882041rev0 Manual Recertificacion HS

CAODC Level IV Recertification
Procedures
HS Top Drive System
HS
DOCUMENT NAME: 882041 REV 0

CAODC LEVEL IV RECERTIFICATION PROCEDURES TABLE OF CONTENTS
TABLE OF CONTENTS
Section 1: Document Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Audience and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Updating This Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1000 Day Recertification Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Other HS(S) Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Section 2: Pre-Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Before you Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Run and Check the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Break Out the Saver Sub and Mudsaver Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Section 3: Disassemble the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Before you Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Check for Endplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Gearbox and Quill for Endplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Calculating Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Check the Slewing Bearing for Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Remove the Inner Grabber Leg and Mount the Top Drive in a Work Stand . . . . . . . . . . . . . . . . . 3-4
Remove the Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Remove the Hydraulic Motor Piping and Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Remove the 8 or 11 Station Auxiliary Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Remove the Gearbox from the Main Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Remove the Hydraulic Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Disassemble the Pipe Handler and Remove the Auxiliary Mainframe Components . . . . . . . . . . 3-6
Remove the Mainframe from the Slewing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Remove the Rotary Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Remove the Slewing Bearing from the Pipe Handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Disassemble the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Disassemble the Grabber Leg and Grabber Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Disassemble the Elevators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Section 4: Inspect the Top Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Before you Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Inspect and Prepare Components for Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
©TESCO CORPORATION, 2007 HCI(S) TOP DRIVE SYSTEM DOC #882041

PAGE II
Shipping Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Section 5: Assemble the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Before you Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Prepare Components for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Assemble the Pipe Handler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Attach and Assemble the Mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Assemble the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Assemble and Install the Bottom Bearing Retainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Install Pinion Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Install the Quill into the Quill Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Assemble the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Attach the Bull Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Attach Hydraulic Motors to the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Attach the Auxiliary Gearbox and Motor Manifold Components . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Attach the Gearbox to the Mainframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Install the 8 or 11 Station Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Install the Load Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Assemble the Grabber Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Assemble the Grabber Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Mount The Top Drive in the Travel Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Install the Load Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assemble the Torque Bushing and Extend Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Assemble the Elevator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Adjust the Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Adjust the Gearbox Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Section 6: Inspect/Service the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Before you Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Inspect and Service the Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Replace the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Check the Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Inspect the Turbo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Check Endplay in the Engine Fan Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Check Endplay in the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Inspect and Service the Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Check the Pump Splines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Check the Pump Shaft Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Replace the Pump Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

PAGE III
Inspect and Service the Closed Loop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Inspect the Loop Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Section 7: Test the Top Drive & Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Before you Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Install the Top Drive in the Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Torque the Dynamometer Saver Sub Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Test Low Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Test High Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Test the Driller's Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Test the Torque Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Test the Rig Savers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Test the Extend Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Test the Cold Climate Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Operations below -10° Celsius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Operations from -10° Celsius to 10° Celsius . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Test the Breakout Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Test the G Cord Torque Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Test the Grabber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Test the Elevator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Test the Mud Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Test the Link Tilt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Test the Robotics On and Auxiliary Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Test the Forward and Reverse Connect Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Set the Forward and Reverse Connect Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Check the Engine High Idle and Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Test the Top Drive High and Low Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Set the Reverse Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Set the Max and Set Torque Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Section 8: Ship the Top Drive & Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Before you Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Prepare the Power Unit for Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Prepare the Top Drive for Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

PAGE IV
CAODC LEVEL IV RECERTIFICATION PROCEDURES DOCUMENT SUMMARY
SECTION 1: DOCUMENT SUMMARY
AUDIENCE AND PURPOSE

This document enables journeyman mechanics to complete mandatory recertification required on all Tesco
HS top drives after 1000 operating days. It assumes that readers are certified journeyman mechanics famil-
iar with the functionality and servicing of Tesco top drives. It also assumes all procedures and practices
will be carried out with adherence to the highest level of safety policy/standards at your workplace.
UPDATING THIS DOCUMENT

We want your feedback to improve this document. If you notice any errors or omissions, write them on the
affected page in red ink and forward it to the Service Shop Manager. If your redline falls within the scope
of 1000-day HS Top Drive System recertification, we will incorporate it into the next release.
1000 DAY RECERTIFICATION OVERVIEW

1000-Day HS Top Drive System recertification includes the following general steps:
• Preparing the unit for recertification by checking the components received, running the top
drive and testing the auxiliary circuits, and then recording performance results.
• Disassembling the top drive and sending components for in house or third party servicing.
• Inspecting the power unit and changing oil and filters.
• Rebuilding the top drive and power unit with replaced or refurbished parts.
• Testing the top drive and comparing performance results to the pre servicing performance
results and to overall top drive specifications.
Throughout the 1000-day recertification process, recording performance results, deficiencies, and service
activities is essential. Pre-service performance results may alert you to potential problems early and can be
compared to post-service performance results to ensure issues are corrected. Documented deficiencies that
fall outside the scope of 1000-day recertification can be discussed with the customer before work begins.
Documented servicing activities facilitate error-tracking and become an important part of a unit’s history
that aids future repairs, inspections, and design efforts.
All checklists and forms that service technicians require to complete servicing activity are referenced in
this document, and are also in the recertification binder available from the Service Shop Manager (filed
according to job number).
©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

PAGE 1-1
CAODC LEVEL IV RECERTIFICATION PROCEDURES DOCUMENT SUMMARY
OTHER HS(S) DOCUMENTATION

The following table lists other HS documents that are available on TescoLink.
For information about Refer to
Maintenance HS Minimum Non-Destructive
Inspection Guidelines
Service Inspection Checklists

PAGE 1-2
CAODC LEVEL IV RECERTIFICATION PROCEDURES PRE-SERVICE PREPARATION
SECTION 2: PRE-SERVICE PREPARATION
Complete receiving
Inspect seriously checklist and
Get unit binder photograph top drive,
Unit damaged equipment for Pressure-
and Servicing power unit, and hose
arrives markings that may reveal wash unit
checklists reel
faulty components
Record top drive

condition in
Move top drive Record
Servicing
and power unit in performance in Disassembl
checklists and give Run top drive
shop and hookup Servicing checklist e top drive
photocopy to shop
for running foreman
BEFORE YOU START

You will need the following items to service the top drive:
• A power unit if the customer did not send one with their top drive.
• All hydraulic and electric cables required to run the top drive.
• Die lock clamp.
• Recertification binder from the Service Shop Foreman or filed by job number.
• Two 4 x 4 in. blocks.
• Valve handling nubbin.
• Receiving/Shipping Checklist
• Pre-Servicing Checklist
• Packing List Checklist
• Pre-start Topdrive Inspection Checklist
• Pre-start Power Unit Inspection Checklist
RUN AND CHECK THE TOP DRIVE

1. Visually inspect damaged equipment writing any clues that indicate the cause of damage on
the Receiving_Checklist.
2. After the top drive is pressure washed, visually inspect the damaged equipment again for fur-
ther clues and add them to the Receiving_Checklist, then photograph all four sides of the top
drive, power unit, and hose reel.
3. Complete the Pre-Servicing Checklist.
4. Ensure the top drive is securely mounted in the travel stand then, using suitable hoisting equip-
ment, set it vertically in the servicing area.

PAGE 2-1
5. Visually inspect the power unit engine, pump drive, and loop system based on the following:
Component Check
Power Unit 1. Gauges are functional and visible.
This includes ensuring gauge glass is not discoloured or cracked and that
multiple gauges for the same reading all display the same reading.
2. Fan cover bolts are securely fastened and fan hubs and belts are in good
condition.
3. Fuel lines are not rubbing or worn.
Pump Drive 1. Gauges are functional and visible. This includes ensuring the gauge glass is
not discoloured or cracked and that multiple gauges for the same reading
all display the same reading.
2. Gearbox breathers are not cracked.
3. Gearbox mounting bolts are intact and securely fastened.
4. Pump drive site glass displays 1/2 to 1 in. of oil when the engine is running
between 140-160° Fahrenheit and oil is not foaming.
Loop System 1. Magnets in flow meters are not stuck at one end of the gauge.
2. Reservoir breathers are not cracked.
3. Cage around shut down valves is securely fastened.
4. Ball valves are free of leaks and handles are in good condition.
5. All electrical cabinet gauges are free of cracks and the seal inside the door
is intact.
6. Hoses, flange connections, and plumbing are free of cracks and leaks.
6. Record any deficiencies in the Packing List.

7. Connect the following to the top drive:
• 37 Pin electrical control cable from the power unit to the driller's panel and then from the
driller's panel to the top drive.
• Closed loop and auxiliary lines from the power unit to the top drive.
• Diesel fuel line from the fuel source to the prime mover.
• Airline from the air source to the diesel engine starter.
• Power electrical cable from the power unit to the MCC.
Note: Ensure you vent the power unit exhaust outside the shop.
8. Complete the Pre-start_topdrive and the Pre-start_Power_Unit_Inspection and give a photo-
copy to the Service Shop Foreman to discuss with the customer.
BREAK OUT THE SAVER SUB AND MUDSAVER VALVE

1. Before completing this section, ensure you set the connect speeds as described in “Run and
Check the Top Drive” on page 2-1.
2. Place a die lock clamp over the joint between the double ball valve and quill and then lift the
grabber leg and grip the saver sub. If the unit is equipped with a spline lock clamp, ensure the
clamp is properly installed on the load sub/MSV connection.
3. Using the top drive, breakout the saver sub and open the grabber.
Note: Only allow the quill to complete one rotation.
4. Unscrew the saver sub by hand, remove the die lock clamp or raise the spline lock clamp, raise
the grabber to the double ball valve, and close the grabber.

PAGE 2-2
5. Using the top drive, breakout the double ball valve and open the grabber.
Note: To break the connection, only allow the quill to complete one rotation.
Note: Ensure the grabber is positioned below the shoulder so the grabber dies make complete
surface contact.
6. Reinstall the die lock/spline lock on the load sub/mudsaver connection.
7. Remove the die lock clamp from the quill/load sub connection. Lift the grabber to the mud-
saver valve and close.
8. Break out the quill/load sub connection and unscrew one revolution.
9. Install a chain through the quill so that it extends out the bottom of the mudsaver valve. Install
a small shackle and lifting plate to the chain. Connect the chain to a suitable lifting device and
take up the slack.
10. Using a chain tong, unscrew the mudsaver valve from the load sub, making sure that the load
sub does not come with it. Once disengaged from the threads, lower the mudsaver down until
it rests on the grabber. Remove the lifting plate and shackle, install the MSV lifting nubbin and
hoist the MSV from the top drive.
11. Reinstall the lifting plate and shackle on the chain and again take up the slack. Using a chain
tong, unscrew the load sub from the quill. Once the threads are disengaged, lower the load sub
down onto the grabber. Remove the lifting plate and shackle and pull out the chain.
12. Install the chain through the load sub so that it extends out the bottom of the load sub. Install
the lifting plate and shackle and take up the slack. Tilt the top of the load sub to one side and
carefully hoist it out of the top drive.
13. Remove the roto actuator from the stabbing valve and place it on a separate pallet.

PAGE 2-3
CAODC LEVEL IV RECERTIFICATION PROCEDURES DISASSEMBLE THE TOP DRIVE
SECTION 3: DISASSEMBLE THE TOP DRIVE
Top Record Remove Mount Remove Remove Remove

drive Endplay grabber Top load pipe slewing
prepare
d for
Disasse Disasse Disassembl Disasse Inspect

mble mble e grabber mble topdrive
BEFORE YOU START

You will need the following before removing top drive components:
• Dial gauge to measure for end play
• Gearbox stand
• Lifting plate for idler gear and quill gear
• Overhead hoist and two slings rated for over 6,000 lbs
• Parts baskets
• Rineer motor lifting tool
• Valve handling nubbin and lifting eyes
• Work stand with vertical stump located below overhead hoisting equipment
• Buckets for draining gearbox oil
GENERAL NOTES
While disassembling the top drive, group components based on the following:
For components that require Place on/in

third party servicing pallet
in-house servicing either a parts basket or large crate
replacing separate pallet or crate
Note: As you disassemble components, do not discard old seals, use them to protect machined
areas of components that must be sand blasted.
Note: To determine what type of servicing a component requires, see the Packing List.

PAGE 3-1
CHECK FOR ENDPLAY

Check for end play in the quill bearings and in the slewing bearing. Record the results in the Pre
start_Topdrive_Inspection.pdf.
The following procedure is a guide for accurate measurement of endplay that may be present in the HS/HC
gearbox assemblies. The required preload for these assemblies is as follows:
Top Drive Bearings

500/650 TON HS/HC New Bearings: pre-load from 0.012 in. to 0.015 in.
Used Bearings: pre-load from 0.000 in. to 0.005 in.
Checking Gearbox and Quill for Endplay

1. Ensure that the Top drive is secured in a stand or pinned to the torque track.
2. Attach a magnetic dial indicator base to the quill.
3. Position the dial indicator with the pin on the bearing retainer.
4. Zero the dial indicator gauge.
5. Position a block of lumber or a steel plate on the grabber box.
6. Position a jacking device, recommended maximum 5 ton, on the protected grabber box.
7. Position protective block or plate below the load sub on top of the jacking device.
8. Slowly apply upward jacking force.
Note: If a jacking device is not available the grabber lift function maybe used.
9. Observe the dial indicator for any movement.
Caution: Document any movement for adjustment calculation. This is
critical.
10. It is strongly advised to repeat steps 8 and 9 at least once to check for accuracy.
Calculating Preload Adjustment

If any amount of quill endplay is noted using the procedure above, the quill preload must be adjusted. In
order to decrease endplay on the quill assembly (increase the preload) shims must be removed from the
shim pack. Typically the specification that must be met in the field is for used bearings, that specification
states a preload of between 0.000 in. to 0.005 in. It is important to remember that no movement should be
present in the quill assembly, this can be achieved with .000” to 0.001 in. just as efficiently as with 0.005
in.
A typical shim pack in a TESCO top drive will have 0.060 in. of shims, 5 x 0.010 in. and 2 x 0.005 in. so
there is not much variance in calculation available.
A formula can be supplied to adjust to the maximum used bearing specification:
(noted endplay) + 0.005 in. = shim removal required.
For example if there is 0.010 in. of movement in the quill a 0.010 in. shim can be removed to achieve the
correct specification. There is limited ability to meet the required shim removal exactly, so a supervisor
should be contacted for final disposition.

PAGE 3-2
Preload Adjustment
1. Remove all upper bearing retainer bolts.
2. Install 2 jacking bolts in the upper retainer.
3. Thread 2 cut off ½” x 3” bolts in opposing holes (alignment pins).
4. Gently separate and lift retainer from gearbox id to allow access to shims.
5. Lift retainer only enough for shim removal to prevent damage to quill seals.
6. Remove required shims from shim pack.
7. Lower retainer back in place.
8. Remove alignment pins (cutoff bolts).
9. Replace all bolts, torque to 100 ft-lb.
10. Re-check quill movement.
Figure 3-1: Preload Adjustment
Check the Slewing Bearing for Wear

1. Attach the magnetic base of a dial gauge to the back of the grabber leg and the stylus to the
mainframe.
2. Using a sling, pull the grabber leg and monitor the end play.
Note: Another indication that the slewing bearing end play may be excessive is when the
spacer plate between the grabber box and grabber leg has been replaced with a thicker spacer
plate.

PAGE 3-3
REMOVE THE INNER GRABBER LEG AND MOUNT THE TOP DRIVE
IN A WORK STAND
Detach, cap and label all grabber lift hoses.

Reference drawing: Grabber Leg Assembly Graphic xxxx.
1. Attach an overhead hoist to the top drive and hoist the top drive from the travel stand.
2. Lower the top drive until the grabber leg is resting on the floor.
3. Detach, cap, and label all grabber lift hydraulic hoses from the rotary seal.
4. Remove the hydraulic lines from the grabber box cylinder.
5. Remove the upper shackle pin and hoist the top drive away from the lower grabber leg and
hydraulic hoses.
6. Hoist and mount the top drive in a work stand.
Note: The workstation includes a vertical stump over which the upper grabber leg fits
Caution: You may also need a front support under the mainframe as the top
dive is front heavy.
REMOVE THE LOAD COLLAR

Note: Complete all previous disassembly procedures before completing this procedure.
1. Remove the grease lines from the rotary seal to the load collar if they are present.
2. Remove the two (2) bolts that attach the kidney manifold to the pipe handler frame so you can
push the kidney manifold closer to the pipe handler frame when removing the load collar.
Note: You may also need to remove the kidney manifold pressure gauge to allow enough room
to remove the load collar.
3. Remove the pins holding the bail retainers to the load collar, remove the bail retainers, and
insert two 12-14 x 1 in. bolts with large washers on either end into the load collar pin holes.
These washers keep the slings from slipping off the ends of the bolts when hoisting.
4. Attach two separate overhead hoists to each of the slings and lift with both hoists simulta-
neously to evenly lift the load collar.
5. Rotate the load collar spring cushion so the two (2) bolts holding the load collar together are
accessible and then remove each spring cushion.
6. Lower the load collar so it rests on the pipe handler frame.
7. Pull the load collar from the pipe handler assembly by lifting up with only one hoist until the
load collar is vertical and then pull it through the pipe handler frame.
8. Lower the load collar onto a pallet.

PAGE 3-4
REMOVE THE HYDRAULIC MOTOR PIPING AND MANIFOLD

Reference Drawing: Bumper Guard Assembly xxxx and Motor and Piping Assembly xxxx
1. Remove the ODS side guard, then remove the three bolts that connect the main header pipes to
the main frame.
2. Open the gearbox ball valves and drain the gearbox oil into a 45-gallon drum.
Note: Take a sample of the gearbox oil while it is draining. This sample is sent for analysis.
3. Close the gearbox drain valve, then disconnect and cap all of the motor case drain hoses.
4. Remove the split flange clamps from the top motor inlet and outlet ports, then remove all
motor pipes connecting the motor manifold to the bottom motors.
5. Install suitable lifting eyes in the top of the motor manifold and attach slings. Remove the bolts
connecting the manifold to the support bracket and hoist the manifold from the gearbox.
6. Remove the remaining piping from the manifold.
REMOVE THE 8 OR 11 STATION AUXILIARY MANIFOLD

1. Remove main pressure and return lines that supply hydraulic power to the 8 or 11 Station aux-
iliary manifold.
2. Using numbered JIC caps and plugs, disconnect and label all plumbing from the rotary seal.
3. Remove all of the bolts and brackets that hold the 8 or 11 Station manifold/panel in place on
the door. Using suitable lifting equipment, remove the 8 or 11 Station manifold/panel and set it
on a pallet.
REMOVE THE GEARBOX FROM THE MAIN FRAME

Reference Drawing: Gearbox Assembly Graphic.
1. Remove the expansion chamber on the gearbox.
2. Remove and cap the counter balance manifold.
3. Remove the proximity switch from the lower bearing flange noting the bolt hole it was
removed from for reassembly.
4. Remove four (4) of the bolts that attach the gearbox lid to the gearbox (two (2) on each side).
Install 3/4 in. lifting eyes in the holes and rig up suitable lifting equipment.
5. Hoist to support the gearbox weight, remove the 4 dowel pin retaining covers, and with a large
slide hammer remove the dowels. Note the condition and position of the dowels.
6. Remove the lock wired bolts that attach the main frame to the gearbox.
Note: You may need to pry the mainframe walls apart to free the gearbox.
7. Using an overhead hoist, lift the gearbox from the mainframe and mount it in the gearbox
stand. If you use adapters to mount the gearbox, use at least four bolts to attach each adapter to
the stand and to attach the gearbox to the adapters.
Note: Ensure the stop pin is in place so the gearbox does not flip over.

PAGE 3-5
REMOVE THE HYDRAULIC MOTORS

Reference Drawing: Motor and Piping Assembly xxxx
1. Remove the 6-5/8 in. motor mounting bolts and using an overhead hoist and motor pulling
bracket, remove the motor located on the top of the mainframe and place it on a pallet.
2. Remove the 5/8 in. bolts that attach the top motors to the gearbox. Install the motor lifting tool
and lift one motor from the gearbox. Repeat for the second motor. Mark the spacer rings and
store in a safe place.
3. Remove the stand stop pin and invert the gearbox. Remove the bottom motors in the same
manner as the top was removed in step 1. Mark and save the spacer rings then turn the gearbox
back over so the lid is on top.
DISASSEMBLE THE PIPE HANDLER AND REMOVE THE AUXILIARY

MAINFRAME COMPONENTS
Reference Drawing: Pipe Handler Assembly xxxx
1. Remove the kidney manifold. You removed the bolts that attach the kidney manifold to the
pipe handler frame while you “Remove the Load Collar” on page 4.
Note: Do not remove the fittings from the kidney manifold.
2. Remove the clamps holding the grabber intensifier cylinder and remove the grabber intensifier
cylinder.
3. Remove and cap all hydraulic hoses attached to the link tilt cylinders.
4. Remove the cotter pin and nut and remove the link tilt cylinders.
5. Remove the Tesco nameplate from the front of the pipe handler housing.
6. Remove the following components from the mainframe:
• Accumulator bottles
• Fittings and hoses from the mainframe housing
• Grabber leg relief valve
• Max and Set Torque Bosch cartridges
• Top drive auxiliary relief valve
• Pipe handler lock
REMOVE THE MAINFRAME FROM THE SLEWING BEARING

Reference Drawing: Mainframe Assembly xxxx
1. Remove and cap remaining upper hoses on the rotary seal.
2. Remove the rotary seal stop bracket and the rotary seal stop lug.
3. Using an overhead hoist, support the weight of the mainframe.
4. Ensure the slewing bearing grease fitting is easily accessible via the access hole in the main-
frame when the pipe handler frame is facing forward.

PAGE 3-6
5. Using a centre punch, mark the slewing bearing and mainframe so you can align these marks
during reassembly so the grease fitting is accessible when the pipe handler frame is in the for-
ward position.
6. Remove the 5/8 x 4 in. bolts attaching the slewing bearing to the mainframe that are accessed
from the under side of the pipe handler.
Note: Rotate the mainframe to access all of the bolts.
7. Using an overhead hoist, place the mainframe on a pallet.
REMOVE THE ROTARY SEAL

Reference Drawing: Rotary Seal Assembly xxxx.
1. From the lower portion of the rotary seal, disconnect and cap all hydraulic lines for the follow-
ing auxiliary components with JIC numbered caps and plugs:
• Kidney Manifold
• Elevators
• Intensifier
• Link tilt cylinders
• Roto actuator
2. Using a centre punch, mark the alignment of the outer rotary sleeve, inner rotary sleeve, and
mainframe so you can align these three marks during reassembly.
3. Bolt the rotary seal lifting tool to 3 bolt holes in the top of the rotary seal.
4. Attach an overhead hoist to the rotary seal lifting tool, remove the 3 bolts that attach the rotary
seal to the pipe handler frame and lift the rotary seal from the main frame and onto a pallet.
REMOVE THE SLEWING BEARING FROM THE PIPE HANDLER

Reference Drawing: Pipe Handler Assembly xxxx
1. Remove the slewing bearing bolts that attach the slewing bearing to the pipe handler frame
that are accessed from the top of the slewing bearing.
2. Insert lifting eyes in slewing bearing mounting holes and attach slings to the eyes and to an
overhead hoist.
3. Using an overhead hoist, support the weight of the slewing bearing.
4. Using a pry bar, dislodge the slewing bearing while simultaneously lifting with the overhead
hoist.
5. Place the slewing bearing onto a pallet.

PAGE 3-7
DISASSEMBLE THE GEARBOX

Reference Drawing: Gearbox Assembly xxxx
1. Remove the bolts attaching the top and bottom quill bearing retainers from the gearbox. Using
a pry bar, remove the top quill bearing retainer. Remove the shim pack and outer bearing race.
Use the pry bar to dislodge the bottom retainer, remove the retainer and the outer race from the
bottom quill bearing.
2. Remove the gearbox lid bolts, install a lifting eye in each of the motor mount flanges, rig suit-
able lifting equipment then use a pry bar to dislodge the lid from the gearbox. Once free, hoist
the lid off the gearbox and set on a pallet.
3. Install the lifting nubbin onto the quill, rig suitable lifting equipment and hoist the quill and
quill gear out of the gearbox. Place on a pallet.
4. Install the pinion lifting tool in one of the pinion gears and hoist it out of the gearbox, set on a
pallet and repeat for the second pinion.
DISASSEMBLE THE GRABBER LEG AND GRABBER BOX

Reference Drawing: Grabber Leg Assembly xxxx.
1. Remove the safety chain from the back of the grabber leg and remove the cylinder base pin
that secures the double-acting cylinder.
2. Remove the double-acting cylinder.
3. Remove the bolts that connect the lower grabber leg to the grabber box.
Note: Record the total thickness of the shim between the lower grabber leg and grabber box
for reassembly.
4. Remove the two retraction pins from the bottom of the grabber box, and then pull out the grab-
ber assembly from the front of the grabber box.
5. Remove bolts from both ends of the clamping box and from either end of the grabber die
holder assembly and slide out the grabber cylinder.
6. Remove the 4 bolts from the retract cap and remove the pressure plate.
7. Remove the cylinder assembly and then remove the die holders and dies and place the cylinder
in a vice.
8. Remove the port extension and then using a gland nut wrench, remove the gland nut using a
bucket to catch the oil.
9. Remove the piston from the cylinder and remove the seals and o-rings.

PAGE 3-8
DISASSEMBLE THE ELEVATORS

Reference Drawing: Elevator Assembly xxxx
1. Remove the pins on the ear brackets and remove the elevator cylinders leaving all hoses to the
manifold connected.
2. Disconnect and cap the hoses attached to the elevator.
3. Remove the snap rings from the latch door pin and carefully remove the latch pin, noting the
position of the spring arms for reassembly.
Caution: The latch pin holds a spring under tension. Use caution when
removing this pin.
4. Remove the retainer clip on the elevator hinge and remove the elevator hinge pin.
5. Remove the Allen bolts that prevent the slip from rotating and remove the slips and check for
wear.

PAGE 3-9
CAODC LEVEL IV RECERTIFICATION PROCEDURES INSPECT THE TOP DRIVE
SECTION 4: INSPECT THE TOP DRIVE
Requires Record Send for MPI

Disassembl Disassemble No Yes serial
Worn? third-party Send for
e top drive component number
servicing? sandblasting,
Yes painting, MPI
Store faulty No
component Yes Replace
Send for
until invoice ?
in-house
paid
servicing
No
Refurbish
Store faulty
Passes Replace Yes Reassemble
No component
MPI? ? until invoice top drive
paid
No
Yes
Refurbish
BEFORE YOU START

You need the following before you inspect:
• HS Packing List
• Pallets, parts baskets, and crates
• Parts List for the HS top drive
GENERAL NOTES
All components require inspection and servicing or replacement before the top drive can be reassembled.
The inspection process includes disassembling components and visually inspecting each piece for wear,
cracks, and bends. Depending on the outcome of the visual inspection, each component is either replaced
or refurbished. All components that are not replaced are sent for Magnetic Particle Inspection (MPI).
Note: Order all replacement parts immediately to ensure reassembly is not delayed by back
orders.

PAGE 4-1
INSPECT AND PREPARE COMPONENTS FOR SERVICING

1. Ensure companies who will provide third party servicing and MPI are aware components will
be sent.
2. Disassemble and clean components checking for wear, cracks, and heat distortions (including
bends and uneven surfaces) and place on pallets based on the requirement defined in the Pack-
ing List for the unit being serviced.
3. Record the requirements and serial number for each component in the Packing_List.pdf.
4. If a component appears worn or cracked, review the tolerance specification sheet and do one
of the following:
• If it falls below the tolerance specification, group the component on a pallet with other faulty
components and highlight a replacement on the parts list. After the customer pays for the 500
day invoice, discard all faulty components.
• If it falls within the allowable tolerance specification, consult the Service Shop Foreman
about refurbishing it.
5. If the component does not appear worn or cracked, record its serial number and servicing
instructions, then prepare it for servicing based on the following:
To Protect This Item Follow These Steps
Gearbox 1. Insert seals in both upper and lower bearing retainers, then insert a wood or
plastic cover the same diameter as the seal and hold in place with one or two
used seals.
2. Using old bolts, attach a wood or plastic cover over the hydraulic motor mounting
flanges.
3. Insert a pipe plug into the filler expansion chamber bore.
4. Insert old bolts in all threaded holes.
5. Insert dowels in dowel bores.
Load Collar 1. Tape underside of load collar where load nut contacts.
2. Tape side hubs on load collar where retainers mount.
Mainframe Bolt a metal template with rubber gasket to surface where the slewing bearing
bolts to mainframe.
Pipe Handler 1. Bolt a metal template with rubber gasket to surface where the slewing bearing
bolts to pipe handler.
2. Slide a piece of pipe over the smooth surface of the link tilt horns and secure the
pipe by threading a nut onto the threaded end of the link tilt horns.
Quill Install thread protectors on the quill ends and cover the quill splines and load nut
grooves with cardboard to protect them.
All machined and Using old bolts, attach a wood or plastic cover.
mounting surfaces
All machined holes Insert bolts that sit proud on both sides of the hole to completely cover all threads.
All housings for fluids, Attach a wood or plastic cover using old bolts or seals.
bearings, and moving
components
6. Document the action required for each component on the Packing List and include a photo-
copy for each destination.
7. Ensure all components are clean.
8. Include a copy of the packing list with each pallet of faulty components for possible future ref-
erence.

PAGE 4-2
SHIPPING COMPONENTS
Inform the Quality Control department that you have a shipment ready for third-party servicing for which
they must produce a bill of lading.
Components that require machining should be machined after being sent for MPI.

PAGE 4-3
CAODC LEVEL IV RECERTIFICATION PROCEDURES ASSEMBLE THE TOP DRIVE
SECTION 5: ASSEMBLE THE TOP DRIVE
New,
refurbished, Verify serial Clean Assemble Assemble
inspected Assemble
numbers components pipe handler mainframe gearbox
components
arrive
Adjust Assemble Attach Attach load Assemble quill

Endplay motor eleven-station collar
manifold
Endplay
No OK? Yes
Assemble Assemble Adjust Assemble Mount in

grabber leg Ship unit
torque and Endplay elevator travel stand
extend frame
Endplay
No OK?
Yes
BEFORE YOU START

You will need the following before you assemble the top drive:
• All ordered, refurbished, and new parts
• Completed Packing list and Parts list
• Dial gauge to measure end play
• Lubricants listed in the HS Fluids Checklist
• Overhead hoist rated for 6,000 lb
• Rineer motor lifting tool
• Slings long enough to reach from the yoke to the floor
• Taps for cleaning bore holes
• Work stand with overhead clearance

PAGE 5-1
PREPARE COMPONENTS FOR ASSEMBLY

1. Using the Packing List, verify serial numbers of all components received from third party ser-
vicing match the serial numbers of the components shipped.
2. Verify all replacement components against the parts lists.
3. Clean all threaded boltholes by screwing in a tap and then blowing in the holes to dispel any
paint or rust particles.
4. Pressure wash then dry all components and ensure they remain clean as you assemble the top
drive.
ASSEMBLE THE PIPE HANDLER

Reference Drawing: Pipe Handler Assembly xxxx and Rotary Seal Assembly xxxx
For bolt specifications, refer to the Bolt Specification Chart.
1. Using an overhead hoist, mount the pipe handler on the work stand stump.
2. Evenly coat the slewing bearing with thread protection spray or molly coat.
3. Remove all paint and debris from the top surface of the pipe handler and the face of the slew-
ing bearing where the two contact to ensure the slewing bearing sits level.
4. Using an overhead hoist, lower the slewing bearing onto the top of the pipe handler. Note
Ensure the mark you made on the slewing bearing with a centre punch during disassembly will
align with the mark you made on the main frame when the main frame is attached to the pipe
handler.
5. Bolt the slewing bearing to the pipe handler.
Caution: Review the torque chart referenced above to determine whether you
should add lock washers to the slewing bearing bolts.
6. Ensure the grease nipple is accessible via the access port.

7. Clean and inspect all rotary seal ports for debris and tap to clean.
8. Ensure the area where the rotary seal mounts is free of paint and debris then mount the rotary
seal on the pipe handler ensuring the marks you made with a centre punch on the inner rotary
sleeve, upper rotary sleeve, and pipe handler during disassembly align.
9. Attach all upper and lower hydraulic lines.
10. Insert the upgrade grease line running from the nipple on the bottom of the pipe handler to the
rotary seal.
11. Insert the kidney manifold, snug the bolts, and then attach all lines for lower hydraulics.
Note: Don't secure the kidney manifold until after you attach the load collar.
12. Insert and mount the intensifier cylinder.
13. Install the 4 link tilt cylinders so the ports for the two front cylinders face forward and the
ports for the two back cylinders face backwards then attach the castle nuts and safety pins.
14. Attach all link tilt hydraulic lines and flow controls.

PAGE 5-2
ATTACH AND ASSEMBLE THE MAINFRAME

For bolt specifications, refer to the Bolt Specification Chart
1. Remove all paint and debris from the bottom surface of the mainframe and the face of the
slewing bearing where the two contact.
2. Using an overhead hoist, mount the mainframe on the slewing bearing ensuring the marks you
made on the slewing bearing and mainframe with a centre punch during disassembly align.
3. Ensure the grease nipples are accessible via the access ports.
4. Bolt the mainframe to the slewing bearing accessing the bolts from inside the pipe handler.
5. Pressure check accumulators before attaching them to the mainframe.
6. Mount and connect the following components:
• Accumulators
• Fittings, brackets, etc.
• Pipe handler lock
• Top drive relief
ASSEMBLE THE GEARBOX

Reference Drawing: Gearbox Assembly xxxx
With the gearbox in the rotating gearbox work stand, inspect the Glyptal coating inside the gearbox hous-
ing and recoat if required.
Assemble and Install the Bottom Bearing Retainer

1. Clean the bottom bearing retainer, replace the grease fittings, and install the three (3) bottom
quill seals noting that they are oriented correctly.
2. Install a new o-ring in the groove, then install the bearing retainer on the bottom of the gearbox
with the grease fittings pointed towards the back of the gearbox.
Install Pinion Gears

1. Preheat all pinion bearings to 325° Fahrenheit and install on pinion gears.
2. Allow bearings to cool then, using suitable lifting equipment, lift the pinion gears into the
gearbox. It may be necessary to use a hammer and brass punch to align the bottom bearings so
that they slide into the pinion bearing bores.
3. Place the o-ring and Spiralox on the lower pinion bearing seat and then attach the bearing seat
to the bottom of the gearbox ensuring the cutaway in the bearing seat aligns with the trunnion
shaft.
4. Remove the lifting tool. Place the o-ring and Spiralox on the upper pinion bearing seat and
then attach the bearing seat to the top of the gearbox ensuring the cutaway in the bearing seat
aligns with the trunnion shaft.

PAGE 5-3
Install the Quill into the Quill Gear

1. Preheat the quill bearings to 325° Fahrenheit.
2. Install the quill on a stand with the bottom pin up, ensure that the bearing seat area is clean and
install the bottom quill bearing. Once installed allow the bearing to cool before proceeding.
3. With the quill gear standing on edge, use suitable lifting equipment to slide the quill into gear.
Install a lifting nubbin in the top end of the quill and place quill/gear assembly back on the
stand with the top of the quill up so that it does not tip over.
4. Ensure that the top bearing seat is clean and install the top quill bearing. Allow to cool before
proceeding.
Assemble the Gearbox

1. Install the quill bottom bearing outer race into the bottom bearing bore of the gearbox.
Note: Use a brass punch to drive it into place.
2. Apply white lithium grease to the bottom quill/gear assembly and install in gearbox taking
care not to roll any of the bottom quill seals.
3. Apply white lithium grease to the top quill bearing. Apply red RTV sealant to the sealing sur-
face of the gearbox housing.
4. Using suitable lifting equipment hoist the gearbox lid onto the gearbox housing. It may be nec-
essary to use a brass punch and hammer to align the pinion bearings with the pinion bores.
5. Install the gearbox lid bolts and torque to specified value.
6. Install the top quill bearing outer race. Clean the quill shim pack (0.075 in. minimum thick-
ness) and install and align with bolt holes.
7. Install the quill top bearing retainer (without the seals or o-ring) and install eight of the bearing
retainer bolts evenly spaced about the retainer.
8. Connect suitable lifting equipment to the quill lift nubbin. Install a dial indicator with the base
on the quill and the stylus on the top quill bearing retainer. Using a soft hammer, drive the quill
downwards and set the indicator at 0. Hoist the quill upward and record the amount of move-
ment indicated. Repeat two or three times to get an accurate value.
9. Remove the bolts holding the top quill bearing retainer, remove the retainer and adjust the
shim pack based on the movement indicated to obtain 0.015 in. maximum preload (0.012 in.
minimum preload).
10. Clean the upper quill bearing retainer, install two (2) new grease fittings, quill seals, and new
o-ring. Note the orientation of the upper quill seal. Apply white lithium grease to the seals and
o-ring and install the upper quill bearing retainer on the gearbox with the grease fittings point-
ing towards the back.
Attach the Bull Gear

1. Place a retaining ring on the quill hub.
2. Preheat the lower quill hub bearing to 300° Fahrenheit and insert it on the bottom of the quill
hub.
3. Attach 2 slings to an overhead hoist and to 2 lifting eyes spaced 180° apart on the bull gear,
then lift the bull gear into the gearbox and insert it through the back opening.
4. Using an overhead hoist and lifting plate, slowly lift the quill hub through the quill bore in the
gearbox and through the bull gear ensuring the splines on the quill hub and inner bore of bull
gear align.

PAGE 5-4
5. Insert an o-ring and 3 oil seals in the lower quill flange ensuring the 3 oil seals face the gear
case then insert the lower bearing race in the gearbox.
6. Slide the lower flange over the lower quill hub and attach the lower flange to the gearbox
ensuring the grease fittings face the back of the top drive.
7. Attach 4 grease fittings in the lower quill gear hub.
8. Insert the bull gear spacer on top of the quill hub.
9. Preheat the upper quill bearing to 300° Fahrenheit and insert on the upper quill hub.
10. Insert the upper bearing race in the gearbox and insert two alignment bolts in the upper flange
boltholes.
11. Insert the quill bearing retainer shim pack adding an additional 0.030" shim.
12. Attach the upper flange without the o-ring and seals using 6 evenly-spaced bolts.
13. Using an overhead hoist and lifting plate complete Adjusting Preload on page 32.
14. Remove the upper flange and insert a new o-ring and 3 new seals ensuring the first 2 seals face
towards the gearbox and the third seal faces away from the gearbox.
15. Attach the upper flange to the gearbox with the flange grease fittings facing towards the rear of
the top drive.
16. Remove the 2 alignment dowels and attach the upper flange with bolts.
Attach Hydraulic Motors to the Gearbox

1. Remove the stand stop pin and rotate the gearbox so that the bottom motor mounting points
are on top.
2. Install the correct motor spacer. Apply a light film of grease to the motor base plate o-ring and
hoist into place. Note: the hydraulic motor ports must be oriented correctly. Use the motor
pipes to determine this orientation if it wasn’t written down. Install the mounting bolts and
torque to specified value.
3. Repeat steps 1 - 2 for the second bottom motor.
4. Remove the stand stop pin and rotate the gearbox so that it is right side up.
5. Repeat the above steps to install the top motors. Make sure the ports are oriented correctly.
Attach the Auxiliary Gearbox and Motor Manifold Components

1. Replace the sight glass on the expansion chamber and install the expansion chamber on the
gearbox.
2. Install the gearbox drain ball valve and fittings.
3. Install the motor manifold support bracket. Torque and lock wire the bolts.
4. Using suitable lifting equipment, hoist the motor manifold into position and secure it. Install
new o-rings in the top motor pipes, lightly grease the o-rings, and install the motor pipes and
flange clamps.
Caution: Do not force the motor manifold into position.
5. Remove the stand stop pin, invert the gearbox and install the bottom motor pipes. Install the
quill spline collar (if equipped). When completed, rotate the gearbox so that it is right side up
and install the stand stop pin.
6. Clean the header pipes, install new 5000 psi rated ball valves, and new o-rings. Lightly grease
the o-rings and install the header pipes on the motor manifold.

PAGE 5-5
Attach the Gearbox to the Mainframe

For bolt specifications, refer to the Bolt Specification chart.
1. Using suitable lifting equipment, hoist the gearbox into the mainframe. It may be necessary to
spread the mainframe slightly to facilitate installation.
2. Apply Loctite to the mainframe and gearbox bolts, align the bolt holes, and install the bolts.
Leave the bolts loose for the moment.
3. Apply anti-seize lubricant to the dowels, align the dowels, and install the dowels and keepers.
4. Tighten the gearbox to mainframe bolts, torque to specified value, and lock wire.
INSTALL THE 8 OR 11 STATION MANIFOLD

Reference Drawing: Bumper Guard Assembly xxxx and Rotary Seal Assembly xxxx
1. Using suitable lifting equipment, hoist the 8 or 11 Station manifold onto the mainframe door
and attach.
Note: For bolt specifications, refer to the Bolt Specification Chart.
2. Attach brackets, braces, and lockwire.
3. Attach hydraulic lines for the transducer, auxiliary pressure, and tank.
4. Attach the proximity switch and bracket to the lower quill hub flange and connect hydraulic
lines to the rotary seal.
5. Install the pipe handler proximity switch.
INSTALL THE LOAD COLLAR

1. Insert two 12 to 14 x 1 in. bolts with large washers in the load collar pin holes and using one
overhead hoist with a sling attached to one of the bolts, lift the load collar until it is vertical.
2. Using a second overhead hoist and sling attached to the other 12 to 14 x 1 in. bolt, slowly lift
the lowest end of the load collar while simultaneously lowering the other hoist until the load
collar is horizontal.
3. Using the overhead hoists, place the load collar into the pipe handler frame and evenly lift
until the load collar seal contacts the pipe handler frame.
Note: Lift carefully so you don't damage the seal.
4. Attach the spring cushion assembly below the load collar.
5. Using an overhead hoist, lower the load collar onto the spring cushion and remove the slings.
6. Attach the bale retainers to hold the load collar in place.
7. Secure the kidney manifold bolts.

PAGE 5-6
ASSEMBLE THE GRABBER BOX

Reference Drawing: Grabber Box xxxx
1. Hone the cylinder to de-glaze it and create a crosshatch pattern.
2. Lubricate the piston ring and slide it onto the piston.
3. Lubricate and insert a parker poly o-ring in the gland nut groove nearest the clamp box cylin-
der with the thick end of the taper towards the clamp box cylinder.
4. Lubricate and insert a parker poly o-ring in the gland nut groove furthest from the clamp box
cylinder with the thick end of the taper away from the clamp box cylinder.
5. Insert the piston into the cylinder, insert the gland nut, and then tighten with a gland spanner.
6. Attach the piston to the clamp box cover with four piston retainers.
7. Bolt the die retainers to the end of the cylinder and attach the assembly to the clamp box on the
end with the two slots for the locating pins.
8. Bolt the die retainers to the clamp box cover and then attach them to the clamp box end, which
is away from the two slots for the location pins.
9. Attach one set of dies to the cylinder with a top retainer. Attach the other set of dies to the
clamp box end cover with another top retainer and then fit the assembly clamp box into the
torque box.
10. Locate the retraction pin opening in the torque box using the retraction pin bolthole and then
insert the retraction pins and lock-wire.
11. Bolt the torque box cover to the front end of the torque box.
12. Attach two JIC port extensions with o-rings to the ports on the grabber piston. Cover with two
1/4 in. JIC caps for protection, and then attach the grabber box assembly to the lower grabber
leg reinserting the original shim.
ASSEMBLE THE GRABBER LEG

Reference Drawing: Grabber Leg Cylinder Assembly xxxx
1. Attach the hydraulic hosing to the grabber leg cylinder.
2. Insert the grabber leg cylinder in the grabber leg and insert a lower cylinder-locking pin coated
with anti-seize compound.
3. Lower two wires through the pipe handler that you can use to fish the hydraulic lines from the
grabber leg through the pipe handler.
4. Using an overhead hoist, suspend the top drive over the grabber leg, attach the fishing wires to
the hydraulic lines and then lower the top drive onto the grabber leg while fishing the hydrau-
lic lines through the pipe handler.
5. Insert the upper cylinder-locking pin coated with anti-seize compound, attach the safety chain,
and attach the remaining hydraulic lines.

PAGE 5-7
MOUNT THE TOP DRIVE IN THE TRAVEL STAND

1. Using an overhead hoist, mount and secure the top drive in a travel stand.
2. Check for hydraulic leaks by applying air to the system. Once satisfied that there are no leaks,
connect the auxiliary pressure and tank hoses, loop hoses, and 37C cable.
3. Complete the Pre-start Topdrive Inspection Checklist.
INSTALL THE LOAD PATH

1. Make sure the rotary seal lock ring is in place then apply joint compound to the quill pin.
2. Clean the Load Sub box and pin then, using suitable lifting equipment, insert the load sub pin
into the grabber, taking care not to damage the threads or splines.
3. Install a chain through the quill so that it extends through the load sub. Attach a shackle and
lifting plate to the chain and take up the slack with the hoist.
4. Carefully hoist the load sub through the load collar, seal, and rotary seal. Use a chain tong to
tighten the load sub onto the quill pin. Remove the lifting plate and chain, then install the load
sub spline collar (if equipped).
5. Using suitable lifting equipment, set the assembled MSV/Actuator into the grabber. Install the
lifting chain through the quill, load sub, and MSV/Actuator. Attach the shackle and lifting
plate to the chain then apply joint compound to the load sub pin.
6. Carefully hoist the MSV/Actuator up to engage the load sub pin. Use a chain tong to tighten
the connection.
ASSEMBLE THE TORQUE BUSHING AND EXTEND FRAME ASSEM-

BLY
Reference Drawing: Torque Bushing and Extend Frame Assembly xxxx

1. Attach the nylon insert wear bushings inside the torque bushing then insert a piece of torque
tube in the torque bushing to ensure snugness.
2. Add or remove shims between the nylon insert wear bushings and the torque bushing until
there is about 1/8 in. play between the nylon insert wear bushing and the torque tube.
Note: Ensure you insert the shim retainer clips.
3. Attach the extend arm assembly to the torque bushing.
4. Install the extend cylinders and hoses.

PAGE 5-8
ASSEMBLE THE ELEVATOR

Reference Drawing: Elevator Assembly xxxx
1. Insert elevator slips in the elevator housing and insert the Allen bolts that hold them in place.
2. Align the two halves of the elevator, insert the hinge pin, and insert the retainer clip.
3. Align the latch door and insert the tension spring pulling the spring arms together to create ten-
sion while quickly inserting the pin in the latch door.
4. Connect any hosing removed from the cylinder and then align the ear and elevator cylinders in
the cylinder bracket and insert the latch pin.
5. Attach the ear bracket to the elevator housing.
ADJUST THE PRELOAD

The amount of force exerted on bearings by an adjacent component is called preload. Adjust preload by
adding or removing shims that support most of the weight of a component that contacts the bearings. See
steps 6-9 under “Assemble the Gearbox” on page 5-3.
The preload formula is as follows:
Preload Formula Example

Endplay Measurement 0.010 in.
+ Ideal Preload + 0.012 - 0.015 in.
= Shims to remove 0.022 - 0.025 in.
Adjust the Gearbox Preload

New quill gear bearings require 0.012 to 0.015 in. preload.
To correct preload between the quill and gearbox, remove the top bearing retainer and remove the desired
amount of shims.

PAGE 5-9
CAODC LEVEL IV RECERTIFICATION PROCEDURES INSPECT/SERVICE THE POWER UNIT
SECTION 6: INSPECT/SERVICE THE POWER UNIT
Visually inspect
Engine Pre- Change pump Change engine oil Engine N Send engine to
engine, pump
Servicing test drive oil and and send oil sample Sample o manufacturer for
drive, and loop
complete inspect oil sample for analysis OK? servicing
system
Yes
Loop Check endplay in

Check loop Yes
reservoir Check radiator Radiator Yes fan bearing, turbo Endplay Yes
reservoir and
and filters fluid fluid OK? inlet, and OK?
filters
OK? crankshaft
No No No
Change oil and Adjust endplay or
filters Top or change fluid replace
component
Pump Yes
Check pump Test
splines
splines unit
OK?
No
Replace pump
splines
BEFORE YOU START

Before inspecting and servicing the power unit, pump drive, and loop system check if the customer docu-
mented any faults like the pump drive oil overfilling.
INSPECT AND SERVICE THE ENGINE COMPONENTS

General Overview
• visually inspect the engine
• replace components as required
• send an oil sample for analysis
• change engine fluids and fluid filters
Visual Inspections
Perform the following visual inspections on the engine components:
• Loosen the hose clamps on the air intake and ensure there are no wear spots inside the pipe
indicating air leaks.
• Visually inspect air cleaner elements.
• Check the exhaust assembly for soot markings that occurred during the Pre Servicing test
indicating leaks, and ensure the exhaust assembly is securely mounted on the engine.
• Ensure the air starter sediment reservoir is relatively free of oil.
• Ensure the gauge panel is securely mounted.

PAGE 6-1
Replace the Engine Oil

1. Run the engine up to operating temperature and then shut down.
2. Remove the oil pan drain, allow the oil to flow for several minutes and then take an oil sample
for analysis.
3. Drain and clean the oil spinner filter.
4. Change the engine oil filters.
5. Insert the cap on the oil pan and add new engine oil. For specifications on engine oil, see HS
Fluids Checklist.
6. Change all fuel filters.
7. Check the Racor fuel filter for build up and the Racor site gauge for particles and if required,
replace. For specifications on Racor fluid, see HS Fluids Checklist.
Note: Ensure you select the proper oil, fuel, and coolant filter elements depending on whether
the engine is Caterpillar or Detroit Diesel.
Check the Radiator

1. Ensure the radiator fins are free of warp and oil deposits.
2. Open the radiator cap and check the radiator cores for corrosion or build up.
3. Test the PH level of the coolant.
4. Check the coolant freeze level.
5. Check the coolant level and add if required. For specifications on radiator fluid, see HS Fluids
Checklist.
Inspect the Turbo

1. Disconnect the intake piping from the engine turbo.
2. Reach inside the turbo inlet and wiggle the impeller to check for end play. Compare the
amount of end play to the manufacturer's specifications.
3. Ensure no oil deposits are visible in the engine turbo.
4. If oil deposits or end play exist, replace the engine turbo.
Check Endplay in the Engine Fan Bearing

1. Loosen the fan belt.
2. Reach under the engine fan guard and wiggle the fan. Significant movement indicates end play
in the fan bearing.
3. If bearing end play seems significant, contact the Service Shop Foreman.
Check Endplay in the Crankshaft

1. Attach the magnetic base of a dial gauge to the skid or engine block and set the stylus against
the dampener.
2. Using a pry bar, move the crankshaft from front to back while monitoring the dial indicator.
The crankshaft should have between 0.010 in. and 0.015 in. of endplay.

PAGE 6-2
INSPECT AND SERVICE THE PUMP DRIVE

Do the following to visually inspect the pump drive:
• Ensure the breather is clean and free of cracks.
• Ensure the site glass is clear, not cracked and that 1/2 to 1 in. of oil is displayed. A greater
amount of oil in the gearbox may indicate a leak in the pump.
• Ensure the gearbox is securely mounted to the skid and bell housing.
• Ensure there are no leaks near the pump drive.
Check the Pump Splines

1. Close the charge pump suction valves and loosen the pump case drain hammer union located
on top of the hydraulic tank.
2. Attach a hoist to the pump to support its weight.
3. Detach any hoses that prevent you from pulling the pump back.
4. Remove the nuts supporting the pump and pull the pump away from the pump drive.
5. Check the spline and spline adapter and replace if necessary.
6. Lubricate and replace the O-ring on the pump mounting face then reattach the pump.
7. Open the charge pump suction valves and tighten the pump case drain hammer union.
Check the Pump Shaft Seals

1. Detach and plug the lube pressure lines.
2. Start the power unit and watch the pressure inlet fitting to ensure no oil appears. Oil indicates
a leak in the pump drive.
Replace the Pump Drive Oil

1. Check the site glass on the pump drive to ensure the site glass displays ½ in. to 1 in. of oil
when the system is at operating temperature. A level higher than this, or foaming oil, may indi-
cate a leaking pump shaft seal.
2. Drain the gearbox lube oil sump, clean and reinstall filter, then refill the sump with the speci-
fied oil. Refer to the HS Fluids Checklist.
3. Drain the oil from the gearbox and take a sample for analysis.
4. Close the gearbox oil drain and fill the gearbox with specified oil until 1/2 in. to 1 in of oil is
showing in the site glass. Refer to the HS Fluids Checklist.

PAGE 6-3
INSPECT AND SERVICE THE CLOSED LOOP SYSTEM

Inspect the loop system including the hydraulic tank and loop hoses.
Inspect the Loop Reservoir

1. Ensure the oil level in the hydraulic tank is nearly full. Refer to the HS Fluids Checklist for
hydraulic oil specifications.
2. Take an oil sample from the loop reservoir and send for analysis.
3. Inspect the filter housing for leaks. If leaks are found, filter housing seals must be replaced.
4. Drain the filter canisters, remove the caps, lift the filters out and inspect. If necessary, replace
the filters. Reuse the connecting elements, install the filters, lube the canister lid threads and
install the lids. Torque to specified value.
5. If rubber pieces were found in the loop filters this may indicate that the internal sleeves of the
loop hoses are deteriorating and should be replaced.

PAGE 6-4
CAODC LEVEL IV RECERTIFICATION PROCEDURES TEST THE TOP DRIVE & POWER UNIT
SECTION 7: TEST THE TOP DRIVE & POWER

UNIT
Remove from
Unit Make connection Test in Dynanometer
Dynanometer
assemble Do pre-tests and insert in and record results
and test
d Dynanometer
functionality
Record results Do final Record results Ship top

inspection drive
BEFORE YOU START

1. Prepare the unit based on the Parts List, then mount the top drive in a Dynamometer. Test the
top drive and record your results in the Dyno Record.
2. Check with the Service Shop Foreman if there are any special testing instructions.
3. Get the following testing checklists:
• Parts List
• Pre Dyno Inspection
• Dyno Record
• Final Inspection Top Drive
• Final Inspection Power Unit
INSTALL THE TOP DRIVE IN THE DYNAMOMETER

1. With the power unit hooked up the top drive, hoist the top drive and then connect the Dyna-
mometer sub using a chain wrench.
2. Attach the HS mounting adapters to the Dynamometer frame then hoist and attach the top
drive to the adapters pinning it to the adapter eyes.

PAGE 7-1
TORQUE THE DYNAMOMETER SAVER SUB CONNECTION

Note: make sure all of the load path connections have been made up and secured before
attempting to make up the dyno sub connection.
1. Start the engine, set the speed to 1,000 rpm adjust the connect speeds to 17 rpm and then turn
the Max and Set relief valves on the hydraulic motor counter clockwise until backed all the
way out.
2. Position the grabber below the seal face of the Dynamometer Saver Sub and on the driller's
panel, close the grabber, select Connect and then torque the Dynamometer adapter to
15,000 ft·lbs.
3. Review the motor net pressure torque chart to determine the 'lbs. to pressure specification.
4. Close the grabber box, select Forward, and press the Max torque button while an assistant
slowly turns the Max relief valve on the hydraulic motor clockwise to achieve the proper
torque.
5. Release the Max torque button and select Neutral while an assistant turns the Max and Set-
screws on the hydraulic motor clockwise completely in.
6. Attach a die lock clamp to the connection.
7. Attach a flow meter to the motor case drain lines.
TEST LOW RANGE

1. To test low range, apply oil to both motors to get high torque and high horsepower.
2. On the driller's panel, select Drill > Forward > Low Speed and complete the Dynamometer
testing report.
Caution: Do not go above 3,800 psi on the driller's gauge.
TEST HIGH RANGE

1. When the low range test is complete, test the high range by applying oil pressure to only one
motor to cause low torque with high available speed.
2. On the driller's panel, select Drill > Forward > High Speed complete the Dynamometer testing
report.
Caution: Do not go above 3,800 psi on the driller's gauge.
TEST THE DRILLER'S CORD

Test the driller's cords that control the mud pump, interlock draw works, interlock chart recorder, and mud
logger brake handle push buttons.
1. Connect the driller's cord to the driller's panel and connect a 120 psi air supply to the air in side
of both the mud pump air valve and the draw works air valve.

PAGE 7-2
2. On the driller's panel, select Valve > Open and ensure the mud pump air valves remain open
and that air flows.
3. Select Valve > Close and ensure the mud pump air valves close and there is no airflow.
4. Select Grabber > Open and ensure the draw works air valves remain open.
5. Select Grabber > Close and ensure the draw works air valves close and there is no air flow.
6. While the grabber is closed, push the red button on the brake handle to override the draw
works air valves and ensure there is air flow in the draw works air valves.
7. To test the elevator close circuit, connect a voltmeter to terminal DPA11 (red) and the return
circuit (black) and then press the black button on the brake handle and ensure the meter dis-
plays 24 volts.
8. Release the black button on the brake handle and ensure the voltmeter still displays 24 volts.
9. On the driller's panel, open the elevator and ensure the voltmeter displays 0.
10. Close the elevator and ensure the voltmeter displays 24 volts.
TEST THE TORQUE SWITCHES

Torque switches enable drillers to drill with maximum torque in either low or high speed for a limited time
without having to lower the top drive to increase the top drive torque reliefs.
1. Adjust the Max torque to 3,000 psi and the Set torque to 2,000 psi.
Note: These values are only used for testing.
2. Set the top drive drill speed to 17 rpm then, on the driller's panel, select Neutral to stop the
quill without decreasing the quill speed.
3. Close the grabber on the mud valve, select Low Speed and select Max torque and then select
Forward.
4. Ensure the pressure displays 3,000 psi, and then turn the torque switch to High and ensure the
pressure displays 2,000 psi.
5. Select Neutral, High Speed, and Max torque.
6. Select Forward and ensure the pressure displays 3,000 psi, and then turn the torque switch to
Low and ensure the pressure displays 2,000 psi.
7. With Low and Forward selected, select Max and ensure the pressure displays 3,000 psi. Turn
Max off and ensure the pressure displays 2,000 psi.
TEST THE RIG SAVERS

The rig saver is a device that shuts down air intake and the engine simultaneously in an emergency. You
must test to ensure the engine light and air intake both shutdown simultaneously. The air intake cannot be
opened for 15 seconds following an emergency shutdown.
1. Turn the engine on but don't run it and within 5 seconds, pull the Emergency Shutdown button
on the driller's panel and monitor the light to ensure the engine run light goes out at the same
time the rig saver closes.
2. Ensure the engine light illuminates after 15 seconds.

PAGE 7-3
TEST THE EXTEND CIRCUIT

The extend circuit includes two cylinders on the extend frame connected by hoses with quick couplers to
the Eleven-Station manifold. There are two circuit relief valves on the Eleven-Station manifold (one to
extend, the other to retract) and two flow control valves with reverse flow checks that are used to reduce
the speed at which the extend frame operates.
1. On the driller's panel, select In and adjust the circuit relieve pressure to 1,850 psi.
2. Select Out and adjust the circuit relief pressure to 1,850 psi and switch the In and Out switch,
ensuring the lines display pressure alternately.
3. Ensure the In Out switch automatically springs to neutral after each use and that the Robotics
On light or Auxiliary light illuminates each time you flick the switch.
TEST THE COLD CLIMATE BUTTON

The cold climate button is used to circulate loop hydraulic oil through the top drive on cold days when the
top drive is not rotating to help keep the hydraulic oil warm and ready for use.
Operations below -10° Celsius

1. With the engine running on slow mode, on the driller's panel, push the Cold Climate button
and select Forward Drill.
2. Maintain 700 psi on the torque pressure gauge.
3. Check the hydraulic pumps to ensure oil is flowing to the top drive.
4. Check driller's gauge to ensure there is no torque to the top drive and ensure the quill does not
turn.
Operations from -10° Celsius to 10° Celsius

1. With the engine running on slow mode, on the driller's panel, push the Cold Climate button
and select Forward Connect.
2. Maintain 700 psi on the torque pressure gauge.
3. Check the hydraulic pumps to ensure oil is flowing to the top drive.
4. Check driller's gauge to ensure there is no torque to the top drive and ensure the quill does not
turn.
TEST THE BREAKOUT FUNCTION

Ideally, the reverse torque should be set so that when in Reverse Connect, the pressure is 1,000 psi and
does not breakout a fully torqued joint. When Breakout is pressed, pressure should rise and the joint should
break.
Note: Test the breakout with a mud valve or Dynamometer sub connected.
5. Ensure the Forward Connect and Reverse Connect speeds are set by turning the Reverse
torque valve counter clockwise until fully backed off, closing the grabber, and then selecting
Connect and Reverse. No torque should be applied to the quill.
6. Turn in the reverse torque relief valve until the driller's gauge displays 1,000 psi.

PAGE 7-4
7. With 1,000 psi torque still applied to the quill, push and release Breakout and ensure the pres-
sure gauge rises and torque on the quill increases. If a sub is in the quill, press Breakout and
break the joint. The pressure should increase to 4,000 psi or break out the joint.
TEST THE G CORD TORQUE CIRCUIT

The G cord A and B pins put out a 4 to 20 mA signal with 12 mA being the base middle (0 psi). Any value
above 12 mA is forward pressure and anything below is reverse pressure.
Note: These pressures are motor net pressure and will be lower than the driller's gauge pres-
sure.
To use a digital multi meter to check this circuit select 20 mA (or slightly higher if no 20 mA range is avail-
able). Some meters may be auto ranging, if this is the case use the to A range. Put the black test wire in the
COM port and to the A pin. Put the red test wire on the mA port and to the B pin.
TRANSDUCER
(supplies torque gauge with an mA signal)
P.S.I. ON DRILLERS GAGE mili AMP
5000 REVERSE 4.00 mA
0 12.00 mA
1000 FORWARD 13.45 mA

PAGE 7-5
TEST THE GRABBER

The HS grabber system includes an intensification feature that uses loop pressure to clamp the grabber
tighter when more quill torque is applied. The loop pressure is also used to hold the grabber open while
drilling.
1. Lower the grabber so it can be closed on the mudsaver valve.
Note: Ensure the grabber is positioned below the shoulder so the grabber dies make complete
surface contact.
2. Ensure that the Forward / Reverse switch is in Neutral and the Auxiliary Pump is on. Close the
grabber box and when you reach full pressure, ensure the Grabber Closed light and the Robot-
ics On light illuminate.
3. Ensure the kidney manifold gauge reads 2,000 psi. Otherwise, ensure the pressure relief set-
tings on the power unit and on the top drive are correct.
4. On the driller's panel, select Forward Connect and turn the relief vale clockwise until the kid-
ney manifold gauge reads at least 4,000 psi.
5. Reduce the torque and set the quill to the neutral position.
6. Open the grabber and ensure the Grabber Close and Robotics On light are off.
7. With the Auxiliary pump still on, turn the top drive at 1 2 rpm and ensure the grabber box is
not closing then gradually increase the rpm to full speed.
TEST THE ELEVATOR

The HS elevator circuit has a safety feature to prevent the elevators accidentally opening. This lockout fea-
ture requires two hands to open the elevators: one to hold the Open lever and the other to push the Open
safety button. There are also 2 circuit reliefs on the elevator circuit located on the Eleven-Station manifold.
There are two circuit reliefs on the elevator circuit located on the Eleven-Station manifold set to 1,500 psi.
This pressure is used to both open and close and then latch the elevator door. If the elevators try to latch
before they close, adjust the sequence valve at the back of the elevator. The brake handle on the drilling rig
is installed with an override push button that can close the elevators remotely from the brake handle or
from the driller's panel.
1. Hook up hydraulic lines to the elevators and then hoist them using slings and turn on the aux-
iliary pump.
2. On the driller's panel, hold the Open Close lever to Open and ensure the elevators remain
closed.
3. Release the lever and press the Open button and ensure the elevators remain closed.
4. On the driller's panel, hold the Open Close lever to Open and while holding, press Open and
ensure the elevators open.
Note: If the elevators attempt to close, reverse the elevator quick couplers.
5. With the elevators open, attach the brake handle control box to the F cord and test the Close
button.
Note: The elevators should close before the elevator door latches. If the elevators are trying to
latch before the elevator completely closes or are latching too slowly, adjust the sequence
valve.
6. Ensure the elevator pressure in both the Open and Close positions is 1,500 psi or adjust the
Circuit Relief Valve.

PAGE 7-6
TEST THE MUD VALVE

The mud valve is controlled by a roto actuator with a piston that turns axles to close and open the mud
valve using a piston. The mud valve includes a timer circuit that only allows the mud valve to switch from
open to close every 5 seconds.
1. On the driller's panel, select Open and ensure the mud valve light goes out and the Auxiliary
light or Robotics light illuminates.
2. Release the Open Close switch and ensure the switch springs back to the home position and
that the auxiliary pump maintains pressure for 5 seconds before the directional valve shifts to
the centre position.
Note: If pressure is not maintained for at least 5 seconds, adjust the timer circuit relay. On
PLC controlled top drives, adjust this in the program using a computer.
3. Ensure the roto actuator is in the open position and the mark on the piston points to the Open
mark on the actuator body.
4. Quickly switch the Open Close switch to Open and then to Close and ensure the lockout func-
tion prevents the mud valve from closing.
5. On the driller's panel, select Close and ensure the mud valve light goes out and the Auxiliary
light or Robotics On light illuminates.
6. Ensure the roto actuator is in the closed position and the mark on the piston points to the Close
mark on the actuator body.
7. Quickly switch the Open Close switch to Close and then to Open and ensure the lockout func-
tion prevents the mud valve from closing.
8. Select Forward and run the top drive up to about 6 to 10 rpm.
9. Turn the mud valve to Open and ensure the quill stops. This feature prevents the rotation seals
in the rotor actuator from being damaged or worn.
10. Select Forward and run the top drive up to about 6 to 10 rpm.
11. Turn the mud valve to Close and ensure the quill stops.
TEST THE LINK TILT

Link tilt cylinders extend and retract the bails that are linked to the elevators to improve pipe handling.
They contain two Parker flow control valves with reverse flow checks that are located on the junction
block on the grabber leg and are used to control the speed at which the link tilt cylinders extend and retract
to provide a slow, even float back to centre.
When Forward is selected on the driller's panel, the link tilt rods should be fully retracted. When Reverse is
selected they should be fully extended. When Float is selected on the driller's panel, the directional valve
for this function stays energized until another selection is made that enables the bails to float back to their
natural centre position. The Float circuit also prevents oil from going over the link tilt circuit relief, when
the elevators pick up a load and the bails are pulled down, until the load nut stops the load collar.
The link tilt cylinders include two reliefs located on the Eleven-Station manifold: one for forward opera-
tion and the other for reverse. When the bails hit a stationary object, these relief circuits release the oil and
protect the system.
1. On the driller's panel, select Forward and ensure the back cylinders extend and the front cylin-
ders retract.
2. Select Reverse and ensure the link tilt cylinders fully extend.

PAGE 7-7
3. Select Forward, ensure the front cylinders fully retract then push Float and ensure the rods
slowly extend from the cylinders until you select Forward or Reverse.
4. Fully extend the cylinders and ensure the top drive auxiliary gauge pressure is 1,850 psi. Oth-
erwise, adjust the forward link tilt circuit relief.
5. Fully retract the cylinders and ensure the top drive auxiliary gauge pressure is 1,850 psi. Oth-
erwise, adjust the reverse link tilt circuit relief.
6. Set the link tilt cylinder speed using the flow control valves so they extend and retract slowly
and evenly.
TEST THE ROBOTICS ON AND AUXILIARY LIGHT

There are two styles of these lights: The Robotics On light and the Auxiliary light. The Robotics On light is
used mainly on PLC controlled top drives in conjunction with an Auxiliary Pump On light that stays illu-
minated when the auxiliary pump is on. The Auxiliary light is used on conventional electrical panels and is
located above the auxiliary pump On Off switch. Both of these lights work the same, even though they are
on different systems.
The Robotics On light and Auxiliary Pump light indicate when the auxiliary system is building pressure.
They illuminate when a robotic function builds over 500 psi. For example, when there are no functions
used and all levers are in neutral, the Robotics On light is off to indicate there are no functions with pres-
sure applied. When a function such as Grabber Close is used, the switch is applied and oil flows into the
cylinder. When the pressure increases to 500 psi the light illuminates.
The Robotics light works with a pressure valve and a micro switch and the pressure can be adjusted using
the pressure valve located near the back of the power unit close to the auxiliary pump. To test the Robotics
On light, select any function and when it builds up to 1,500 psi the light illuminates. When the function is
off and the auxiliary pump is circulating oil through the system, the light is off.
TEST THE FORWARD AND REVERSE CONNECT OPERATION

When testing the top drive forward and reverse, turn the Max and Set relief valves on the top drive and the
reverse torque relief located on the filter manifold of the power unit clockwise until they are closed. When
closed, oil won't bypass them and give a false reading for the oil flow and quill rpm ratio.
Set the Forward and Reverse Connect Speeds

1. On the driller's panel, select Connect and select Neutral for the quill direction, then turn the
engine switch to Slow.
2. Run the engine at 1,000 rpm, ensure the grabber box is open, and select Forward for the quill
direction.
3. With the quill turning, ensure the speed displayed on the driller's panel is 17 18 rpm.
Note: Adjust the rpm using the pot resistor marked Forward in the main panel. Back off the
jam nut and turn the resistor clockwise to increase the rpm or counter clockwise to reduce it.
4. Select Reverse for the quill direction and, if required, adjust the pot resistor marked Reverse in
the main panel until the speed displayed on the driller's panel is 17 18 rpm.

PAGE 7-8
Check the Engine High Idle and Low Idle

To test the engine speed and drill connect switches, run the engine and check the high and low idle. Ideally,
with the engine speed switch in Slow the engine runs at a low idle of 1,000 rpm in connect and drill mode.
With the engine speed switch in Neutral, it runs at a low idle of 1,000 rpm in Connect mode but will switch
to high idle, full speed when Drill is selected. With the engine speed switch in High position, the engine
should run at high idle, full speed in both connect and drill mode.
The typical position for the engine speed when running on the rig is Neutral. This enables the engine run at
high idle when the top drive is drilling and low idle when a connection is being made without turning two
switches.
Test the Top Drive High and Low Speeds

1. The high and low function does not affect the speed of the quill while it is in Connect mode
2. On the driller's panel, select Forward and Connect and ensure the top drive is turning at 17 18
rpm.
Note: If the top drive is not turning at 17 18 rpm. Ensure the engine speed switch is in Neutral
and the engine is running at 1,000 rpm.
3. Alternate the Connect mode switch between High and Low and ensure the quill rpm does not
change.
4. Select Drill mode and Low range and increase the top drive speed to 100 rpm.
5. With Drill mode still selected, slow the top drive and select High and then increase the top
drive speed to 200 rpm.
6. On the driller's panel, select Reverse and Connect and ensure the top drive is turning at 17 18
rpm.
Note: If the top drive is not turning at 17 18 rpm. Ensure the engine speed switch is in Neutral
and the engine is running at 1,000 rpm.
7. Alternate the Connect mode switch between High and Low and ensure the quill rpm does not
change.
8. Select Drill mode and Low range and increase the top drive speed to 100 rpm.
9. With Drill mode still selected, slow the top drive and select High and then increase the top
drive speed to 200 rpm.
Set the Reverse Torque

1. On the power unit, set the engine to 1,000 rpm and back the Reverse torque relief valve out
fully.
2. Lower the grabber and close on the Dynamometer adapter just below the seal face.
3. On the driller's panel, select Reverse Connect and turn the relief valve clockwise until the
driller's gauge reads 1,000 psi.
4. Select Neutral and remove die lock clamp and then reattach the grabber and push Breakout.
Note: Pressure should only go above 1,000 psi when Breakout is pushed.
5. When the connection breaks, select Neutral and then open the grabber.
6. Using a chain tong, unscrew the Dynamometer adapter from the Dynamometer sub and then
using a spreader lifting bar, remove the top drive from the Dynamometer and mount it in the
travel stand.
7. Clean and inspect the Dynamometer adapter threads and inform the Service Shop Foreman of
any thread damage.

PAGE 7-9
Set the Max and Set Torque Relief Valves

There are two torque relief valves located on the top drive filter manifold. The Max torque relief valve is
used in conjunction with the Max torque button on the driller's panel. It is set higher that the set torque and
is used to make connections. The Set torque is set lower than Max torque to ensure that while drilling the
pipe cannot be over torqued.
Note: Always set Max torque before setting Set torque.
1. Turn the Max and Set valves counter clockwise until they are completely backed off and close
the grabber on the quill.
2. On the driller's panel, select Connect mode and Forward and ensure there is no torque on the
quill and that the driller's gauge reads 300 psi or less.
3. Push the Max torque button and ensure the torque does not change. Hold the Max torque but-
ton while your assistant turns the Max torque relief valve clockwise until the driller's gauge
reads 3,000 psi.
4. Release the Max torque button and press the Set torque button. Hold the Set torque button
while your assistant turns the Set torque relief valve clockwise until the driller's gauge reads
2,000 psi.

PAGE 7-10
CAODC LEVEL IV RECERTIFICATION PROCEDURES SHIP THE TOP DRIVE & POWER UNIT
SECTION 8: SHIP THE TOP DRIVE & POWER

UNIT
BEFORE YOU START

You need the following before you ship the unit:
• All unit and skid components thoroughly power washed
• Paint to touch up the unit if required
• Sash cords
PREPARE THE POWER UNIT FOR SHIPPING

1. Determine if the hose reel was detached from the power unit when the unit arrived. If so,
remove the hose reel from the skid.
2. Tape down the exhaust flap on the exhaust system.
3. Cap and plug all auxiliary loop lines and tie auxiliary hoses to the hose reel with sash cord.
4. Latch all panel doors.
5. Secure 480 volt line to skid or unit with sash cord.
6. Close reservoir tank valves and attach a tag that says “Closed”.
7. For US of international units, drain all fuel and hydraulic oil.
8. For international and US units, drain all hydraulic oil and fuel.
PREPARE THE TOP DRIVE FOR SHIPPING

1. Close and tape shut the ball valves on the gearbox vents.
2. Retract the link tilt cylinders and bind them to the mudsaver valve with sash cord.
3. Close the grabber around the mud valve or saver sub.
4. Ensure all safety pins to mount the top drive to the travel stand are in place and that there are
bolts in the pins.
5. For international and US units, drain all hydraulic oil and fuel.

PAGE 8-1

882041rev0 Manual Recertificacion HS

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882041rev0 Manual Recertificacion HS

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CAODC Level IV Recertification

HS Top Drive System

DOCUMENT NAME: 882041 REV 0

Section 2: Pre-Service Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section 3: Disassemble the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section 4: Inspect the Top Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

©TESCO CORPORATION, 2007 HCI(S) TOP DRIVE SYSTEM DOC #882041

Shipping Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Section 5: Assemble the Top Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Section 6: Inspect/Service the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

©TESCO CORPORATION, 2007 HCI(S) TOP DRIVE SYSTEM DOC #882041

Inspect and Service the Closed Loop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Section 7: Test the Top Drive & Power Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Section 8: Ship the Top Drive & Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

©TESCO CORPORATION, 2007 HCI(S) TOP DRIVE SYSTEM DOC #882041

SECTION 1: DOCUMENT SUMMARY

AUDIENCE AND PURPOSE

UPDATING THIS DOCUMENT

1000 DAY RECERTIFICATION OVERVIEW

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

OTHER HS(S) DOCUMENTATION

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

SECTION 2: PRE-SERVICE PREPARATION

Record top drive

BEFORE YOU START

RUN AND CHECK THE TOP DRIVE

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

6. Record any deficiencies in the Packing List.

BREAK OUT THE SAVER SUB AND MUDSAVER VALVE

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

SECTION 3: DISASSEMBLE THE TOP DRIVE

Top Record Remove Mount Remove Remove Remove

Disasse Disasse Disassembl Disasse Inspect

BEFORE YOU START

For components that require Place on/in

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

CHECK FOR ENDPLAY

Top Drive Bearings

Checking Gearbox and Quill for Endplay

Calculating Preload Adjustment

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

Check the Slewing Bearing for Wear

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

Detach, cap and label all grabber lift hoses.

REMOVE THE LOAD COLLAR

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

REMOVE THE HYDRAULIC MOTOR PIPING AND MANIFOLD

REMOVE THE 8 OR 11 STATION AUXILIARY MANIFOLD

REMOVE THE GEARBOX FROM THE MAIN FRAME

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

REMOVE THE HYDRAULIC MOTORS

DISASSEMBLE THE PIPE HANDLER AND REMOVE THE AUXILIARY

REMOVE THE MAINFRAME FROM THE SLEWING BEARING

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

REMOVE THE ROTARY SEAL

REMOVE THE SLEWING BEARING FROM THE PIPE HANDLER

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

DISASSEMBLE THE GEARBOX

DISASSEMBLE THE GRABBER LEG AND GRABBER BOX

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041

DISASSEMBLE THE ELEVATORS

©TESCO CORPORATION, 2007 HS TOP DRIVE SYSTEM DOC #882041