPLODED VIEW
Seal Alignment
1 1 O-ring
2 1 Seal, uni-ring
6
3 2 Seal, polypak
5 4 2 Plug
5 1 Cylinder
6 1 Gland nut
3 4
7 1 Piston
1
2
7
3
6
Figure 9.2: Grabber cylinder assembly

GRABBER LEG ASSEMBLY
LOWER GRABBER LEG EXPLODED VIEW

10
6 (54" long)
5
9
7
Typ 10 plcs
8 10
12 10
1 3 6 (15" long)
18
14
10
11
14
14
15
2 13
Typ 4 places 16 13
17 15
15 13
Figure 9.3: Lower grabber leg assembly
CHAPTER 9
LOWER GRABBER LEG PARTS LIST

1 1 Grabber assembly 10 4 Anchor shackle, 3/8"
2 1 Split guide 11 1 Shackle, 1/2"
3 1 Spacer 12 10 Lockwasher, 1"
4 1 Lower grabber leg 13 3 Hex head capscrew, 5/8"-11UNCx2"
5 1 Grabber lift cylinder 14 3 Hex locknut, nylon, 5/8"-11UNC
6 6 Chain, 3/8" 15 3 Cotter pin, 1/8"ODx1-1/2"
7 1 O-ring 16 4 Lockwasher, 3/4"
8 10 Hex head capscrew, 1"-8UNCx7-1/2" 17 4 Hex head capscrew, 3/4"-10UNCx1-1/2"
9 1 Pin 18 2 Decal “Caution Rotating Equipment”

UPPER LEG EXPLODED VIEW UPPER LEG PARTS LIST

19 Item Qty Description
18
Typ 10 plcs. 14 1 Upper grabber leg
17
16
15 10 Lockwasher, 1"
15
16 10 Socket head capscrew, 1"-8UNCx9"
23 Typ 4 plcs.
17 1 Pin
22
19 1 Hex head capscrew, 3/8"-16UNCx1"
20 2 Breakaway stem
Typ 2 places.
21 2 Pin, 3/16"ODx1"
21
22 Nameplate
20
23 4 Socket head capscrew, 1/4"-20UNCx1"
28 1 Actuator stop bracket
37
18
30 4 Hex head capscrew, 1/2"-13UNCx1-1/4"
18 38 37 1 Hose guard
38 38 2 Hex head capscrew, 3/8"-16UNCx3/4"
14
28
29 Typ 4 plcs.
30
Figure 9.4: Upper grabber leg assembly
CHAPTER 9
UPPER GRABBER LEG HYDRAULICS EXPLODED VIEW

34
35
Typ 3 plcs.
12
7 9
14
33
Upper Grabber Leg

ref. only
36
10
9
Typ 4 plcs.
7
11
15
13
Typ 4 plcs.
16
17
Figure 9.5: Upper grabber leg hydraulics
UPPER GRABBER LEG HYDRAULICS PARTS LIST

7 7 Lockwasher, 3/8" 15 1 Clamp, 3-1/2"IDx3/8"-16UNC
9 1 Grabber lift manifold assembly 16 4 Lockwasher, 3/8"
10 1 Mini-booster manifold 17 4 Socket head capscrew, 3/8"-16UNCx1"
11 4 Hex head capscrew, ,3/8"-16UNCx4-1/2" 33 1 Safety cable
12 3 Hex head capscrew, 3/8”-16UNCx5” 34 2 Cotter pin, 1/8"ODx1"
13 1 Intensifier guard 35 2 Hex locknut, nylon, 3/8"-16UNC
14 1 Mount, clamp 36 2 Hex head capscrew, 3/8"-24UNFx1/2"

GRABBER LIFT MANIFOLD LINK TILT EXPLODED VIEW

EXPLODED VIEW
6
2 Upper Leg
5
ref. only
1
1
8
7 52
4
5
3 1
2
5
4
3
2
3
4
Figure 9.6: Grabber lift manifold assembly 5
2
GRABBER LIFT MANIFOLD Figure 9.7: Link tilt assembly
PARTS LIST LINK TILT PARTS LIST

1 1 Manifold 1 2 Cylinder
2 1 Accumulator 2 4 Safety pin, 1/8"wireODx3-1/8"
3 1 Fitting, straight, #12MORBx#12MNPT 3 2 Rod end screw, 1"-8UNCx3"
4 1 Relief valve 4 2 Rod end spacer, 1.160"ODx0.985"ID
5 1 Gauge, liquid filled 5 4 Slotted hex nut, 1"-8UNC
6 1 Plug
7 1 Plug, fitting, #6MORB
8 1 Plug, fitting, #4MORB
CHAPTER 9
DISASSEMBLY
Remove the Split Pipe Guide
1. Detach the short chain from the split guide and the
lower grabber leg.
the split guide to the grabber box.
3. Remove the 4 bolts and lockwashers that hold the split
guide to the grabber box.
4. Remove the guide from the grabber box.
5. Separate the two halves of the guide:
a. Cut and remove the cotter pins.
b. Remove the 3 bolts and locknuts.
Remove the Link Tilt Cylinders

1. Remove the safety pins from the breakaway pins on the
upper leg.
2. Remove the slotted nuts.
3. Remove the top of the cylinders from the breakaway
pins.
4. Remove the pins and slotted nuts from the lower end
of the cylinders.
5. Remove the fittings from the cylinder.

Remove the Grabber Leg Assembly from the

Pipe Handler
1. Attach a sling to support the grabber leg assembly.
2. Cut and remove the safety wire on the 10 bolts that
hold the grabber leg assembly to the pipe handler
adapter.
3. Remove the 10 bolts and lockwashers.
4. Lift the grabber leg assembly away from the pipe

handler and move to an upright position.
Remove the Upper Leg from the Lower Leg

1. Detach the 54 in. chain from the upper and lower legs.
CHAPTER 9
1. Remove the pin that holds the upper end of the

cylinder to the upper leg.
2. Lift the upper leg off the lower leg and move to a
support stand.
Remove the Manifolds from the Upper Leg

1. Remove the mini-booster manifold.

2. Remove the grabber lift manifold.
Disassemble the Upper Leg

the actuator stop bracket to the upper leg.
3. Remove the bracket.
the hose guard to the side of the upper leg.
6. Remove the hose guard.
7. Remove the split pins (A) from the breakaway pins (B).
8. Remove the breakaway pins.
Disassemble the Lower Grabber Leg

1. Remove the cylinder from the lower grabber leg:
a. Remove the pin (C) that holds the lower end of the
cylinder in the lower grabber leg. C
b. Remove and discard the O-ring from the pin.
CHAPTER 9
c. Remove the cylinder from the lower grabber leg.
d. Cut the tiewraps that hold the hoses together.

e. Remove the hoses.
f. Remove the fittings from the cylinder.
2. Remove the grabber box from the lower grabber leg:

a. Cut and remove the safety wire on the bolts that
hold the lower leg to the grabber.
b. Remove the 10 bolts and lockwashers that hold the
lower leg to the grabber.
c. Lift the leg away from the grabber.
d. Remove the spacer between the leg and grabber.

Disassemble the Grabber

Remove the Clamping Box from the Torquing Box [Photo of hose guard installed on torquing box,
1. Cut and remove the safety wire on the bolts that hold safety wired]
the hose guard to the torquing box.
3. Remove the hose guard.
4. Install a swivel lifting eye into the retraction cap on the

clamping box. Torque to 28 ft-lbs.
5. Stand the assembly upright.
6. Cut and remove the safety wire on the two retraction
pins.
[Photo of clamping box being lifted from torquing box]
7. Remove the retraction pins.
8. Lift the clamping box out of the torquing box and
move to a work table.
Remove the Grabber Cylinder from the Clamping

Box
1. Remove the fitting caps.
[Photo of o-rings, extensions and fittings installed
2. Remove the dirt cover. in cylinder ports]
3. Remove the fittings and port extensions from the
cylinder.
5. Install plugs with lubricated O-rings in the ports to
prevent contamination.
6. Lay the clamping box on its side with the square
opening in a vertical position.
7. Remove the swivel lifting eye from the retraction cap.
CHAPTER 9
the retraction cap on the clamping box.
10. Remove the retraction cap.
11. Remove the bolts that hold the keeper plates over the
die tongs.
12. Remove the keeper plates.
[Photo of keeper plates bolted over die tongs ]
13. Slide the 4 die tongs out of the slots in the die holders.
[Photo of die tongs inserted in die holders]
14. Slide the cylinder with the cylinder shoes toward the
square opening in the side of the clamping box.
15. Pry up on the lower shoe and work the cylinder out of
the clamping box. [Photo of cylinder being removed from clamping box]

Remove the Die Holders

1. Remove the bolts that hold the die holder in the
clamping box.
2. Pry the die holder out of the clamping box. [Photo of die holder being removed from clamping box]
3. Remove the bolts that hold the die holder to the base
of the grabber cylinder.
4. Pry the die holder out of the base.
[Photo of die holder being removed

from base of grabber cylinder]
Disassemble the Grabber Cylinder

1. Remove the gland nut using a specialized wrench.
2. Remove and discard the O-ring (F) and seals (E) from
the gland nut. E
CHAPTER 9
3. Remove the piston from the cylinder.
4. Remove and discard the grabber seal from the piston.
INSPECTION

REASSEMBLY
Assemble the Grabber Cylinder
1. Clean the inside of the cylinder with a lint-free cloth.
2. Lubricate the grabber seal with hydraulic oil and install
onto the clamping box piston.
3. Lubricate the cylinder walls with hydraulic oil.
4. Slide the piston into the cylinder.
CHAPTER 9
5. Lubricate the poly-pak seals (E) and install in the

gland nut. Note the orientation of the seals in Figure E
9.2 on page 78.
6. Lubricate and install the O-ring onto the gland nut.
7. Install the gland nut using a specialized wrench to

tighten. Tighten by hand first; then strike once with a
hammer.
8. Install test fittings and pressure test to 2000 psi at full

extension and full retraction for approximately 5
minutes for each side.
Important: A drop in pressure of approximately 5% over

this time span is acceptable.
9. Install the plugs with lubricated O-rings to prevent

contamination.

Assemble the Grabber Box

Install the Die Holders
1. Install one die holder onto the base of the grabber
cylinder:
[Photo of die holder in base of grabber cylinder]
Important: The hydraulic openings at the output end of
the cylinder must face the direction opposite to that of the
cutout in the base of the cylinder in order to allow
hydraulic connections and die changeouts to be made.
a. Fit the die holder in the opening using a soft blow

hammer, if necessary, to seat the holder.
b. Secure the holder with 4 bolts, using Loctite 243
on the threads. Torque to 75 ft-lbs.
2. Install the second die holder into the clamping box:
a. Fit the die holder into the opening in the base of
the clamping box, using a soft blow hammer, if
necessary, to seat the holder. [Photo of die holder in clamping box]
b. Secure the holder with 4 bolts, using Loctite 243
Install the Grabber Cylinder in the Clamping Box

1. Clean the inside of the clamping box to remove
contaminants.
2. Apply Lubriplate 105 to the inside of the box where
the cylinder shoes ride.
CHAPTER 9
3. Orient the grabber cylinder so that the hydraulic

connections face away from the clamping box and the
cutout in the cylinder base faces the clamping box. The
die holders in the box and on the cylinder are facing
each other. [Photo of grabber cylinder and cylinder shoes arranged
at opening of clamping box]
4. Place the cylinder shoe on the edge of the opening of
the clamping box.
5. Place the cylinder on top of the shoe with the dogs
fitting over the ends of the cylinder.
6. Place the second cylinder shoe on top of the cylinder
with the dogs engaged over the end of the cylinder.
7. Use pry bars to lift the edge of the cylinder/shoe

assembly level and then slide into the opening in the
clamping box.
8. Slide the cylinder toward the circular opening in the [Photo of die tongs inserted in die holders]
end of the clamping box so that the die holders straddle
the opening.
9. Slide the 4 die tongs into the slots in the die holders.
10. Lock the die tongs in place with the 2 keeper plates.
Bolt each keeper plate with 2 bolts, using Loctite 243
[Photo of keeper plates bolted over die tongs ]
11. Install the retraction cap on the end of the clamping

box. Secure with 4 bolts and lockwashers using Loctite
243 on the threads. Torque to 75 ft-lbs.

13. Install a swivel lifting eye into the retraction cap.

14. Stand the assembly upright.
[Photo of clamping box upright, showing block to keep
Important: In order to avoid injury, block the cylinder cylinder body from sliding down]
body so that it does not come down while the fittings are
being installed.
15. Lubricate with Lubriplate 105 and install the 2

O-rings on the port extensions.
16. Remove the plugs from the cylinder ports and install
the extensions. Tighten. [Photo of o-rings, extensions and fittings installed
in cylinder ports]
17. Lubricate the O-rings on the fittings with Lubriplate
105 and install the fittings into the extensions.
Important: Make sure that the fitting for the open

function and the fitting for the close function are each
connected to the correct port. Refer to Figure 9.1 on
page 77 for details.
18. Tap the dirt cover into place over the hydraulic fittings.
19. Install caps on the fittings.
[Photo of dirt cover installed over fittings]
Install the Clamping Box in the Torquing Box

1. Make sure that all caps have been removed from inside
the torquing box and the threads are clean. Wipe the
inside of the box with a lint-free cloth.
2. Lift the clamping box and lower into the torquing box [Photo of clamping box being lowered into torquing box]
until the square opening in the clamping box is aligned
with the 2 threaded holes at the top of the torquing
box.
CHAPTER 9
3. Insert the retraction pins in the holes, using Loctite

243 on the threads. Tighten securely.
4. Safety-wire the pins.
[Photo of 2 retraction pins in torquing box, safety wired]
5. Install the hose guard on the torquing box over the

fittings. Fasten with bolts and lockwashers, using
Loctite 243 on the threads. Tighten securely.
[Photo of hose guard installed on torquing box,
6. Safety-wire the bolts. safety wired]
Important: The grabber is now ready for testing.

Connect a portable hydraulic power unit to the cylinder
fittings. Operate the cylinder to its fully extended and
retracted positions using a pressure of 2500 psi. Verify
smooth operation in both directions and check the
assembly for leaks.
Assemble the Lower Grabber Leg
Important: Before assembly, fit the lower leg into the

upper leg to make sure that there are no issues when
putting them together later.
1. Attach the lower leg to the grabber box:

a. Place the spacer plate against the back of the grab-
ber box assembly.
b. Position the leg section against the spacer, using
dowels as guides.

c. Bolt with the 10 bolts and lockwashers, using

Loctite 243 on the threads. Torque to approx 600
ft-lbs.
d. Safety-wire the bolts.
2. Insert the cylinder in the lower leg:

a. Install the hydraulic fittings on the cylinder, using
Loctite 567 thread sealant.
b. Attach the hoses to the fittings, using Loctite 243
on the threads. Tighten snugly.
c. Insert the cylinder into the lower leg.
CHAPTER 9
d. Install the O-ring on the pin and grease the

O-ring.
e. Apply anti-seize compound on the threads of the
pin.
f. Insert the pin (C) into the leg and through the C
lower bore of the cylinder.
Assemble the Upper Leg

1. Install the breakaway stems (B) into the upper leg,
using Loctite 243 on the threads. Torque to 1000 ft-
lbs. B
D
2. Install the split pins (A) for the breakaway pins.
3. Apply anti-seize compound to the exposed threads
(D).
4. Attach the hose guard to the side of the upper leg with
2 bolts and lockwashers, using Loctite 243 on the
threads. A
6. Attach the actuator stop bracket with 4 bolts and
lockwashers, using Loctite 243 on the threads.
Install the Manifolds on the Upper Leg

1. Charge the accumulator to 2000 psi. Engrave the
pressure on the top guard.
2. Assemble the grabber lift manifold. Refer to Figure 9.4
on page 81 for ease of assembly.
3. Install the manifold on the upper leg with safety cable.
Refer to Figure 9.5 on page 82.

5. Install the mini-booster manifold. Refer to Figure 9.5

on page 82.
Install the Upper Leg on the Lower Leg

1. Apply grease to the unpainted surface of the lower leg.
2. Lift the upper leg and position it over the lower leg.
3. Guide the hoses up into the upper leg.
4. Lower the upper leg over the lower leg until the top of
the cylinder aligns with the hole in the upper leg.
5. Apply anti-seize compound to the grabber lift pin and

insert through the hole in the upper leg and into the
bore at the top of the cylinder.
6. Secure the plate of the pin to the upper leg with the
bolt and lockwasher, using Loctite 243 on the threads.
7. Safety-wire the bolt.

CHAPTER 9
8. Attach one end of the 54" chain to the upper leg and
the other end to the lower leg with shackles and secure
with cotter pins.
Install the Grabber Leg Assembly onto the

Pipe Handler
1. Lift the grabber leg assembly and position over the
pipe handler adapter. Align the bolt holes.
2. Attach the leg assembly to the pipe handler adapter

with 10 bolts and lockwashers, using Loctite 243 on
the threads. Torque to 600 ft-lbs.
4. Rotate the grabber leg assembly 180° in preparation for
installing the link tilt cylinders.

Install the Link Tilt Cylinders

1. Install the fittings on the cylinders so that they point
toward the top of the cylinder. Use Loctite 587 pipe
sealant.
2. Insert the pin in the bottom of the cylinder.

3. Secure with the slotted nut.
4. Insert the safety pin through the pin.
5. Install the top of the cylinder on the breakaway pin on

the upper grabber leg.
6. Secure with the slotted nut and insert the safety pin
through the breakaway pin.
7. Repeat for the other cylinder.

CHAPTER 9
Install the Split Pipe Guide

The split pipe guide is installed after the mud saver valve is
installed and after testing.
1. Bolt together the two halves of the split guide with 3
bolts, locknuts, and cotter pins.
2. Attach the 15 in. chain to the guide with shackles.
Secure the shackles with bolt, nut, and cotter pin.
3. Attach the guide to the bottom of the grabber with 4
bolts and lockwashers, using Loctite 243 on the
threads. Torque to 250 ft-lbs.
4. Safety-wire the bolts to the guide.
5. Attach the other end of the chain to the lower grabber

leg with the shackle. Secure the shackle with bolt, nut,
and cotter pin.

12-STATION MANIFOLD CHAPTER
10
MANIFOLD EXPLODED VIEW

O-ring
Four per valve.
Supplied with valve.
1
Door removed
Typ 48 plcs.
RELIEF
5 7
SPEED 2
4
UNLOADER
6
GRABBER LIFT
3
ELEVATOR
3
GRABBER
4
EXTEND
3
P.H. ROTATE 8
4
P.H. LOCK Typ 26 plcs.
3
M.S.V.
4
TILT
3
FLOAT
3
Figure 10.1: 12-Station manifold assembly

CHAPTER 10
MANIFOLD PARTS LIST

1 1 Electrical panel assembly 6 1 Valve
2 1 Manifold assembly 7 1 Valve
3 6 Valve 8 26 Socket button head capscrew,
1/4"-20UNCx1/2"
4 4 Valve
9 1 Transducer
5 48 Socket head capscrew, #10-24UNCx1-1/4"
TRANSDUCER EXPLODED VIEW TRANSDUCER PARTS LIST

2 1 1 Transducer
2 1 Tube fitting, straight, #4TUBEx#4MNPT
1
3 1 Fitting, straight, #4MNPTx#4MJIC
3
4 1 Tube
5 1 Tube fitting, straight, #4TUBEX#4MJIC
4
6 2 Seal, 7/16"
HIG
H
6
3
LO
5 W
6
5
Figure 10.2: Transducer assembly and installation

12-STATION MANIFOLD
12-STATION MANIFOLD 12-STATION MANIFOLD

INSTALLATION EXPLODED VIEW INSTALLATION PARTS LIST
2 1 1 Manifold assembly
37
2 1 Mount
5 8 Hex head capscrew, 3/8"-16UNCx3/4"
6 8 Hex head capscrew, 1/2"-13UNCx1-1/4"
15
35 7 8 Lockwasher, 3/8"
34
15 1 Clamp, 3-1/2"IDx3/8"-16UNC
6 34 2 Cotter pin, 1/8"ODx1"
8
Typ 8 plcs. 36 35 2 Hex locknut, nylon, 3/8"-16UNC
36 3 Hex head capscrew, 3/8"-24UNFx1/2"
37 1 Accumulator
1
Enclosure
removed
for clarity.
7
Typ 8 plcs. 5
Figure 10.3: 12-Station manifold installation

CHAPTER 10
DISASSEMBLY

system.
Disconnect all hoses and wiring from the 12-station

manifold before disassembly.
Remove the 12-Station Manifold

1. Cut and remove the safety wire on the bolts (A) that A
hold the manifold to the mounting bracket.
2. Support the manifold with slings and a crane.
3. Remove the 8 bolts (A) and lockwashers that hold the
manifold to the bracket.
4. Lift the manifold away from the bracket.
Remove the Accumulator

system.
1. Remove the cotter pins and nuts from the clamp that
supports the accumulator.
2. Remove the clamp from the mounting bracket.
the accumulator to the bracket.
4. Remove the 3 bolts that hold the accumulator to the
bracket.
5. Remove the accumulator.

12-STATION MANIFOLD
Remove the 12-Station Manifold Mounting

Bracket
1. Cut and remove the safety wire on the bolts (B) that
hold the mounting bracket to the gearbox.
2. Support the mounting bracket with slings and a crane.
3. Remove the bolts (B) and lockwashers that hold the B
mounting bracket to the gearbox.
4. Lift the bracket away from the gearbox.
Remove the Wiring

1. Ohm out the coils on the DCVs.
2. Remove any damaged wiring.
3. Make note of any wires that have moved on the output
side of the terminal block to the DCVs. There could be
a damaged pigtail or “A” cord.
Disassemble the Transducer

1. Loosen the fittings (C).
D
2. Remove the tubing (D).
3. Remove the fittings (C) and sealing washers.
C
4. Remove the transducer (E) from the bulkhead of the
manifold.

CHAPTER 10
Disassemble the 12-Station Manifold

1. Remove each solenoid valve:
a. Remove the lid of the valve.
b. Remove the 4 bolts that hold the valve in the
block.
c. Remove the valve from the manifold.
d. Remove and discard the 4 O-rings on the bottom
of the valve.
2. When all the valves are removed, remove the 26 bolts

that hold the enclosure to the manifold block.
3. Pry gently around the join to release the silicone and
remove the enclosure from the block.
4. Remove the ORB fittings and plugs.
INSPECTION
Check wiring for bends and breaks.

12-STATION MANIFOLD
REASSEMBLY
Assemble the 12-Station Manifold
1. Remove all point plugs and clean the manifold in a
G
solvent tank. Blow out all excess solvent and wipe down
with a clean rag. Make sure all ports are clear of debris.
2. Lubricate the O-rings on the ORB fittings and plugs. F
3. Install the ORB fittings and plugs (F) according to the
drawing 1320065Rev4.
4. Lubricate the O-rings on the pressure relief valve
cartridge.
5. Install the pressure relief valve cartridge as shown in
the drawing. (See Figure 10.1 on page 105.)
6. Run a bead of clear silicone around the top edge the
block flange (G).
7. Set the enclosure onto the manifold block and fasten
down with the 26 bolts, using Loctite 243 on the
threads. Tighten snug.
8. Install the solenoid valves as indicated in the drawing.
(See Figure 10.1 on page 105.)
a. Remove the lid of the valve.
b. Make sure that the four o-rings are present in the
bottom of the valve.
c. Confirm that the alignment dowel is in place.

d. Seat the valve on the block.
e. Install the 4 bolts.
f. Reinstall the lid.
g. Engrave the function ( J) on the lid according to

the drawing.
J

CHAPTER 10
Assemble the Transducer H

1. Install the fittings (C) in the transducer. Use the first
bulkhead fitting on the high port side (H). Use a D
1/4 in. tube adapter fitting on the low pressure side (L).
2. Loosely bolt into the panel with sealing washers in C L
place and Loctite 243 on the threads.
3. Loosely bolt the second bulkhead fitting with sealing
washers in place and Loctite 243 on the threads.
4. Measure the tubing (D) and make two 90° bends. E
5. Install the tubing between the low pressure port and
the second bulkhead fitting.
6. Tighten all fittings.
Install the Wiring

Replace any damaged wires.
Install the 12-Station Manifold Mounting

Bracket
1. Install the mounting bracket for the 12-station
manifold on the gearbox.
Important: Measure the holes in the back of the manifold K

to determine which holes to match in the bracket. For
ease of installation, insert bolts (K) with lockwashers in
these holes before attaching the mounting bracket. M
2. Bolt the bracket to the gearbox with 8 bolts (M) and

to 75 ft-lbs.

12-STATION MANIFOLD
Install the Accumulator

1. Charge the accumulator with nitrogen to 800 psi. Mark
this number on the accumulator.
2. Install the fitting on the bottom of the accumulator.
3. Attach the accumulator to the bracket with 3 bolts,
using Loctite 243 on the threads.
5. Secure the accumulator with the clamp using nylon

locknuts and cotter pins.
Install the 12-Station Manifold

1. Lift the manifold into position on the mounting
bracket, using dowel pins in the bolt holes as a guide.
2. Install the 8 bolts (A) with lockwashers, using Loctite
243 on the threads. Tighten the hard-to-reach bolts
first. Torque to 75 ft-lbs. A

CHAPTER 10

AUXILIARY HYDRAULICS CHAPTER
11
EXPLODED VIEWS
B4 A4
114
222
221 22
117
116
Figure 11.1: Pipe handler rotate motor hydraulics

CHAPTER 11
6
4 8
Typ 2 plcs.
Gearbox
ref. only
B3 A3
219
220
Lo
ck
Clo
se
Lo
ck
Op 129
en
220 219
Rear View
Figure 11.2: Pipe handler lock hydraulics

AUXILIARY HYDRAULICS
37 REF.
8 140
136 B
To
A 8
To
212
229
230
111
Po
Po rt
110
3
135
109 r t1 103 13 103
104 2
139
PB
103 T
109 111
L
CH
K
138
PA
243
115 R
103 116
137
231 117 203
136
206 111
Figure 11.3: Grabber lift cylinder hydraulics

CHAPTER 11
114
Port 2
22
Port 3
88
117
116 109
108
rt 2
Po
108
212 rt 3
Po
214
B1 A1
211
213
227
216
118
118
118
118
Figure 11.4: Link tilt cylinders hydraulics

119
130
122 124
131
120 130
29 234 30
123
121
31
232
235
124
233
125
119
231
Po
rt 119
14
14
12 13
10 11
8
6
9
7
103
4 5
2 3
101 101
1
28 27
21
20
Figure 11.5: Motor hydraulics

CHAPTER 11
B2 A2
114 Port 4
Port 5
218
217
109
t4
Por
Mudsaver 5
Valve open rt
Po
109
210
Mudsaver
Valve close
Figure 11.6: Mudsaver valve hydraulics

225 226 114 Por t 7
Port 8
8
Por t
109
B6 rt 7
A6 Po
209 103
18
115 110
105
103
208 106
103
127
205
106 107
32
204
Figure 11.7: Grabber box hydraulics

CHAPTER 11
B7 A7
207 228 227

Port 10
103
Port 11
10
109 Port 103
109
11
o rt
P
113 113
25
23
26
24
Figure 11.8: Ports 10 and 11 capped

B5
A5
224
26
223
25
22
24
23
102
116
Figure 11.9: A5 and B5 capped

CHAPTER 11
1
P1 237
1
A1
238
107
0 238
B1
109
107
107 B10
P 10
109
0
A1
236 A10
107 107
237
0 A1 126
P1 1
P1
1
109
107 127
Figure 11.10: Motor manifold hydraulics

19
132
H
HIG 240
W FO
LO 241 RW 126
AR
D 127
242
G E
ERS
R EV
128
Figure 11.11: Transducer to motor manifold hydraulics

CHAPTER 11
PARTS LIST
1 1 12-station manifold assembly 31 1 Relief valve
2 1 Mount, 12-station manifold 32 10 ft Hose sleeve, 1.53" ID
3 1 Breather, air muffler 33 1 Safety cable, 1/8" dia, 3/8" hole x 6" long
4 1 Hose guard, gearbox 34 4 Cotter pin, 1/8"ODx1"
5 8 Hex head capscrew, 3/8" -16UNC x 3/4" 35 4 Hex locknut, nylon, 3/8"-16UNC
6 10 Hex head capscrew, 1/2"-13UNCx1-1/4" 36 4 Hex head capscrew, 3/8"-24UNFx1/2"
7 15 Lockwasher, 3/8" 37 1 Accumulator, ,#12FORB
8 10 Lockwasher, 1/2" 101 2 Fitting, straight, #16MNPTx#16MNPT
9 1 Manifold assembly, grabber lift 102 2 Fitting, straight, #6MNPTx#4MNPT
10 1 Mini-booster manifold 103 10 Fitting, 90° elbow, #6MJICx#6MORB
11 4 Hex head capscrew, 3/8"-16UNCx4-1/2" 104 1 Fitting, 90° elbow, #6MJICx#8MORB
12 3 Hex head capscrew, 3/8”-16UNCx5” 105 1 Fitting, tee, #6MJICx#6MJICx#6MORB-BR
13 1 Guard, mini-booster 106 2 Fitting, straight, #6FJICx#4MJIC
14 1 Mount, accumulator clamp 107 7 Fitting, 90° elbow, #6MJICx#6FJIC
15 2 Clamp 108 2 Fitting, tee, #6MJICx#6MJICx#6FJIC-BR
16 4 Lockwasher, 3/8" 109 14 Fitting, straight, #6MJICx#6MORB
17 4 Socket head capscrew, ,3/8"-16UNCx1" 110 1 Fitting, straight, #6FNPTx#6FJIC-SWVL
18 1 Gauge, liquid filled 111 3 Fitting, 90° elbow, #6MJICx#4MNPT
19 1 Gauge, liquid filled 112 not used
20 1 Plug, quick disconnect coupler, 1" 113 2 Fitting, straight, #6MJICx#6MNPT
21 1 Cap, quick disconnect nipple, 1" 114 8 Fitting, 45° elbow, #6MJICx#6MORB
22 6 Control valve 115 2 Fitting, socket head plug, #6MORB
23 2 Coupler, quick disconnect, 3/8"x3/8"FNPT 116 7 Fitting, straight, #6MJICx#4MNPT
24 2 Cap, quick disconnect coupler, 3/8" 117 5 Fitting, straight, #4MNPTx#6FJIC
25 2 Nipple, quick disconnect, 3/8"x3/8"FNPT 118 4 Fitting, 90° elbow, #6MJICx#6MNPT
26 2 Cap, quick disconnect nipple, 3/8" 119 3 Fitting, 90° elbow, #8MJICx#8MNPT
27 1 Coupler, quick disconnect, 1"x1"FNPT 120 1 Fitting, straight, #8MNPTx#8MNPT
28 1 Nipple, quick disconnect, 1"x1"FNPT 121 1 Fitting, straight, #8MNPTx#8FJIC
29 1 Check valve, inline, 1/2"FNPT 122 1 Fitting, tee, #8FNPTx#8FNPTx#8FNPT
30 1 Body, cartridge relief valve, #8 SAE 123 1 Fitting, straight, #8MJICx#8MNPT


124 2 Fitting, tee, #8MJICx#8MJICx#8MJIC 214 1 Hose #6 x 65”
125 1 Fitting, straight, #8FJICx#6MJIC 215 not used
126 3 Fitting, straight, #4MJICx#6MORB 216 1 Hose #6 x 21”
127 4 Fitting, 90° elbow, #4MJICx#4FJIC-Swvl 217 1 Hose #6 x 21”
128 1 Fitting, 45° elbow, #4MJICx#6MORB 218 1 Hose #6 x 22.5”
129 2 Fitting, 90° elbow, #4MJICx#4 FNPT 219 1 Hose #4 x 52”
130 2 Fitting, straight, #8MORBx#8FJIC 220 1 Hose #4 x 49”
131 1 Fitting, 90° elbow, #8MJICx#8FJIC 221 1 Hose #6 x 36.5”
132 1 Fitting, 90° elbow, #4MJICx#4MNPT 222 1 Hose #6 x 41”
133 not used 223 1 Hose #6 x 44”
134 not used 224 1 Hose #6 x 44”
135 1 Cap, fitting, #6FJIC 225 1 Hose #6 x 21”
136 2 Fitting, tee, #6MJICx#6FJIC-Swvl-Run x 226 1 Hose #6 x 23.5”
#6MJIC
227 2 Hose #6 x 31”
137 1 Needle valve, 1/4"FNPTx1/4"FNPT
228 1 Hose #6 x 29.5”
138 1 Fitting, 45° elbow, #6MJICx#6FJIC-Swvl
229 1 Hose #6 x 38”
139 1 Fitting, socket head plug, #4MORB
230 1 Hose #6 x 38”
140 1 Fitting, straight, #6MJICx#12MORB
231 2 Hose #6 x 24”
200 Kit – all hoses
232 1 Hose #8 x 43”
201 not used
233 1 Hose #8 x 13”
202 not used
234 1 Hose #8 x 33.5”
203 1 Hose #4 x 137”
235 1 Hose #8 x 32”
204 1 Hose #4 x 123”
236 1 Hose #6 x 25”
205 1 Hose #6 x 123”
237 2 Hose #6 x 32”
206 1 Hose #4 x 126”
238 2 Hose #4 x 41”
207 2 Hose #6 x 143”
239 not used
208 1 Hose #6 x 25”
240 1 Hose #4 x 40.5”
209 1 Hose #6 x 23”
241 1 Hose #4 x 48”
210 2 Hose #6 x 73”
242 1 Hose #4 x 44.5”
211 1 Hose #6 x 72”
243 1 Hose #4 x 115”
212 2 Hose #6 x56”
213 1 Hose #6 x 58”

CHAPTER 11
DISASSEMBLY
system.
Disconnect fittings and remove hoses in an organized

manner, grouped by assembly, if possible. Match-mark the
connecting parts for ease in reassembly.
INSPECTION
Check fittings, hoses, and cables for wear, damage, and
weathering. Do not reuse hoses that are bent, split,
stretched, or abraded.
Replace worn or damaged parts.
REASSEMBLY
Assembly Preparation and Tips
Keep track Order of assembly
• Sort and organize fittings and hoses so that they are • Start with the deepest, hardest-to-reach fittings and
easy to identity and retrieve as needed. hoses for easier wrench access.
• Refer to the drawings for assembly. • Then work your way toward the outer edges.
• Mark on the drawings the fittings and hoses as you
install them to make sure that none are missed. Confirm hose length
• Connect both ends of the hose loosely at first.
Routing • Check that the hose is of sufficient length, is routed
• Route cables and hoses so that they cannot be well, does not bend too much, is not stretched, and
damaged by stretching, bending, or rubbing against will not interfere with moving parts.
sharp edges during top drive operation. • Then tighten the connections.
• Make sure that hoses do not block access to valves • If a hose appears to be too short or is tight fitting,
and connections that may need to be adjusted or check its part number to make sure that it is the
replaced in the field. correct hose.

Pipe Handler Rotate Motor

Install the fittings and hoses for the pipe handler motor.
See Figure 11.1 on page 115.
Pipe Handler Lock

1. Install the fittings and hoses for the pipe handler lock.
2. Install the hose guard with 2 bolts and lockwashers,
using Loctite 243 on the threads. Torque to 75 ft-lbs.
Grabber Lift Cylinder

1. Connect the hoses on the grabber lift cylinder to the
ports on the rotary seal. See Figure 11.3 on page 117.
2. Install the remaining fittings and hoses for this
function.
Link Tilt Cylinders

Install the fittings and hoses for the link tilt cylinders. See
Figure 11.4 on page 118.

CHAPTER 11
Motor
1. Assemble the motor relief valve and install on the
motor with fittings. See Figure 11.5 on page 119.
2. Install the fittings and hoses according to the drawing.
Mudsaver Valve
Install the fittings and hoses for the mudsaver valve. See
Grabber Box
Install the fittings and hoses for the grabber box. See

Capped Hoses
Install the fittings and hoses from ports A7 and B7 in the
12-station manifold to ports 10 and 11 in the rotary seal.
Install the fittings and hoses for ports A5 and B5. See
Motor Manifold
1. Install the fittings and hoses from the 12-station
manifold to the motor manifold. See Figure 11.10 on
page 124.
2. Install the fittings and hoses from the transducer to the

motor manifold. See Figure 11.11 on page 125.
3. Install the fittings and hose for the liquid-filled gauge

on the 12-station manifold mounting bracket.

CHAPTER 11

MUDSAVER VALVE CHAPTER
12
EXPLODED VIEW
Quill
ref. only
3
4
1
Clamp
ref. only
2
7
5
Saver Sub Fit block within

ref. only Stop Bracket
7
5
Stop Bracket
ref. only
Figure 12.1: Mudsaver valve installation

CHAPTER 12
PARTS LIST
1 1 Dual ball valve 4 2 Setscrew, socket drive, 1/2"-13UNCx3/4"
2 1 Actuator 5 2 Fitting, 90° elbow, #6MJICx#6MORB
3 1 Spline lock collar 7 2 Cap, fitting, #6 FJIC
DISASSEMBLY
Remove the Mudsaver Valve
A
1. Release the ball valve (A) from the grabber clamp (B).
2. Disconnect the hoses and remove the fittings from the

actuator.
3. Loosen the 2 setscrews (C) in the spline lock collar

(D).
C

MUDSAVER VALVE
4. Slide the spline lock collar (D) off the joint between
the ball valve (A) and the quill (E). D A
E
5. Unscrew the ball valve from the quill.
6. Lift the mudsaver valve away from the quill and place
on a work table.
7. Slide the spline lock collar off the quill.
Disassemble the Mudsaver Valve

1. Loosen the clamps (F) around the actuator and slide
them off the dowel holes. G F
2. Loosen the 8 dowels/setscrews (G) in the actuator.
G
3. Remove and discard the O-rings (H) between the ball
valve and the actuator. H
4. Remove the snap rings ( J) that hold the 2 hex dowels

(K) in place.
5. Remove the hex dowels with a slide hammer. J
K

CHAPTER 12
6. Lift the ball valve out of the actuator.
INSPECTION

MUDSAVER VALVE
REASSEMBLY
Assemble the Mudsaver Valve
1. Loosen the clamps (F) around the actuator and slide
them off the dowel holes.
G
Important: To lift the actuator, replace two opposite
dowels with lifting pins.
F
G
2. Loosen all 8 dowels so that they are fully retracted from

the surface of the inner bore. Tap from inside.
G
G
3. Remove the protective covers from the new ball valve.

4. Make sure that both ball valves are OPEN. Also make
sure that the actuator is in the OPEN position.

CHAPTER 12
5. Lift the ball valve and lower it into the actuator.

6. Align the serial numbers of the two parts. This ensures
that the dimples in the ball valve match with the
dowels in the actuator.
7. Apply anti-seize compound to the ball valve on the

area between the upper and lower dimples.
8. Lower the ball valve to align the hex holes.

9. Insert the hex dowels (K) on either side and tap to seat
in the holes.
K

MUDSAVER VALVE
10. Insert the snap ring ( J) and seat in the groove in the
bore.
J
K
11. Tighten the 4 top dowels/setscrews in opposite pairs

and alternate tightening and loosening to achieve 0.007
in. clearance all around. Check the clearance with
feeler gauges.
12. When balanced clearance is achieved, torque the
dowels to 100 ft-lbs.
Important: The dowels have internal springs that can

become dislodged. If this occurs, then remove the outer
dowel and put the spring back into the inner dowel.
13. Slide the clamp (F) back over the dowels (G) and seat
in the recess. Tighten the clamp. H
14. Insert the O-ring (H) into the gap between the ball
valve and actuator. Lubricate with lithium grease.
15. Use a flat blade screwdriver to press the O-ring in at 90
degree intervals, then continue to halve the intervals
G
until the O-ring is evenly seated without bunching.
F
16. Turn the assembly over and repeat steps 11-15 for the
other 4 dowels and O-ring.
Install the Mudsaver Valve

1. Slide the spline lock collar (D) onto the quill (E). D A
E
2. Screw the top of the ball valve (A) onto the quill (E),
making sure to line up the splines.

CHAPTER 12
3. At the same time, make sure that the actuator block (L)
seats in the bracket (M) on the grabber leg.
M
4. Slide the spline lock collar (D) over the joint.

5. Tighten the 2 setscrews (C) in the spline lock collar.
C
6. Install the fittings on the actuator.

7. Connect the hoses.
Important: Test the upper ball valve with hydraulics to

open and close. Test the lower ball valve manually.
8. Move the grabber up around the ball valve (A) and

close the clamp (B) on it. A

SWIVEL YOKE AND COUNTER CHAPTER
BALANCE 13
EXPLODED VIEWS
5
10 Typ. 4 plcs.
9
1 3
4
6
8
11
19 7 7
6
6 DETAIL A
4 7
23 21 3 Typ. 4 plcs.
5
14
A
20 14
24
23
8
Typ.
22 4 plcs. 9 10
18 Typ. 4 plcs.
19 19
Typ. 4 plcs.
17
15 16
12
11
21 23
2
24 19
18 19
Typ. 4 plcs. 20
19 18 13
Typ. 4 plcs. 2 23
15
17 19
Typ. 4 plcs.
22
Figure 13.1: Swivel yoke and counter balance assembly

CHAPTER 13
B
39
41 53
50
40
44 42 52
41
42
54 40 39
45
46 50
47
48
49
51 Cut in half
35
34
36
37
31
33 38 43
32
30
25
Typ. 4 plcs. 26 29
27
28
DETAIL B
Figure 13.2: Swivel yoke and counter balance hydraulics

SWIVEL YOKE AND COUNTER BALANCE
PARTS LIST
1 1 Swivel yoke 28 4 Hex locknut, nylon, 1/4"-20UNC
2 2 Swivel link 29 1 Plug, fitting, #4MORB
3 2 Swivel link pin 30 1 Fitting, straight, #8MORBx#4FNPT
4 2 Retainer 31 1 Fitting, 90° elbow, #4MNPTx#4FNPT
5 6 Grease fitting, straight, 1/8"MNPT 32 1 Gauge, liquid filled
6 4 Lockwasher, 1/2" 33 1 Fitting, straight, #8MORBx#6MNPT
7 4 Hex head capscrew, 1/2"-13UNCx1-1/2" 34 1 Body, relief valve
8 2 Lug, upper 35 1 Relief valve
9 8 Belleville washer, 1/2"IDx1.26"OD 36 1 Fitting, straight, #8MORBx#8FNPT
10 8 Hex head capscrew, 1/2 x2" 37 1 Air breather, 1/2"MNPT
11 2 Anchor shackle, 3/4" 38 1 Fitting, straight, #12MJICx#8MORB
12 1 Mount, accumulator DS 39 2 Fitting, 90° elbow, #12MJICx#8MNPT
13 1 Mount, accumulator ODS 40 2 Fitting, 90° elbow, #8MJICx#8MNPT
14 2 Accumlator 41 2 Fitting, straight, #16MORBx#12FNPT
15 2 Lug, lower 42 2 Fitting, tee, #12MJICx#12MJICx#12MNPT
16 1 Bracket, relief manifold 43 1 Fitting, straight, #12MJICx#12MORB
17 8 Hex head capscrew, 3/4" 44 1 Fitting, 90° elbow, #12MJICx#12MORB
18 12 Hex locknut, nylon, 1/2"-13UNC 45 1 Fitting, straight, #8MJICx#6MNPT
19 16 Cotter pin, 1/8"ODx1-1/2" 46 1 Needle valve
20 2 Cylinder 47 1 Fitting, straight, #6MNPTx#6MNPT
21 2 Hex head capscrew, 1"-8UNCx4" 48 1 Nipple, quick disconnect, 3/8"x3/8"FNPT
22 2 Hex head capscrew, 1"-8UNCx3-1/2" 49 1 Cap, quick disconnect, 3/8"
23 4 Slotted hex nut, 1"-8UNC 50 2 Hose, #12x33"
24 4 Hex head capscrew, 1/2"-13UNCx4" 51 1 Hose, #8x32"
25 1 Manifold, counter balance 52 1 Hose, #12x23.5"
26 4 Hex head capscrew, 1/4"-20UNCx3" 53 1 Hose, #12x46"
27 4 Lockwasher, 1/4" 54 1 Hose, #8x36"

CHAPTER 13
DISASSEMBLY
Uninstall the Swivel Yoke and Counter
Balance Assembly
Caution: Make sure that there is no tension

on the stop plate from the swivel
link.
the swivel link stop plates to the gearbox.
3. Remove the stop plates.
4. Disconnect the hoses and fittings. See Figure 13.2 on
page 142.

system.
the retainers over the swivel link pins in the gearbox.
7. Remove the swivel link pins from the gearbox using a

slide hammer (A).
Important: Reinstall the swivel link pins after the swivel

yoke and counter balance assembly are removed. This will
facilitate the lifting of the gearbox, if necessary. Do not
safety-wire the bolts at this time.

8. Attach slings around the lower ends of the links and

through the swivel yoke.
9. Use cranes to draw the links out of the gearbox.
10. Lift the swivel yoke and counter balance assembly away
from the gearbox and move to a workspace.
Disassemble the Swivel Yoke and Counter

Balance Assembly
1. Remove the cotter pins from the bolts that hold the
accumulator bracket to the links. Remove the cotter
pins from the bolts that hold the cylinder shackles.
2. Remove the bolt (B) and nut that hold the cylinder
shackle (C) to the upper lug (D) and disengage the
upper end of the cylinder (E).
D
E
B C

CHAPTER 13
3. Disconnect the hoses from the cylinder (E) and

accumulator (F).
Warning! Accumulators used in the auxiliary F

done on the auxiliary hydraulic E
system.
4. Unbolt the upper clamp (G) on the accumulator (F).

5. Slide the accumulator out of the bracket. F
6. Remove the bolts and nuts that hold the lower end of
the accumulator bracket and lower lug to the link.

7. Remove the cylinder and the lower lug (H).
8. Remove the bolts and nuts that hold the upper end of
the accumulator bracket to the link.
9. Remove the accumulator bracket.
10. Cut and remove the safety wires on the bolts that hold
the upper lug (D) to the link.
11. Unbolt and remove the upper lug. D

CHAPTER 13
12. Unbolt and remove the strap from over the swivel yoke
pin and remove the pin.
13. Lift the swivel yoke link out of the yoke.

14. Repeat this procedure on other side.
INSPECTION
Check for wear and distortion of the bore on the upper
lugs.
Replace worn and damaged parts.

REASSEMBLY
Assemble the Swivel Yoke and Counter
Balance Assembly
1. Lower the link into the yoke.
2. Align the bores.
3. Grease the bores with multi-purpose or assembly
grease.
4. Insert the swivel yoke pins ( J) with the grease nipples

(K) oriented toward the top. Tap in the pins with a soft K
hammer if necessary. D
J
5. Bolt on the strap with bolts and lockwashers, using
Loctite 243 on the threads. Torque to 75 ft-lbs.
7. Bolt on the upper lug (D) with 4 bolts and
to 75 ft-lbs.
9. Install the accumulator bracket on the link. Fasten the
upper bolts and nuts first; hold the lower end in place
with one bolt.
10. Install the cylinder in the lower lug with a bolt and
slotted hex nut. Insert a cotter pin in the bolt.
11. Attach the lower end of the accumulator bracket with
bolts through the lower lug, the bracket, and the link.
Secure with nuts and torque to 75 ft-lbs.
H
12. Insert cotter pins in all the bolts.

CHAPTER 13
13. Slide the accumulator (F) into the bracket.

G F
14. Attach the hoses to the accumulator fittings. Tighten.
15. Bolt the upper accumulator clamp (G) snug.
16. Attach the upper cylinder shackle (C) to the upper lug
(D) with bolt (B), nut, and cotter pin. C
B
D
17. Safety-wire the accumulator protection cap to the

accumulator bracket.
Install the Swivel Yoke and Counter

Balance Assembly
1. Remove the bolts and lockwashers that hold the
retainers over the swivel link pins on either side of the
gearbox. Remove the retainers.
2. Use a slide hammer to remove the swivel link pins.

3. Lift and position the swivel yoke and counter balance

assembly over upper end of the top drive unit.
4. Slide the ends of the counter balance link arms into the
slot in the gearbox.
5. Align the bores.
6. Coat the bores with anti-seize compound.
7. Insert the swivel link pins and tap into place with a soft
hammer. Make sure that the grease nipples are
positioned toward the bottom.
8. Bolt the retaining strap over the pin with 2 bolts and
lockwashers, using Loctite 243 on the bolt threads.
Torque the bolts to 75 ft-lbs.
10. Connect the hoses and tighten the fittings. See Figure
13.2 on page 142.

CHAPTER 13
11. Install the swivel link stop plates where the arm enters
the gearbox.
12. Fasten each plate with two bolts and lockwashers.

ACCESSORIES CHAPTER
14
EXPLODED VIEW
Typ. 17
4 plcs. 4
1 18
Typ. 8 plcs.
11
10
5
9
8 7
6 6
19
9
6
8
6
19
15
Typ. 14
4 plcs.
16
12 Typ. 4 plcs. 20
13
Top Drive
ref. only
Typ. 4 plcs.
12
13
Figure 14.1: Top drive accessories

CHAPTER 14
PARTS LIST
1 1 Mount, front guard 11 8 Lockwasher, 3/4"
2 1 Front guard, tugger line 12 8 Hex head capscrew, 1/2"-13UNCx1-1/4"
3 2 Side guard 13 8 Lockwasher, 1/2"
4 2 Stop plate, swivel link 14 4 Pin, extend arm, 1.5"ODx6-1/4"
5 1 Travel stand assembly 15 4 Hex head capscrew, 3/8"-16UNCx2-1/4"
6 6 Anchor shackle, 3/8" 16 4 Hex locknut, nylon, 3/8"-16UNC
7 2 Anchor shackle, 1/2" 17 4 Hex head capscrew, 1/2"-13UNCx1-1/2"
8 2 Safety pin, 1/8" wire -ODx3-1/8" 18 4 Lockwasher, 1/2"
9 2 Pin, guard 19 2 Chain, 3/16" x 10"
10 8 Hex head capscrew, 3/4"-10UNCx5-1/2" 20 4 Cotter pin, 3/32"OD x 3/4"
DISASSEMBLY
Remove the Front Guard
1. Remove the safety pins from the guard pins that hold
the front guard to the front guard mount.
2. Remove the guard pins from the front guard and
mount.
3. Attach 3/8 in. lift eyes and slings to the front guard and
slide the guard away from the notches in the mounting
bracket.

ACCESSORIES
4. Lift the guard up and away from the unit.
5. Unbolt the shackles (B) and chains (A) from the front
guard mount.
6. Unbolt the guard pins (C) from the shackles (B).
C B
B
Remove the Swivel Link Stop Plates

This procedure is also included in Chapter 13 Swivel Yoke
and Counter Balance.
Caution: Make sure that there is no tension

on the stop plate from the swivel
link.
the swivel link stop plates to the gearbox.
3. Remove the stop plates.

CHAPTER 14
Remove the Side Guards

the side guards to the gearbox.
3. Remove the side guards.
Remove the Front Guard Mount

the front guard mount to the gearbox.
3. Attach slings and lift the mount up and away from the
unit.

ACCESSORIES
Remove the Gearbox Assembly from the

Travel Stand K
This procedure is also included in Chapter 3 Gearbox.

1. Remove the bolts and locknuts ( J) from the pins (K)
that hold the extend frame (L) to the travel stand.
J
L
2. Place slings around the swivel link pins in the gearbox

and around the quill and lift off from the travel stand.
Important: Inspect the rigging before lifting the unit.
3. Raise the slings on the gearbox and lower the sling on

the quill until the assembly is vertical.
INSPECTION
pitting.
Replace worn and damaged parts.

CHAPTER 14
REASSEMBLY
Install the Gearbox Assembly on the Travel
Stand
This procedure is also included in Chapter 3 Gearbox.
1. Lift the gearbox assembly straight up until the quill is
completely clear of the work stand.
2. Attach a sling to the quill and lift the quill to a
horizontal position with the extend frame pointing
down.
3. Lower the assembly into position on the travel stand.
4. Apply anti-seize compound to the 4 pins (K) and insert
the pins to hold the extend frame (L) to the travel K
stand.
5. Insert a bolt ( J) through the hole in each pin and secure
with a locknut.
J
L
Install the Front Guard Mount

The front guard mount is typically installed after the
grabber leg assembly is installed and before the hoses are
attached to the 12-station manifold.
1. Lift and lower the front guard mount onto the gearbox.
2. Attach the mount to the gearbox with 8 bolts and

to 250 ft-lbs.

ACCESSORIES
Install the Side Guards

1. Attach the side guard to the gearbox with 4 bolts and
to 75 ft-lbs.
3. Repeat this procedure on the other side of the gearbox.
Install the Swivel Link Stop Plates

The swivel link stop plates are installed after the swivel
yoke and counter balance assembly has been installed on
the gearbox.
1. Install the swivel link stop plates where the arm enters
the gearbox.
2. Fasten each plate with two bolts and lockwashers.
Install the Front Guard

The front guard is installed after all assembly has been
completed.
1. Assemble the chains (A) and shackles (B).
B
2. Attach the pins (C) to one end of each chain/shackle
and bolt the other end to the front guard mount. A
C B
B

CHAPTER 14
3. Lift the guard over the unit.
4. Slide the guard into the matching notches on the

mounting bracket.
5. On the other end, align the bores of the front guard

and the mounting bracket.
6. Insert the pins from inner to outer.

7. Insert safety pins in the end of the pins.

TORQUE STANDARDS FOR HIGH APPENDIX
STRENGTH FASTENERS A
The following information originated from the Standards document STD0015.
PURPOSE
This Standard should be used as a guideline for all fasteners used in production where the torque values are not specified on
the engineering documentation and drawings. All TESCO Standards on fasteners should be adhered to, as non-confor-
mance can lead to the following:
• low quality products
• rework cost
• warranty claims
• late delivery
• customer dissatisfaction
• lower production
STANDARDS
1. All capscrews, bolts and nuts must be Grade 8 or equivalent unless noted otherwise (U.N.O.).
2. Fasteners must be torqued in accordance with Table A-1, Table A-2, and Table A-3 U.N.O. Torques should be applied
smoothly and with a calibrated wrench.
3. Multiple fastener arrays must be made up evenly using an appropriate torque sequence to minimize distortion.
Fasteners shall be tightened using intermediate torque settings of 40% and 75% of values in the tables. All fasteners
must be made up snug prior to starting the tightening sequence.
4. Fastener torques for bolting dissimilar materials must be based on the torque requirements for the lower strength
material U.N.O.
5. Fasteners and holes should be free of burrs or damage. Damaged threads must be repaired using the appropriate tooling
to ensure a free and smooth assembly.
6. When thread locking compound is used, holes and fasteners should be cleaned (free of oil or grease) and the compound
should be applied in conformance with manufacturer’s recommendations.
7. Allowable bolt tension and torque based on bolt thread engagement must be in accordance with Table A-4 U.N.O.
8. Special fasteners must be installed and torqued in accordance with Table A-2.
9. When threadlock is used, fasteners must be torqued in accordance with Table A-1, Table A-2, and Table A-3, using
the “Lubricated” torque data U.N.O.
10. For torque values for B7 studs with 2H nuts, see Table A-3.
11. Lubricated fasteners must have oil or thread locking compound applied to the threads only.
12. Where metals with strongly varying electromotive properties are bolted together, such as steel and aluminum, thread
locking compounds should be applied to limit the effects of galvanic corrosion.
13. A minimum of two full threads should project above any nut or locknut installed on a stud or as part of a bolted
connection. Additional length is allowed to install safety pines or cotter pins to prevent fasteners from falling into
overhead equipment.

APPENDIX A
TABLES
Table A-1: Standard Torques
Material Aluminum (ft-lbs) Mild Steel (ft-lbs) High Strength Steel (ft-lbs)
Size Dry Lubricated Dry Lubricated Dry Lubricated
1/4 in.-20 UNC 9 7 10 8 12 9
5/16 in.-18 UNC 16 12 19 15 25 19
3/8 in.-16 UNC 33 25 40 30 45 34
7/16 in.-14 UNC 47 36 57 43 70 53
1/2 in.-13 UNC 86 64 100 75 110 83
9/16 in.-12 UNC 118 88 141 106 160 120
5/8 in.-11 UNC 163 122 195 146 220 165
3/4 in.-10 UNC 278 209 333 250 400 300
7/8 in.-9 UNC 436 327 523 393 645 484
1 in.-8 UNC 667 500 800 600 970 728
1-1/8 in.-7 UNC 950 713 1142 856 1370 1028
1-1/4 in.-7 UNC 1317 988 1575 1181 1900 1425
1-1/2 in.-6 UNC 2283 1713 2742 2056 3200 2400
Recommended torques are based on bolt tensions of approximately 80% of the yield strength and a minimum of one bolt
diameter class 2B thread engagement in the material, or bolt head bearing pressures, whichever is less.
Table A-2: Special Fastener Torques

Mild Steel (ft-lbs) High Strength Steel (ft-lbs)
Minimum
Fastener Description Dry Lubricated Dry Lubricated
Engagement
UNBRAKO 5/16 in.-18 UNRC 3/8 in. 27 20 35 26
Special fasteners shall be used only in critical locations or special applications. Thread engagement is based on the
minimum class 2B tapped threads in mild steel capable of developing bolt tension 80% of bolt yield. When using
hardened steel washers on mild steel, use torque values for high strength steel.

Table A-3: B7 Stud Torques
Stud Size Dry (ft-lbs) Lubricated (ft-lbs)
1/2 in.-3 UNC 85 64
5/8 in.-11 UNC 175 131
3/4 in.-10 UNC 300 225
7/8 in.-9 UNC 450 338
1 in.-8 UNC 680 510
1-1/8 in.-7 UNC 880 660
1-1/4 in.-7 UNC 1260 945
1-3/8 in.-6 UNC 1700 1275
1-1/2 in.-8 UN 2300 1725
Recommended torques are based on bolt tensions of approximately
75% of stud yield strength.
Table A-4: Thread Engagement

Material Aluminum Mild Steel High Strength Steel
Engagement* % of Full Torque % of Full Torque % of Full Torque
100% 100% 100% 100%
90% 100% 100% 100%
80% 100% 100% 100%
70% 100% 100% 100%
60% 90% 100% 100%
50% 70% 100% 100%
40% 60% 75% 100%
30% 45% 60% 75%
20% 30% 40% 55%
* Engagement as a % of the bolt diameter
Values represent the percentage of torque from Table A-1. Engagement does
not include chamfer or incomplete threads. Engagements of less than one bolt
diameter in tapped holes shall not be used without the engineer’s approval.

APPENDIX A

MAINTENANCE AND SERVICE APPENDIX
SCHEDULES B
Important: To ensure that the equipment operates Important: This equipment was filled at the factory with
properly and to prevent downtime, check the pressure and TESCO ULTREX brand fluids and greases. To ensure
temperature gauges, all fluid levels, and flow meters daily. maximum performance and to avoid cross-contamination,
we strongly recommend the continued usage of TESCO
ULTREX lubricants, unless otherwise specified.
Warning! Do not perform the following
checks unless the main panel and
auxiliary panel are both
disconnected and locked out.
LOCK-OUT METHODS
An undesired action/movement of equipment may provides specific lock-out methods for this unit and should
accidently be initiated during maintenance or repair of be used in conjunction with the lock-out procedures
equipment that is not isolated from its power source. recommended by the Safety or Loss Prevention
Always lock-out the equipment first before performing any department.
top drive system maintenance or repairs. The following list
Equipment Under
Location of Lock-Out Lock-Out Method
Maintenance or Repair
Top drive main hydraulic motor Engine control panel Set the key switch to “OFF” and remove the key.
Auxiliary HPU electrical panel Set breaker “MB7-Aux HPU Supply” to “OFF” and
lock the breaker.
Top drive robotic functions
Power unit main electrical panel Set breaker “CB1-24VDC Control Power” to
“OFF” and lock the breaker.
DAILY TOP DRIVE SERVICE

Inspection
Perform the following visual inspection at least once every
operating day. More frequent inspections might be required Important: This equipment was filled at the factory with
if operating the top drive in harsh or demanding drilling TESCO ULTREX brand fluids and greases. To ensure
environments. maximum performance and to avoid cross-contamination,
Inspect For
Gearbox oil level Correct oil level: halfway up the sight glass
Fill with TESCO p/n 731140
Hydraulic hoses and connections Leaks, damage, excessive wear, hardness, heat cracking.
Replace if necessary.

APPENDIX B
Inspect For
Grabber dies Excessive wear
Save sub threads Excessive wear
Connection locking clamps Tightness
Lubrication
The following lubrication should be performed at least once
every operating day. More frequent lubrication might be Important: This equipment was filled at the factory with
required if operating the top drive in harsh or demanding TESCO ULTREX brand fluids and greases. To ensure
drilling environments. Refer to Figure B.1 on page 167 for maximum performance and to avoid cross-contamination,
lubrication points. we strongly recommend the continued usage of TESCO
Lubricate Qty Item # (Fig) With # Shots

Upper quill bearing retainer 1 5 TESCO Ultrex, NLGI #1 or 2 2 each
Lower quill bearing retainer 1 7 TESCO Ultrex, NLGI #1 or 2 2 each
Load collar grease port 1 9 TESCO Ultrex, NLGI #1 or 2 5 each
Link tilt cylinders 4 10 TESCO Ultrex, NLGI #1 or 2 2 each
Extend cylinders 4 3 TESCO Ultrex, NLGI #1 or 2 2 each
Elevator handle pins 2 12 TESCO Ultrex, NLGI #1 or 2 3 each
Elevator hinge pin 1 11 TESCO Ultrex, NLGI #1 or 2 3 each
Mudsaver valve actuator 1 13 TESCO Ultrex, NLGI #1 or 2 Fill grease reservoir
Swivel pins 6 6 TESCO Ultrex, NLGI #1 or 2 2 each
Yoke pins 6 1 TESCO Ultrex, NLGI #1 or 2 2 each
Washpipe 1 4 TESCO Ultrex, NLGI #1 or 2 5 each

1
1. Yoke pins (6) (3 per pin, each side)
2. Extend frame hinge pins (typ)
3. Extend cylinders (4), (2 per cylinder, each 2
side)
4. Washpipe (1)
5. Upper bearing retainer (1)
6. Swivel pin (6) (3 per pin, each side)
7. Lower bearing retainer
8. Slewing bearing (2) 3
9. Load collar (1)
10. Tilt cylinders (4) (2 per cylinder, each side)
11. Elevator hinge pin (1) 5
4
12. Elevator handle pins (2) (one each end of pin)
13. Mudsaver valve actuator (1)
Load Collar
(rear view)
10
Indicator Pins
(Grease sufficiently FRONT
to ensure the indicator

pins are fully extended)
13
12
11
Figure B.1: Lubrication points for the 250 HXI 700 Top Drive

APPENDIX B
WEEKLY TOP DRIVE SERVICE

Inspection
The following visual checks should be performed at least be required if operating the top drive in harsh or
once every operating week. More frequent inspection might demanding drilling environments.
Inspect For
Hydraulic fittings Tightness/leaks
Mudsaver valve actuator sleeve (if General condition; disassemble, clean, grease,
applicable) coat with corrosion inhibitor, and reinstall
Counter balance system Cushion height = 4 in. (10 cm)
12-station manifold junction box • Moisture
• Tightness of wire terminations
Pipe handler rotation motor Leaks
Load collar springs • Damage
• Breaks
All fasteners (nuts, bolts, safety wires) Tightness
Safety chain on grabber leg • Broken components
• Loose wires
MONTHLY (PERIODIC) TOP DRIVE SERVICE

Inspection
The following visual checks should be performed at least operating the top drive in harsh or demanding drilling
once every operating month or as indicated in the following environments.
table. More frequent inspection might be required if
Inspect For
Grabber dies Excessive wear
12-station manifold General conditions/leaks
Load collar Correct spacing between load collar and load
nut must be 0.25 in. (0.6 cm)
Quill end play No end play
Main auxiliary hydraulics relief valve Correct setting
Mudsaver valve lower ball Manually operate to ensure correct function
Top drive hydraulic connections and Oil leaks/deformation; replace if damaged
hoses

Inspect For
Tugger line guard/motor guard Dents or bends that may indicate bolt damage
Hammer union on Kelly hose • Integrity
• Tightness
Grabber/drawworks and mud valve/ Function test
mud pump interlocks
Gearbox oil analysis • Abnormalities (take samples to test for
water, metal particles, etc)
• Replace every three months with
approximately 8.75 gallons (33 liters) of
TESCO Ultrex p/n 731140
Wash pipe Leakage; replace seals if leaking
Robotic cable connectors • Damage
• Tightness
Lubrication
every operating month. More frequent lubrication might be Important: This equipment was filled at the factory with
drilling environments. Refer to Figure B.1 on page 167. maximum performance and to avoid cross-contamination,
Lubricate With
Hinge pins and extend frame (if applicable) Spray with penetrating oil (WD40 or spray lithium.
SIX-MONTH TOP DRIVE SERVICE

Lubrication
every six months. More frequent lubrication might be Important: This equipment was filled at the factory with
drilling environments. Refer to Figure B.1 on page 167. maximum performance and to avoid cross-contamination,
Lubricate With
Slewing bearing TESCO Ultrex, NLGI #1 or 2

APPENDIX B
1,000 OPERATING DAY TOP DRIVE SERVICE

Replace all auxiliary hydraulic and lubrication system hoses.
TESCO ULTREXTM LUBRICANTS QUICK REFERENCE GUIDE

Component Fluid Description TESCO Part #
Gear box hydraulic top drive (HXI) Advanced Performance Multi Grade Gear Oil 80W-90 731140
Advanced Performance Gear and Bearing Oil ISO 220 731133
All swivels
Advanced Performance Multi Grade Gear Oil 80W-90 731140
Advanced Performance Hydraulic Oil ISO 68 731143
Hydraulic system
Biodegradeable Hydraulic Oil ISO 68 731138
NLGI #1 (cold weather) 48 tubes 731142-48T
Grease for top drive
NLGI #2 (hot weather) 48 tubes 731141-48T

CHECK AND ADJUST PRELOAD FOR THE QUILL UPPER BEARING
When the top drive is manufactured, TESCO adjusts the preload for the quill upper bearing by placing a shim pack
between the top bearing retainer and the gearbox.
When the retainer bolts on the top bearing are torqued, this exerts a clamping force on the quill upper bearing and thrust
bearing. This force prevents the quill from exhibiting end play during operation of the top drive. Preload is measured in
0.000 of an inch. The ideal preload is 0.005 to 0.007 in.
Over time, bearing and component wear will reduce the preload. If the preload is reduced too much, quill end play will
result. Even the smallest amount of end play will result in damage to the bearings and mating components.
For this reason, quill end play should be checked every month, or after any severe operating event such as jarring or rough
drilling. The end play can be checked while the top drive is installed in the mast.
Check for Quill End Play 1

1. Remove the washpipe.
3
2. Install a heavy wooden block across the grabber box. 2
3. Attach the magnetic base of a dial gauge to the top 4
surface of the quill.
6
4. Position the dial needle on the bearing retainer.
5. Set the dial gauge to zero. 1. Magnetic base dial
6. Position a jack on top of the block on the grabber. indicator
2. Upper quill bearing
7. Install a protective plate between the jack and the quill. 3. Shim pack
8. With the quill plate in position, use a jack to lift the 4. Gearbox housing
5. Thrust bearing 5
quill upward.
6. Quill
9. Monitor the dial gauge for any sign of movement. 7. Protective plate
4
8. Jack
Important: Any movement of the dial gauge indicates that 9. Heavy wooden plank
there is quill end play.
10. To ensure that an accurate reading of quill movement is

obtained, repeat steps 8 and 9.
Figure B.2: Check for quill end play

APPENDIX B
Figure B.3: Measure quill end play
Calculate the Preload Adjustment

If the previous procedure reveals any amount of quill end play, the quill preload must be adjusted. To decrease end play in
the quill (increase the preload), the shims muat be removed from the shim pack. Use the following calculation to determine
how many shims to remove.
observed quill end play (in 0.000 in.) + 0.005 in. = the thickness of shims to be removed
Sample Calculation
If the quill end play is 0.019 in., then 0.019 in. + 0.005 in. = 0.024 in. (+0.002/ -0.000)
Between 0.024 to 0.026 in. of shims must be removed to adjust the preload to the correct force.

Adjust the Preload
Important: Keep all components clean and free of grit

and debris. Ensure that the working area is clean before
performing this procedure.
1. Remove the washpipe and bonnet.

2. Remove all upper bearing retainer bolts.
3. Thread two long 0.625 in.-11UNC bolts into the
retainer bolt holes (these are used as alignment pins).
4. Install four lifting eyes into threaded holes.
5. Using a chain fall or other lifting device, remove the
quill retainer to allow access to the shim pack.
6. Remove the required shims from the shim pack.
Important: Shim packs typically contain 0.010 in.,

0.005 in., and 0.002 in. shims. Remove the shims to achieve
a preload of 0.005 to 0.007 in. If required, shims are
available from TESCO.
7. Use a chain fall or other lifting device to lower the

bearing retainer back into position.
8. Remove the alignment pins.
9. Replace all upper bearing retainer bolts.
Figure B.4: Preload adjustment
Important: To check preload again, replace every second
retainer bolt and re-test according the procedure “Check
for Quill End Play” on page 171.

APPENDIX B

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ii 250 HXI 700 Top Drive System

TESCO Corporation iii

Chapter 1: General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

vi 250 HXI 700 Top Drive System

Load Nut Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

TESCO Corporation vii

viii 250 HXI 700 Top Drive System

x 250 HXI 700 Top Drive System

Caution: Only authorized personnel can

Warning! Temperature of equipment can

Top Drive Specifications Imperial Metric*

2 250 HXI 700 Top Drive System

4 250 HXI 700 Top Drive System

Figure 2.1: 250 HXI Top Drive general assembly

LOAD COLLAR AND LOAD NUT

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TOP DRIVE POWER

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GEARBOX EXPLODED VIEW

GEARBOX PARTS LIST

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EXPANSION BOTTLE VIEW EXTEND FRAME EXPLODED VIEW

EXTEND FRAME PARTS LIST

EXPANSION BOTTLE PARTS LIST

Remove the Lower Quill Bearing Retainer

2. Slide the retainer (C) off the quill (D).

Remove the Lube Line

Remove the Expansion Bottle

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Remove the Gearbox Assembly from the

1. Remove the bolts and locknuts ( J) from the pins (K)

2. Place slings around the swivel link pins in the gearbox

3. Raise the slings on the gearbox and lower the sling on

Remove the Sleeve

Caution: Wear insulated gloves when

Remove the Quill Bearing

Caution: Wear insulated gloves when

4. Move the gearbox assembly to a work table above a

Remove the Extend Frame

Remove the Bonnet and Washpipe

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Remove the Motor

Remove the Pinion Gear Retainer

Remove the Upper Quill Bearing Retainer V

7. Remove and discard the O-ring and the two seals.

Remove the Gearbox Lid

5. Lift the lid from the gearbox.

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Remove and Disassemble the Quill

3. Push the pinion gear (Z) to the side.

6. Remove the 14 bolts and lockwashers that hold the bull

9. Heat the thrust bearing plate (BB) with a torch and

Caution: Place a piece of wood underneath

Remove and Disassemble the Pinion Gear

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4. If you are replacing the bottom retainer, pre-fit the

6. If you are replacing the thrust bearing, remove the

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8. Place the quill upside down on an assembly stand.

9. Place the other half of the cleaned thrust bearing onto

Caution: Use appropriate rigging equipment

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