Nov.

9,1994

Maintenance and
Troubleshooting Guide

Contents
A. INSPECTION ..................................................................................................... 3
1. TDS Swing Out Procedure ........................................................................ 3
2. DC Drilling Motor .............................................................................................. 5
3. Air Exhaust Muffler ............................................................................................. 5
4. Derrick Termination Kit Air Filter/Regulator/Lubricators ............................... 5
5. Pipehandler ......................................................................................................... 6

6. Drill Stem Load Carrying Components ............................................................ 7

a. Visual Inspection .......................................................................................... 7
b. Magnetic Particle Inspection ..................................................................... 11
c. Ultrasonic Inspection ................................................................................. 12
B. LUBRICATION .......................................................................................................... 13
1. Motor/Motor Support Bonnet Assembly ........................................................ 13
a. Gearbox ....................................................................................................... 13
b. Initial Oil Change Period ............................................................................ 13
c. Oil Capacity ................................................................................................. 13
d. DC Motor ..................................................................................................... 14
2. Lubricating the Washpipe ................................................................................ 15
3. Lubricating the Rotating Head ......................................................................... 15
4. Lubricating the Link Adapter ........................................................................... 16
5. Lubricating the Torque Wrench ....................................................................... 17
6. Lubricating the Safety Valve Actuator ............................................................ 17
7. Lubricating the Upper IBOP Safety Valve ...................................................... 18
8. Lubricating the Varco BNC Drill Pipe Elevator .............................................. 18
9. Lubricating the Elevator Support and Master Bushing Wear Guide ........... 19
10. Lubricating the RBS .......................................................................................... 19
11. Lubricating the Guide Dolly Assembly .......................................................... 20
12. Lubricating the Bail Pins .................................................................................. 22
13. Lubricating the Cooling System ...................................................................... 23
14. Lubrication Schedule ........................................................................................ 23
15. Lubricant Specifications .................................................................................. 24

1
Nov. 9,1994

C. MAINTENANCE ........................................................................................................ 26
1. Adjustment ........................................................................................... 26
a. Torque Wrench ................................................................................ 26
b. Upper Safety Valve (IBOP) and Safety Valve Actuator System ........... 28
c. Counterbalance System ............................................................................. 28
d. Motor Alignment Cylinder System ............................................................30
e. Pre-charging the Counterbalance System .............................................. 32

2. Assembly and Disassembly ............................................................................. 34
a. Pipehandler (PH-60d) .............................................................. 34
1. Torque Wrench Disassembly .............................................................. 34
2. Rotating Head Glyd Ring Replacement ............................................. 39
3. Link Tilt Air Actuator Replacement ................................................... 42
b. Tong Die Removal ........................................................... 44
c. Jaw Removal Procedure ............................................................................ 45
d. Upper IBOP Safety Valve ............................................................. 45
e. Lower IBOP Safety Valve ..................................................................... 45
f. Removing Motor Assembly from Dolly .................................................... 45
g. Disassembly/Assembly of Drilling Motor and Motor Support Bonnet .. 47
h. Installing Top Drive Motor Pinion .............................................. 50
3. Safety Wiring ................................................................................... 52
D. TROUBLESHOOTING .............................................................................. 54
1. Counterbalance Troubleshooting Table ........................................................ 54
2. Motor Alignment Cylinder Troubleshooting Table ........................................ 56
3. Drilling Motor and Guide Dolly Troubleshooting Tables .............................. 57
a. Motor Air Brake - Troubleshooting Table ............................................... 57
b. Transmission - Troubleshooting Table ................................................... 58

c. Oil Pump - Troubleshooting Table .......................................................... 59
d. Cooling System - Troubleshooting Table ............................................ 60
4. Pipehandler Troubleshooting Tables .............................................................. 62
a. Torque Wrench - Troubleshooting Table ................................................ 62
b. Safety Valve Actuator - Troubleshooting Table ..................................... 64
c. Link Tilt - Troubleshooting Table .................................................. 65
d. Troubleshooting Pipehandler at the Counterbalance Manifold ........... 66
e. Six-Gang Air Valve Assembly Illustration ............................................... 67

NOTE
This section contains some information regarding the
GEMotor. Refer to the GE Motor maintenance manual,
included in Book 7, for the following information:

o Inspection and Maintenance Schedule

o Recommended Storage Instructions - Drilling Motors

& Generators

o Removing Motors or Generators from Storage

2

 Nov.9,1994

A. INSPECTION

1. TOS Swing Out Procedure

VarcolBJ top drives with swing-out guide dollies can be quickly swung aside on its own
dolly frame for inspection, maintenance, running casing, or to allow drilling operations
requiring a kelly and rotary table. Electrical, hydraulic and air supplies do not have to be
disconnected. Use the following procedure to swing out the TDS only if your rig has a
guide dolly with hinge pins (refer to Book 5 - Parts Data and Drawings for information
and drawings specific to your rig configuration):

1. On configurations with a retract guide dolly, operate the switch on the driller's console
to retract the TDS.

2. Slowly lower the TDS until the elevator nears the rig floor.

3. Remove the elevator and elevator links.

4. Lower the TDS guide dolly to the stop.

NOTE
On some rigs, it may be necessary to secure the traveling

block frame to the guide dolly frame using chain and/or

rope.

5. Tum off the hydraulic power unit and bleed down hydraulic pressure by opening the
needle valve (NV) on the counterbalance manifold. (The counterbalance manifold is
located on the upper motor frame.)

6. Detach the counterbalance system cylinders from the hook or block by unhooking the
pear links from the ears on the hook or block.

7. Disconnect the air intake hose.

8. Disconnect the mud hose from the TDS S-tube.

WARNING
Unlatching the hook from the integrated swivel
bail may cause the TDS motor assembly and/or the
hook to lurch suddenly. Always keep adequate
tension on the tailing lines to prevent sudden move-

ment of these assemblies.

3
Nov.9,1994

9. Unlatch the hook.

10. Attach tugger lines to the TDS motor frame, opposite the frame hinges, to assist in
swinging out the TDS motor assembly. Use tailing lines on the motor frame to control
swing out.

11. Unfasten the two swing-out bolts, opposite the hinges, holding the motor frame to the
guide dolly.

12. Operate the air tuggers to slowly pull on the motor frame while unhooking the traveling
block from the swivel bail.

13. When the traveling block is disconnected, continue swinging out the TDS 1800 and
secure the motor assembly to the derrick with chain and/or rope.

To swing the TDS back in for operation after inspection or maintenance, perform the
following procedure:

1. Lower the traveling block guide dolly far enough to allow swinging the TDS back into
place.

2. Retract the TDS and secure it.

WARNING
While latching the hook to the swivel bail, the swivel
and/or the TDS motor assembly may suddenly
lurch. Always keep adequate tension on tailing lines
to prevent sudden movement of these assemblies.

3. Attach tugger lines to the TDS motor assembly, opposite the hinges, to aid in swinging
back the TDS assembly. Use tailing lines on the motor frame to control swing back.

4. Release the chain and/or rope securing the TDS motor assembly to the derrick and
slowly swing back the TDS motor assembly to the guide dolly. While swinging it
back, latch the hook onto the swivel.

5. Secure the motor frame to the guide dolly with the two swing-out bolts opposite the
hinges.

6. Connect the mud hose to the S-tube.

7. Connect the air intake hose.

8. Hook the counterbalance system pear links onto the ears of the hook or block.

9. Tum the hydraulic power unit on and bleed air out of the system.

10. Adjust the hydraulics as outlined later in this section.

4
 Nov. 9,1994

2. DC Drilling Motor
Thoroughly inspect the TDS, motor support bonnet, and guide dolly assembly for loose
bolts and fittings daily. If any safety wire or cotter pins were removed to facilitate repairs,
replace them immediately. Refer to Maintenance, Part "C" of this book for procedures.

NOTE
The DC motor has a complete manufacturers instruc-
tion manual for your reference provided as a separate
book in this manual.

3. Air Exhaust Muffler

Varco installs air exhaust mufflers on the exhaust ports of the multi-gang solenoid valve
manifold for noise abatement. All such mufflers reduce noise and collect contaminants
that can eventually restrict the air passage. Air passage constriction results in back
pressure on all of the solenoid valves and erratic valve operation. It also holds pressure
on the air brake.
Periodically remove the mufflers and clean or replace them.

If noise abatement is not an issue on the rig, replace the fine mesh silencing material in

the mufflers with simple pipe elbows.

4. Derrick Termination Kit Air Filter/Regulator/Lubricators

Top drives that rely on rig air to power link tilt, upper mop, brake and torque wrench
makeup/breakout sequence pilot signal functions require regular inspection. The air
valves, cylinders and actuators for these functions require proper lubrication and
moisture-free and particle contaminant-free air. Moisture in the air can cause corrosion
on internal cylinder surfaces. Particle contamination can damage the seals in moving
parts and cause solenoid valves to stick. Oil, injected by the lubricator and carried by the
air, reduces friction between moving parts and increases the life of seals in valves and
actuators.

NOTE
Varco supplies a filter/regulatorllubricator in the der-
rick installation kit and recommends installing it at the
fingerboard level in the derrick. Improperly adjusted
regulators can cause poor device performance at re-
duced pressures, or valve and cylinder seals and 0-
ring extrusion at excessive pressures.

Inspect the entire filter/regulatorllubricator monthly for damage to the filter bowl, overall
body, or inlet and outlet fittings. Replace any damaged, corroded, or improperly
functioning components.

5
Nov. 9, 1994

Adjust the pressure regulator outlet pressure to 100-120 psig monthly. Clean and drain
the filter weekly. Fill the lubricator with petroleum-based hydraulic oil with a fluid
viscosity of 100-200 SSU at 100F (ISO 32/34).

NOTE
Do not use fluids such as "Marvel Mystery Oil," motor
oil, or Dextron II in the lubricator. Swollen seals may
result.

5. Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings daily. If any safety wire
or cotter pins were removed during repairs, replace them immediately.
Inspect the hinge bolts daily to make sure that they are not separating from the
pipehandler. Make sure the hinge pins are not loose either because of excessive wear in
the bore of the clamp clevis or a broken retaining bolt.

WARNING
Inspect the link tilt intermediate stop and adjust-
ment device for overall integrity weekly. Replace
the components ifthere is excessive looseness ofthe

threaded rod in the threaded hole of the pivot arm
(refer to the figure in the air actuator replacement
procedure outlined later in this book). An indica-
tion of a possible problem is if the two intermediate
stops are not adjusted "equally" (i.e., if the thread
engagement differs between the two stops). Failure
to perform this inspection and/or component re-
placement can result in injury to rig personnel.

6

 Nov. 9,1994

6. Drill Stem Load Carrying Components

Because the drill stem load carrying components are critical, VarcolBJ recommends
performing the following procedures and inspections on a regular basis.

A. VISUAL INSPECTION

Use calipers on a regular basis to measure the amount of wear on the elevator link eyes
(Figure 1). Compare the measurements with the Wear Chart (Figure 1) to determine
the current strength of the elevator links. The capacity of the links equals the capacity
of the weakest link.

Upper
Eye
(Hook)
C
Wear chart - Forged Links
Upper Lower Capacity
Eye Eye (Per Set)
Dimen- Dimen- In
sionC sionA Tons
B = 3-1/2 in., 3S0-Ton
5 2-3/4 350
4-13/16 2-9116 300

4-5/8 2-3/8 225 B

~
4-7/16 2-3/16 175

B =4-1/2 in., SOO-Ton

6
5-3/4
3-1/2
3-1/4
500
420
T
5-1/2 3 325
5-1/4 2-3/4 250
B =6-1/4 in., 7S0-Ton (Each)
7-1/2 7-1/2 350
7-1/4 7-1/4 300
7 7 225
6-3/4 6-3/4 175

To Determine the strength of worn links,

measure (with calipers) the amount of eye
A
wear and compare the measurements
with the above Wear Chart to find the Lower
current capacity. The capacity of the set of Eye
links is determined by the weakest link. (Elevator)

Figure 1. Visual Inspection of Elevator Links

7
Nov.9,1994

1. Landing Collar

Disassemble and inspect the landing collar every six months. Use the following
procedure to disassemble the landing collar (Figure 4, Book 2) for inspection:
a. Disconnect the top drive from the drill string.
b. Remove the mops and pipe handler.
c. Raise the solid body elevator to expose the landing collar retainer.
d. Straighten the retainer tabs.
e. Slide the retainer ring above the split landing collar halves.
f. Drive out one roll pin.
g. Remove the landing collar halves.
h. Slide the retainer off the drive stem.
After disassembly, inspect all landing collar parts for wear, damage, or corrosion.
Check for:
o Grooves or other radial wear marks indicating that the bore of the solid body
elevator is rubbing on the outside diameter of the landing collar retainer shell
o Radial grooves on the inside diameter of the retainer shell
o Missing tabs from the retainer shell
o Wear or corrosion induced pitting on the retainer shell shoulder
o Wear, corrosion, or fatigue cracks on the inside or outside diameter of the landing

o
o
collar halves
Evidence of drive stem contact with the solid body elevator
Evidence of inside bore wear on the solid body elevator indicating contact with
the drive stem or landing collar retainer. Wear on the inside shoulder of the

elevator should not exceed 118"
o Evidence of wear, corrosion or fatigue cracks on the safety links

Replace the appropriate part(s) if any of the above conditions exist. Use the following
procedure to reassemble the landing collar:

a. Replace the existing a-ring in the retainer shell.

b. Grease the inside diameter of the retainer shell.
c. Slide the retainer onto the drive stem above the landing collar grooves.
d. Install one new roll pin and safety links on the split landing collar halves.
e. Coat the landing collar halves with a generous amount of water resistant grease.
f. Place the landing collar halves on the drive stem with 15 taper closest to the top drive.
g. Drive in the remaining roll pin.
h. Slide the retainer shell over the landing collar halves.
i. Use a hammer and drift to bend all 32 retainer tabs to secure the retainer shell.
j. Coat the retainer shell and drive stem with a generous amount of water resistant
grease to prevent corrosion.

k. Reinstall the mops and pipehandler.

8
 Nov. 9,1994

2. Main Shaft

Regularly inspect and measure the drive stem/main shaft for wear. Remove the drive
stem/mainshaft from service if bore wear is greater than the dimensions shown in
Figure 2.

Determine inspection frequency according to API Recommended Practice 8B,

Section 2 for power swivels and power subs.

VarcolBJ recommends the use of API RP 7G and API RP 8B as guidelines for

interpreting and performing inspections. Measurement techniques are specified in
API RP 7G, Section 10. Use API Bulletin 5Tl to identify and define imperfections
found during inspections.

1.20 UIN 0 LANDING

COLlAR GROOVES
(1.82 NEW) (3.0 DIA. NEW)

~~~~~~~~~~---~--I~-H----~~-~-----+----~

6 5/8 API REG R.H.

,.. See Figure 3

6.250-3-ACUE-3G-LH
THREAD

Figure 2. TDS-3S 500-Ton Minimum Bore Wear Dimensions

9
Nov. 9, 1994

Use the following API recommended guidelines (Figure 3) to determine the tensile
load bearing capacities of the drive stem/main shaft landing collar.

2400000

2300000
~~
I
~
New Co hdi1 ion

I
2200000

2100000
I
I
I
"" "-
~
~
I
I I
2000000 I

"" '"
I
I f'...
1900000

-en
.c 1800000
I
I
I
"" "-
-
...I I

"C

...I
as
0
1700000

1600000
I
I
I
I
"" ~
~
1500000
j
I
I
.~
1400000
I
~

I
1300000
~
I
I
1200000
I
I
~
1100000

1000000
I
I '\
~ 0 ~ 0 ~ 0 ~ 0 ~ 0 ~ 0 ~ 0 ~ 0 ~
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
~ ~ ~ ~ ~ ~ 000 0 0 0 0 0 0 0 0

Remaining Wall Thickness Under Pin Thread Relief

Groove (Inches)

Figure 3. 500-Ton Drive Stem IMain Shaft Landing Col/ar

Tensile Dimensions

10

 Nov. 9, 1994

B. MAGNETIC PARTICLE INSPECTION

After approximately three to six months, depending on the severity of operating

conditions, or 1,500 operating hours, Varco recommends performing a Magnetic
Particle Inspection of the exposed surfaces of all load bearing components and load
collar grooves to reveal any fatigue or crack indications. Any indications found are
a potential cause for the replacement of the suspect component. Round bottom pits
and erosion are acceptable as long as the defect is less than 1/8" deep. Larger defects
or any crack indications are cause for replacing the suspect component.

After approximately five years or 15,000 operating hours, depending on the severity
of operating conditions, Varco recommends performing a Magnetic Particle Inspection
of all load bearing components over their entire surface (including internal bores) to
reveal any fatigue or crack indications. Any indications found are a potential cause
for the replacement of the suspect component. Round bottom pits and erosion are
acceptable as long as the defect is less than 118" deep. Larger defects or any crack
indications are cause for replacing the suspect component. These components are:

o Drive stem/main shaft (lower portion)

o Landing collar
o Upper and lower mops
o

Drill pipe elevator

o Link adapter
o Saver and spacer subs
o Power subs
o Power swivels
o Elevator links

11
Nov.9,1994

C. ULTRASONIC INSPECTION

In addition to the Magnetic particle Inspection, Varco also recommends performing

an Ultrasonic Inspection of the above components to detect any erosion of the inside
diameter. Any erosion reduces the load-carrying capability of the part. Any subsur-

face irregularity can also compromise a component's integrity.

Details on Magnetic Particle and Ultrasonic Inspection procedures are in the

following publications:

I.A.D.C. Drilling Manual, 9th Edition

Std. Method for Magnetic Particle Inspection of Steel Forgings
ASTMA-275
Std. Recommended Practice for Magnetic particle Inspection
ASTME-709
Std. Practice for Ultrasonic Examination ofHeavy Steel Forgings
ASTMA-388

1. Safety Valve Inspection Procedures (IBOP)

NOTE
Upper and lower safety valves, because of their inter-
nal grooves and shoulders, are particularly susceptible

to corrosion fatigue cracking. These internal diameter
changes act as stress risers for bending and tensile
loads. It is especially important to properly inspect the
safety valves on a frequent basis. Be sure to read and
use the safety valve inspection procedures described
in the [BOP Service Manual included as a separate
book in this manual.

12
 Nov. 9,1994

B. LUBRICATION
1. Motor/Motor Support Bonnet Assembly

A. GEARBOX
Check oil daily. With the motor off, check to see that the oil level i5 at the middle of
the sight glass located on the side of the main body. Drain and refill the gearbox every
1,500 operating hours or three months, whichever occurs first (Refer to Oil Capacities
below).

B. INITIAL OIL CHANGE PERIOD

Drain and refill the gearbox after the first 500 operating hours or four weeks,
whichever occurs first.

Remove and clean the oil pump suction strainer (or oil filter-depending on the
model and configuration) when changing the oil.

C. OIL CAPACITY

The TDS-3S holds approximately 10-20 gallons of oil, but oil capacities vary
according to the type of cooling systems, etc. installed. Always fill the transmission
to the middle of the sight glass. Use the following procedure to fill the transmission
for the first time on a new top drive:

1. Fill the gearbox to the top of the sight glass (approximately 10-20 gallons).

2. Operate the top drive 10-15 minutes and check the sight glass.

3. The oil level should be near the middle of the sight glass. If the oil level is below
the middle of the sight glass, add more oil until the level reaches the middle of the
sight glass. If the oil level is at, or above the middle of the sight glass, do not add
any additional oil to the gearcase.

After installation and initial operation of the top drive, always fill the transmission to
the middle of the sight glass.

When draining oil from the drain plug at the bottom of the gearcase, only the 5-6
gallons of oil at the bottom of the gearcase actually drains. Oil still remains in the
rotating head cavity (approximately 1-2 gallons), the oil lube/pump/cooler system
(approximately 1-2 gallons), and the wetted surfaces inside the motor housing
assembly (approximately 2-3 gallons). Removing the suction hose from the cover

plate below the pinion shaft allows more oil to drain and also removes sediment that
collects there.

13
Nov. 9,1994

D. DC MOTOR
The upper motor armature bearings have grease points located on the brake adapter
plate attached to the top ofthe motor. The lower armature bearing grease point on the
GE motor is at the end of a small diameter tube projecting toward the back of the tool.

The grease points all have plugs or relief fittings installed during operation. Install
grease fittings to lubricate and then remove the fittings and replace the plugs for
operation. Lubricate the pinion (transmission) end bearing every 750 hours, or 90
days, with 2 ounce by weight Shell Cyprina RATM. Lubricate the commutator (brake)
end bearing every 1,500 hours, or six months, with 2 ounce by weight Shell Cyprina
RATM.

CAUTION
Excessive lubrication of electric motors can cause
motor failure due to shorting or heat buildup from
grease coming in contact with the field windings.

14
 Nov. 9, 1994

2. Lubricating the Washpipe

Apply grease daily to the washpipe grease fitting.

3. Lubricating the Rotating Head

Apply grease daily at the seven fittings (Figure 4). Inspect for seal leakage around the
lower bearing retainer weekly.

Grease Fitings

Figure 4. Lubricating the Rotating Head

15
Nov. 9, 1994

4. Lubricating the Link Adapter

Apply grease to the two fittings weekly (Figure 5).

SOOTon
Solid Body Elevator
Grease Fittings
2 places
as shown.

Figure 5. Lubricating the Link Adapter

16

 Nov. 9, 1994

5. Lubricating the Torque Wrench

Lubricate the 12 fittings daily. Inspect the stabbing for excessive wear or cracks. Replace
as necessary.

6. Lubricating the Safety Valve Actuator

Apply grease to the four fittings on the actuator stabilizer arms daily. Loosen two bolts
on the actuator shell at each crank to reveal grease fittings (Figure 6).

Check for worn components and operate the valve to verify correct adjustment weekly.

r---- -----,,
,

Open Closed
Position Position

t
Crank Arm
Grease Port-~"""""",~

Actuator Arm
Groove

";;rTT'"
I: : : : : :::: I
1'1 I I I I I I I 1,1
I I I I I I I I I I I

Illi. Illi.
Figure 6. Lubricating the IBOP Actuator Shell

17
....................------------------------.
Nov.9,1994

7. Lubricating the Upper IBOP Safety Valve

Lubricate the upper mop daily at the lubrication fittings located directly below the
actuator cranks in the recessed counter bores (Figure 6). Refer to the IBOP Service
Manual included as a separate book in this manual for details on mop lubrication
procedures.

8. Lubricating the Varco BNC Drill Pipe Elevator

Lubricate the two grease fittings on the BNC elevator each trip (Figure 7), and inspect the
tool for wear on the bore, the link ears and to make sure that the latch mechanism operates
correctly.

Grease Fittings as Shown

Figure 7. Lubricating the SHe Drill Pipe Elevator

18

 Nov.9,1994

9. Lubricating the Elevator Support and Master Bushing Wear Guide

Apply grease to the seven fittings on the elevator support weekly. The master bushing
wear guide has four fittings (Figure 8). Lubricate weekly. Inspect the guide ring
periodically for wear or damage and replace it as necessary.

Grease Fittings
2 places as shown
and 2 places
opposite side.
(4 Total)

Figure 8. Lubricating the Master Bushing Wear Guide

10. Lubricating the RBS

Grease the 17 fittings each trip. Also check for worn tong dies in the clap jaws and replace
as necessary. RBS units with stabbing heads have an additional ten fittings-lubricate all
ten each trip .

19
Nov. 9, 1994

11. Lubricating the Guide Dolly Assembly

Lubricate the 20 guide rollers weekly at the four manifolds (5 fittings each) located on
each corner of the guide dolly (Figure 9). Check guide rollers weekly for cracks or
excessive axial or radial play and replace as necessary. Lubricate the hinges (on swing-
out dollies only-one place on each hinge) once each trip.

It is possible to over grease (too much pressure, not volume) the guide rollers. This can
push the plugs out. Visually inspect all of the guide rollers for evidence of grease
extruding from the end(s) of the shaft. If you discover over greasing, perfonn the
following procedure:

1. Remove and disassemble the roller assembly.

2. Thoroughly clean and inspect all parts.

3. If the component parts are still serviceable, drill and tap the shaft end(s) for 1/8" NPT
threads and install internal wrenching pipe plugs after thoroughly cleaning metal
chips from the grease ports in the roller shaft.

4. Pre grease roller bearings before reassembling and installing the rollers and shaft.

5. Regrease roller bearings through grease lines to make sure lubricant is pumping
through the roller bearings. Some grease should extrude between the rollers and roller
shaft.

6. Replace unserviceable assemblies.

7. Improve plug retention on roller assemblies with intact sheet metal plugs by staking
the edges of the port(s). To do this:
a. Remove the roller or roller bracket assembly to improve accessibility.
b. Use a hammer and chisel to stake the port edges.

A preferred method is to rework the roller assembly for drill and tap operation, but the
staking method is also effective.

At each bottom corner of the motor frame are the grease points for the motor trunnions
(Figure 10). Lubricate these daily.

Lubricate the washpipe packing every eight hours with the mud pump off.

Daily, with the hydraulic power on, check the filter gauge on the pressure filter to
detennine the condition of the filter element. Replace the element when a bypass

condition is indicated.

20
 Nov.9,1994

CAUTION
Do not weld or torch cut on or near the motor frame
without removing hydraulic accumulators.

Lubrication
Manifold (4)

Figure 9. Typical Guide Dolly Assembly (Rear Half)

21
Nov. 9, 1994

-- \

~
W" P,essu"
Filter

~4
1\

Figure 10. Typical Motor Frame/Guide Dolly Assembly (Front)

12. Lubricating the Bail Pins

Lubricate the bail pins weekly, at the same time the dolly rollers are lubricated, at the two
fittings, one on each bail pin.

22
 Nov.9,1994

13. Lubricating the Cooling System

Lubricate AC blower motors every three months. On rigs with closed loop cooling
systems also check the heat exchangers for water leakage weekly, and remove the access
covers and operate the blower to remove dust buildup every 500 operating hours.

14. Lubrication Schedule

#of Lubricant
Frequency Location Pts. Code*
Daily Torque Wrench 12 1
Daily Gearbox Oil (Check Level) 1 2
Daily Rotating Head 7 1
Daily Safety Valve Actuator Cranks 2 1
Daily Hydraulic Pressure Filtert - -
Daily Wash Pipe Assembly 1 1
Each trip BNC Drill Pipe Elevator 7 1
Each trip PS-16 Power Slip 8 1
Each trip RBS 17 1
Each trip RBS Stabbing Head 10 1
Weekly Dolly Motor Trunnions 2 1

Weekly
Weekly
Weekly
Weekly
Weekly
Air Filter/Regulator/Lubricatort
IBOP Actuator Arms
Link Adapter
Master Bushing Wear Guide
Link Tilt (Check Condition)
-
4
2
4
-
-
1
1
1
-
Weekly Guide Dolly Rollers 20 1
Weekly Bail Pins 2 1
750 hrs or 3 mos. GE Drilling Motor Pinion Bearing - 3
1500 hrs or 6 mos. GE Drilling Motor Commutator Bearing - 3
Monthly Motor Frame/Dolly Hinges 4 1
Monthly Cooling System Cleaning - -
3 months AC Blower Motor 2 1
3 months Change Gearbox Oil 1 2
3 months Gear Oil Filter/Suction Strainert 1 -
*See Lubricant Specification Table
tCheck condition and replace as necessary

CAUTION
Use only 10-wt. hydraulic oil or non-detergent motor

oil as a lubricant in the air control system. Using any

other type of oil or synthetic additive causes the seals
in the air valves to swell and cease to function.

23
Nov. 9, 1994

15. Lubricant Specifications

TDS transmissions operate under a combination of heavy and shock loads. Under these
conditions oil tends to extrude out of the gear mesh. Keeping an effective film of oil on
the gear mesh requires oil with an AGMA "extra pressure" rating, and a minimum
viscosity of 100 SUS at operating temperature.

Varco top drives also operate under a wide variety of temperatures. Select lubrication for
the TDS based on the minimum ambient temperature to be expected before the next oil
change. Under all but the most severe operating conditions, Varco recommends changing
the oil every three months. Introducing an oil viscosity greater than required by the
ambient temperature can:

o Damage the gearbox due to reduced oil flow

o Damage the oil pump because of excessive load
All oils change viscosity with temperature and "EP" oil is no exception. The TDS
transmission lubrication system is limited to pumping oils of a maximum of 9,000 SUS
viscosity.

Varco/BJ recommends measuring the oil temperature with a contact thermometer.

Measure on the pump discharge fitting on the TDS.

The following tables will aid in your lubricant selection and keep your TDS-S transmis-

sion operating properly:

Minimum Ambient Oil Type Required Varco Part Number

Temperature
of (OC)
Below 20 (-6) See Note Below* See Note Below*
20-60 (-6-16) 2EP, ISO 68 56004-1
45-85 (7-30 4EP, ISO 150 56004-BSC
Above 70 (21) 6EP, ISO 320 56004-2
NOTE
For minimum temperatures below 20F, the TDS must
be warmed up by rotating at a very light load (less than
200 amps) and at very slow speeds (less than 50 RPM)
until the oil temperature climbs above 20F.
If the oil temperature falls below 20F, Varco recommends running the TDS at very light
loads (less than 100 amps) until the oil is above 20F. If drilling conditions dictate oil
temperatures below 20F, consult Varco/BJ engineering.

If the oil temperature rises above 200 oP, Varco recommends shutting down or reducing
drilling loads to stabilize the oil temperature below 200F. If drilling conditions dictate

oil temperatures above 200F, consult Varco/BJ engineering.

24

Lube code 1 2 3 4

Description General-purpose EP grease Gear oil Motor grease Hydraulic oil

Ambient Above -20C Below-20C All Above -20C Below -20C

temperature tempe rall res
range

Castrol MP grease Alpha LS-320 Alpha -150 Alpha LS-68 - Hyspin AWS-46 Hyspin AWS-32

Chevron Avi-Motive Avi-Motive W Alpha LS-320 NL Gear 150 NLGear68 - AWHyd oil 46 AW Hydoil32
.
Exxon Lidok EP2 Lidok EP1 Alpha LS-320 Spartan EP150 Spartan EP68 - Nuto H46 Nuto H32

Gulf Gulf Crown EP32 Gulf Crown EP31 EP Lube HD320 EP Lube HD150 EP Lube HD68 - Harmony 46AW Harmony 32AW

Mobil Mobilux EP2 Mobilux EP1 MobilGear 632 MobilGear 629 MobilGear 626 - DTE25 DTE24
I\)
01 Shell Alvania EP2 Alvania EP1 Omala320 Omala 150 Omala68 Cyprina RA Tellus46 TeliusT

Statoil Uniway EP2N UniwayEP2N Loadway EP320 Loadway EP150 Loadway EP68 - Hydraway HMA Hydraway HMA
46 32

Texaco Multifak EP2 Multifak Ep1 Meropa320 Meropa 150 Meropa 68 - Rando oil HD46 Rando oil HD32

Total Multis EP2 Multis EP1 Carter EP 320 Carter EP 150 Carter EP 68 - AzollaZS 46 Equivis ZS 32

Union Unoba EP2 Unoba EP1 Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP - UnaxAW46 UnaxAW32

NGL1 2 1 - - - - - -
AGMA - - 6EP 4EP 2EP - 1 -
ISO Viscosi~ - - 320 150 68 - 46 32
Grade

z
~
co
.....
co
co
~
Nov. 9,1994

C. MAINTENANCE

1. Adjustment
A. TORQUE WRENCH

Use the following procedure to adjust the pipehandler torque wrench:

CAUTION
The pipehandler torque wrench is properly adjusted
and tested in the factory before it is shipped. Perform
the adjustment procedure after performing mainte-
nance on the torque wrench or if the torque wrench
does not function correctly.

1. Connect a pup joint or joint of drill pipe to the saver sub and makeup hand tight.
Be sure to use the correct thread compound when making up.

NOTE
When adjusting torque wrench manifold needle valves,
loosen the locknut around the valve stem and use a 5/32"
hex wrench to adjust the valve. After obtaining desired
setting tighten locknut around valve stem.

2. With the hydraulic power unit off, screw the RECYCLE, CLAMP, and TORQUE
sequence valves on the torque wrench manifold fully in (Figure 11).

3. Fully back out the pressure reducing valve (PRV), then screw in one turn.

4. Turn the liftllower flow control valve fully in, and then back it out three turns.

5. Turn on the hydraulic power unit.

6. If the torque cylinders are in their full clockwise position, set the MakelBreak
valve to MAKE. If they are in their full counterclockwise position, set Makel
Break valve to BREAK. Note that torque cylinders should not move if the recycle
sequence valve is fully in.
7. Slowly back out the recycle sequence valve until torque cylinders just start to
move, then screw out an additional full turn.
8. Move the Make/Break valve to BREAK. Set the pressure reducing valve to 750 psi.
9. Switch the lever between Make and Break to adjust recycle sequence valve until
full rotation in each direction takes six to eight seconds. Tighten the locknut
around the recycle sequence valve adjustment screw.

26
 Nov.9,1994

MakelBreak
Valve
Torque
Wrench
Manifold

Hydraulic
Pressure
Return

LifVLower
Flow Control -"'-'--~
Valve
Pressure
Gauge
0- 3000 PSI

Figure 11. Torque Wrench Control Manifold

10. Set the MakelBreak valve to MAKE.

11. Depress and hold the torque wrench operating button on the driller's console. The

torque wrench should lift and the clamp jaws should remain retracted.
12. Slowly back out the clamp sequence valve until the clamp jaws just begin to clamp
onto the tool joint. Screw out an additional half tum. Lock the clamp sequence
valve adjustment screw in position by tightening the locknut.

13. Back out the torque sequence valve until the torque cylinders just begin to stroke,
then back out an additional half tum. Tighten the locknut around the torque
sequence valve adjustment screw.
14. Release the torque wrench operating button on the driller's console. The torque
wrench should start to unclamp and drop, then the torque cylinders should
recycle.
15. If the torque cylinders recycle before the clamp cylinders retract, screw in the
recycle sequence valve until the torque cylinders do not move before clamp
cylinders have fully retracted. Tighten the recycle sequence valve adjustment
screw locknut.
16. Cycle the torque wrench as many times as required to makeup the connection.

17. Set the MakelBreak Valve to BREAK.

18. Verify that the torque wrench correctly breaks out the drill pipe from the saver sub,

without breaking out the saver sub or lower IBOP.

19. The torque wrench is ready for operation.

27
 Nov. 9, 1994

Upper Motor Frame

Crossmember

Pressure Redu .
Valve clng
Pressure

Figure 12 C Gauge
. ounterbalance Manifold

29
Nov.9,1994

B. UPPER SAFETY VALVE (IBOP) AND SAFETY VALVE ACTUATOR SYSTEM

Refer to the [BOP Service Manual included as a separate book in this manual for
upper mop and safety valve actuator system adjustment procedures.

C. COUNTERBALANCE SYSTEM

The hydraulic power unit should be on during the entire adjustment procedure, and
the TDS should be disconnected from the drill string, near the bottom of the rails, but
well off the stops.

1. Remove the caps and loosen the lock nuts on the needle valve and pressure
reducing valve located on the counterbalance manifold (Figure 12). It is not
necessary to remove the front guard for access to the manifold. A small amount
of oil will leak around the adjusting stems after removing the caps.
2. Open the needle valve and let the stem circulate for two minutes. Crack both upper
cylinder fittings and bleed air from system. Tighten the fittings. Close the needle
valve.

3. Using a hex wrench, screw in the pressure reducing valve until the cylinder
retracts, raising the TDS.

4. Slowly back out the pressure reducing valve. The pressure decreases and the
cylinder rods begin extending. When the integrated swivel bail contacts the hook,
note the pressure on the gauge. Allow the pressure to decrease an additional 25
psi and tighten the locknut. Replace the caps on the valve adjustment stem.

28
Nov. 9,1994

D. MOTOR ALIGNMENT CYLINDER SYSTEM

Once the alignment cylinder is installed, use the following procedure to properly
adjust the motor alignment before operating TDS-S systems that have a separate
alignment cylinder accumulator and valve manifold.
1. With the hydraulic power unit turned off, bleed down the alignment cylinder
accumulator by opening the needle valve located at the alignment cylinder valve
manifold (Figure 13).
2. Remove the split shipping brace from the motor alignment cylinder (Figure 14).
3. Tum on the power unit and allow the system to circulate for approximately two
minutes.
4. Close the needle valve.
5. Open the two flow control valves located at the alignment cylinder supply return
lines 1-112 turns off their seats.

Alignment Cylinder
Lug (ref)
Pressure Reducing
Valve

Needle Valve

Cylinder
Manifold
Accumulator

Bracket
Gas Valve

Figure 13. Motor Alignment Cylinder Manifold

30

 Nov.9,1994

Motor
Alignment
Cylinder

Motor
Frame Dolly (Ref)
Figure 14. Removing Alignment Cylinder Shipping Brace

NOTE
The pressure setting is adjusted by screwing the pres-
sure reducing valve in or out with a hex wrench.
Screwing in the valve increases pressure and moves
the saver sub toward the rails. Backing out the pressure
reducing valve reduces pressure and moves the saver
sub away from the rails (see additional notes at the end
of this procedure).

6. Verify the correct pressure setting using the following procedure:

a. With the power unit on, back down the pressure using the pressure reducing
valve (PRV) until the saver sub begins to pivot away from the rails. Record this
pressure.
b. Slowly increase the pressure until the saver sub no longer moves closer to the
rails as pressure increases. At this time, the cylinder should be in a "dead band" area
c. Slowly increase the pressure until the saver sub begins to move toward the
rails again. Record the pressure reading when this occurs.
d. To determine the correct pressure setting, add the average pressure readings
from steps a and c above and divide by two. The resulting pressure "dead band"
provides equal pre-load in each direction--both toward and away from the rails.
e. Record the pressure setting for future reference .

7. Set a joint of drill pipe in the slips.

31
Nov. 9,1994

8. Bring the top drive down as if stabbing the saver sub into the box. The pin and the
box should be in alignment so that the O.D. of the pin clears the shoulder of the
box. If adjustment is necessary, use the following procedure:
a. Measure how far and in what direction (toward or away from the rails) the pin
must move to line up with drill pipe box.
b. Tum off the hydraulic power unit and bleed down the alignment cylinder

accumulator. This allows the motor alignment cy linder to relax and the motor
to rotate on its trunnions, until the swivel contacts the motor frame.
c. Loosen the lock tab and jam nut on the cylinder clevis.
d. Use a wrench on the cylinder rod flats to screw the rod into or out of the clevis,
in the same direction the saver sub pin is to be moved. A 114" of pin movement
results from a 3/4 tum of the rod. The alignment cylinder rod extension should
be 2-3/8" 1/8" gland to rod threads when the system is properly aligned.
e. Secure the jam nut and lock tab.
f. The nominal position of the two flow control valves is 1-112 turns off their
seats. Should heavy drill pipe vibration be encountered, first attempt to
control it with non-rotating stabilizers in the casing close to the surface. If
motor movement becomes excessive due to continued vibration (more than 11
2" of cylinder stroke), the flow control valves may be closed to 3/4 tum off
their seats.
g. Tighten the lock nuts and replace the caps on all valve stems.

NOTES
If the alignment cy linder is removed for service, install
the alignment cylinder replacement brace to support
the motor housing assembly while continuing to oper-
ate the TDS. After reinstalling the alignment cylinder,

use the three bleed holes (located along top of cylinder
barrel) to remove air trapped in the cylinder.
Rail spacing and setback from the centerline of the
well must be held within recommended tolerances in
order to maintain vertical alignment of the TDS.

E. PRECHARGING THE COUNTERBALANCE SYSTEM

Please read these instructions completely before precharging, making note of the
special cautions at the end of the section.
1. Use an inert gas such as Nitrogen for precharging accumulators. If oil-pumped is
not available, use dry, water-pumped Nitrogen gas.
2. Before "precharging", make certain:
o The accumulator end caps are screwed flush into the accumulator body.
o
o
The gas valve is screwed in tight.
No oil remains trapped in the top end of the accumulator.

32

 Nov.9,1994

3. Remove the gas valve protector and the gas valve cap .
4. Attach the charging hose to the nitrogen bottle and to the gas valve using the
following procedure:
a. Use thread sealing and lubricating compound on the pipe threads of the gauge.
b. Back the gas chuck stem completely out of the way before attaching the
assembly to the accumulator gas valve.
c. Use a wrench to tighten the gas chuck swivel nut onto the gas valve. Close the
bleeder valve.
d. Tum the gas chuck stem all of the way down, depressing the core in the
accumulator gas valve.
e. Only crack open the nitrogen bottle valve to slowly fill the accumulator. Shut
it off when the gauge indicates 900 psi.
f. If the 900 psi pre-charge pressure is exceeded, make sure the nitrogen bottle
valve is closed, then open the bleeder valve (opposite gas valve below gauge)
slightly, but only momentarily, to reduce pressure.
g. Before loosening the swivel nut, tum the gas chuck stem out all of the way,
then open the bleeder valve.
h. Prevent the gas valve from turning, loosen swivel nut, and remove the
assembly.
5. When precharging is complete, replace the cap on the gas valve and install the gas
valve protector.

CAUTION
Do not loop or twist hose as it stiffens when gas
pressure is released from nitrogen bottles.

Never loosen the swivel nut attached to the gas valve

in the accumulator without first backing the gas chuck
stem all of the way out.
Do not reduce accumulator pre-charge by depressing
valve core (high pressure may rupture rubber valve
seat). Instead, slowly tum gas valve out until gas
begins to escape through bleed hole drilled through
threads of valve. This hole is a safety feature, it warns
of stored pressure whenever gas valve is being re-
moved. Install new gas valve "0" ring each time gas
valve is removed .

33
Nov. 9,1994

2. Assembly and Disassembly

A. PIPEHANDLER (PH-60d)

1. Torque Wrench Disassembly

(Figures 15)

a. Remove the guard.

b. Disconnect the hard plumbing from the quick disconnects near the left torque
cylinder.

c. Remove the bolts holding the frame onto the cast body and lift off.

d. Remove the pins holding the torque tube in place and remove.

e. Disconnect and label the hoses from the torque cylinders and remove the
cylinders.

f. Disconnect and label the remaining plumbing, and remove the MakelBreak
manifold assembly.

g. Remove the jaws.

h. Remove the stabbing guide.

1. Remove the retaining bolts, hinge pins and outer body.

J. Remove the cylinder ring from the clamping piston bore.

k. Pressurize the blind end of the clamping cylinder to remove the gland and piston.

CAUTION
Use care in this operation. High pressure air can be
explosive!

34

 Nov. 9,1994

l
Frame

I'~
'I ' l Mounting
Safety
Valve
I
T I Shaft
Actuating I
Cylinders (2) ____~~;;! Vertical 'I

Positing
Cylinder ,
I

Torque
Tube
Stabilizer /'
/'j'
, I
/ . I
, I

Stop
Tube

Guard

Clamp Cylinder Body

Stabbing
Guide

Clamping
Clamping Cylinder
Jaws (2) Piston Control
e Manifold
~

Figure 15. Torq ue Wrench AssemblylDisassembly

35
Nov.9,1994

Reassembly is accomplished in the reverse order of the above procedure. Pay close
attention to the following points:

a. Replace all seals.

b. Take great care when installing the clamping piston and gland. If they are not

closely aligned with the bore, they may become jammed and could be extremely
difficult to remove.

c. Use the following torque values:

Cylinder rod end to cylinder rod* 944 ft lb

Frame to clamp cylinder body 250 ft lb
Stabbing guide to body 250 ft lb
Die retainer screws 380 ft lb
Body hinge pin retainer screws 150 ft lb
Stabbing guide spring retainer screws 75 ft lb
Jaw retaining screws 110 ft lb

*The torque cylinder rod ends are threaded into the rods with locktite and cross
pinned.

a. Torque Wrench Clamping Piston Seal Replacement

The following procedures require that the torque wrench be removed from the
pipehandler.

Front and Rear Piston Seal Replacement

Parts required front and rear piston seal replacement:

Qty. PIN Description

3 72219 Piston seal

2 72220 Rod seal
2 72221 Rod wiper

36

 Nov. 9,1994

Disassembly:

1. Remove the slotted hex nut and cotter pin attaching the two halves of the
stabbing guide together at the front and swing the guides out to each side.

2. Vent the clamping cylinder as follows: disconnect the hydraulic lines to the
clamp port and front unclamp port on the clamp body cylinder at the torque
wrench manifold clamp and unclamp ports.

3. Remove the jaw pins from the rear clamping jaw and remove the jaw.

4. Remove the two screws holding the jaw spacer to the front clamp cylinder
piston and remove the spacer and jaw spacer.

5. Remove the two screws holding the clamp clevis to the rear clamp cylinder
piston.

6. Remove the pins holding the clamp body to the clamp clevis and remove the
clamp clevis. Be sure to remove the spacer from the piston rod slot.

7. Push in the cy linder gland from the rear cylinder head retainer ring and remove

the ring with a screwdriver.

8. Attach the sliding hammer to the rear piston rod and carefully pull the piston
until the cylinder gland can be removed.

9. Continue to pull until the piston comes out.

10. Using a piece of wood or brass bar, tap the front clamp piston from the front
and remove it from the rear.

11. Remove and discard the piston seals, rod seals and rod wipers.

12. Remove the front piston rod seal and rod wiper from the clamp cylinder body
and discard.

13. Inspect the clamp cylinder bore thoroughly for dirt, burrs, nicks, gouges and
pitting. Repair and clean as necessary.

37
Nov. 9, 1994

Assembly:
1. Insert a new front rod seal and rod wiper in the clamp cylinder body and
lubricate with clean hydraulic fluid.
2. Install a new piston seal in the front piston groove and lubricate with hydraulic
fluid.
3. Insert the front piston into the clamp cylinder body with the two jaw spacer
screws holes orientated vertically.

4. Gently and evenly tap the piston into place until the rod appears beyond the
front cylinder bore.
5. Install new piston seal in rear piston groove and lubricate with hydraulic fluid.
6. Insert rear piston into the clamp cylinder body with the two screws holes on
the rod oriented to the horizontal position.
7. Gently tap piston into place until there is enough space between the piston face
and retaining ring groove to insert cylinder gland and retainer ring.

8. Install rod seal and rod wiper in inside grooves of the cylinder gland.

9. Install piston seal in outside groove.

10. Lubricate all seals with hydraulic fluid.
11. Insert cylinder gland into bore rod and piston seals first. Push gland past
retainer groove and install retainer ring.
12. Insert the spacer and attach the clamp clevis to the rear cylinder rod with the

two hex head cap screws and flat washers. Tighten firmly and lockwire.

13. Adjust orientation of the clamp clevis and attach to the clamp body using the
two clevis pins and cotter pins.
14. Attach the rear clamping jaw spacer to the front piston rod using the spacer
and two hex head cap screws and flat washers. Tighten firmly and lockwire.

15. Attach the clamping jaw with the two jaw pins.
16 Swing the stabbing guide back into position and attach with the slotted nut and
cotter pin.
17. Reconnect the hydraulic lines from the clamp body cylinder clamp port and
front unclamp port at the torque wrench manifold clamp and unclamp ports.

18. Reinstall and perform Torque Wrench Adjustment Procedure.

38

 Nov.9,1994

2. Rotating Head Glyd Ring Replacement

NOTE
Rotary glyd ring replacement is indicated when hy-
draulic oil is detected in the pipehandler air supply. An
indication of oil contaminating the air supply would be
an accumulation of oil in the link tilt air actuator (bag).

The following disassembly and assembly procedures assume that the TDS is swung
out for maintenance in accordance with the TDS Swing Out procedures. Refer to
Figures 16 and 17, when performing the following procedures.

Stationary Flange

~ Auto-Return
Swivel Block
Cylinder

Locking
Lever
Figure 16. Rotating Head Assembly

Disassembly:
1. Order eight replacement glyd rings, two gearcase seals, one flange gasket, and one
excluder cap gasket from VarcolBJ. Contact the nearest VarcolBJ Service Center
for details about building an appropriate stand for working on the rotating head
when removed from the TDS for service or maintenance.
2. Disconnect the hydraulic and air hoses from the rotating head rotating block to the
various pipehandler components.

3. Support the torque wrench.

4. Disconnect the mop actuator arms and hoses .

5. Remove the pin attaching the hanger to the rotating block clevis, and remove the
torque wrench.

39
Nov. 9,1994

Gearcase
Seals
Stationary Flange
Cam Follower

Return Cylinder
Clevis (2)

Cam Follower

Return Cylinder

Return Cylinder
Clevis Pin (2)

Retainer Ring

Figure 17. Rotating Head Assembly/Disassembly

40
 Nov. 9,1994

bl hl emoving the pins attaching

Support the link tilt and link adapter assem Yw 1 e r

6. the torque arrestors to the rotating block.
Remove the torque arrestors, link tilt and link adapter.
:: Place the rotating head stand, built prior to disassembly, under the TOS and lower

the TDS until the rotating head rests on the stano.

9. Remove the flange nuts and lift the block, leaving the rotating head on the stand.

10. Remove the quick disconnect fittings from the rotating block hydraulic lines and
drain the hydraulic fluid from the system.

11. Remove the cotter pin from the return cylinder clevis pin.

12. Remove the hex-slotted nut and remove the clevis pin.

13. Push the cam follower away from the rotating block cam.

14. Remove the safety wire from the ten hex -head screws attaching the rotating block
to the stationary flange.

15. Support the rotating block and remove the ten screws.

16. Remove the rotating block and glyd rings .

17. Remove the excluder cap and gasket.

18. Remove the glyd rings from the rotating block and discard.

19. Remove excluder cap gasket and replace with new gasket.

Assembly:

1. Lubricate the eight new glyd rings with hydraulic fluid and insert them into the
glyd ring grooves inside the rotating block.
2. Place the excluder cap and gasket on the bottom of the rotating block.
3. Using a tugger or other support, carefully mate the rotating block to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.

5. Safety wire the screws per standard safety wire procedures.

6. Reinstall the quick disconnect hydraulic fittings on the rotating block.
7. Attach the return cylinder rod to the clevis with the clevis pin and install the slotted
hex-head nut and cotter pin.
8. Reinstall the pipehandler components per the procedures detailed in the Installa-

tion and Commissioning Guide .

41
Nov. 9, 1994

3. Link Tilt Air Actuator Replacement

Use the following procedure to replace the link tilt air actuator (Figure 18).

Parts Required: (1) Air actuator (PIN 82353)

(18) Button head cap screws (PIN 50186-10-01)

Disassembly:

1. Disconnect the air hose from the rotating head rotating block to the link tilt
assembly.

2. Support the link tilt and remove the two upper and two lower screws attaching the
link tilt to the link adapter.

3. Lower the link tilt to the floor with the air actuator to be replaced facing up.

4. Remove the cotter key and pin from one end of chain connecting the two sealing
plates.

5. Remove the safety wire from the four hex-head cap screws holding the air actuator

sealing plate to the link tilt base or lever and remove the screws.

6. Lift the lever or base off the air actuator sealing plate, and rotate it 1800 on the link
tilt pivot pin and lay down.

7. Remove the 18 nuts and washers holding sealing plate to the air actuator and
remove the plate.

8. U sing a pry bar or screwdriver, pry the air actuator away from the screws attaching
the actuator to the hanger plate and remove the screws using a hex wrench.

9. Remove and discard the air actuator.

10. Remove any burrs or gouges on sealing surfaces of the hanger and sealing plates .

42

...................-----------------------. Nov. 9, 1994

Lever Weldment

Sealing Plate (2)

~
Pressure
Regulator
e1'(
Air Actuator ~~
i ~~
~ ~
1
Lever III J \ Quick
"() CJ \ (;")1 Exhaust
". " fb 'r I': Valve

~~ ~ l:)
@~
']-~~~
II;:Z % ~
I(
0--~-D,i -~ tRl - I
~, ~
"--

,ot""''''''' 0 I::.J
.__------ . / ~(2) 0'V ~~o4~f'@,
I
Connecting Chain ~~
) 1 -. . . . . fk J~
~ II '~/~ Buttonhead

:
~ "_:_, I -.. . : ~"'-..-_ Capscrew (18)

~titl' ~ ~"~" ~r~~~

~
\V
'!

Elevator Link (Ref)

~
f~~
1/

Stop Release
Stop Pivot Arm

Loop

Figure 18. Link Tilt Assembly/Disassembly

Assembly:

1. Place a new actuator on the hanger plate.

2. Attach the air actuator to the hanger plate with the 18 button head cap screws. Coat
the screw threads with locktite before installation.

CAUTION
The air actuator has aluminum neck bead rings on both
sealing surfaces. These beads must be compressed
equally to ensure a good air seal. This requires more

than one tightening pass to accomplish. Over-torquing
may cause hex sockets to strip.

43
Nov. 9, 1994

4. Torque the cap screws to the hanger plate at 80 ft lb.

5. Insert the 18 bolts into the neck ring of the air actuator.

6. Reinstall the air actuator sealing plate, coat the bolt threads with locktite and
fasten with the lockwashers and nuts provided.

7. Torque the nuts to the sealing plate at 80 ft lb (See Caution above).

8. Lift and rotate the link tilt lever or base to line up with the air actuator sealing plate.
Attach with the four hex-head cap screws and torque to 250 ft lb.

9. Safety wire the four screws.

10. Reconnect the chain between the two sealing plates.

11. Reinstall and adjust the link tilt per the Installation and Commissioning Guide.

B. TONG DIE REMOVAL

1. Front Jaw

a. Remove the cotter pin from the retaining bolts and slotted nut.
b. Remove the nuts securing the die retainer to the jaw.
c. Remove the die retainer from the jaw.

d. Remove the tong dies from the jaw.

2. RearJaw
a. On rear the jaw, remove the cotter pins from the retaining bolts and slotted nuts.

b. Support the retaining bolt while removing the slotted nut.

c. Remove the retaining bolt from the piston jaw.
d. Support the remaining retaining bolt while removing the slotted nut and upper die
retainer.
e. Remove the retaining bolt and lower die retainer.
f. Remove the tong dies from the jaw.

44

 Nov.9,1994

C. JAW REMOVAL PROCEDURE

1. Front Jaw

a. Loosen the socket head cap screws securing the jaw assembly to the torque
wrench body.
b. Support the jaw and remove the socket head cap screws and washers from the jaw
assembly and the torque wrench body.
c. Remove the front jaw assembly from the torque wrench body.

2. Rear Jaw

a. Loosen the socket head cap screws securing the jaw assembly to the piston.
b. Support the jaw assembly and remove the socket head cap screws and washers
from the jaw assembly and piston.
c. Remove the rear jaw assembly from the piston.

D. UPPER IBOP SAFETY VALVE

Refer to the [BOP Service Manual (included as a separate book in this manual) for

upper mop safety valve assembly and disassembly procedures.

E. LOWER IBOP SAFETY VALVE

Refer to the [BOP Service Manual (included as separate book in this manual) for
lower mop safety valve assembly and disassembly procedures.

F. REMOVING MOTOR ASSEMBLY FROM DOLLY (AFTER UNIT IS RIGGED DOWN):

You can perform some service procedures on top drives (i.e. upper drive stem bearing
and seal, air brake or locally mounted cooling system) without removing the drilling
motor assembly from the dolly. If service is required on the lower end (i.e. gear set,
lower bearings or seals), you must remove the drilling motor from the dolly.
1. Set TDS down horizontally on a good flat surface.

2. Make sure that none of the components protrude past the guide dolly roller
brackets before setting the TDS down. If so, block the guide dolly up accordingly.

3. Disconnect all wiring and hoses between transmission and guide dolly frame.

4. Remove any cooling ducts (heat exchanger, spark arrestor, etc.) that interfere with
removing the transmission from guide dolly frame.

45
Nov. 9,1994

5. Use a suitable sling to support the weight of the TDS and motor support bonnet
(approximately 1O,000Ib).

6. Take up the slack and remove the trunnion blocks that hold the transmission to the
guide dolly frame.

7. Hoist the transmission out of the guide dolly frame.

8. Set the TDS and motor support bonnet down on wooden chocks, being careful not
to damage components.

9. Disconnect the wiring between the motor and motor support bonnet.

10. Make sure the transmission is in neutral.

11. Remove the dowel pins in the motor feet.

12. Remove the four large motor bolts.

13. Lift the transmission off of the motor, angling the upper end slightly to clear the
motor support bonnet, and sliding the housing off of the motor toward the
gearcase end.

14. Remove the blower and brake assemblies.

15. Reverse this procedure for reassembly.

46
~ ......---------------- Nov. 9,1994

G. DISASSEMBLY/ASSEMBLY OF DRILLING MOTOR AND MOTOR SUPPORT BONNET

1. Remove the upper bearing cover and grease seal (Figure 19).

2. Pressurize the air brake to hold the drive mechanism in place.

3. Remove cotter pins, slotted nuts and the rotating head.

4. Remove the lower gearcase, carefully avoiding damage to the lower gearcase
locator dowel pins.

5. Carefully remove the bull gear, avoiding damage to the bearing surfaces or wear
sleeves. Do not remove the gear from the shaft unless you are replacing it.

6. Remove the pinion seal and retaining ring.

7. Remove the main body.

8. On the opposite end of the motor, remove the magnetic pickup and brake cover.

9. Remove the brake for service .

47
Nov. 9,1994

Gooseneck

Air
Brake

Motor
Support
Bull
Bonnet D.C.
Gear
Drilling
Motor

Drive Gear
Stem Case

Figure 19. Drilling Motor and Motor Support Bonnet Assembly/Disassembly

48

 Nov. 9, 1994

Refer to the GE electric motor manual included as a separate book in this manual for
procedures to remove the pinion or hub on the armature shaft, or to service the motor
itself.

Once the unit has been disassembled, inspect the following assemblies for any wear
or damage that may be critical:

1. Gear set: Check the teeth and splines for chips or heavy spalling. The wear pattern
should be even and symmetrical. If not, replace it. Expect some small surface
pitting. It is not cause for replacing the gear set.

2. Bearings: Clean thoroughly in solvent, then rotate and listen for any roughness
during rotation.

3. Main shaft: Check splines and tool joints for wear. Replace the shaft if spline wear
exceeds 0.090" .

4. Main shaft: Check fit to bull gear, wear sleeve surfaces and retaining threads.
5. Seals: Always replace seals and gaskets when removed.

6. Main shaft housing: The bore for the upper bearing and the pilot diameter for the
lower gearcase are critical. Clean up any nicks or gouges prior to reassembly.

7. Air brake: Check the brake for air leakage and the pads for wear.
8. Wear sleeves: These should be free of any imperfections on the sealing surface.
9. Blower: Clean any accumulation of dust from the ducting, then operate the unit
and correct any interference between the impeller and housing.
10. Air valve assembly: If any air-operated systems are malfunctioning, remove the
appropriate valve and repair or replace.

Reassemble the drilling motor and motor support bonnet by reversing steps in the
disassembly procedure. Replace all grease seals and a-rings, and refer to the
following torque chart for bolt tightening guidelines.

Torque Chart
Motor support !bonnet to main body 7850 ft lb
Main body to motor bonnet 1100 ft Ib
Bull gear to hub 580 ft lb
Lower gear case to main body 250 ft lb
Rotating head to lower gearcase 250 ft Ib
Brake adapter ring to motor 250 ft lb
Brake to brake adapter plate 50 ft lb

Brake drum to hub 250 ft lb

Brake cover to brake 50 ft lb

49
Nov. 9,1994

H. INSTALLING TOP DRIVE MOTOR PINION

WARNING
Installing a pinion gear can be dangerous to per-
sonnel installing it as well as anyone witnessing the
procedure. Exercise caution at all times.

Use the following procedure to install a top drive motor pinion (Figure 19):
1. Clean the motor shaft and cover with a thin layer of "Engineer's Blue."

2. Place the pinion on the motor shaft. Mark reference lines on the pinion and the
shaft to ensure identical orientation each time.

3. There must be 75% surface contact between the pinion and motor shaft. Dress the
motor shaft/pinion and repeat the "blueing" procedure if necessary until there is
at least 75% surface contact between the pinion and motor shaft.

4. After thoroughly cleaning all blueing, oil, and lor grease from the pinion bore and
shaft, trial mount the cold pinion gear on the motor shaft, lining up the reference
marks.

5. Make sure the fixture is clean and the "horse shoe" face and bar are parallel.

6. Place the fixture on the motor shaft with the "horse shoe" end against the inner face
of the seal and the bar against the outer face of the gear-sandwiching the pinion
gear in the fixture.

7. Adjust the adjusting screw to butt against the motor shaft.

8. Attach a calibrated dial indicator gauge to the fixture and set to zero.

9. Back off the adjusting screw until the gauge reads 0.072 - 0.074". Then lock the
screw in place with a locknut.

1O. Remove the fixture from the pinion gear assembly.

CAUTION
Do not put the fixture in the oven.

11. Heat the pinion gear to 375~00F (190-205C) for three hours in an oven. After
heating for three hours, remove the pinion gear assembly and immediately attach
the fixture.

50

 Nov. 9, 1994

12. Place the pinion gear assembly and fixture on the motor shaft, lining up the
reference marks.
13. Gently tap the pinion gear assembly and fixture into place until the adjusting
screw butts against the motor shaft.

14. Wait 2-3 minutes and back off the nuts holding the fixture in place. There may be
some noise as the pinion gear cools.
15. The pinion creeps up the shaft as it cools to the required position of 0.085 O.OOS"
advancement.

16. When the pinion is fully cooled, fit the fixture and check advancement.
17. Complete the required documentation recording pinion advancement.

51
--------------------.......................
Nov. 9, 1994

3. Safety Wiring

Most of the assemblies require that the fasteners be safety wired. This procedure is
generalized and applies to all top drive systems.

a. Before any screw, nut, plug or other fastener is lockwired, torque it down snugly but
do not over torque or loosen a torque fastener to align safety wire holes.

b. Use the size and type of safety wire (available at your local aircraft distributor) called
for in the applicable specifications. Do not reuse safety wire.

c. Open the jaws of the safety twist pliers by squeezing the handles together to unlock
the round, perforated slider in the center of the pliers from the hook-lock.

d. Grip both safety wires in the jaw, squeeze the handles together with one hand and pull
the slider toward the rear of the pliers with your other hand in order to lock the pliers.
e. Twist the safety wire by pulling the aluminum knob and twist rod out from the pliers,
letting the pliers spin free (Figure 20).

f. Return the knob and twist rod by holding the pliers steady with one hand and pushing
the flat of your other hand against the end of the knob as in Figure 20.
g. Repeat the above twisting cycle.

Figure 20. Safety Wiring Procedures

52

 Nov. 9,1994

h. Whenever possible, employ double-twist safety wiring (Figure 21). After threading

i.
safety wire through the hold in the fastener, pull the wire straight through so as not
to skin the outside of the wire.
Twist to a tightness of four to five complete revolutions per inch.

J. Refer to Figure 21 for additional examples of double-twist safety wiring.

k. Limit single-twist safety wiring to small screws located in closely spaced, closed
geometrical patterns (triangle, square, rectangle, circle, etc.) or parts in electrical
systems or parts that are difficult to reach.

1. Do not pull the safety wire so hard that it stretches or is nicked by the edge of the hole
in the fastener.

Double-Twist Safety Wiring

Figure 21. Safety Wiring Examples

m. Do not let kinks develop.
n. Orient safety wire so the pull exerted by the wire tends to tighten the nut. This is
accomplished when the wire leaves the fastener in a clockwise direction.

o. Make twists tight, even, and as taut as possible without over-twisting to the point
where the safety wire is weakened.
p. Twist the safety wire so the loop around the bolt or head has sufficient tension to keep
it from slipping up and over the bolt head, with resulting slack in the safety wiring.

q. When castellated nuts are secured with safety wire, tighten the nut to the low side of
the selected torque range, unless otherwise specified, and if necessary, continue
tightening (within specified torque limits) until a slot aligns with the hole.
r. Make a pigtail of 1/4" to 112" length (four twists minimum) at the end of the wiring
and bend back or under to prevent it from becoming a snag.

s. The number of nuts, bolts or screws that may be safely wired together depends on the
application, but as a guide, when safety wiring widely-spaced bolts by the double-
twist method, a group of three 24" long safety wires is usually the maximum.

53
Nov. 9,1994

D. TROUBLESHOOTING

1. Counterbalance Troubleshooting Table

Probable Cause Remedy

Symptom
See adjustment procedure and
System does not hold Needle valve is not closed. check needle valve.
pressure.

Cy linder rod seals leak. Replace seals.

Tighten or replace as required.

Fittings or hoses leak.

Dirty or defective PRV See adjustment procedure. Clean

Valve. or replace.

Dirty or stuck check valve. Clean or replace.

Adjust per adjustment procedure.

Cylinder rods remain Pressure setting too high.
retracted (Closed).
NOTE: When activating or
reactivating the counterbalance
system, never start an empty system
with the needle valve closed.
Always start hydraulic unit first,
run for 3-5 minutes, then slowly
close needle valve with hydraulic
unit running. If an empty system is
started up with needle valve closed
there is a good potential for
damaging counterbalance cylinder
seals.

54
 Nov. 9,1994

1. Counterbalance Troubleshooting Table (Cont.)

Problem Probable Cause Remedy

Alignment cylinder Transmission trunnion pins Free trunnion pins as needed and
fails to move will not pivot in dolly lubricate area regularly.
transmission at support brackets, from lack
trunnion pivot points of lubrication.
with recommended
pressure setting.

Counterbalance Possible problem with Check Counterbalance

system works system hydraulic
erratically or does components.
not work at all.
Loss of nitrogen precharge
in accumulators located in
motor dolly upright frame.
troubleshooting section.
Recharge accumulators as per
procedure in Counterbalance
section.

55
Nov. 9,1994

2. Motor Alignment Cylinder Troubleshooting Table

Symptom Probable Cause

System does not hold Needle valve is not closed.

pressure.
Remedy

See Adjustment procedure.

Cylinder rod seals leak. Replace seals.

Fittings or hoses leak. Tighten or replace as required.

Dirty or defective PRV Clean or replace.

Valve.

Saver sub on TDS Alignment cylinder See Adjustment procedure.

does not align with pressure too high or too
drill pipe. low.

Alignment cylinder rod Adjust according to procedure.

adjustment too long or
short.

Rails not properly aligned

with centerline of well.
Check to make sure that rotary is in
center of floor and then check
alignment of rails in relation to
rotary.
Excessive motor Alignment cylinder fluid See Adjustment procedure.
movement. flow not adequately Normal adjustment is 1 112 turns
throttled. from full closed position on flow
control valves. If there is excessive
movement close to 3/4 tum from
full closed position.

56
 Nov.9,1994

3. Drilling Motor and Guide Dolly Troubleshooting Tables

A. MOTOR AIR BRAKE - TROUBLESHOOTING TABLE

Symptom Probable Cause

Brake does not hold. Insufficient air supply.
Solenoid valve not shifting.
Remedy
Check air supply pressure, 90 psi
minimum required.
Check electrical continuity.

Check lubricator on air supply.

Check mechanical operation of

solenoid valve.

Brake drum contaminated Inspect and replace if necessary.

with grease or pads worn or
burnt.

Brake does not Solenoid valve sticking.

release. Lubricate, repair with repair kit or
replace valve.

Check air supply lubricator.

Quick exhaust valve not Clean or replace.
functioning properly.
 Nov.9,1994

3. Drilling Motor and Guide Dolly Troubleshooting Tables

A. MOTOR AIR BRAKE - TROUBLESHOOTING TABLE

Symptom Probable Cause Remedy

Brake does not hold. Insufficient air supply. Check air supply pressure, 90 psi
minimum required.

Solenoid valve not shifting. Check electrical continuity.

Check lubricator on air supply.

Check mechanical operation of

solenoid valve.
Brake drum contaminated Inspect and replace if necessary.
with grease or pads worn or
burnt.

Brake does not Solenoid valve sticking. Lubricate, repair with repair kit or
release. replace valve.

Check air supply lubricator.

Quick exhaust valve not

functioning properly.
Clean or replace.

57
Nov. 9, 1994

B. TRANSMISSION - TROUBLESHOOTING TABLE

Problem

Oil leaking from

lower seal.
Probable Cause

Lower gear case seals are

dry or damaged.
Remedy

Apply grease to seal. Grease fitting

daily.

If problem persists replace gearcase
seals and bearing.

Oil leaking from Oil level too high. Adjust oil level per recommended
shaft housing specification.
breather.
Incorrect lubricant used.

Oil is foaming. Replace oil.

Gearbox temperature Oil level too low or too Adjust oil level to recommended
is excessive. high. level in sight glass.

Incorrect lubricant used. Check recommended lubricants

chart and replace as needed.

Clogged oil suction screen. Remove suction screen for oil

pump check discharge or pressure
hoses at outlets to confirm
circulation.

Clogged or dirty heat Check heat exchangers for air flow

exchangers on unit or water flow to ensure adequate
equipped with such. heat transfer and dissipation.

58

 Nov.9,1994

C. OIL PUMP - TROUBLESHOOTING TABLE

Problem Probable Cause Remedy

Oil Pump Loss alann Motor is not running. Check electrical components to
is on. ensure power is available to motor
Repair or replace as needed.

Incorrect motor rotation. Verify proper rotation and correct

if necessary.

Dirty or clogged oil pump Remove and clean suction screen

suction screen. making sure to properly seal screen
cover when installing.

Oil Pump cavitating- Check all connections and suction

evidence of air bubbles in screen cover plate to ensure there
discharge lines. are no air leaks on suction side of
oil pump.

Repair as needed.

Defective or improperly Check switch operation and repair

adjusted pressure switch. or replace as needed.

Failure of oil pump drive Inspect, repair or replace as

coupling. necessary.

Faulty or worn oil pump. Check relief valve on back of

pump. Install test gauge in
discharge line and adjust to 10 psi.

If unable to make oil pump work

after checking all of the above,
repair or replace as needed.

Incorrect lubricant used. Check recommended lubricants

chart to make sure proper viscosity
of oil is used.

59
Nov. 9, 1994

D. COOLING SYSTEM - TROUBLESHOOTING TABLE

Problem Probable Cause Remedy

Mechanical noise in Loose impeller. Reinstall impeller and hub and

blower. locktite screws.

Faulty Motor Bearings. Repair or replace as needed.

Blower runs Faulty or loose wiring. Locate and repair as needed.

intermittently.
Faulty motor starter. Check for dirt or trash between
starter coil. Repair or replace as
needed.

Excessive air loss in Worn or defective seal or Replace as needed.

blower motor shaft wear sleeve.
area.
Loose or vibrating blower Correct blower mounting problem
motor wearing seals or faulty motor bearing and replace
excessively. blower shaft seals.

DC Motor
overheating,
overtemp alarm stays
on with blower
running.
Incorrect blower rotation. Verify blower rotation correct.

Dirty or clogged spark Remove spark arrestors from motor
arrestors (local or remote and clean screens if screens are
cooling systems). damaged with holes. Replace as
needed.

Clogged water or air Remove and clean passages as

passages in water cooled needed.
exchangers (closed loop
cooling).

60

 Nov. 9,1994

D. COOLING SYSTEM - TROUBLESHOOTING TABLE (CONT.)

Problem

DC Motor
overheating,
Probable Cause

Continuous drilling amps

over recommended levels.
Remedy

Check service manual for

continuous amp motor rating and
overtemp alarm stays adjust drilling program
on with blower accordingly.
running.

Motor being stalled for over DC Motor should never be stalled

recommended periods of for more than 5 seconds with over
time. 300 amps applied.

NOTE: Serious damage could

occur to the motor if this is done.

Faulty temperature switch Repair or replace as needed.

or probe. NOTE: Do not readjust or raise
heat range setting.

Improper cooling water See service manual installation

flow or incoming water section for recommended or
temp too high (closed loop required flow rates and water temp.
cooling).

Restricted air flow (local or Check and clean spark arrestors as

remote cooling). needed.

Check air intake on blower to

ensure there are no restrictions.

Verify proper blower rotation.

Water detector alarm Moisture in air inside DC Check for leaks in heat exchanger.
is on (closed loop motor. Check air purge line filters. Ensure
system). dry air is going into motor.

Dirty or faulty water Clean or replace as needed.

detector .

61
Nov.9,1994

4. Pipehandler Troubleshooting Tables

A. TORQUE WRENCH - TROUBLESHOOTING TABLE

S~m~tom

Tool Does not cycle

Probable Cause

Valves in manifold out of

Remed~

Readjust.

properly. adjustment.

Supply and Return hoses Reconnect hoses correctly.

are crossed.

Improperly connected quick Check quick disconnects to make

disconnects. sure they are properly plugged
together and flowing in both
directions.

Needle valve in Close needle valve (always with

counterbalance manifold is power unit running).
open.

Defective cartridge valve or Inspect valves for damaged seals or

PRVvalve. stuck spools. Replace if necessary.

Improper component or Valve cartridge replaced with

component installation. wrong type.

Tool does not cycle Power unit not functioning.

NOTE: When changing Make-
Break valve make sure valve is
properly oriented when installed.

Make sure hydraulic system is on.

at all. Check pressure.

Solenoid valve not shifting. Check electrical continuity.

Check spool mechanical operation.

Lubricate if necessary.

Lift cylinder bypassing Repair cylinder

fluid

62

 Nov. 9, 1994

A. TORQUE WRENCH - TROUBLESHOOTING TABLE (CO NT.)

Symptom

Tool goes up,

clamps, and cycles
Probable Cause

Air pilot valve on counter-

balance manifold stuck or
Remedy

Remove air supply line to verify air

supply when solenoid valve is
but remains clamped inoperative. activated.
of pipe when switch
is released.

Pilot valve dirty. If air supply is available remove

end cap on pilot valve, clean and
lubricate.

Improperly connected quick If air pilot valve is operable hook

disconnects. both Pipehandler hoses together
and verify flow in both directions
by activating switch with
hydraulics on. If there is flow in
only one direction-check QD's.

If QD's properly connected check

hydraulic pilot valve for stuck
spool.

Hydraulic valve not Repair or replace .

shifting.

Saver sub breaks out Saver sub not made up Make up saver sub per procedure
instead of tool joint. properly. described in mop Service Manual,
increase previous torque makeup
by 10% to maximum torque
remcommended in mop Service
Manual (for original Varco OEM
subs).

Tong Dies break or Valves in manifold out of Readjust per procedure.

score drill pipe. adjustment.

Tong Dies worn. Replace Tong Dies.

Connection overtorqued. If saver sub is made up to

recommended torque and continues
to break out instead of drill pipe
connection - break out using rig
tongs - If saver sub or drill pipe
will not break out using
pipehandler, remove pipehandler
and break out with rig tongs at

63
floor .
Nov. 9,1994

A. TORQUE WRENCH - TROUBLESHOOTING TABLE (CONT.)

Symptom Probable Cause Remedy

Die Retainer and Die Improper saver sub length Saver sub length too long. Sub
Retainer bolts or machining. should also have proper chamfer on
damaged while both shoulders.
breaking out
connections.

Torque Wrench does Oil bypass in pipehandler Listen for oil bypassing in
not lift. hydraulic components. pipehandler Cylinders or manifold.
Locate and repair bypass as
necessary.

B. SAFETY VALVE ACTUATOR - TROUBLESHOOTING TABLE

Problem Probable Cause Remedy

Safety Valve leaks. Internal parts worn out. Check for washouts or defective

parts Repair as needed.

Actuator out of adjustment. Check electrical continuity.

Check spool mechanical operation.

Lubricate if needed.

Check actuator cylinder adjustment

(see procedure).

Excessive vibration Actuator support roller Check actuator shell adjustment

or wobble while brackets bent or out of and crank assembly operation.
rotating. adjustment.

Worn cam rollers. Repair or replace rollers and roller

brackets, shimming as needed to
maintain smooth operation.

64

 Nov.9,1994

c.

Problem
LINK TILT - TROUBLESHOOTING TABLE

Does not tilt.

Probable Cause

Solenoid valve not shifting.

Remedy

Check electrical continuity.

Check spool mechanical operation

and lubricate as needed.

Does not reach Improperly adjusted. Readjust chains, shorten if

mousehole. necessary.

Retracts slowly. Quick exhaust valve not Clean or replace.

functioning.

Solenoid valve stuck in Repair or replace mechanical valve

neutral position - Check quick exhaust valve.
maintaining pressure on Replace as needed.
quick exhaust.

65
Nov.9,1994

D. TROUBLESHOOTING PIPEHANDLER AT THE COUNTERBALANCE MANIFOLD

Problem Probable Cause Remed~

Pipehandler goes up Improperly connected quick Check all quick disconnects to

and clamps when disconnects. make sure that they are properly
power unit is turned connected, also making sure that
on without pressing each half is intact and not coming
switch. apart and restricting fluid.

Solenoid valve stuck or Disconnect air line from solenoid

inoperative. to air pilot valve. If there is a
constant air flow that means the
solenoid valve is stuck in the open
position. Remove solenoid and
valve. Clean as needed.
Repair or replace valve as
necessary.

Check oil lubricator to make sure

valves are being lubricated.

Air Pilot Valve sticking. If there is no constant air flow from

air line, remove end cover on air
pilot valve and check spool to see if
it is operating freely. Clean as

needed and lubricate.

Repair or replace valve as

necessary.

IBOP valve actuator Faulty or loose wiring. Check electrical continuity to

remains either in switches and solenoids.
closed or open
position.

No air supply or air supply Check air supply. There must be

incorrect. 90 psi minimum pressure.

Crank assembly, actuator Check crank assembly, actuator

arms or cylinders sticking. arms and cylinders. Repair as
needed.

Solenoid valves stuck in the Check solenoid valves to see if

open position or in center they are not stuck in the open
position. position or in center position.

Repair or replace valve as needed.

66
....--------------------...........-
Nov. 9, 1994

40. TROUBLESHOOTING PIPEHANDLER AT THE COUNTERBALANCE MANIFOLD (CONT.)

Problem Probable Cause Remedy

mop valve does not Actuator cylinder out of
fully open or close. adjustment.
Cam follower rollers
sticking.
Crank assembly retainer
bolts loose.
Check actuator cylinder adjustment
and adjust as needed.
Check cam follower rollers on
crank assembly and arms.
Check crank assembly retainer
bolts to assure tightness.

NOTE: Crank assembly retainer

bolts should be checked once a
week to make sure that they remain
tight.

E. SIX-GANG AIR VALVE ASSEMBLY ILLUSTRATION

6) Torque Wrench

5) Motor Air Brake

4) IBOP Close

3) Link Tilt

2) IBOP Open

1) Spare

67