Training Manual PDF

Top Drive
Training Manual
Company
Owner
Varco Technical Education Centre

Montrose Scotland
TOP DRIVE
Training Manual
Description
Training Manual

Montrose Scotland
TOP DRIVE
Training Manual
Installation
Chapter 1
Preparation
Preinstallation checklist
The following assumes that all preinstallation planning and rig-up
has been accomplished prior to installation of the TDS. This
includes:
1. Guide rails and bracing are installed and inspected to
conform to Varco specification and installation tolerances
(Figures 1, 2, and 3).
2. Stops are ready for installation at the bottom of the rails.
3. Hydraulic and air standpipes are installed in the derrick,
flushed clean and pressure tested. Water piping is installed,
flushed and pressure tested as well for configurations with
closed loop cooling systems.
4. All electronics are installed up to the derrick junction box:
DC power leads, AC leads for blower motor, and control/
alarm signals.
5. The transfer panel is installed.
6. Rigging of the tong lines, etc. are inspected to ensure that
they will not foul with the TDS and other rig equipment.
Training Manual June 99
Chapter 2
Installation
Derrick electrical termination kit

Installation
Refer to Figures 1, 2 and 3 for typical mounting dimensions of
the plate assembly. Mount it at racking board height within 15' of
the service loop support bracket. Remember to provide
convenient access for wiring and maintenance.
Usually, mounting the plate so that the J-box is four to five feet
above the walk-around and near the service loop support bracket
is adequate. If a walk-around does not exist, then construct a
work platform to allow access to the J-boxes. Manufacture
appropriate brackets and clamps to attach the plate to the derrick
structure.
1/4"
OVER FULL LENGTH
3/8
1/8"
C
L RAIL
C
L RAIL
OVER FULL LENGTH
WITHIN 25' OF FLOOR
C
L RAIL
C
L RAIL
CL WELL
3/8" OVER FULL LENGTH

1/8" WITHIN 25' OF FLOOR
CL WELL
TDS BACK
OPERATIONAL CLEARANCE BETWEEN TOP DRIVE
& NEAREST GIRT OR FASTLINE SHOULD BE 3 MINIMUM
GUIDE RAILS
NEAREST GIRT
SPLICE
CLEARANCE
SPLICE PLATES
OR BOLTS ARE
NOT PERMISSABLE
ON INSIDE
SURFACES OF
BEAM
DOLLY
OVERHANG
MAXIMUM RAIL
SUPPORT SPACING
16 FT FOR W12x53 RAILS
25 FT FOR W14x74 RAILS
6" RAIL
STOP
GUIDE
DOLLY
CONFIG
10' 6" +0"/-4"
39 X 66
48 X 62
30 X 72
30 X 72
RAIL
SIZE
W14X74
W14X74
W12X53
W14X74
DRILL FLOOR
C
L WELL
Figure 1. General rail installation data
SPLICE DOLLY
CLEAR OVERHANG
INCHES
3.3
3.3
3.3
2.3
0
0
1.6
0.5
16.0
DERRICK J-BOX PLATE
CLEARANCE HOLE
FOR .75 DIA BOLT
4 PLACES
INSTRUMENT J-BOX **
MOTOR J-BOX **
BRACES *
16.0
CONVENIENT
WORKING HEIGHT
ABOVE WALKAROUND
16.0
B
MUST SUPPORT
4000 LBS
16.00
ELECTRICAL SERVICE LOOP **

HYDRAULIC
STANDPIPES
TO BE
1-1/2
SCHED 80 PIPE*
AIR
STANDPIPES
TO BE
1-1/2
SCHED 40 PIPE*
WATER
STANDPIPES
TO BE 2 SCHED 40 PIPE*
VIEW A-A
TYPICAL SERVICE LOOP TERMINATION
A
86 FT.
SERVICE
LOOPS
A
GUSSETS *
75 FT.
MUD
HOSE
REF
73 FT. MUD HOSE

CONNECTION
SERVICE
LOOP
BRACKET**
EXISTING GIRT *
VIEW B-B
83 FT. HYD, AIR & WATER

STANDPIPE HEIGHT &
SERVICE LOOP BRACKET
LOCATION
* CUSTUMER SUPPLIED
** VARCO SUPPLIED
10' 6"+0"/-4"
7 FT REF
TYPICAL EQUIPMENT STACK-UP
Figure 2. Derrick services/general installation data
Motor Frame
Setback
Rails
L
9'3" TDS-3S
10'3" TDS-4S
7'0" TDS-3S
8'0"TDS-4S,
TDS-6S
Rail Stops
L
42,600 LBS for a typical TDS-3S
Rail Loading with TDS in Setback position

Load P - LBS
Rail Spacing
TDS-3S
TDS-4S
39 x 66
18,600
18,900
48 x 62
18,600
18,900
30 x 72
17,500
17,800
Rail Loading while Drilling - 38,000 FT LBS for TDS-3S,

60,000 FT LBS for TDS-4S, 68,000 FT LBS for TDS-6S,
and 34,000 FT LBS for TDS-7S.
Load L - LBS
Rail Spacing
TDS-3S
TDS-4S
TDS-6S
TDS-7S
39 x 66
3450
5450
--
3090
48 x 62
3680
5800
--
3290
30 x 72
3170
5000
--
2840
91/101 x 108
--
3330
3780
--
Figure 3. General installation data

Motor Frame
Setback
Rails
L
L
10'3" TDS-4H
7'0"TDS-4H,
L
Rail Stops
L
48,000 LBS for a typical TDS-4H
Rail Loading with TDS in Setback position

Load P - LBS
Rail Spacing
TDS-4H
39 x 66
18,900
48 x 62
18,900
30 x 72
17,800
Rail Loading while Drilling - 60,000 FT LBS
Load L - LBS
Rail Spacing
TDS-4H
39 x 66
5450
48 x 62
5800
30 x 72
5000
91/101 x 108
3330
Figure 1c. General installation data (cont.)
Wiring
The electrical installation requires routing power to the transfer
panel and then to the TDS through the service loops (Figure 4).
In addition, control cables are required between the service loop,
the transfer panel, the SCR, the TDS drillers console, the SCRs
drillers console, the hydraulic and water pumps and the drilling
recorder.
Derrick
Power
J Box
Transfer Panel
#12AWG/20C
#10AWG/4C
#14AWG/2 Pr Shld
#6AWG/2C*
Shunt Field
Derrick
A.C.
J Box
(4)646MCM*
Top
Drive
System
AC
Power
HYD
Pump
#2
#16AWG/10C
#16AWG/10C
Existing
Driller's Console
#16AWG/10C
#10AWG/4C
#10AWG/4C
#6AWG/4C
#6AWG/4C
TDS
Driller's Console
HYD
Pump
#1
Rotary
Table
RBS
Controls
#12AWG/3C
E/P
RPM
Existing
Power
Cables
#16AWG/10C
E/P
Torq
#14AWG/2 Pr Shld
#12AWG/3C
#14AWG/37C
#12AWG/20C
#12AWG/20C
#16AWG/10C
#12AWG/20C
#10AWG/4C
#14AWG/2 Pr Shld
#12AWG/3C
SCR
Room
Service Loop
#6AWG/2C*
Shunt Field
#16AWG/10C
Water
Pump
#1
Water
Pump
#2
Figure 4. Typical cabling diagram

The cable requirements, depending on options selected are:

Cable
Runs
646MCM (4 Shunt)
SCR room to transfer panel
(8 Series)
Transfer panel to derrick J-box

Transfer panel to rotary
#6AWG/2C (Shunt only)
SCR Room to transfer panel

Transfer panel to rotary
#6AWG/4C
AC Power to hydraulic pumps
#10AWG/4C
AC Power to water pumps

AC Power to transfer panel
#12AWG/20C

Transfer panel to hydraulic pumps
Transfer panel to water pumps
#12AWG/3C
Transfer panel to RBS unit

Transfer panel to drillers console
RBS unit to drillers console
#14AWG/37C
#14AWG/2PR SHLD

Transfer panel to drilling recorder
#16AWG/10C
Transfer panel to SCR console

Transfer panel to SCR room
Purge control system (not shown)

#12AWG/3C
Purge control unit to transfer panel

Isolation unit to floor air control unit
Transfer panel protection unit to isolation unit
#16AWG/10C
Purge control unit to transfer panel

Drillers console protection unit to isolation unit
#14AWG/2PR SHLD
Terminate the J-boxes per the electrical schematic. Follow

applicable electrical codes during installation. Cable glands are
provided for the service loop cables. Cable glands for the
incoming power, control and signal cables are not provided.
Plumbing
The plumbing connections should terminate near the service loop
bracket. The mating halves are preassembled on the service loop.
Specifications for specific lines are described in the following
sections.
Hydraulic
Hydraulic lines should be cleaned and pickled, black pipe lines
(one pressure and one return) 1 1/2" or 2" schedule 80 pipe.
Install shut-off valves at the drill floor or racking board level. The
derrick connections are reduced to 1" NPT female pressure and
fluid return for connection to the service loop.
Air
Air lines should be schedule 40, 1" or 1 1/2" pipe in the case of
the purge supply for the TDS. Install a shut-off valve at drill floor
or racking board level. The air lines connect to the filtered and
lubricated supply. The derrick connections are reduced to 1"
NPT female for the purge line (if required) and 1/2" for the air
line in order for the fluids service loop to match.
Do not connect purge air lines to the lubricator. Only use clean,
dry air in the purge air system.
Water
The two cooling lines should be schedule 40, 2" pipe. Install
shut-off valves at the drill floor or racking board level. See the
cooling system specifications for water supply requirements. The
derrick connections are reduced to 1 1/4" NPT female pressure
and return for connection to the fluids service loop.
September 16, 1996
Rig-up procedure
z
Refer to the engineering drawings to install the TDS.

1. Change out the swivel bail pins with the longer ones supplied
(Figure 3). A welder may be required to weld in the pin
retainers, depending on the manufacturer of the swivel.
Unless a new or recently-overhauled swivel is used, the old bail

pins may need to be machined out.
2. Install the nipple and female union sub for the S-tube onto
the swivel gooseneck.
3. Hang the swivel from the hook or block and makeup the
main shaft to the swivel stem using a thread compound of
60% lead by weight (Refer to the IBOP Service Manual
included as a separate book in this manual for torque
specifications).
Generally, a swivel saver sub is not used unless a crossover sub is

required.
The connection on the main shaft is 7-5/8 API regular left hand.
The bail bumper on the swivel faces the guide rails. On some
swivel/rail setback combinations, the bumper side ears may
require trimming to clear the motor guide dolly.
4. Loosely install the bearing shield around the flange on the
main shaft with the T-bolt clamp supplied. After the main
shaft is stabbed into the quill shaft, adjust the shield and
tighten the clamp.
16
TDS-4H Installation and commissiioning
September 16, 1996
5. Use the four lift slings from the crane, one attached at each
corner of the guide dolly, to lift the top drive motor and dolly
assembly onto the rig floor. If possible, set it on the rig floor
with the crane - do not drag it up the V-door. Position it on the
rotary table with the swivel end under the guide rails. The
slings must be a minimum of 15' long (equal length) and
capable of lifting 40,000 lb combined. (BOP lift slings are
usually adequate.)
Figure 3. Swivel assembly
TDS-4H Installation and commissioning
17
September 16, 1996
6. Attach lifting slings to the pad eyes located at the swivel end
of the motor frame and lift the TDS into the guide rails.
On some configurations it may be necessary to remove the upper

roller brackets from the dolly to allow the unit to engage the
guide rails.
7. Once the TDS is fully engaged on the guide rails, install the
stops at the bottom of the guide rails and lower the TDS onto
the stops.
8. Apply a liberal amount of grease to the main shaft from 6"
below the splines up to the top flange. Also grease the top and
bottom 18"of the quill shaft I.D. Pack both the main shaft
and bull gear splines flush with grease. Check the O-ring in
the groove located 12" inside the quill shaft to be sure it is
greased and located properly.
9. Spread apart the swivel links and stab the swivel/main shaft
through the quill shaft with care, until the drive splines are
fully engaged. Slide the swivel links onto the extended bail
pins and install the retainers with the bolts, lockwashers and
safety wire supplied.
10. Slide the link adapter onto the main shaft and support it up
against the rotating head with adequate rigging and an air
winch. Be certain that the link tilt mounting bosses are
opposite from the torque wrench mounting clevis on the
rotating head.
11. Slide the landing collar retainer onto the drive stem as shown
in Figure 4. Install the O-ring in the uppermost groove on the
stem. Load the O-ring and remaining grooves with a
waterproof grease. Place the split landing collar around the
grooves of the drive stem, and drive in the remaining roll pin.
Grease the O.D. liberally, and slide the retainer down,
covering the split landing collar. Use a hammer and drift to
bend all 32 tabs on the retainer to secure the split landing
collar. Wipe off excess grease.
12. Use the pipehandler to tighten the connection between the
lower IBOP/saver sub assembly to the upper IBOP.
18
September 16, 1996
Landing
Collar
Retainer
Landing Collar
Retainer Tabs
O-Ring
Drive
Stem
Roll Pin (4)
Split Landing
Collar (2)
Safety Link (4)
Figure 4. Landing collar installation
19
September 16, 1996
13. Pull up on the release handle and unlock the rotating head.
Rotate the link adapter and the rotating head so that the
mounting point for the torque wrench is at the front of the
tool. Raise the torque wrench with the air winch and pin into
place. Adjust hanging position per the procedure described in
Book 4. Rotate the pipehandler assembly to the rear and
connect the two air hoses and two hydraulic hoses. Quick
disconnects on the hoses allow connection in only one way so
that the hoses cannot be interchanged.
14. Connect the hose to the back of the link tilt actuator. Use the
four bolts, lockwashers and safety wire provided to install the
link tilt acutator to the link adapter. Connect the opposite
end of the hose to the quick disconnect on the rotating head
assembly.
15. Install the elevator links and drill pipe elevator. Attach the
link tilt clamps to the bails (U-bolts on the inside). Allow for
1/2" slack in the chains.
16. Install the counterbalance system as follows (Figure 5):
a. Install pear links to ears on hook-block.
b. With the hook supporting the top drive, measure distance
from bottom of pear link to top of mounting lug on
swivel link (Dimension A).
c. Subtract 37 1/4" from dimension A.
d. Cut chain to the length obtained in step c (measure inside
chain links per illustration). The tolerance is: +3 1/4"/-0".
e. Assemble remaining components and install per the
illustration.
20
September 16, 1996
Figure 5. Counterbalance system
21
September 16, 1996
17. Attach the service loops to the bracket on the top drive frame.
Use the cable clamps provided on the motor frame to route
the electrical cables over the gear box and into the junction
boxes. The front guard swings aside for access to the junction
boxes by removing the attachment bolts on one side.
Use the electrical schematic (refer to the engineering
drawings) to make the connections. Be certain that the cables
are securely tied or clamped to the structure along their
length. Route the hoses to the bulkhead and plug in the quick
disconnects. Follow the stamped code numbers to confirm
each type and identify spares.
18. Attach the S-tube to the swivel gooseneck and the side of the
motor frame as follows (Figure 6):
a. Makeup the upper union just before clamping S-tube to
side of motor frame.
b. Install the drill pipe rubber onto the S-tube aligned with
mounting saddle on the frame.
c. Attach the mud hose to the bottom connection of S-tube.
d. Position 15 S-tube elbow on bottom of S-tube to adjust
the hanging direction of mud hose.
22
September 16, 1996
Figure 6. S-Tube installation
23
August 22, 1997
Rig-up procedure
z
Refer to the engineering drawings to install the TDS.

1. Using four lift slings from the crane, one attached at each
corner of the guide dolly, lift the TDS motor and dolly
assembly to the V-door.
2. Attach the lifting slings from the hook or block to the pad
eyes located at the swivel end of the motor support bonnet
and lift the TDS into the guide rails. The slings must be a
minimum of 15' long (equal length) and capable of lifting
40,000 lb combined. (BOP stack lift slings are usually
adequate.)
On some configurations it may be necessary to remove the upper

roller brackets from the dolly to allow the unit to engage the
guide rails.
3. Once the TDS is fully engaged on the guide rails, install the
stops at the bottom of the guide rails and lower the TDS onto
the stops.
4. Slide the link adapter onto the drive stem and support it up
against the rotating head with adequate rigging and an air
winch. Be certain that the link tilt mounting bosses are
opposite from the torque wrench mounting clevis on the
rotating head.
5. Slide the landing collar retainer onto the drive stem as shown
in Figure 5. Install the O-ring in the uppermost groove on the
stem. Load the O-ring and remaining grooves with a
waterproof grease. Place the split landing collar around the
grooves of the drive stem. Grease the O.D. liberally, and slide
the retainer down, covering the split landing collar. Use a
hammer and drift to bend all 32 tabs on the retainer to secure
the split landing collar. Wipe off excess grease.
6. Use the installation procedure in the IBOP Service Manual
(included as a separate book in this manual) to install the
pipehandler assembly.
7. Use the pipehandler to tighten the connection between the
lower IBOP/saver sub assembly to the upper IBOP.
16
TDS-4S Installation
Landing
Collar
Retainer
O-Ring
Landing Collar
Retainer Tabs
Drive
Stem
Split Landing
Collar (2)
Figure 5. Landing collar installation
TDS-4S Installation
17
August 22, 1997
8. Connect the hose to the back of the link tilt actuator. Use the
four bolts, lock washers and safety wire provided to install this
assembly to the link adapter. Connect the opposite end of the
hose to the quick disconnect on the rotating head assembly.
9. Install the elevator links and drill pipe elevator. Attach the
link tilt clamps to the bails (U-bolts on the inside). There
should be about 1/2 inch slack in the chains.
10. Install the counterbalance system as illustrated in Figure 6.
When using chain, use the following procedure to determine
the chain length required:
a. Install pear links to ears on hook-block.
b. With the hook supporting the TDS, measure the distance
from the point of contact inside the pear link to the top
of the mounting lug on the integrated swivel bail.
c. Subtract 37 1/4" from the measurement in step b.
d. Cut the chain to the length obtained in step c. The
tolerance is: +3-1/4" or -0".
e. Assemble remaining components and install per Figure 6.
Pear Link
Connecting
Link
Hydraulic
Accumulator
(Inside Motor Frame)
Counterbalance
Manifold
(On Guide Dolly)
Motor Frame &

Guide Dolly Assy.
Counterbalance
Cylinder Assy. (2)
Counterbalance
Lug
(Bolted to Bail)
Integrated
Swivel
Bail
Figure 6. Counterbalance system

18
TDS-4S Installation
11. Attach the service loops to the bracket on the TDS dolly
frame. Using the cable clamps provided on the motor support
bonnet, route the electrical cables over the gear box and into
the junction boxes. The front guard folds down for access to
the junction boxes.
Use the electrical schematic (refer to the engineering
drawings) to make the connections. Be certain that the cables
are securely tied or clamped to the structure along their
length. Route the hoses to the bulkhead and plug in the quick
disconnects. Follow the stamped code numbers to confirm
each type, and identify spares.
12. Attach the S-tube to the swivel gooseneck and the side of the
motor frame as follows:
a. Make up the upper union just before clamping the
S-tube to the side of the motor frame.
b. Install the drill pipe rubber onto the S-tube aligned with
the mounting saddle on the frame.
c. Attach the mud hose to the bottom connection of the
S-tube.
d. Position the 20 S-tube elbow on the bottom of the
S-tube to adjust the hanging direction of mud hose.
13. Remove the exhaust duct shipping cover from the spark
arrestors on the air exhaust duct at each side of the DC
motor. Save the covers for use during future shipping or
storage.
Never operate the top drive with the exhaust duct covers
attached to the spark arrestors on the air exhaust ducts. Doing
so severely restricts air flow through the motor, causing
overheating and potential damage. They can also fall off
during operation and injure personnel working below. Attach
the covers only during shipping and storage.
TDS-4S Installation
19
August 22, 1997
Counterbalance system
Figure 6 illustrates the installation arrangement for this system.
Please see the Maintenance and troubleshooting book for the
adjustment procedures.
This assembly is pre-charged when it is shipped by land or water
transport. When this assembly is shipped by air freight, it must be
pre-charged according to the instructions inthe Maintenance and
troubleshooting book.
20
TDS-4S Installation
Motor alignment cylinder system

Figure 7 shows the motor alignment cylinder installed on a
typical motor frame.
The split shipping brace, shown exploded from the cylinder rod,
is only removed after unit is fully installed. If the brace is removed
before the hydraulic system is powered, the motor will tend to
rotate on its trunnions.
If the cylinder is removed for service, use the three bleed holes
(located along the top of the cylinder barrel) to remove trapped
air from the cylinder before operating the unit. Refer to the
Maintenance and troubleshooting book for the adjustment
procedure, as this dimension can vary.
Split
Shipping
Brace
Motor
Alignment
Cylinder
Motor
Frame Dolly (Ref)
Figure 7. Motor alignment cylinder
TDS-4S Installation
21
August 22, 1997
Drillers controls and instrumentation

The controls and instrumentation described in the following
sections are, or must be, supplied for operation of the TDS
system.
Drillers console
Mount the drillers console within easy reach and in plain view of
the driller while he is operating the drawworks brake and
clutches. The gauges must be easily seen by the driller during
drilling operations. Provide appropriate cable glands for the
electric cables.
Throttle and torque limit controls

The throttle and torque limit controls are the standard controls
used for the independent rotary drive table. If not using an
independent rotary drive, then these controls must be added by
the SCR manufacturer.
Wiring
Refer to the electrical schematics in the engineering drawings.
Customers who choose to use control systems not manufactured

by Varco should be aware that Varco systems are specifically
designed with operational interlocks and safety devices to
prevent possible injury to personnel or damage to the system.
Other systems must meet Varco requirements. Varco highly
recommends the use of its system as it is specifically made for
use with the TDS system.
Service loops
Installation
Install the service loops as follows:
1. Fabricate the appropriate brackets and clamps to attach the
service loop mounting bracket to the derrick structure.
2. Place the service loop derrick mounting bracket at the height
specified on the derrick interface drawing provided in the
engineering drawings. Locate the bracket on the side of the
derrick adjacent to the hinges on the TDS and as far as
practical toward the corner where the guide rail bracing is
attached. The bracket must be located far enough from the
corner to insure the loops do not catch under the guide rails
during operations, but far enough back to provide clearance
for tong lines, the stabbing board, tugger lines, etc.
3. Do not unpack the service loops from the shipping protective
crate until they are ready to hang in the derrick. Lift the
service loops onto the rig floor (still in the crates) and then
remove them from the crates with the lifting eyes provided.
Use care in lifting gear rigging so as not to damage electrical

conductors. Use lifting eyes only. Do not bend the service loops tighter
than a three foot bend radius. Tighter bends damage the loops.
4. Attach a sling to the top drive end of the service loop and lift
using the lifting eyes only. Allow enough room for the 86-foot
long service loop to hang and untwist.
5. Use the lifting eyes to pull the derrick end of the loop
through the "V" door and attach it to the air tugger. Hoist
this end of the loop into the derrick while slacking off at the
crane end. Do not drag the loop on any sharp areas on the
derrick . Disconnect the crane from the sling and continue
hoisting the loop into the derrick.
6. Check that the derrick end of the loop is hanging toward the
crown. Attach the derrick end to the derrick service loop bracket
and hold in place with flange clamps (Figures 1 and 2).
August 22, 1997
7. Pick up the TDS end of the loops and attach them to the
service loop bracket at the bottom of the motor frame.
8. Complete the terminations of the two loops as outlined in the
following sections.
Electrical loop
1. Connect the pre-terminated wire ends at the motor J-boxes
using the appropriate glands. Refer to the electrical schematic
provided to ensure proper terminal block assignments.
2
Cut wires and cables to length and terminate them at the

derrick end to attach them to the derrick J-boxes.
Terminal ends and lugs are supplied, but proper assembly

equipment (crimping pliers, wire strippers, and hydraulic crimper
for the DC power lugs with the correct dies for the cable) must be
provided by the installer. Installation practices should comply
with applicable electrical codes (i.e., NEC, etc.).
Fluids loop
1. Before connecting the hoses from the service loop, be certain
that the service stand pipes have been flushed free of any
contamination.
Use only 10 wt. hydraulic oil or non-detergent motor oil as a

lubricant in the air system. Use of any other type of oil (i.e., Marvel
Mystery Oil, etc.) or synthetic additive will cause the seals in the air
valves to swell and cease to function.
2. Plug the quick disconnects into the appropriate mating end
on the TDS. The quick disconnects are arranged to connect
only one way so that the hoses cannot be mixed up. The
hydraulic and air lines are identification stamped at both ends
so they can be verified and connected properly.
An assortment of pipe fittings are supplied with the
termination kit to attach the fluid service loop hoses to the
top of the standpipes in the derrick (Figure 2).
Training Manual June 99n
3. Connect the service loop to the standpipes, noting the codes

(i.e., A for air, H for hydraulic, etc.) to separate the hoses.
The hoses in the fluid loop only extend 11' from the mounting
bracket. It may be necessary to make jumper hoses to reach the
standpipes.
Air loop
To reduce the possibility of accidental opening of the air operated

elevator attach the airlines from the air operated elevators to the spare
port S1 on the rotating head whenever possible. Port S1 is located
next to the hydraulic return port in the rotating head. Port S2 is next
to the hydraulic press port.
Install a pressure relief valve on the elevator and set at 200 psi.
Chapter 3
Commissioning
Checkout procedure
1. Turn on the hydraulic and air power and check for leaks.
Repair as required.
2. Turn on the electric power (drillers controls only).
3. Check the function of switches and solenoids. There is an
audible click when each solenoid is actuated.
4. Actuate the link tilt. Be sure that it operates smoothly and the
elevator reaches a joint in the mousehole.
5. Adjust the intermediate stop so that the elevator clears the
monkey-board when actuated. Refer to the Maintenance and
troubleshooting book if a problem occurs.
6. Actuate the motor brake. There is a loud sound as the air
escapes when the brake releases.
7. Move the make/break valve located on the manifold at the back
of the pipehandler torque wrench to the BREAK position.
8. Turn on the hydraulic power supply and adjust the pressure
reducing valve (also located on the torque wrench manifold)
to the appropriate pressure for the lower IBOP connection.
August 22, 1997
9. Return the Make/Break valve to the MAKE position.

10. Torque the connection between the upper and lower safety
valves. The torque wrench automatic sequence is adjusted at
the factory, but be sure that it follows the proper sequence. If
necessary, refer to the Maintenance and troubleshooting book
for the adjustment procedure.
11. Push and hold the control button on the drillers console a
sufficient number of times to make up the connection.
12. Make up the lower IBOP to the saver sub.
13. Reset pressure to the appropriate setting for drill pipe
connections (you can preset the pressure with the Make/Break
valve in the MAKE position).
14. Use the procedure outlined in the Maintenance and
Troubleshooting book to adjust the safety valve actuator
mechanism.
15. Actuate the safety valve. Verify that the stroke adjustment is
correct and that no binding occurs.
It is extremely important to verify that the stroke adjustment is correct

and that no binding occurs as the valve will fail prematurely (wash
out) if it does not open and close fully.
16. Verify that the indicator light on the drillers console lights up
when the safety valve is closed.
17. Assign the TDS at the drillers console and check that the
blower operates.
18. Advance the throttle and be sure that the motor is operating
properly in both directions.
19. Calibrate the Amp meter and RPM meter.
20. With the hydraulic power unit off, bleed down the TDS
accumulators (HYD SIDE, not gas side).
21. Remove the split shipping brace (Figure 12 book 1) from the
motor alignment cylinder.
22. Open the two flow control valves 1-1/2 turns off their seats.
24. Set a joint of drill pipe in the slips.
25. Bring the TDS down as if stabbing the saver sub into box.
The pin and box should be in alignment. 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 the drill
pipe box.
b. Turn off the hydraulic power unit and bleed down the
cylinder accumulator (open the needle valve on the back
of the manifold). This allows the motor alignment
cylinder to relax and the motor to rotate on its trunnions
until the integrated swivel bail contacts the motor support
bonnet.
c. Loosen the lock tab and jam nut on the cylinder clevis.
d. With a wrench located on the cylinder rod flats, screw the
rod into or out of the clevis, in the same direction the
saver sub pin is to be moved.
e. Secure the jam nut and lock tab.
f. The nominal position of the two cylinder flow control
valves is 1-1/2 turn off their seats. If you experience heavy
drill pipe vibration, first attempt to control it with nonrotating stabilizers if the casing shoe is close to the surface.
If motor movement becomes excessive due to continued
vibration, (more than 1/2" of total cylinder stroke) close
the flow controls to 3/4 turn off their seats.
August 22, 1997
Long term TDS storage procedures

1. Palletize the main unit for indoor storage. A cargo container is
appropriate for indoor/outdoor storage.
2. Avoid wide variations in temperature and high humidity. The
preferred environment is clean and dry at 60 F ambient. If
high humidity is unavoidable, 70 F is recommended.
3. All exposed unpainted metal surfaces are coated with a rust
preventive at the factory prior to shipment, however, check
these surfaces periodically to be sure that no corrosion is
taking place. The recommended rust preventive (slushing
compound) for bare metal surfaces is Kendall Grade 5
(GE-D6C6A1) or equivalent.
4. Cover all openings to prevent water or dust from entering. Leave
enough space around the drilling motor to allow the machine to
breathe. Do not use silica gel or a dehydrating agent.
5. During storage, lubricant drains from the top half of the roller
bearings in the motor, allowing corrosion to take place on the
exposed areas. In order to counteract this, rotate the motor
and gear train periodically to distribute lubricant over the top
of the bearings. Perform this at three month intervals if stored
indoors, and at one month intervals if stored outdoors.
6. The drilling motor is equipped with AC space heaters in
order to keep the internal motor temperature above ambient,
preventing condensation. Connect power to the space heaters
at terminals 1 and 2 in the AC motor J-box (see electrical
schematic in the back of this section for proper voltage).
Be sure to reseal the protective covering after connection.
7. Megger the drilling motor armature and field (static voltage of
1,000 VAC and 2 meg ohm minimum) when placed into
storage and at three month intervals thereafter (one month if
stored outside). Keep a record of the readings, as a drop
between readings indicates an increase in moisture in the
windings created by inadequate storage protection. If megger
readings drop, bake the motor as soon as possible to restore
proper resistance and avoid further damage.
8. Varco recommends adding one gallon of Mobilarma 524 Rust
Preventive prior to shutdown. Or drain the oil and mix with a
rust preventive, then replace the oil, run the oil pump and
rotate motor to insure 100% coverage.
Returning the TDS to service after storage

Before placing the TDS back into service, verify the following
items:
1. Remove all rust preventive and any corrosion that may have
taken place, taking special care with all load carrying
components.
2. Follow the procedure in the drilling motor service manual
included in this manual. To verify the condition of the motor,
take note of the following:
a. Blow out all dust and dirt that may have accumulated in
the windings with clean, dry air.
b. Visually inspect for spring corrosion, sticking brushes and
general defects.
c. Remove the brushes from holders, inspect and replace
them as necessary prior to operation.
d. Check the winding insulation continuity to ground with a
1000 volt megger. If the reading is less than two meg
ohms, bake the winding until the moisture content is
sufficiently reduced to produce an acceptable reading.
3. Perform a complete system test and adjustment as detailed in
the next section.
TDS Installation checklists (QA00026)

Use the checklists on the following pages to rig up the TDS.

Montrose Scotland
TOP DRIVE
Training Manual
Counterbalance
Counterbalance System
---------------------------------------------------------------------------------------------------------------------------------------------------
Counterbalance systems vary widely in configuration

The principles are the same regardless of which
counterbalance configuration the drilling rig uses. For
description purposes this section of the module
describes all Varco counterbalance arrangements
used in the Varco Top Drive Systems.
Q. What does the counterbalance do

A. The counterbalance system prevents damage to
the threads of the saver sub and drill pipe by offsetting
the weight of the Top Drive while stabbing into a
connection.
Q. What does the counterbalance system consist of.

A. The counterbalance system consists primarily of
two hydraulic cylinders, a counterbalance manifold,
cartridge valves, two hydraulic accumulators, and
connecting links
Q. How does the counterbalance function.

A. The two hydraulic cylinders are connected to the
two hydraulic accumulators, the accumulators are precharged to 900 psi, When properly adjusted the
counterbalance systems supports all but about 800lbs
of the weight of the Top Drive over full 8 to 10 in stroke
of travel.
Q. What is the function of the accumulators and where

are they situated.
A. The counterbalance accumulators are situated in

each leg of the dolly frame. The two accumulators
constantly maintained at system pressure, are always
able to provide pressure to the counterbalance
cylinders if the main hydraulic power unit is switched
off. The accumulator is charged with nitrogen and a
predetermined hydraulic pressure setting by the
counterbalance circuit in the hydraulic control manifold.
Q. What type of accumulators do Varco use

A. They are piston type with a shreader valve
Q. How many different counterbalance configuration
does Varco have, and what are the differences in each
of the systems.
A. The are four different configurations, TDS-AC

System, IDS (Integrated Drilling System) with on
board hydraulics and IDS without onboard hydraulics
and the TDS DC system. There is also the PRS (Pipe
Racking System) that uses a counterbalance system.
Each system uses different types of cartridge valves
Q. What system uses what cartridge valves

A. The TDS AC System uses a pressure
reducing/pressure relieving valve to set the system
along with a pilot to open check valve.
The IDS with onboard hydraulics uses a pressure
reducing pressure relieving valve with a pilot to open
check valve and a needle valve.
The IDS without onboard hydraulics uses a pressure
reducing valve and a flow control valve.
The TDS DC System uses a pressure reducing valve
along with a needle valve and pilot open check valve.
All systems have a pressure relief valve for safety

Montrose Scotland
TOP DRIVE
Installation
Installation of Counterbalance System

Install counterbalance system as illustrated.
When using chains use the following procedure to
determine the chain length required.
a) Install Pear links onto hook-block
b) With the hook supporting the TDS, measure the
distance from point of contact inside the pear link to
top of the mounting lug on the integrated swivel
bail.
c) Subtract 37/-14 from the measurement in step b.
d) Cut the chain to length obtained in step c. The
tolerance is + 3-1/4 or 0
e) Assemble remaining components and install.
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, waterpumped Nitrogen gas.
2. Before precharging, make certain:
The accumulator end caps are screwed flush into the
accumulator body.
The gas valve is screwed in tight.
No oil remains trapped in the top end of the accumulator.
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. Turn 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, turn 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.

Montrose Scotland
TOP DRIVE
Training Manual
Hydraulic Components
Accumulators
The main task of an accumulator is to take a specific
amount of fluid under pressure from the hydraulic
system and store it until it is required within the
system.
As the fluid is under pressure, accumulators are treated
as pressure vessels and must be designed taking into
account the max operating pressure. How ever they
must also pass the acceptance standards in the
country in which they are being used.
In order to store energy in accumulators, the fluid in an
accumulator is weight or spring loaded or pressurised
by gas. Therefore a balance is maintained between the
pressure in a fluid and opposing pressure produced by
the weight, spring or pressure created by gas.
In most hydraulic systems hydro-pneumatic (gas
pressurised) accumulators with a separating element
are used. Depending on the type of separating element
used, accumulators are categorised into Bladder,
Piston and membrane accumulators.
Function
Accumulators have to carry out various functions in a
hydraulic system:Energy storage
Fluid reserve
Emergency operation
Balance in forces
Damping of mechanical shocks
Damping of pressure shocks
Compensation of oil leakage
Damping of shocks and vibrations
Damping suspension
Reclaiming of deceleration energy
Maintaining constant pressure
Compensation of flow (expansion tank)
Pressure Relief Valve

Pressure relief valves are used in hydraulic systems to
limit the system pressure to a specific set level. If this
set level is reached the pressure relief valve is
activated and feeds the excess flow from system to
tank
Theory of Operation
The basic principle of all pressure relief valves is that
the inlet pressure is fed to a measuring surface which
is acted on by force. The inlet pressure loads the
poppet or lower side of the control spool with hydraulic
force. The force of the pre-tensioned spring acts in the
direction of the closure. The spring chamber is
unloaded to tank. As long as the spring force is larger
than the pressure force, the seating element stays on
its seat. If the pressure force exceeds the spring force
the element pushes against the spring and opens the
connection. The excess fluid returns to tank. As the
fluid flows away via the pressure control valve,
hydraulic energy is converted into heat
Pilot Operated Check Valves

The pilot operated check valve positively locks a
pressure load, but releases the load upon application
of a pressure signal at the pilot port. This valve is
normally used to lock an actuator in position when the
directional control valve is centered. It it used in
applications where overrunning load control and or a
relief function is not needed or is provided by other
means.
Theory of Operation
A pilot operated check valve consists of a valve body
with inlet and outlet ports and a poppet held against a
seat by a spring. Directly opposite the check valve
poppet are a plunger and a plunger piston that are
biased by a light spring. Pilot pressure is sensed at the
plunger piston through the pilot port. The valve allows
free flow from its inlet port to its outlet port. Fluid flow
attempting to pass through the valve from the outlet
port to the inlet forces the poppet to its seat, blocking
flow through the valve. When enough pilot pressure is
sensed at the plunger piston, the plunger moves and
unseats the check valve allowing fluid to pass. The
ratio of the load pressure to the pilot presure required
to release the load is called the pilot ratio.
Needle Valve
Needle valves are commonly used to meter accurate
and precise flow of the fluid within a hydraulic
system. It can also be used to as a positive shut off for
the hydraulic system.
Reducing /Relieving Valve

These valves are dual purpose valves the Reducing
part of the valve maintains pressure at steady flow rate
while ensuring that the hydraulic system does not
become over pressurised
tank.
The pressure reducing valves are used to influence the
output pressure.
The reduction of input pressure or the maintenance of
output pressure is achieved at set value, which is
below the charging pressure available in the main
circuit. It is thus possible to reduce the pressure in one
part of the system to a level lower than system
pressure.
Theory of Operation
The basic principle of all pressure Reducing /Relieving
valve is not to let the output pressure rise above a
certain level, the relief valve monitors the pressure on
the system, when the system pressure rises above a
set pressure it returns the fluid back to tank. This
pressure can be influenced by the relief port .
(See hyd schematic)

Montrose Scotland
TOP DRIVE
Set Up Procedure
Set up Procedures
TDS DC System
The way to set up the TDS DC System is as follows:e
Check you have the following tools:9/16 Spanner and a 5/32 Allen Key
Check you have the following drawings available:-
Drawing
VM 2126 SHEETS 1 T0 5
Drawing
92114
Drawing
75420
Drawing
107530
Drawing
110407
Check the following valves are correctly installed:Pilot to open check valve
Needle Valve
Pressure Reducing Valve
Pressure Relief Valve
e
e
e
e
e
P/N
P/N
P/N
P/N
77616
76419
77615
94522-21N
Check all connecting liks are secure and all bolts are
safety wired.
Check TDS is not sitting on the guide stops .
Check the Hydraulic reservoir is full and all quick
disconnects are installed properly.
Check all hose connections are tight.
Check the 2 accumulators are pre-charged with 900
psi of Nitrogen.
Check hydraulic power supply is set to 2000 psi.
Adjustment Procedure
Screw needle valve counterclockwise until fully open.
Screw pressure reducing valve counterclockwise until
fully open.
Start hydraulic power unit and let hydraulic oil flow for
2 minutes.
Bleed system cylinders.
Screw needle vale clockwise until fully closed.
Screw pressure reducing valve clockwise until
cylinders start to retract raising the TDS.
Slowly screw the pressure reducing valve
counterclockwise reducing the pressure to the
cylinders.
When the swivel bail just contacts the hook note the
pressure and decrease it by 25psi tighten lock nut.
Troubleshooting the counterbalance

Symptom
Probable cause
Remedy
System does not hold

pressure.
Needle valve is not closed.
See adjustment procedure and check

needle valve.
Cylinder rod seals leak.

Fittings or hoses leak.
Dirty or defective PRV valve
Dirty or stuck check valve.
Replace seals.
Tighten or replace as required.
. See adjustment procedure.
Clean or replace.
Clean or replace.
Counterbalance control valve Return valve to drilling position.

in rig down position.
Cylinder rods remain
retracted (closed).
Pressure setting too high.
Adjust per adjustment procedure.
activating or reactivating the counterbalance system, never

z When
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.
1) Where is the counterbalance manifold situated?
____________________________________
____________________________________
____________________________________
____________________________________
2) Name the three valves in the counterbalance manifold?
_______________________________________
_______________________________________
_______________________________________
3) What stops the counterbalance system from being over pressurized?
____________________________________
____________________________________
4) Where are the Counterbalance Accumulators situated ?
____________________________________
____________________________________
____________________________________
____________________________________
5) What type of valve is on the Counterbalance Accumulators ?
____________________________________
____________________________________
____________________________________
6) What type of Accumulators are the Counterbalance Accumulators?
____________________________________
____________________________________
7) What is the reason for having a counterbalance system ?
____________________________________
____________________________________
8) What indicates that the Counterbalance is faulty or not set up properly?
9) Check the following drawings and mark up any defects missing parts.
___________________________________________________________
___________________________________________________________
___________________________________________________________
10) What tools are required to set up the counterbalance system?

___________________________________________________________
____________________________________________________________
____________________________________________________________

Montrose Scotland
TOP DRIVE
Training Manual
Alignment
Training Manual
Motor Alignment System

All Varco DC Top Drives have an Alignment
System, One Top Drive System Model that differs
from the other DC Models is the TDS 6S, and this is
due the size and weight of that particular model.
What does the Alignment System do
The alignment cylinder is not intended to

be used to align the pin
with the box at the well bore. It is a
device to counterbalance the
offset weight of the DC motor and allow
the system to accommodate
external forces. It is adjustable to ensure
that the mainshaft is straight
at well centerto compensate for
design tolerances in the guide rails
and dolly. To work properly, the guide
rails must be properly located,
and the dolly must fit within design
tolerances..
What does the system consist of
The earlier Top Drive systems (TDS 3)Models

did not have a separate accumulator system, but
all other models do have a separate accumulator
for the system. The system with the separate
accumulator consist of a duplex counterbalance
cylinder with 2 flow control valves attached,
hydraulic accumulator, hydraulic manifold with a
pressure reducing cartridge valve a needle
valve, and a pilot to open check valve.
Where is the system fitted
The duplex cylinder is attached to a pad eye on

the lower gear case and another pad eye
attached to the motor guide frame.
Alignment
Training Manual
Adjusting the motor alignment cylinder

For units without a separate alignment cylinder accumulator
The counterbalance system must be properly adjusted before
attempting to adjust the alignment cylinder.
Turn off the hydraulic power unit and bleed down the TDS
accumulators by opening the needle valve located on the
counterbalance valve manifold. Remove the split shipping brace
from the motor alignment cylinder, then open the two flow control
valves by 1 turns each these valve are located on the motor
alignment cylinder supply and return lines. Close the needle valve
and turn the hydraulic unit back on, then verify the pressure is
1100-psi +/- 100 psi.
Set a joint or stand in the rotary slips, (do not use a pup joint as
this could give a false position). Bring the TDS down until it is
stabbed into the box. The pin and box should be in alignment
within +/ - . The OD of the pin should clear the shoulder of the
box so that the connection can be made up without damaging the
threads. If adjustments are necessary, use the following
procedure.
a) Measure how far and in what direction the pin has to move to
line up the pin and box.
b) Turn off the hydraulic power unit and bleed down the system
then loosen the lock tab and jam nut on the cylinder clevis.
c) Using an open ended spanner (wrench),(do not use a pipe
wrench) on the cylinder rod flats screw the rod in the direction
required. turn on the rod results in the pin movement of .
Note
Alignment cylinder rod extension should be 2 3/8 +/ -1/8
Gland to rod threads when aligned properly.
d) Secure the jam nut and lock the tab when alignment is set.
Alignment
Training Manual
For units with a separate alignment cylinder accumulator

Check you have a pre-charge of 900 psi in the accumulator
The counterbalance system must be properly adjusted before
attempting to adjust the alignment cylinder.
The pressure setting is adjusted by screwing the pressure
reducing
valve in or out with a hex wrench (Figure 13). 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).
1. 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 preload in each direction both toward and away from the rails.
e. Record the pressure setting for future reference.
2. Set a joint of drill pipe in the slips.
3. 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:
Alignment
Training Manual
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. Turn off the hydraulic power unit and bleed down the
alignment cylinder accumulator. This allows the motor
alignment cylinder 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 1/4" of pin movement results
from a 3/4 turn 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
1-1/2 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 1/2" of cylinder stroke), the flow
control valves may be closed to 3/4 turn off their seats.
g. Tighten the lock nuts and replace the caps on all valve
stems.
If the alignment cylinder is removed for service, install the
alignment cylinder replacement brace to support the motor
housing assembly while continuing to operate 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.
Alignment
Alignment Cylinder
Lug (ref)
Pressure Reducing
Valve
Needle Valve
Motor Frame (ref)
Alignment
Cylinder
Manifold
Accumulator
Bracket
Gas Valve
Motor alignment cylinder manifold
Split
Shipping
Brace
Motor
Alignment
Cylinder
Motor
Frame Dolly (Ref)
Alignment cylinder
Troubleshooting the Motor

Alignment Cylinder
Symptom
Probable cause
Remedy
Alignment cylinder
fails to move
transmission at
trunnion pivot points
with recommended
pressure setting.
Transmission trunnion pins

will not pivot in dolly
support brackets, from lack
of lubrication.
Free trunnion pins as needed and

lubricate area regularly.
Possible problem with

Counterbalance
system hydraulic
system works
erratically or does not components.
work at all.
Chec kTroubleshooting the

Counterbalance section of this book.
Loss of nitrogen precharge in Recharge accumulators as per the

procedure in th Counterbalance
e
accumulators located in
section of this book.
motor dolly upright frame.
System does not hold
pressure.
Saver sub on TDS

does not align with
drill pipe.
Needle valve is not closed.
Adjustment
Se e
procedure.
Cylinder rod seals leak.
Replace seals.
Fittings or hoses leak.
Tighten or replace as required.
Dirty or defective PRV valve
. Clean or replace.
Alignment cylinder pressure

too high or too low.
Se eAdjustment procedure.
Alignment cylinder rod

Adjust according to procedure.
adjustment too long or short.
Excessive motor
movement.
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.
Alignment cylinder fluid

flow not adequately
throttled.
Se eAdjustment procedure. Normal

adjustment is 1 1/2 turns from full
closed position on flow control
valves. If there is excessive movement
close to 3/4 turn from full closed
position.
Pilot Operated Check Valves

The pilot operated check valve positively locks a
pressure load, but releases the load upon application
of a pressure signal at the pilot port. This valve is
normally used to lock an actuator in position when the
directional control valve is centered. It it used in
applications where overrunning load control and or a
relief function is not needed or is provided by other
means.
Theory of Operation
A pilot operated check valve consists of a valve body
with inlet and outlet ports and a poppet held against a
seat by a spring. Directly opposite the check valve
poppet are a plunger and a plunger piston that are
biased by a light spring. Pilot pressure is sensed at the
plunger piston through the pilot port. The valve allows
free flow from its inlet port to its outlet port. Fluid flow
attempting to pass through the valve from the outlet
port to the inlet forces the poppet to its seat, blocking
flow through the valve. When enough pilot pressure is
sensed at the plunger piston, the plunger moves and
unseats the check valve allowing fluid to pass. The
ratio of the load pressure to the pilot presure required
to release the load is called the pilot ratio.
Needle Valve
Needle valves are commonly used to meter accurate
and precise flow of the fluid within a hydraulic
system. It can also be used to as a positive shut off for
the hydraulic system.
Reducing /Relieving Valve

These valves are dual purpose valves the Reducing
part of the valve maintains pressure at steady flow rate
while ensuring that the hydraulic system does not
become over pressurised
tank.
The pressure reducing valves are used to influence the
output pressure.
The reduction of input pressure or the maintenance of
output pressure is achieved at set value, which is
below the charging pressure available in the main
circuit. It is thus possible to reduce the pressure in one
part of the system to a level lower than system
pressure.
Theory of Operation
The basic principle of all pressure Reducing /Relieving
valve is not to let the output pressure rise above a
certain level, the relief valve monitors the pressure on
the system, when the system pressure rises above a
set pressure it returns the fluid back to tank. This
pressure can be influenced by the relief port .
(See hyd schematic)

Montrose Scotland
TOP DRIVE
Training Manual
Cooling Motor
Cooling Systems
Varco has four types of cooling systems the
customer can choose from to cool the Varco
Top Drive Drilling Motor.
1.
2.
3.
4.
Closed Loop Cooling

Local Blower
Local blower with extended air intake
Remote blower
Q Why have so many different systems.

A The main reason is that countries around
the world have their own underlying
certifying authorities how govern their
policies on certification. Many of these
authorities have different rules governing
specifications
on
electrical
motors.
Depending on where the drilling rig is going
to operate will depend on what cooling
system will be used.
A Rig working in the North Sea may only
have 2 systems to choose from, a Remote
Blower system or a Closed Loop cooling
System.
A rig working in the Gulf of Mexico can have
all 4 systems to choose from.
Before a Top drive is sold a survey should
be carried out on the installation to check the
Top Drive System components conforms to
the particular area where it is going to work.
Q What is the best system
A Each system has its own unique
advantages
and
disadvantages,
the
following pages describe all four systems.
Closed Loop
Closed Loop System

The Close Loop Cooling System can use EXD OR UL
components to meet all world underlying Authorities, by using
EXD or UL components the Top Drive with closed loop cooling
can have classification to work any where in the world. The
system should be capable of producing a CFM of 3200.
The closed Loop system consists of the following main parts :20 HP Blower motor
Heat exchangers
Air Flow Ducts
Water detectors
Differential pressure switch
Pressure switch
Temperature switch
Expo purge system
Water pumps
Flow indicator
Service loop containing water hoses
Blower Motors
The blower motor is a dual shaft 20 HP AC, that is attached to
the blower mount brake cover. The motors are EXD or Ul rated it
is always best to check the name plate before installing.
The impellers are attached to each shaft end and are fixed by a
taper lock mechanism.
The Blower impellers are then incased in the ducting assembly.

A 8 flex connects to the ducts on the GE 752 or EMD Drilling
Motor. The Blower inlets are connected to the heat exchangers
.
.
Heat Exchangers
The closed loop cooling system consists of two tube fin type heat
exchangers cooled by twin blowers driven by a double ended AC
Motor. Ducting passes air out the motor exhausts port to the heat
exchangers and back to the blower inlets. The heat exchangers
are built from Cupro Nickel tubes and the headers are pressure
tested to 250 psi.
The system requires a supply of liquid coolant (Sea Water,
Chilled fresh water or Glycol) at 50 gpm ( in the case of a TSD
6S each motor requires 50gpm) at a maximum inlet temperature
OF 90F.
As the drilling motor rotates carbon dust is being produced by the

wear of the brushes inside the drilling motor. As the air flows round
the system the carbon dust can then build up on the commutator
and can cause a flash over inside the drilling motor resulting in a
motor change There are Carbon dust filters that can be installed.
These filters are an aid in stopping build up of the carbon but they
must be replaced at regular intervals
Water Detectors
System operation
The sensor is mounted in the scroll of the blower housing of
drilling motor at such a position that the air circulation pattern
from the blower,s impeller will cause leaking coolant water
particles to strike the sensitive sensor element. If water is
present the sensors resistance lowers causing the water detector
amplifier to conduct a 24 Vdc to the Programmable Logic
Controller (PLC). The PLC then sounds the warning horn and
illuminates the Drillers console water detection indicator lamp.
Pressure/ Temperature Switches

Differential pressure switch
The reason for having a differential pressure switch is to monitor
the flow of pressure in the system.
A line is connected to a fitting on the duct at the commutator end
of the main drilling motor and attached to the high port fitting of
the switch, and another line is connected to a fitting in the
opposite air duct at the pinion end of the drilling Motor and
connected to the fitting on the low pressure of the switch.
Dureing normal operation the blower differential pressure switch
on the TDS is in the open position. Upon Blower failure the
pressure switch senses low or zero output pressure and the
switch closes to supply a 24Vdc signal to the Programmable
Logic Controller (PLC) Module. In addition another 24Vdc signal
is sent to the auxiliary contacts of the Blower Starter Relay to the
PLC. When the PLC receives the pressure switch signal and the
auxiliary signal from the blower motor starter it sends no signal
to the Drillers Console. If either signal is lost the PLC sends a
pulse 24Vdc signal to the Blower Fail Indicator on the Drillers
Console for a a flashing ON indication and sounds the warning
alarm. If The operator depresses the alarm silence button to
silence the alarm , the flashing indicator changes to a steady
indication . After 5 minutes if the malfunction still exists then the
indicator will revert back to flashing indicator and the warning horn
will sound
A clogged carbon filter can restrict the airflow and can cause the
differential alarm.
Cooling Air Temperature switch

The cooling Air Over-temperature switch monitors the Drilling
Motor outlet air temperature to alert the operator of dangerously
high temperature. It is a normally open pressure switch with a
liquid filled temperature bulb connected to the pressure inlet of the
switch with a capillary tube. The temperature bulb is mounted in
the exhaust air outlet in the TDS Main Drilling Motor duct When
air temperature exceeds 170 the switch closes sending a 24VDC
signal to the PLC. The PLC activates the warning horn and
illuminates the TDS OVERTEMP Indicator Lamp.
If the water pumps are not producing 50 GPM or the flow is
restricted this would cause an alarm situation.
A flow switch is installed on the return pipe work which is usually

placed near the water reservoir, (except in the case of the TDS6S
its switch is usually placed up at the diving board level )
When the blower is running the system is in a negative state and
requires a purge air rate of 70 scfm per motor at 1.0 psig to
provide a positive system. A purge control system is required to
monitor system pressure for safe operations.
Local Blower
Local Blower System

The Local Blower System can be use UL or EX components to meet
all world underlying authorities, by using EX or UL components the
Top Drive with the Local blower can have classification to work in
most areas where drilling operations are required. There are different
classifications within the European Nations, (British Sector,
Norwegian Sector, Danish Sector, Dutch Sector to name but a few.
The Hazardous area zones differ in shape and sizes for most
sectors,
There is a hazardous area course that covers all these zones along
with other important issues.
(It would be beneficial to all Engineers if they attend one of
these courses)
The Local Blower Components consists of the following main Parts:20HP Blower Motor
Spark Arrestors
Air flow ducts
Differential Pressure Switch
Temperature Switch
Pressure Switch
Flex cooling Duct ( For extended intake system)
Local Blower
The basic local blower system is designed to provide local cooling air
to the drilling motor. It receives air from approx 20 feet above the rig
floor at the lowest point of the motors travel.
A heavy constructed pressure blower is mounted to the motor. The
motor is directly driven by an explosion proof 20 HP, 3450 rpm AC
electrical motor.( older versions may have an 15 HP Motor) The
motor is connected to the blower with a rigid duct.
The design provides highly reliable service with positive ventilation
through its normal inlet and spark arrestor protected outlets. It
provides a safe, visibly verifiable system that will prevent explosion of
flammable gasses or vapors coming from the well bore.
The system should be capable of producing a CFM of 3200.
The system is monitored in the same way as the closed loop system,
and gives the operator the same alarms.
Local Blower with Extended Intake

To comply with certain Authorities requirements, the minimum intake
height must be raised. In order to accomplish this is to fit an extended
intake. This system consist of the standard type local blower with
ducting to allow the intake to be mounted on the hook or traveling
block with a flexible hose running down to the motor. This raises the
air intake height to approximately 30 feet above the rig floor.
Axial Fan
20 hp
Blower Motor
Transmission
Cooler
Locking Key
Oil Fittings (2)
Blower Housing
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
FLL-X Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Typical local blower cooling system
Spark Arrestor
Typical local blower cooling system

(Shown with optional extended intake)
Lubricating the cooling system

Lubricate AC blower motors every three months .
Explosion Proof AC Blower Motor

Grease Fitting
Grease Fitting
Motor Cooling Blower
Transmission Cooler
. Lubricating the local cooling system
Use the following procedure to install a new motor in the local

cooling system:
1. Install wear sleeves on the blower motor shaft.
2. Bolt the blower motor onto the blower motor mount and
safetywire the bolts.
3. Install the blower housing and inner plate assemblies on both
sides of the blower motor frame as follows:
a. Use two 3/8 in. bolts in the threaded alignment bolt holes
on both sides to line up the blower housing and inner
plate assemblies with the blower motor frame on both
sides.
b. Gradually insert and tighten the bolts that connect the
blower housing and inner plate assemblies on both sides
to the blower motor frame. Check the alignment holes as
you tighten the bolts to make sure both assemblies line up
properly on the blower motor frame.
4. Install shaft seal assemblies inside both blower housing
assemblies. Make sure the seals are centered.
5. Tighten and safetywire the retainer plates in place on both
sides.
6. Install the impellers and taper lock bushings on both sides
and safetywire the bolts.
7. Install the blower inlet duct assemblies to the blower housing
on both sides using the same alignment holes used in Step 3a.
8. Hoist the entire cooling system assembly onto the TDS. If the
alignment holes were properly used, the cooling system
assembly should line up perfectly on the TDS.
9. Install and safetywire the four bolts connecting the blower
mount to the brake cover.
10. Install and safetywire the four bolts on each side connecting
the heat exchange duct housing assemblies to the blower inlet
duct assemblies.
11. Install and safetywire the six bolts on each side connecting the
transmission ducts to the blower housing ducts.
12. Connect the electrical wires to the blower motor.
Remote Blower
Remote Blower System

The Local Blower System can be use UL or EX components to
meet all world underlying authorities, by using EX or UL
components the Top Drive with the Local blower can have
classification to work in anywhere drilling operations are required.
The remote Blower cooling system consists of the following
components:40 HP Blower Motor
Skid for Blower to mount on
Spark Arrestors
8 flexible hose
Differential Pressure switch
Temperature switch
Water detector (optional extra)
The remote blower system is normally used when the rig cannot
be assured of good safe cooling air. The system works the same
as the Local system except that a 40HP motor is placed in the
Derrick at diving board level and receives air from out side the
derrick walls. The extra horse power is required to force the air
down through the hose and through the motor, keeping it in a
positive state. The system is monitored the same as the closed
loop cooling system, and the Local Blower system, giving the
operator the same alarms.
The system should be capable of producing a CFM of 3200.
The impeller is fitted the same way as the Closed Loop System
and there is a mist filter to stop moisture getting into the system.
Air Inlet
40 hp Explosion Proof
Electric Motor (AC)
and Centrifugal
Pressure Blower
Wind Wall
Racking Platform
at Racking Board Level
Rigid Cooling Duct
Spark Arrestor
Motor Dolly Assembly
86' Flex Air Duct
Typical remote blower cooling system
Trouble-Shooting
Troubleshooting the cooling system

Symptom
Probable cause
Remedy
Mechanical noise in
blower.
Loose impeller.
Reinstall impeller and hub and

locktite screws.
Faulty motor bearings.
Repair or replace as needed.
Faulty or loose wiring.
Locate and repair as needed.
Faulty motor starter.
Check for dirt or trash between

starter coil. Repair or replace as
needed.
Worn or defective seal or

wear sleeve.
Replace as needed.
Loose or vibrating blower

motor, wearing seals
excessively.
Correct blower mounting problem

or faulty motor bearing and replace
blower shaft seals.
Incorrect blower rotation.
Verify blower rotation. Correct as

needed.
Dirty or clogged spark

arrestors (local or remote
cooling systems).
Remove spark arrestors from motor

and clean screens if screens are
damaged with holes. Replace as
needed.
Blower runs
intermittently.
Excessive air loss in

blower motor shaft
area.
DC MOTOR
OVERHEATING,
OVERTEMP alarm
stays on with blower
running.
Clogged water or air passages Remove and clean passages as

needed.
in water cooled exchangers
(closed loop cooling).
Troubleshooting the cooling system (cont.)
Symptom
Probable cause
Remedy
DC MOTOR
OVERHEATING,
OVERTEMP alarm
stays on with blower
running.
Continuous drilling Amps

over recommended levels.
Check service manual for continuous

Amp motor rating and adjust
drilling program accordingly.
Motor being stalled for over

recommended periods of
time.
DC motor should never be stalled

for more than 5 seconds with over
300 Amps applied.
Serious damage could occur to the

motor if this is done.
Faulty temperature switch or Repair or replace as needed.

probe.
Do not readjust or raise heat range

setting.
Improper cooling water flow See the Installation and

or incoming water temp too Commissioning book for
recommended or required flow rates
high (closed loop cooling).
and water temp.
Restricted air flow (local or
remote cooling).
Check and clean spark arrestors as

needed.
Check air intake on blower to ensure
there are no restrictions.
Verify proper blower rotation.
WATER
DETECTOR
alarm is on
(closed loop system).
Moisture in air inside DC

motor.
Check for leaks in heat exchanger.

Check air purge line filters. Ensure
dry air is going into motor.
Dirty or faulty water

detector.
Clean or replace as needed.
COOLING SYSTEMS TEST

Name
Position
1) Name the different cooling systems Varco uses

_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
_____________________________________________________________
2) Explain why Varco uses different systems?
____________________________________
____________________________________
____________________________________
____________________________________
3) What size of Blower Motor is used on the Closed Loop System?
_______________________________________
_______________________________________
4) What GPM is required for the cooling of the TDS 6S Model?
____________________________________
5) Why does the Local Cooling System require a Differential Pressure

Switch ?
____________________________________
____________________________________
6) What is the Air Temperature switch set at ?
____________________________________
____________________________________
7) What Cooling System requires a CFM OF 3200?
____________________________________
8) What keeps the impeller in place on the Remote Cooling System?
____________________________________
____________________________________
9) What causes excessive air loss in the Remote Blower Cooling system?
____________________________________
____________________________________
10) What Direction Should the Local blower motor run ?
______________________________________________________________________________________
______________________________________________________________________________________

Montrose Scotland
TOP DRIVE
Training Manual
Motor Brake
Training Manual
Top Drive Brake
10
5
6
3A
Note:
OptionalQuickRelease
Valve. Notavailable for
11.5VC500.
2
12
11
Ventilated Construction
Friction shoe backing plates have large air passages

through the entire length. This constuction coupled with
scallop side plates allow cooling air to flow through the element
In addition the large exposed inside diameter assures the
coolest possible operation. None of the heat is generated deep
in the element's internal parts where it can be trapped.
The open construction assures rapid heat dissipation.
Item
ComponentDescription
Rim
Tube(withvalvestemsnapringswhererequired)
ElbowAssembly
3A
Optiona
l - QuickReleaseValveAssembly
CompressionRing(includedwithitems 3 & 3A)
Air ConnectionTube
Air ConnectionGasket
FrictionShoeAssembly
Air TubeGroup(DualMounted)
SpacerGroup(DualMounted)
10
ReplacementFrictionLining & FastenerKit
11
Side Plate(2 required)
12
TorqueBar
13
ReleaseSpring
7, 12, & 13
FrictionShoe, TorqueBar & SpringKit
13

Montrose Scotland
TOP DRIVE
Training Manual
Motor Housing

Montrose Scotland
TOP DRIVE
Training Manual
Washpipe Assay
Washpipe assembly
1. With the packing box upside down, assemble the
packing seals and spacers into the packing box
using care to line up the upper spacer slot with the
dowel pin.
2. Hand pack all seals with multipurpose lithium-based
outside diameter of the spacers.
3. Install the socket head dog nose screw, ensuring
that the screw nose is fully engaged in the groove
of the lower spacer.
4. Install the grease fitting and turn the packing box
upright.
5. Install the wash pipe into the packing box assembly
(slotted end up).
6. Install the wash pipe nut onto the wash pipe.
7. Grease the packing seal and install into the holding
ring using care not to grease the outside diameter
of the holding ring.
8. Install the packing seal and holding ring over the
slotted endof the wash pipe.
9. Install the snap ring.
10. Install the upper and lower o-rings using grease to
hold them in place.
11. Compress the assembly to the length of the wash
pipe.
Disassemble the washpipe packing in the reverse
order of the
above procedure. Refer to the Washpipe Assembly
Guide, P/N 128844.

Montrose Scotland
TOP DRIVE
Training Manual
Drilling Motor
D.C. Motor Identification
Section 1 - Introduction
Varco has used two different types of Electrical DC motors on their DC Top Drive
range they are from EMD (Electro Motive Diesel) and from GE (General Electric).
The fist ever Top Drive built, TDS-1 utilized an EMD M89VTS series motor, and this
motor had been previously used on a Locomotive. This Top Drive went to work on
board the Sedco 201 rig in the Arabian Gulf on 1st April 1982. Initially the EMD
motor was preferred, but as to production demands etc. Varco decided to utilize a
second company (GE) in 1983, this then gave the option of utilizing either a Shunt or
Series type motor as opposed to EMD who only supplied a Series type motor.
The main operating difference between the Series and the Shunt type motors
is the output Torque and Speed control. Where the Series motor has a slightly
greater Output Torque, the Shunt motor gives greater speed control with the ability
to also alter the Field current with an Active Field Supply and thus get greater speed
control. This is one of the main reasons why a Shunt motor is more commonly
specified as opposed to a Series motor on Top Drive applications.
In 1989 GE introduced their new High Torque motors, this motor was able to
increase the Top Drive torque output, this is now used as standard when a new
motor is obtained from GE.
The charts below show examples of the differences between Shunt and Series
motors, and between Standard Torque and High Torque motors for continuous
drilling maximum Top Drive output Torques.
Shunt @ 57A
TDS-3
TDS-4(Low gear)
TDS-4(High gear)
TDS-5
Standard Torque motor

26,400 Ft/Lbs. @195 RPM
38,700 Ft/Lbs. @130 RPM
24,800 Ft/Lbs. @200 RPM
33,000 Ft/Lbs. @155 RPM
High Torque motor

31,000 Ft/Lbs. @165 RPM
45,000 Ft/Lbs. @130 RPM
29,100 Ft/Lbs. @200 RPM
38,700 Ft/Lbs. @130 RPM
Series
TDS-3
TDS-4(Low gear)
TDS-4(High gear)
TDS-5
Standard Torque motor

27,800 Ft/Lbs. @185 RPM
40,900 Ft/Lbs. @125 RPM
26,100 Ft/Lbs. @195 RPM
34,800 Ft/Lbs. @150 RPM
High Torque motor

34,700 Ft/Lbs. @150 RPM
50,900 Ft/Lbs. @100 RPM
32,500 Ft/Lbs. @160 RPM
43,300 Ft/Lbs. @125 RPM
The above picture shows the EMD Series motor that was used in the construction of
the First Top Drive. The commutator and shaft were removed and machined to fit
the requirements of the Top Drive gearbox.
Section 3 DC Motor Types

General Electric
TDS 3,4,5+6
GE 752 AUP 1,2,3. Series wound standard torque motor
Cable size 535 MCM
P/N
75989-1
GE 752 UP 1,2,3. Shunt wound standard torque motor P/N

Cable size 646 MCM
75989-2
GE 752 AUT 1,2,3. Series wound high torque motor

Cable size 535 MCM
P/N
GE 752 US 1,2, Shunt wound high torque motor

Cable size 646 MCM
P/N
IDS
GE752IDS Shunt wound high torque motor
Cable size 646 MCM
86542-1
87966
PN
103609
P/N
77029
EMD
TDS - 3
M89VTS Series wound standard torque motor
Cable size 444 MCM
DC Motor Connectors
GE Motor connectors (TDS 3,4,5 +6)
GE Motor Connectors (IDS Integrated J/B)
EMD Motor connectors (TDS 3)
P/N 79826
P/N 79826 * 1
P/N 99580 * 2
P/N 79835
Section 4 - Cooling Ducts Identification

To identify the motor type visually by the cooling ducts in the pinion end cover, 4
cooling holes is a standard Torque and 10 cooling holes high Torque, this is
illustrated in the pictures below.
Above is a standard torque motor, with 4 cooling ports on the lower face with bolt on
cooling ducting as used on TDS 3 and TDS 5 applications.
Above is a high torque motor with 4 cooling ports on lower face plus 6
circumferential slots in the main end cover.
Section 5 - Gearcase Identification

The gearcase application for a standard torque and high torque motor is also
different, details of these is shown below.
Above is a standard torque motor gearcase application where the gearcase is

separate from the cooling system and the ducting bolts directly to the motor.
Above is a high torque gearcase application where the gearcase is an interregnal

part of the cooling system and the motor seals against the gearcase.
Section 6 - Testing the GE752 Motor

1. Remove commutator covers on motor to inspect and ensure all
brushes are fully seated and their retaining springs are in place.
2. Check armature and field cables for signs of wear or damage and
ensure all tails are sitting clear of both the motor and the shop floor.
3. Select the 1000V range on the Megger and check that the battery
is O.K
4. Connect one lead from the Megger to the motor frame ensuring a
good connection. Connect the other lead to one of the armature
cables. Press the test pushbutton on the Megger and note down
value below.
5. Repeat step 4 but this time move lead from the armature cable to
the armature cable screen and note down value below.
6. Repeat steps 4 & 5 but this time use one of the field cables and
note values below.
7. Connect one lead from the armature cable and the other from the
field cable. Press test button on Megger and note down value below.
Armature to Ground / Screen
Megger Reading
This should give a reading somewhere in the region from 500M Ohms to 50M
Ohms. When new this should be expected to be reasonably high. The lowest
reading that the motor should be operated at is 0.5M Ohms, once the motor is
electrically energized, this should rise. If the megger reading is lower than 0.5M
Ohms, the motor should be heated up before use, as most SCR systems will fault
below this level and there is also a possibility of damage to the motor.
Field to Ground / Screen Megger Reading

This reading should be about 500M Ohms, if this reading is lower, the motor should
also be heated to bring the value a higher.
10
Training Manual
PINION GEAR
INSTALLATION
Training Manual
PINION GEAR INSTALLATION

SUBJECT: Pinion Gear and Drive Train Life.
PURPOSE: To notify users of proper assembly
procedures for Pinion Gears and Hubs to Top Drive
drilling motors.
EFFECTIVITY: All Varco BJ Top Drive Drilling
Systems.
Assembly of the Pinion Gear or Pinion Gear Hub to the
Top Drive drilling motor shaft is extremely critical to the
life expectancy to the drive train. The Pinion Gear and
Hub used on the Varco Top Drive is unique to this
application and the fit to the motor shaft is not
necessarily the same as other gears, hubs, sprockets, etc,
which may be used on other types of machinery.
Improper assembly may lead to premature failure
through material fractures and/or separation of the gear
or hub from the shaft.
Training Manual
PINION GEAR INSTALLATION
Proper fit requires hand fitting and polishing of the

mating surfaces while maintaining precise tolerances in
relation to other dimensions of the pinion. Successful
assembly depends a great deal on skill, knowledge, and
training of the personnel performing the work. Final
verification of correct installation dimensions is
essential.
Here is an example of the Pinion Gear being heated

using the Induction Heater.
Current date
Installing the top drive motor pinion
Installing a pinion gear can be dangerous to personnel

installing it as well as anyone witnessing the procedure.
Exercise caution at all times.
Use the following procedure to install a TDS motor pinion:
1. Clean the motor shaft by hand and cover with a thin layer of
Engineers Blue.
2. Firmly install the pinion on the motor shaft by hand. Mark
reference lines on the pinion and the shaft to ensure identical
angular orientation each time.
3. There must be a minimum of 75% surface contact between
the pinion and motor shaft. Dress the motor shaft/pinion
very lightly with a fine emery cloth 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/or 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 gear 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 end of 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 to
0.074 in. Then lock the screw in place with a locknut.
10. Remove the fixture from the pinion gear assembly.
e
4-70
Do not put the fixture in the oven.
TDS-3H Maintenance and Troubleshooting
11. Heat the pinion gear to 360 - 385F (182 - 196C) for three
hours in an oven. After heating for three hours, remove the
pinion gear assembly and immediately attach the fixture.
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 0.005 in. advancement.
16. When the pinion is fully cooled, fit the fixture and check final
advancement.
17. Complete the required documentation recording pinion
advancement.
4-71

Montrose Scotland
TOP DRIVE
Training Manual
Gearbox

Montrose Scotland
TOP DRIVE
Training Manual
Motor Removal
Removing the motor assembly from the

guide dolly
You can perform some service procedures on top drives (i.e. upper
quill shaft 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 the TDS down horizontally on a good flat surface. Make

sure that none of the components protrude past the guide
dolly roller brackets before setting down. If so, block dolly up
accordingly.
2. Disconnect all wiring and hoses between the transmission and

guide dolly frame.
3. Remove any cooling ducts (heat exchanger, spark arrestor,
etc.) that interfere with removing the transmission from the
guide dolly frame.
4. Run a suitable sling through the quill shaft to support the
weight of the motor and housing assembly (approximately
10,000 lb).
5. Attach the sling to the crane, take up slack and remove the
trunnion blocks that hold the transmission to the guide dolly
frame.
6. Hoist the transmission out of the guide dolly frame.
7. Set the motor and housing assembly down on wooden
chocks, being careful not to damage the components.
8. Disconnect the wiring between the motor and the housing.
Make sure the transmission is in neutral.
9. Remove the dowel pins in the motor feet.
10. Remove the four large motor bolts.
11. Lift the transmission off of the motor, angling the upper end
slightly to clear the motor frame, and sliding the housing off
of the motor towards the gearcase end.
12. Remove the blower and brake assemblies.
13. Reverse this procedure for reassembly.
TDS-3H Maintenance
Training Manual
Removing the drilling motor from

the housing assembly
1. Remove the upper bearing cover and grease seal.
2. Pressurize the air brake to hold the drive mechanism in place
and remove the quill shaft locknut.
3. Remove the cotter pins, slotted nuts and rotating head.
4. Remove the lower gear case. The lower gear case is located
with dowel pins.
5. Carefully remove the quill shaft with bull gear so as to avoid
damaging the bearing surfaces or wear sleeves. Do not remove
the gear from the shaft unless replacing it.
6. Remove the large quill shaft bearings.
7. Remove the pinion seal and retaining ring.
8. Remove the upper gear case.
9. On the opposite end of the motor, remove the magnetic
pickup and brake cover.
10. The brake may now be removed for service.
Refer to the electric motor sections to remove the pinion or hub
on the armature shaft or to service the motor itself.
Once the unit has been disassembled, inspect the assemblies for
any wear or damage that may be critical, as follows:
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. Some small surface pitting is to be expected
and 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 in.
4. Main shaft: Check fit to bull gear, wear sleeve surfaces and
retaining threads.
5. Seals: Always replace seals and gaskets when removed.
TDS-3H Maintenance
6. Main shaft housing: The bore for the upper bearing and the
pilot diameter for the lower gear case are critical. Any nicks or
gouges must be cleaned up prior to re-assembly.
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 have been
malfunctioning, remove the appropriate valve and repair or
replace.
Reassemble the drilling motor and housing assembly by reversing
the steps in the above disassembly procedure. Replace all grease
seals and O-rings. Refer to the following torque chart for bolt
tightening guidelines.
Torque chart
Motor housing to motor
Upper gear case to housing assembly
Bull gear to hub
Lower gear case to main body
Rotating head to lower gear case
Brake adapter ring to motor
Brake to brake adapter plate
Brake drum to hub
Brake cover to brake
Upper seal retainer to motor housing
1750 ft lb.
1100 ft lb
580 ft lb
250 ft lb
250 ft lb
250 ft lb
50 ft lb
250 ft lb
50 ft lb
75 ft lb
(2373 N.m)
(1492 N.m)
(786 N.m)
(339 N.m)
(339 N.m)
(339 N.m)
(68 N.m)
(339 N.m)
(68 N.m)
(102 N.m)
TDS-3H Maintenance
Training Manual
Gooseneck
Main
Body
Air
Brake
Motor
Support
Bonnet
Bull
Gear
D.C.
Drilling
Motor
Pinion
Gear
Drive
Stem
Motor
Alignment
Cylinder
(Ref.)
Lower
Gear
Case
Figure 19. Drilling motor and motor support bonnet assembly/disassembly
TDS-3S Maintenance
Training Manual

guide dolly
drive stem bearing and seal, air brake or locally mounted cooling
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.
etc.) that interfere with removing the transmission from guide
dolly frame.
5. Use a suitable sling to support the weight of the TDS and
motor support bonnet (approximately 10,000 lb).
6. Take up the slack and remove the trunnion blocks that hold
the transmission to 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.
slightly to clear the motor support bonnet, and sliding the
housing off of the motor toward the gearcase end.
TDS3 Maintenance
Training Manual
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.
7. Remove the main body.
9. Remove the brake for service.
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.
3. Main shaft: Check splines and tool joints for wear. Replace
the shaft if spline wear exceeds 0.090".
retaining threads.
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.
TDS3 Maintenance
Training Manual
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 O-rings, and refer to the following torque chart for bolt
Torque Chart
Motor support /bonnet to main body 7850 ft lb
Main body to motor bonnet 1100 ft lb
Bull gear to hub 580 ft lb
Lower gear case to main body 250 ft lb
Rotating head to lower gearcase 250 ft lb
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
TDS3 Maintenance
Training Manual
Gooseneck
Main
Body
Air
Brake
Motor
Support
Bonnet
Bull
Gear
D.C.
Drilling
Motor
Pinion
Gear
Drive
Stem
Motor
Alignment
Cylinder
(Ref.)
Lower
Gear
Case
TDS-3S Maintenance
Training Manual

guide dolly
quill shaft bearing and seal, air brake or locally mounted cooling
bearings or seals), you must remove the drilling motor from the
dolly.
1
Set TDS down horizontally on a flat surface. Make sure that

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

guide dolly frame.
dolly frame.
4. Run a suitable sling through quill shaft to support weight of
motor and housing assembly (approximately 10,000 lb).
5. Attach sling to crane, take up slack and remove trunnion
blocks that hold the transmission to the guide dolly frame.
7. Set motor and housing assembly down on wooden chocks,
being careful not to damage components.
8. Disconnect the wiring between the motor and the housing.
Make sure the transmission is in neutral.
9. Remove the dowel pins in motor feet.
11. Lift transmission off of motor by slightly angling upper end
to clear the motor frame, and slide the housing off of the
motor towards the gear case end.
TDS-4H Maintenance
Training Manual
Removing the drilling motor from

the housing assembly
1. Remove upper bearing cover and grease seal.
2. Pressurize air brake to hold drive mechanism in place and
remove quill shaft locknut.
3. Remove cotter pins, slotted nuts and rotating head.
4. Remove the lower gear case. Lower gear case is located with
dowel pins (Figure 20).
5. Carefully remove quill shaft with bull gear so as to avoid
damaging bearing surfaces or wear sleeves. Do not remove the
gear from the shaft except to replace it.
6. Remove large quill shaft bearings.
7. Remove pinion seal and retaining ring.
8. Remove upper gear case.
9. On opposite end of motor, remove magnetic pickup and
brake cover.
10. Brake may now be removed for service.
Refer to electric motor sections to remove the pinion or hub on
armature shaft or to service the motor.
TDS-4H Maintenance
Training Manual
Figure 20. Gear case assembly/disassembly
TDS-4H Maintenance
Training Manual
Once the unit has been disassembled, inspect the assemblies for
any wear or damage that may be critical, as follows:
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. Some small surface pitting is to be expected
and is not cause for replacing the gear set.
retaining threads.
pilot diameter for the lower gear case are critical. Any nicks or
gouges must be cleaned up prior to reassembly.
wear.
10. Air valve assembly: If any air-operated systems have been
malfunctioning, remove the appropriate valve and repair or
replace.
TDS-4H Maintenance
September 16, 1996

76 TDS-4H Maintenance and troubleshooting
Re-assemble the drilling motor and housing assembly by reversing

the steps in the preceding disassembly procedure. Replace all
grease seals and O-rings, and refer to the following torque chart
for bolt tightening guidelines.
Torque chart
Motor housing to motor 1750 ft lb
Upper gear case to housing assembly 1100 ft lb
Bull gear to hub 580 ft lb
Lower gear case to main body 250 ft lb
Rotating head to lower gear case 250 ft lb
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
Upper seal retainer to motor housing 75 ft lb
Training Manual

guide dolly
drive stem bearing and seal, air brake or locally mounted cooling
bearings or seals), the drilling motor must be removed 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 up the guide dolly accordingly.
guide dolly frame.
dolly frame.
5. Use a suitable sling to support the weight of the TDS and
motor support bonnet (approximately 10,000 lb).
6. Take up the slack and remove the trunnion blocks that hold
the transmission to 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.
slightly to clear the motor support bonnet, and sliding housing off of the motor toward the gearcase
TDS-4S Maintenance
Training Manual
Disassembly/assembly of drilling
motor and motor support bonnet
1. Remove the upper bearing cover and grease seal (Figure 20).
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.
7. Remove the main body.
9. Remove the brake for service.
TDS-4S Maintenance
Training Manual
Main
Body
Air
Brake
Low
Gear
Assembly
D.C.
Drilling
Motor
Bull
Gear
High
Gear
Assembly
Pinion
Gear
Manual
Shifter
Input
Geneva
Mechanism
Shaft
HI
LO
Oil
Level
Sight Glass
Motor
Pinion
Seal
Lower
Gear
Case
Motor
Alignment
Cylinder
Gear
Selection
Indicator
TDS-4S Maintenance
Training Manual
Refer to the GE Electric Motor 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 wear.
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.
4. Main shaft: Check fit to bull gear, wear sleeve surfaces and retaining threads.
pilot diameter for the lower gearcase are critical. Clean up any
nicks or gouges prior to reassembly.
wear.
10. Air valve assembly: If any air-operated systems are malfunctioning, remove the appropriate valve and repair or replace.
TDS-4S Maintenance
Training Manual
Reassemble the drilling motor and motor support bonnet by reversing the steps in the disassembly procedure. Replace all grease
seals and O-rings, and refer to the following torque chart for bolt
Torque Chart
Motor support/bonnet to main body
Main body to motor bonnet
Bull gear to hub
Lower gearcase to main body
Rotating head to lower gearcase
Brake adapter ring to motor
Brake to brake adapter plate
Brake drum to hub
Brake cover to brake
TDS-4S Maintenance
1100 ft lb
1100 ft lb
580 ft lb
250 ft lb
250 ft lb
250 ft lb
50 ft lb
250 ft lb
50 ft lb

Montrose Scotland
TOP DRIVE
Training Manual
Gearbox Lubrication

Montrose Scotland
TOP DRIVE
Training Manual
Rotating Head
Training Manual
Rotating head
The rotating head allows transferring pneumatic and hydraulic
pressure from stationary ports on the TDS drilling motor housing
to rotating ports on the rotating head (Figure 9). It features two
hydraulic passages, three pneumatic passages, and two spare passages capable of transferring either pneumatic or hydraulic fluid
(all are rated at 2000 psi).
The rotating head assembly consists of:
A stationary flange
Eight rotary glyd rings
A swivel block
A cam
A return cylinder
A cam follower
Swivel block locking mechanism
The hydraulic and air lines for the various pipehandler functions
(link tilt, torque wrench, etc.) run from their respective solenoid
valves to the stationary flange. The fluids travel from the flange to
the swivel block via sealed rotating passages.
Additional hoses connect the ports in the swivel block to the corresponding devices (link tilt, etc.). The swivel block rotates
relative to the flange without twisting or damaging any hoses.
There is also a lug for mounting the torque wrench hanger and
holes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom of
the gearcase with the drive stem running through the center.
There is also a return cylinder mounted on the stationary flange.
The return cylinder is hydraulically connected to the counterbalance manifold. The rod end of the cylinder connects to a cam
follower assembly that tracks the cam mounted to the swivel
block.
TDS-Rotating Head
Training Manual
Stationary Flange
Cam
Follower
Cam
Auto-Return
Cylinder
Locking
Lever
Swivel Block
Figure 9. Rotating head assembly
Integrated swivel and swivel

washpipe
The integrated swivel is a bearing assembly that allows transfer of
the rotating load to the lifting components (Figure 2). The swivel
washpipe is a rotating seal that allows mud to flow to the rotating
drill string.
TDS-Rotating Head
Training Manuale
Replacing the rotating head glyd ring
Rotary glyd ring replacement is indicated when hydraulic 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 4-16 and 4-17,
when performing the following procedures:
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one

flange gasket, and one excluder cap gasket from Varco.
Contact the nearest Varco 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 IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating block
clevis, and remove the torque wrench.
6. Support the link tilt and link adapter assembly while
removing the pins attaching the torque arrestors to the
rotating block.
7. Remove the torque arrestors, link tilt and link adapter.
8. Place the rotating head stand, built prior to disassembly,
under the TDS and lower the TDS until the rotating head
rests on the stand.
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.
TDS-500 Ton Rotating Head
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.
Stationary Flange
Cam
Follower
Cam
Auto-Return
Cylinder
Locking
Lever
Swivel Block
Figure 4-16. Rotating head assembly
Training Manual
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 Installation and Commissioning book of this
manual.
Gearcase
Seals
Stationary Flange
Cam Follower
Return Cylinder
Clevis (2)
Hex Nut (2)
Cotter
Pin (2)
Cam Follower
Return
Cylinder
Return Cylinder
Clevis Pin (2)
Glyd Rings (8)
Retainer Ring
Figure 4-17. Rotating head assembly/disassembly
TDS-500 ton Rotating Head1
Training Manual
Replacing the rotating head glyd ring
Rotary glyd ring replacement is indicated when hydraulic 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 17 and 18, when
performing the following procedures.
Stationary Flange
Cam
Follower
Cam
Auto-Return
Cylinder
Locking
Lever
Swivel Block
Figure 17. Rotating head assembly
Training Manual
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one

flange gasket, and one excluder cap gasket from Varco. Contact the nearest Varco 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 IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating block
clevis, and remove the torque wrench.
Training Manual
Cam Assembly
Locking Handle
Return Cylinder
Return
Cylinder
Clevis Pin
Return
Cylinder
Rod End Detail
Hex Nut
CAM
Cotter Pin
,,
Cylinder Clevis
,,,,,
,
,
,
,
,,,,,
,
,
,
,
,,,,,
,
,
,
,
,,,,,
,
,
,
,
,,,,,
Excluder
Cap
Detail C
Retainer Ring
Glyd Ring (8)
Ball Bearing
Excluder Cap
Gasket
Cam
Ball Bearing
C
Stationary Flange
Bull Gear
Lip Seal
Figure 18. Rotating head glyd ring replacement
Training Manual
6. Support the link tilt and link adapter assembly while removing the pins attaching the torque arrestors to the rotating
block.
7. Remove the torque arrestors, link tilt and link adapter.
8. Place the rotating head stand, built prior to disassembly, under the TDS and lower the TDS until the rotating head rests
on the stand.
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.

Montrose Scotland
TOP DRIVE
Training Manual
Link Tilt
Current date
Replacing the link tilt air actuator

There is an air actuator on the link tilt mechanism (Figure 4-18).
The following procedure details the replacement of the actuators:
Parts required: 1 Air actuator (P/N 82353)
18 Button head cap screws (P/N 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 180 on the link tilt pivot pin and lay down.
7. Remove the 18 nuts and washers holding the sealing plate to
the air actuator and remove the plate.
8. Using 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.
4-62
Lever Weldment
Pivot Pin
Sealing Plate (2)
Nuts, Lock
Washers (18)
Pressure
Regulator
Air Actuator
Base
Hanger Plate
Sealing Plate
Bolt (4)
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Buttonhead
Capscrew (18)
Stop Pivot Arm

Elevator Link (Ref)
Stop Release
Loop
Figure 4-18. Link tilt assembly/disassembly
4-63
Current date
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.
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. Over-torquing may
cause hex sockets to strip.
3. Torque the cap screws to the hanger plate at 80 ft lb.
4. Insert the 18 bolts into the neck ring of the air actuator.
5. Reinstall the air actuator sealing plate, coat the bolt threads
with locktite and fasten with the lockwashers and nuts
provided.
6. Torque the nuts to the sealing plate at 80 ft lb (see caution
above).
7. 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.
8. Safety wire the four screws.
9. Reconnect the chain between the two sealing plates.
10. Reinstall and adjust the link tilt per the procedure outlined in
the Installation and Commissioning book.
4-64

Montrose Scotland
TOP DRIVE
Training Manual
Torque Arrestors
Torque Arrestors
The Link Adapter (Solid body Elevator), link tilt, Link
Bails and Pipe elevators are supported on components
called Torque Arrestors. They are pinned to the rotating
Head mounted on the bottom of the gear case. The torque
arrestors contain compression springs that keeps the Solid
body Elevator, link adapter, Link Bails and Pipe elevators
above the load collar on the main shaft. The springs do
provide a pre-load sufficient to support a stand of drill
pipe in the full full up position. When hoisting these
torque arrestor springs will be compressed by the
hoisting load allowing the link adapter ( solid body
elevator) to be pulled down onto the load collar
transferring the load to the main shaft. Two torque
arrestors are used in the 500 ton version TDS and four
torque arrestors are used in the 650/750 ton version TDS
Caution:
Under No circumstances should Torque
Arrestors be disassembled in the field as the
contain powerful springs under compression
and could cause serious injury and damage if
released inadvertently.

Montrose Scotland
TOP DRIVE
Training Manual
IBOP
IBOP Control Circuit

Q
Why is there 30 psi on the actuator shell at all times.
A,
During rough drilling conditions especially surface hole, Vertical vibration of the drill
string can cause the upper ibop actuator shell to hammer on the the ibop crank
assembly damaging the crank arms and the bearings
The IBOP Control circuit prevents excessive damage to the actuator and bearings
by holding the shell down with a force of 500 lbs in the open position. There is an
reducing valve on the circuit which is set to 30 psi. The control circuit has a 30
second timer,( controlled by the PLC) when the open solenoid is operated it stays
fully open for 30 seconds then shuts of and the pressure is reduced to 30psi from a
prv on the close circuit.
Rig air 90 psi
Schematic showing circuit after timer operation
To manifold
vent
Close solenoid
Open solenoid
Shuttle Valve
PRV set at 30psi

30 PSI on
cylinders
Actuator Cylinders

Rig air 90 psi
Schematic showing circuit in close operation
To manifold
vent
Close solenoid
Open solenoid
Shuttle Valve
PRV set at 30psi

30 PSI on
cylinders
Actuator Cylinders
Rig air 90 psi
Schematic showing circuit before end of timer operation
To manifold
vent
Close solenoid
Open solenoid
Shuttle Valve
PRV set at 30psi

90 PSI on
cylinders
Actuator Cylinders
Safety Valve
(IBOP)
Service Manual
DRILLING SYSTEMS
Feb. 2, 1994
Feb. 2, 1994
Feb. 2, 1994
Contents
GENERAL DESCRIPTION.............................................................................. 1
PH-60 IBOP/ACTUATOR UPGRADE KIT.......................................................... 5
Introduction .................................................................................................. 5
Principle Features ................................................................................... 5
Remote IBOP Actuator Improvements ........................................................ 7
Internal Valve Mechanism Improvements.................................................... 8
INSTALLATION ............................................................................................ 9
OPERATION .............................................................................................. 16
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve .......... 17
LUBRICATION ........................................................................................... 18
INSPECTION ............................................................................................ 21
Magnetic Particle Inspection ...................................................................... 21
Safety Valve Inspection Procedures .......................................................... 21
Visual Inspection ................................................................................... 22
ADJUSTING THE SAFETY VALVE ACTUATOR ................................................. 23
MAINTENANCE ......................................................................................... 25
Seal Replacement ..................................................................................... 25
Shop Assembly and Disassembly ............................................................. 27
Disassembly.......................................................................................... 28
Assembly .............................................................................................. 32
IBOP Valve Testing in the Shop ............................................................ 39
APPENDIX ................................................................................................ 40
Feb. 2, 1994
ii
Feb. 2, 1994
Varco/BJ
Safety Valves
(IBOPs)
GENERAL DESCRIPTION
The Varco/BJ Drill Stem Upper Safety Valves (IBOPs) are ball type valves with full internal
openings to provide unrestricted flow of drilling fluids. The IBOPs are rated at 15,000 psi
working pressure.
If the driller notices a kick developing, the upper IBOP can be closed remotely, and the lower
IBOP can be closed manually. The lower IBOP can be broken out by the torque wrench and left
in the string if required.
The splined upper valves are an integral part of the Varco pipehandler of the TDS Drilling System
(Figures 1 & 2). A remotely operated actuator is attached to the upper IBOP and may be operated
at any height in the derrick from the drillers console. The upper IBOP can also be operated
manually using a 7/8" hex wrench.
There is a port on the upper IBOP below the valve crank for a grease fitting and reducer bushing
for purging any debris that may get in the wave spring area.
Feb. 2, 1994
Link
Tilt
Rotating
Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Adapter
Support
Plate
Splined
Upper
Safety
Valve
Safety Valve
Actuator
350 Ton
108" Links
(Ref.)
Torque
Wrench
Plain Lower
Safety Valve
Saver
Sub
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 1. Typical Safety Valve in Relation to Other TDS Assemblies (PH-60)
Feb. 2, 1994
Link
Tilt
Rotating
Head (Ref.)
Link
Adapter
Torque
Arrestor
Link
Adapter
Support
Plate
Splined
Upper
Safety
Valve
V
a
r
c
o
Safety Valve
Actuator
350 Ton
108" Links
(Ref.)
Torque
Wrench
Plain Lower
Safety Valve
Saver
Sub
350 Ton
Center-Latch
Drill Pipe
Elevator
(Ref.)
Figure 2. Typical Safety Valve in Relation to Other TDS Assemblies (PH-85, PH-60d)
3
Feb. 2, 1994
Thread
Protector
Body
Retaining Ring
Upper Seat
Plug
Back-up Rings
OPE
CL SD
Back-up
Rings
O-Ring
O-Ring
Ball
Sleeve
Seal Ring
Stabilizer
Ring
Crank
Grease/
Mud Seal
Seat
Wave
Spring
Back-up Ring
O-Ring
Figure 3. Typical Upper Safety Valve (IBOP)
Thread
Protector
Feb. 2, 1994
PH-60 IBOP/Actuator Upgrade Kit

Introduction
Installation of this comprehensive upper IBOP valve and actuator upgrade kit onto an existing
PH-60 pipe handler will dramatically improve the reliability of the remote-operated system, both
as a primary safety valve and as a mud saver while drilling ahead.
Maintenance and operating costs will be greatly reduced, allowing a minimum planned
maintenance interval of six months for the upper IBOP.
PRINCIPLE FEATURES
The upper IBOP valves (2 ea.) are equipped with:
PH-85 style dual-path operating systems
New low-stress inside body contours
Completely redesigned long-life internals
The new actuator shell is solid steel and bronze linedeliminating bolted-on external guides.
The new cylinders operating the upper IBOP are 45% larger for positive closure and they
eliminate the need for periodic adjustment.
The dual external crank assemblies share the operating loads. Each is reinforced, with
improved sealing and retention.
The new ball rotation stops (renewable) are enclosed in pressure-sealed cavities, greasepacked, and completely isolated from mud caking and corrosion to ensure full bore opening.
Feb. 2, 1994
ACTUATOR CYLINDER
MOUNTING BRACKET
REQUIRES NO ADJUSTMENT
LARGE BORE,
LONG STROKE IBOP
ACTUATOR CYLINDERS (2)
SOLID, ONE-PIECE,
JOURNAL-GUIDED
IBOP ACTUATOR SHELL
REINFORCED DUAL
EXTERNAL CRANKS AND
HOUSINGS WITH IMPROVED
BALL ROTATION STOPS
IMPROVED DESIGN
DUAL-CRANK
UPPER IBOP VALVE
Aug. 9, 1993. A.N.
Figure 4. PH-60 Upgrade Kit
Feb. 2, 1994
Remote IBOP Actuator Improvements

(Refer to Drawing 99261 in the Appendix)
1. Air cylinders which operate the IBOP are increased in both diameter and stroke. The 45%
larger piston area ensures positive, complete ball rotation under the most arduous conditions.
A 60% increase in available cylinder stroke eliminates the need for sensitive position
adjustments, both at initial rig-up as well as over the life of the system.
2. A solid, one-piece, journal-guided design (as on current PH-85 models) replaces the current
multi-piece actuator shell assembly, eliminating the separately attached (and vulnerable)
guide roller assemblies. The bronze-lined internal diameter of the new actuator shell rides
directly on the IBOP outer diameter. The new design is very robust, requires no adjustments,
and is able to withstand punishing environments without damage.
3. Dual external operating cranks, as on the PH-85, replace the single crank arrangement. This
change reduces the operating and environmental forces on the internal and external components
by 50%. It also provides a balanced reaction force to the actuating levers. This force balance
allows elimination of the bolt-on guide roller assemblies.
Each of the two external crank housings is anchored to the IBOP body with 1/2" screws
instead of the 3/8" screws used in the previous design. The crank housings are also secured
to react the ball stop torque using a close-tolerance fit between the base of the housing and
the machined recess in the IBOP valve body. When required, jacking screws make removing
the housings easier.
Feb. 2, 1994
Internal Valve Mechanism Improvements

1. Internal stress concentrations at the valves operating crank bores are eliminated. They are
replaced with a smooth bore through the ball and seat region. This significantly lowers the
maximum stress in the valve body and effectively eliminates the possibility of leaks caused
by cracking at the crank bores under corrosive mud conditions.
2. Contact between a strut on the internal crank and a shoulder in the IBOP body causes ball
rotation stop in the previous design. The crank was easily replaced, but the body was not
repairable after stop shoulder wear. The wear-induced loss of ball stop accuracy over
extended use could eventually allow the ball to over-travel, leading to washouts.
In the new design, the IBOP body is no longer part of the ball rotation stop. Only the internal
cranks (2) and external crank housings (2) need replacement should they ever become worn.
The external crank housings in the new design serve as the ball rotation stops. Each external
crank housing has two struts which contact the internal crank to stop the ball precisely at the
open or closed position. The torque required to stop the ball is then shared by four surfaces
rather than the previous designs single surface.
The stop device is no longer in the ball and seat cavity, it is now in the sealed, lubricated
regions beneath the external cranks. This eliminates the presence of caked drilling fluid
around the stop mechanism and is more reliable.
3. A second ball-actuating crank is added to the valve, as in the latest generation pipehandler,
the PH-85. This effectively cuts the operating forces in half on the critical ball actuating and
locating components, decreasing wear and eliminating mechanical failure.
Feb. 2, 1994
INSTALLATION
The following installation procedure assumes that all other rig components are already installed.
1. Use slips to install a joint of drill pipe into the rotary table.
2. Install the saver sub hand tight onto the drill pipe.
3. Install the lower IBOP hand tight onto the saver sub.
4. Install the upper IBOP hand tight onto the lower IBOP.
5. Screw the stem/main shaft and upper IBOP together.
CAUTION
The same care should be taken with these valves as would be any
other threaded valve. Be sure to use a thread compound with 60%
lead by weight or Kopper Kote. Varco does not recommend using
a zinc thread compound. If making up new threads for the first
time, use the following procedure:
a. Torque up to the recommended torque value (Table 1).
b. Back off the connection and inspect the threads and face.
c. Torque up to the recommended torque value (Table 1).
Feb. 2, 1994
Table 1. Make-Up Torque Values

Components
I.D.
Connection
O.D.
Torque (ft-lb)
(min.)
(max.)
Mainshaft to Upper
IBOP Safety Valve*
3"
6-5/8 API Reg.
7-3/4
60,000
70,000
Upper IBOP Safety

Valve to Lower
IBOP Valve
3"
6-5/8 API Reg.
7-3/4
50,000
70,000
Lower IBOP Valve

to Saver Sub
3"
6-5/8 API Reg.
7-3/8
46,000
64,000
Crossover Sub to
Lower IBOP Safety
Valve
3"
6-5/8 API Reg.
7-3/8
46,000
60,000
Mainshaft to Upper
IBOP Safety
Valve**
3"
7-5/8 API Reg.
83,000
91,000
Upper IBOP Safety

Valve to Lower
IBOP
3"
7-5/8 API Reg.
75,000
91,000
Lower IBOP Valve

to Saver Sub
3"
7-5/8 API Reg.
8-5/8
66,000
85,000
Crossover Sub to
Lower IBOP Valve
3"
7-5/8 API Reg.
75,000
91,000
* 500 Ton
** 650 Ton
6. Install the dual crank PH-85 and the PH-60d upper IBOP safety valve actuator as follows
(Figures 5 & 6):
a.
b.
c.
d.
e.
f.
Carefully grind off any raised tong marks on the O.D. of the safety valves.
Open the valve exactly halfway (45 degree rotation of the actuator).
Orient the levers on the crank assemblies horizontally as shown.
Slide the shell up onto the valve with the actuator arm groove on the bottom.
Hold the shell in position relative to the valve operating sockets.
Using the bolts provided, install the two crank assemblies, sliding the safety tabs through
and the cam follower into the horizontal slot. Use the lock tabs on the retaining screws
and locktite on the bolt threads to secure the assemblies.
g. Manually operate the actuator to ensure free movement though a full 90 of crank travel.
10
Feb. 2, 1994
Install the single crank PH-60 upper IBOP safety valve actuator as follows (Figures 7 & 8):
a. Carefully grind off any raised tong marks on O.D. of the safety valves.
b. Open the valve exactly halfway (45 degree rotation of actuator).
c. Orient the lever on the crank assembly horizontally as shown (be sure the safety wire
groove on side of crank body is to the right and the safety tab is on the left).
d. Slide the shell up onto the valve with the roller groove at the bottom.
e. Hold the shell in position relative to the valve operating socket.
f. Using the two bolts provided, install the crank assembly, sliding the safety tab through
and the cam follower into the horizontal slot. Use locktite on the bolt threads. Safety wire
the bolt heads, routing lock wire around the right side of the crank body through the safety
wire groove.
g. Install the two roller assemblies nearest the crank slot, and then using shims provided,
install the third roller assembly, maintaining .005" to .010" clearance between the third
roller assembly and the safety valve body with the shell vertically centered on the valve.
h. Manually operate the actuator to ensure free movement through full 90 of crank travel.
NOTE
When the actuator is in the lowest position, the valve should be
open.
7. Install the torque wrench assembly and adjust as necessary (refer to the TDS Service Manual
for the installation and adjustment procedures).
8. Use the torque wrench to make up the saver sub to the lower IBOP.
9. Use the torque wrench to make up the lower IBOP to the upper IBOP.
11
Feb. 2, 1994
Crank Assembly
Retaining Screw
And Lock Tabs
Crank
Assembly
Slot
Actuator
Shell
Crank Arm*
Actuator Arm
Groove
Lock Tabs
Crank
Assembly
Safety Wire
Groove
Upper IBOP
Valve
7/8" Allen Crank
*Note Orientation
Cam Follower
Figure 5. Installing the IBOP and Safety Valve Actuator Shell for the PH-85 & PH-60d
12
Feb. 2, 1994
Open
Position
Closed
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 6. PH-85 & PH-60d IBOP Actuator Shell in the Open and Closed Positions
13
Feb. 2, 1994
Roller
Assembly (3)
Crank Assembly
Retaining Screw
Crank
Assembly
Slot
Roller
Assembly
(3)
Actuator
Shell
Crank*
Roller
Assembly (3)
Actuator
Arm
Groove
Safety
Valve
Safety Wire
Groove
Shim
Crank
Assembly
*Note Orientation
Figure 7. Installing the Single Crank IBOP and Safety Valve Actuator Shell for the
PH-60
14
Feb. 2, 1994
Closed
Position
Open
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 8. Single Crank PH-60 IBOP Actuator Shell in the Open and Closed Positions
15
Feb. 2, 1994
OPERATION
Operating the switch on the drillers console to the IBOP Close position causes the two (2)
actuator air cylinder rods to extend moving the arms and the actuator shell body upward. This
upward movement causes the crank assemblies to rotate 90, closing the IBOP ball valve.
Operating the switch to the Open position retracts the cylinder rods and opens the IBOP.
16
Feb. 2, 1994
Erosion Prevention of the Ball and Seats in the Lower IBOP Valve
To maintain normal torque levels on the ball, operate the lower IBOP valve fully open and fully
closed at least one time each shift change. The valves can partially open without being externally
actuatedwhen there is a loss of friction between the ball and upper, pin end seats. The ball and
seats erode when the lower IBOP is actuated with the valves partially open. Varco/BJ recommends
removing the lip seal from the spring loaded (floating) seat to correct this problem.
Perform the following procedure to remove the lip seal from the floating (pin end) seat (Figure 9):
1. Breakout and remove the lower IBOP.
2. Disassemble the valve and remove the lip seal from the floating (pin end) seat.
3. Replace the O-rings and back-up rings on the fixed and floating seats.
4. Re-assemble the valves.
5. Reinstall and torque the lower valve.
Figure 9. Lower IBOP Seal Removal
17
Feb. 2, 1994
LUBRICATION
Lubricate the IBOPs weekly at the lubrication fitting located directly below the actuator crank
in the recessed counter bore. There are three reasons for lubricating the valve:
1. To verify the integrity of the grease seal.
2. To lubricate the floating seat.
3. To flush mud and debris from the spring cavity.
Use the following procedure to lubricate the IBOP valves (Figures 10 & 11):
1. Remove the plug from the 1/4" N.P.T. port of the valve body, while listening for a release of
pressure. A release of pressure indicates the mud/grease seal is not functioning properly
the valve should be serviced.
2. Install a suitable grease fitting.
3. Open the valve.
4. Lubricate the valve with approximately 10 full strokes from a manual grease gun or an
equivalent amount from an air powered grease injector. The grease pressure should not
exceed 300 psi. Pressures greater than 300 psi may cause the mud/grease seal to extrude into
the clearance between the floating seat and the valve body.
5. Remove the grease fitting and the reducer bushing and reinstall the 1/4" N.P.T. plug,
tightening securely.
CAUTION
The plug must be replaced in the valve prior to use to maintain
pressure integrity.
18
WAVE SPRING
MUD/ GREASE SEAL
SEAL RING STABILIZER
FIXED SEAT
19
Figure 10. Lubricating a Typical Upper IBOP
C
L
BALL
C
L
FLOATING
SEAT
PRESSURE
SEALS
SPRING
CAVITY
VALVE
BODY
GREASE PORT
Feb. 2, 1994
PRESSURE PLUG
WAVE SPRING
C
L
FLOATING
SEAT
PRESSURE
SEALS
SPRING
CAVITY
Feb. 2, 1994
VALVE
BODY
PRESSURE PLUG
GREASE PORT
20
C
L
BALL
Figure 11. Lubricating a Typical Lower IBOP
FIXED SEAT
Feb. 2, 1994
INSPECTION
Magnetic Particle Inspection
After approximately three to six months (depending on the severity of operating conditions)
Varco recommends performing a Magnetic Particle Inspection of all load bearing components
including IBOPs over their entire surface and internal bores to reveal any fatigue or crack
indications (Figure 11). Any indications found are a potential cause for the replacement of the
suspect component.
Details on Magnetic Particle Inspection procedures are in the following publications:
I.A.D.C.
ASTM A-275
ASTM E-709
Drilling Manual, 9th Edition

Std. Method for Magnetic Particle Inspection of Steel Forgings
Std. Recommended Practice for Magnetic Particle
Safety Valve Inspection Procedures

Upper and lower safety valves, because of their internal grooves and shoulders, are particularly
susceptible to corrosion fatigue cracking. These internal diameter changes act as stress risers for
bending and tensile loads. If corrosion pits develop near one of these stress risers, a fatigue crack
may begin at the root of the pit.
Chlorides and sulfides present in the drilling fluid can promote such corrosion, as well as PH
levels below 9.0. Inspect safety valves operated under such exposures for internal, transverse
cracks every three to six months, depending on the severity of the exposure.
Visual examination is insufficient to detect corrosion fatigue cracks, because cracks can be
hidden under corrosion products. Use the magnetic particle inspection procedure.
Concentrate attention on (Figure 12):
The area inside the operating crank window

The fillet radii of internal grooves and shoulders
The last engaged threads of box connections
The IBOP actuator shell
21
Feb. 2, 1994
Recommended
Inspection Areas
Figure 12. IBOP Inspection Points
NOTE
Repairing valve body cracks is not practical because of the close
tolerances of internal components and the metallurgy of the valve
material. Remove from service and scrap any safety valve body
showing positive crack indications.
VISUAL INSPECTION
Whenever connections are broken, clean and check them for the following:
1. Thread and shoulder condition. Threads should be inspected for galling, stretching or other
abnormal conditions. Check shoulders for any marks, gouges or other damage.
2. Outer surface. Examine for excessive tong marks and corrosion. Check splines on upper
safety valve for wear.
NOTE
Remove any surface imperfections on upper (splined) safety
valves after the valve is made up into string to prevent remote
actuator malfunctions, causing the valve to wash out.
22
Feb. 2, 1994
ADJUSTING THE SAFETY VALVE ACTUATOR

Proper safety valve actuator installation and adjustment is essential to assure proper action of the
mechanism and to minimize mechanical component wear. The actuator shell installs over the
upper IBOP safety valve. Changing the position of the two threaded eye bolts that suspend the
safety valve actuator air cylinders on the PH-85, PH-60d and single crank PH-60 (Figure 13)
adjusts the safety valve actuator. Adjust the PH-85, PH-60d and single crank PH-60 actuator
shell as follows:
1. After removing the crank assemblies, make sure the actuator shell easily moves up and down
over the upper IBOP.
NOTE
There is only one crank on upper IBOPs for the PH-60 pipehandler.
There are also three roller assemblies.
2. With the IBOP valve at mid-stroke, reinstall the crank assemblies.
3. Torque the 3/8" retaining bolts to 30-35 ft/lbs, lock tab.
4. Using a hex wrench, manually shift the IBOP valve through the crank assemblies and check
for signs of binding. Make sure the shell travels freely throughout its full range of travel. If
binding exists, troubleshoot to eliminate any problems before returning to service.
5. Actuate the control switch on the driller's console to the open the safety valve. The cylinders
should retract and the actuator ring should be down.
6. For the PH-85, PH-60d and single crank PH-60 only, measure the distance between the
cylinder rod end and the cylinder gland on each actuating cylinder (Figure 13). If that distance
is not 1 inch, adjust the cylinder rod locknuts until it measures exactly 1 inch.
7. Actuate the valve to make sure it opens and closes fully.
23
Feb. 2, 1994
DriveStem
(Ref.)
Link
Adapter
Cylinder
Adjustment
Bolts (4)
Landing Collar
Eye Bolts (2)
Upper IBOP Valve

Actuator Shell
Upper IBOP Valve

Actuator Air Cylinders (2)
Crank Assy(Shown with

Valve OPEN. Note Crank
Assy Position
C L OS E
OP E N
*1 Inch
Cylinder
in OPEN
Position
Rod
End
Actuator
Arm
5/8 max 3/8 min
Cylinder
Gland
Upper IBOP
Torque Tube
*IMPORTANT
Lower IBOP
Saver Sub
F igure 13. A djus ting the S afety V alve A c tuator S ys tem for the P H-85, P H-60d &
S ingle C rank P H-60
24
Feb. 2, 1994
MAINTENANCE
Seal Replacement
Replace seals at six month intervals under normal operating conditions (Figure 14). If there are
signs of wear, replace the ball and seat every six months. If the valve is used with oil-based or
high salt content drilling fluids, shorter intervals may be necessary.
13
17
19
10
18
14
15
20
16
8
2X 4
3
9
12
11
12
7/8" Hex
Note: Dual Crank Remote IBOP Shown

Single Crank Remote and Lower IBOP
have similar construction.
Figure 14. IBOP Safety Valve Illustrated Parts List
25
Feb. 2, 1994
Parts List
ITEM
QYT. / KIT
DESCRIPTION
PART NUMBERS
BALL, DUAL CRANK (SET)
90939-5
RETAINING RING
89141-1
O'RING
90441-9
BACK-UP RING
90441-10
LOWER SEAT (SET)
90939-5
UPPER SEAT (SET)
90939-5
POLYSEAL
96439
BACK-UP RING
89141-13
CROWN SEAL
89141-8
10
SLEEVE
90441-7 (93806-12 for Dual Crank)
11
O'RING
89141-11
12
BACKING RING
89141-12
13
CRANK, RIGHT HAND
89141-7 (93806-10 for Dual Crank)
14
WAVE SPRING
89141-9
15
BODY
16
O'RING
17
NYLON PLUG
18
CRANK, LEFT HAND
19
PLUG
20
SEAL RING STABILIZER
89141-3
93806-11
96438
REPAIR KIT - SINGLE CRANK

Refer to the Appendix for Part Numbers
REPAIR KIT - DUAL CRANK
REPAIR KIT - SOFT SEAL ONLY
(For either Single or Dual Crank)
BALL/SEAT SET
Figure 14. IBOP Illustrated Parts List (Cont.)

26
Feb. 2, 1994
Shop Assembly and Disassembly

The following tools are required (Figure 15):
Crank wrench
Varco Part No. 77408
Seat puller
Varco Part No. 79489-14
Nut wrench (for internal nut)
Bushing installation tool
Open end or adjustable wrenches
Two large flat screwdrivers or light pry bars
1/4" and 3/4" allen wrenches
Pipe vise or suitable holding device to hold valve secure
Before disassembly, thoroughly clean the valve using a high-pressure wash or steam cleaner or
mild acid bath. If available, an ultrasonic cleaner is ideal, because it not only cleans the valve,
but also serves to loosen internal components. Follow these general rules while working on the
valve:
1. Take proper precautions while working with the components of the valve to make sure
precision matched surfaces and seal contact surfaces are not damaged.
2. After removing each part, thoroughly clean the exposed area to prevent damage to other parts
as they are removed.
7.5"
3"
22"
Load Bar
15.25"
3"
Maximum
Nut Wrench for DSV Models
Seat Puller For All Models

7/8" Hex Wrench For All Models

Figure 15. IBOP Tools
27
Feb. 2, 1994
DISASSEMBLY
Starting with the valve in the closed position, disassemble the IBOP as follows:
1. Place the valve in a vise or
clamp to hold the valve
securely (Figure 16).
Figure 16
2. Engage the seat puller in
the inside groove of the
lower seat (Figure 17).
3. Using the load bar across
the face of the connection,
tighten the nut against the
load bar to compress the
wave spring approximately
0.030" (Figure 17).
Figure 17
28
Feb. 2, 1994
4. At the other end of the

valve, insert the upper seat
wrench, P/N 89141-18, into
the upper seat engaging the
wrench lugs into the mating
slots (Figure 18).
5. Using the crank wrench,
P/N 77408, as a lever in the
hole provided in the upper
seat wrench, rotate the
upper seat clockwise until
it stops (Figure 18).
Figure 18
6. Remove the wrench.

7. Remove the retainer ring
from the groove in the valve
body by using a screwdriver
to pry one end of the retainer
ring out of the groove. The
ring can then be removed
by hand (Figure 19).
Figure 19
8. Re-insert the upper seat
wrench into the upper seat.
9. Rotate the upper seat
counterclockwise until it
disengages from the body
threads.
10. Remove the wrench and the
upper seat (Figure 20).
Figure 20
29
Feb. 2, 1994
11. Remove the ball valve

(Figure 21).
Figure 21
12. From the outside of the
valve, push the crank into
the valve body and remove
them (Figure 22).
Figure 22
13. Remove the pulling tool
from the lower seat.
14. Insert the pulling tool from
the opposite end of the
valve and engage the
groove on the I.D. of the
Figure 23
30
Feb. 2, 1994
15. Using the load bar across

tighten the nut against it to
remove the lower seat and
the wave spring (Figures
24 and 25).
16. Remove and discard the
seals from all IBOP
components.
17. Thoroughly clean and
inspect each item.
Figure 24
Figure 25
31
Feb. 2, 1994
ASSEMBLY
1. Inspect the lower seat.

Look carefully for signs of
corrosion, pitting and
gaulling especially in the
sealing areas (Figure 26).
2. Make sure the wave spring
is not broken or damaged
(Figure 26).
3. Inspect the steel stabilizer
ring, making sure it is not
worn, pitted or damaged
(Figure 26).
Figure 26
4. Replace all O-rings, backup

rings and seals (Figure 26).
5. Install the steel stabilizer
and seal on the lower seat
(floating seat), by placing
the steel stabilizer in the
groove of the U-cup seal
and, starting on one side of
the seat, work the stabilizer
and seal around the seat
using a screw driver (Figure
27).
NOTE
The steel stabilizer ring
should be inside the seal
when properly installed.
Figure 27
32
Feb. 2, 1994
6. Install the wave spring on

the lower seat (Figure 28).
Figure 28
7. Inspect the ball valve for
corrosion, pitting and
gaulling (Figure 29).
Figure 29
33
Feb. 2, 1994
8. Install new nylon plugs on

the upper stationary seat
(Figure 30).
Figure 30
9. Make sure the snap ring is
not broken or damaged
(Figure 31).
Figure 31
34
Feb. 2, 1994
10. Make sure the crank

assembly notches are not
worn and there is no pitting
on the outside (Figure 32).
Check for a sliding fit with
the slots in the ball.
11. Install the seals on the crank
assembly.
12. Inspect the crank sleeve for
wear and washouts.
Replace as necessary.
Figure 32
13. Thoroughly lubricate the
valve bore with a thin film
of multipurpose grease of
NLGI Grade 2.
14. Insert the pulling tool into
the O-ring end of the lower
seat engaging the I.D.
groove (Figure 33).
15. Apply a generous coat of
grease to the O.D. of the
lower seat.
16. Slide the wave spring down
the threaded rod of the
pulling tool until it seats on
the spring surface of the
Figure 33
17. Insert the threaded rod of

the pulling tool first into
the box opposite the splined
end of the upper valve,
pulling the lower seat into
place in the valve body
(Figure 33).
35
Feb. 2, 1994
18. Using the load bar against

tighten the nut to firmly
seat the lower seat in the
valve body (Figure 34).
Figure 34
grease to the outside of the
sleeve and crank.
20. From the inside of the valve
body, install the crank
sleeve in the body. Insert
the crank into the sleeve
(Figure 35).
Figure 35
21. Make sure the crank moves
90 to the Open and Closed
position (the flat sides of
the crank are parallel to the
valve body).
22. Position the crank in the
Closed position.
grease to the entire outside
of the ball, but make sure
the holes are clear (Figure 36).
Figure 36
36
Feb. 2, 1994
24. Slide the ball onto the crank

inside the valve body. The
keyway must be in the
Closed position, or parallel
to the key of the crank.
grease to the outside threads
and seal of the upper seat.
26. Insert the upper seat into
the valve body, engaging
the threads (Figure 37).
Figure 37
27. Insert the upper seat wrench

into the mating slots of the
upper seat.
28. Rotate the wrench
clockwise until the upper
seat sets firmly against the
ball.
29. Remove the upper seat
wrench and install the
retainer ring firmly into the
groove of the body (Figure
38).
Figure 38
30. Insert the upper seat wrench

into the mating slots of the
upper seat.
31. Rotate the upper seat
counterclockwise until the
seat is firmly against the
retainer ring.
32. Remove the puller and use
an allen wrench to make
sure the valve functions
properly.
33. Leave the valve in the Open
position.
34. Remove the wrench.
37
Feb. 2, 1994
35. Grease the valve through

the pressure plug until
grease extrudes from inside
the valve (Figure 39).
NOTE
The grease pressure should not exceed
300 psi. Excess pressure can cause the
mud/grease seal to extrude.
Figure 39
36. Install the 1/4" N.P.T. plug
into the lubrication port of
the body. Torque this plug
to approximately 15 to 20
ft.-lbs.
Assembly is now complete. With the 7/8" hex wrench, open and close the valve several times
to assure smooth operation. Test the valve according to the procedure in the following
section.
38
Feb. 2, 1994
IBOP VALVE TESTING IN THE SHOP

Testing IBOP safety valves requires proper test plugs for the valve ends and a hydrostatic test
pump capable of reaching 10,000 or 15,000 psi (cold working pressure of the valve). Use the
following procedure to test IBOPs:
1. Rotate the valve crank to the Open position.
2. Install test plugs into both ends of the valve. Connect the hydrostatic test pump to the plug
in the splined end of the upper IBOP (box end of the lower IBOP). Connect a bleed valve
to the plug in the opposite end.
3. Place the valve in the vertical position (splined end down for upper IBOP, box end down for
lower IBOP) with the ball and the bleed valve in the Open position.
4. Fill the valve with hydraulic oil. Note: Water can be used when hydraulic oil is impractical,
but using water increases the liklihood of corrosion in the valve bodyespecially when the
valve is not in use for a prolonged period of time.
NOTE
Open and close the valve five times to release trapped air and
overflow through the bleed valve for approximately 30 seconds to
assure complete filling of the valve cavity.
5. Open the bleed valve to reduce internal pressure to zero psi. Rotate the ball to the Closed
position.
6. With the bleed valve Open, pressurize the lower cavity to the rated cold working pressure plus
1,000 psi and hold for three minutes. Allowable seepage is 1,000 over the duration of the test.
7. Open the bleed valve to reduce the internal pressure to zero psi. Disconnect the hydrostatic
test pump and the bleed valve. Reverse the orientation of the valve (splined end up for upper
IBOP, box end up for lower IBOP).
8. Connect the hydrostatic test pump to the test plug opposite the splined end of the upper IBOP
(pin end of the lower IBOP).
9. Fill the valve cavity with water while rotating the ball full open to closed five times to release
trapped air. Overflow through the bleed valve for 30 seconds. Pressure to the cold working
pressure plus 1,000 psi and hold for three minutes. Allowable seepage is 1,000 psi over the
duration of the test.
10. Open the bleed valve to reduce the internal pressure to zero psi. Open and close the valve to
insure smooth operation.
11. Measure the torque required to operate the valve. A torque value of less than 50 ft-lbs. is
acceptable.
12. Drain the valve cavity and remove the test plugs. Open and close the ball several times to
release trapped fluid. When testing with water, coat the valve internals with a preservative
to prevent oxidation and install thread protectors.
39
Feb. 2, 1994
APPENDIX
IBOP Part Numbers
IBOP
PART NO.
TYPE OF
SERVICE
DESCRIPTION
REPAIR KIT
PART NO.
SOFT SEALS BALL/SEAT

PART NO.
PART NO.
94769-500
94769-502
94769-501
STD
H2S
NAM
Upper Valve-PH60
6 5/8 Box X 6 5/8 Box (Spl End)
Load Collar Design
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94770-500
94770-502
94770-501
STD
H2S
NAM
Upper Valve-PH60
Load Collar Design
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94099-500
94099-502
94099-501
STD
H2S
NAM
Upper Valve - PH60

Landing Collar Design
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
94100-500
94100-502
94100-501
STD
H2S
NAM
Upper Valve - PH60

90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
90815
-
STD
H2S
NAM
Upper Valve - PH85

Land Collar Design
93806
-
93806-1
-
90939-5
-
90814
-
STD
H2S
NAM
Upper Valve - PH85

Load Collar Design
93806
-
93806-1
-
90939-5
-
90813
-
STD
H2S
NAM
Upper Valve - PH85

Load Collar Design
93806
-
93806-1
-
90939-5
-
90812
-
STD
H2S
NAM
Upper Valve - PH85

Load Collar Design
93806
-
93806-1
-
90939-5
-
94206-500
94206-501
94206-502
STD
H2S
NAM
Upper Valve - PH85

93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
94205-500
94205-501
94205-502
STD
H2S
NAM
Upper Valve - PH85

93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
94204-500
94204-501
94204-502
STD
H2S
NAM
Upper Valve - PH85

93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
40
Feb. 2, 1994
IBOP Part Numbers (Cont.)

IBOP
PART NO.
TYPE OF
SERVICE
DESCRIPTION
REPAIR KIT
PART NO.
SOFT SEALS BALL/SEAT

PART NO.
PART NO.
94203-500
94203-501
94203-502
STD
H2S
NAM
Upper Valve - PH85

93806
89453-SP
93806
93806-1
93806-1
90939-5
89453-15
90939-5
91138
-
STD
H2S
NAM
Upper Valve - PH85 - Big Bore

Load Collar Design
95384
-
91137-SP
-
91137-1
-
89451-501
89491-503
86434
STD
H2S
NAM
Lower Valve
6 5/8 Pin X 6 5/8 Box
90939-2
89453-SP
90939-1
-
90939-5
89453-15
89452-501
89492-502
-
STD
H2S
NAM
Lower Valve-Stepped
6 5/8 Pin X 6 5/8 Box
90939-2
89453-SP
90939-2
90939-1
90939-1
90939-5
89453-15
90939-5
90811
-
STD
H2S
NAM
Lower Valve
7 5/8 Pin X 7 5/8 Box
93807
-
93807-1
-
90939-5
-
91138
-
STD
H2S
NAM
Lower Valve - Big Bore

7 5/8 Pin X 7 5/8 Box
94385
-
91137-SP
-
91137-1
-
105629
-
STD
H2S
NAM
Upper Valve - Type "E"

6 5/8 Pin X 6 5/8 Box For Ids Only
90939-5
-
103220
-
STD
H2S
NAM
Upper Valve - Type "E"

6 5/8 Pin X 6 5/8 Box
For TDS and SDS
90939-2
-
90939-1
-
90939-5
-
98977-500
98977-502
98977-501
STD
H2S
NAM
Upper Valve, PH60 Dual Crank

6 5/8 Box X 6 5/8 Pin
99468-2
99469-SP
99468-2
99468-1
99468-1
65170014
98966
65170014
99461-500
STD
H2S
NAM
Upper Valve, PH60 Dual Crank

6 5/8 Box X 6 5/8 Pin
99468-2
99469-SP
99468-2
99468-1
99468-1
65170014
98966
65170014
41
Feb. 2, 1994
Identifying Varco Safety Valves

42
Feb. 2, 1994
43
Feb. 2, 1994
44
Feb. 2, 1994
45
Feb. 2, 1994
46

Montrose Scotland
TOP DRIVE
Training Manual
Pipe Handler
Adjusting the Torque Wrench

Use the following procedure to adjust the pipe handler
torque wrench.
The pipe handler torque wrench is properly adjusted in the

factory before it is shipped. Perform the adjustment
procedure after performing maintenance on the torque
wrench or if the torque wrench does not function correctly.
1.
Connect a pup joint or a joint of drill pipe to the saver sub and
make up hand tight. Be sure to use the correct thread
compound when making up.
K When adjusting torque wrench manifold valves loosen the lock

nut with a 9/16 wrench and use a 5/32 allen key to adjust the
valve. After obtaining the correct setting tighten locknut
around valve stem.
K For PH85 ONLY Close one of the rotation speed valves 3
turns and adjust the second valve approximately 4 turns
until the tube stays centered when operated.
K The above operation should only be carried out if the
torque tube is out of center when operating
2
With the hydraulic unit switched off, fully screw in all

sequence valves including lift lower valve. The PRV valve
should be set at a minimum pressure of 750 psi,
Turn the hydraulic power unit on.
If the torque cylinders are in there full clockwise position, set

the make/break valve to MAKE. If the torque cylinders are in
the full counterclockwise position the set the make/break valve
to BREAK.
NOTE The torque cylinders should not move if the recycle valve is fully in.
5
Set make/break valve to MAKE/BRAKE
Back out the recycle valve until you have the cylinders
recycling at 7-9 second speed then tighten the lock nut.
Set Make Brake Valve to MAKE
Depress and hold the torque wrench operating button on the

drillers console. Back out the lift/lower sequence valve until it
starts to lift then adjust an additional half turn.
Back out the clamp sequence valve until the clamp cylinder
starts to move then an additional of a turn.
10 Back out the torque valve until the torque cylinders start to
move the an additional of a turn.
11 Release the torque wrench operating button on the drillers
console and observe the toque wrench function it should start
to unclamp then drop and recycle. If the torque wrench drops
before unclamping adjust the lift/lower valve in a of a turn
and back out the clamp sequence valve an additional turn.
Supply Flow
Return Flow
Air - Piloted
Hydraulic Valve
1
Lift
Lift
1200 PSI
Sequence
1500 PSI
Sequence
1200 PSI
Sequence
Clamp
1500 PSI
Sequence
Torque
Clamp
Torque
3
Pressure
Adjust
Pressure
Adjust
Torque wrench hydraulic operation schematic
TDS-TW Operation
Trouble Shooting Pipe Handler

The Driller presses the TW Button but nothing functions :Check
Check
Check
Check
Check
Check
Quick Disconnects
Hydraulic Supply
Air Supply
Drill/Spin /Torque switch is in Drill position
Throttle is in the off position
Electrical Supply, (Solenoids, Wiring, VDC Switches)
Assembly and disassembly

Pipehandler (PH-60d)
Torque wrench disassembly
(Figure 4-15)
1. Remove the guard.
2. Disconnect the hard plumbing from the quick disconnects
near the left torque cylinder.
3. Remove the bolts holding the frame onto the cast body and
lift off.
4. Remove the pins holding the torque tube in place.
5. Disconnect and label the hoses from the torque cylinders and
remove the cylinders.
6. Disconnect and label the remaining plumbing, and remove
the Make/Break manifold assembly.
7. Remove the jaws.
8. Remove the stabbing guide.
9. Remove the retaining bolts, hinge pins and outer body.
10. Remove the cylinder ring from the clamping piston bore.
11. Pressurize the blind end of the clamping cylinder to remove
the gland and piston.
Use care in this operation. High pressure air can be explosive.
Training Maual June 99
Frame
Mounting
Shaft
Safety Valve
Actuating
Cylinders (2)
Vertical
Positing
Cylinder
Safety Valve
Actuating
Arm (2)
Torque
Tube
Stabilizer
Stop Tube
Hanging Height
Adjustment Shim
Torque
Tube
Guard
Body
Torque
Cylinder (2)
Clamp Cylinder Body
Stabbing
Guide
Clamping
Jaws (2)
Clamping
Cylinder
Piston
Control
Manifold
Figure 4-15. Torque wrench assembly/disassembly
Reassembly is accomplished in the reverse order of the above

procedure. Pay close attention to the following points:
1. Replace all seals.
2. 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.
3. Use the following torque values:
Cylinder rod end to cylinder rod *
Frame to clamp cylinder body
Stabbing guide to body
Die retainer screws
Body hinge pin retainer screws
Stabbing guide spring retainer screws
Jaw retaining screws
*
944 ft lb (1275 N.m)

250 ft lb (339 N.m)
250 ft lb (339 N.m)
380 ft lb (515 N.m)
150 ft lb (203 N.m)
75 ft lb (102 N.m)
110 ft lb (149 N.m)
The torque cylinder rod ends are threaded into the rods with
lock-tite and cross pinned.
Replacing the torque wrench clamping piston seal
The following procedures require removing the torque wrench

from the pipehandler.
Parts required for replacing the front and rear piston seal
Qty.
3
2
2
P/N
72219
72220
72221
Description
Piston seal
Rod seal
Rod wiper
Disassembly
1. Remove the pins from the torque wrench guard and remove
the guard.
2. 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.
3. 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.
4. Remove the jaw pins from the rear clamping jaw and remove
the jaw.
5. Remove the two screws holding the jaw spacer to the front
clamp cylinder piston and remove the spacer and jaw spacer.
6. Remove the two screws holding the clamp clevis to the rear
clamp cylinder piston.
7. 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.
8. Push in the cylinder gland from the rear cylinder head
retainer ring and remove the ring with a screwdriver.
9. Attach the sliding hammer to the rear piston rod and carefully
pull the piston until the cylinder gland can be removed.
10. Continue to pull until the piston comes out.
11. Using a piece of wood or brass bar, tap the front clamp piston
from the front and remove it from the rear.
12. Remove and discard the piston seals, rod seals and rod wipers.
13. Remove the front piston rod seal and rod wiper from the
clamp cylinder body and discard.
14. Inspect the clamp cylinder bore thoroughly for dirt, burrs,
nicks, gouges and pitting. Repair and clean as necessary.
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 the Torque wrench adjustment procedure.
May 22, 1996
Assembly and disassembly

Pipehandler (PH-85)
Torque wrench disassembly
(Figures 16a, 16b, 16c and 16d)
1. Remove the guard.
2. Disconnect the hard plumbing from the quick disconnects
near the left torque cylinder.
3. Remove the bolts holding the frame onto the cast body and
lift off.
4. Remove the pins holding the torque tube in place and remove.
5. Disconnect and label the hoses from the torque cylinders and
remove the cylinders.
6. Disconnect and label the remaining plumbing, and remove
the Make/Break manifold assembly.
7. Remove the jaws.
8. Remove the stabbing guide.
9. Remove the retaining bolts, hinge pins and outer body.
10. Remove the cylinder ring from the clamping piston bore.
11. Pressurize the blind end of the clamping cylinder to remove
the gland and piston.
Use care in this operation. High pressure air can be explosive!
TDS-4S Maintenance and troubleshooting
57
May 22, 1996
TORQUE
TUBE
V
a
r
c
o
TORQUE
CYLINDERS (2)
Figure 16a. Torque wrench assembly/disassembly
58
May 22, 1996
BODY
CLAMPING
JAWS (2)
CLAMP CYLINDER
BODY
STABBING
GUIDE
CLAMP
CYLINDER
PISTON
Figure 16b. Torque wrench assembly/disassembly
59
May 22, 1996
MOUNTING
SHAFT
FRAME
SAFETY
VALVE
ACTUATING
CYLINDERS (2)
VERTICAL
POSITIONG
CYLINDER
HANGING
HEIGHT
ADJUSTMENT
GUARD
Figure 16c. Torque wrench assembly/disassembly
60
May 22, 1996
Figure 16d. Torque wrench assembly/disassembly

(optional link retractor)
61
May 22, 1996
Reassembly is accomplished in the reverse order of the above procedure. Pay close attention to the following points:
1. Replace all seals.
2. 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.
3. 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.
Replacing the torque wrench clamping piston seal
The following procedures require that the torque wrench be removed from the pipehandler.
Replacing the front and rear piston seal
Parts required front and rear piston seal replacement:

Qty.
3
2
2
P/N
72219
72220
72221
Description
Piston seal
Rod seal
Rod wiper
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.
62
May 22, 1996
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 cylinder 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.
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.
63
May 22, 1996
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.
64

Montrose Scotland
TOP DRIVE
Training Manual
Lubrication
September 16, 1996
Chapter 2
Lubrication
Lubricating the motor and motor housing

assembly
Lubricating the main shaft spline
There is a lube point on the quill shaft located behind the large
plug on the side of the motor housing just below the trunnion.
Lubricate it weekly.
Gearbox
Check the oil daily. With the motor off, check to see that the oil
level is 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).
TDS-4H Maintenance and troubleshooting
23
September 16, 1996
Properly maintaining the TDS gear shifting mechanism increases

the operational life of the top drive. Use the following procedure
to maintain proper gear lubrication:
1. Shift all top drive two speed gearboxes from one gear to the
other and back again at least once a week. This helps to
distribute lubricant and prevents contaminant buildup.
2. Remove the gear indicator lever assembly and the indicator
gear case cover.
3. Repack the inside area with grease every six months.
4. Inspect the gears for corrosion or damage. Clean, lubricate or
replace components as required. There is a timing mark on
the gears to ensure correct orientation. If these marks are not
visible when removing the gears, mark the gears before
removal to ensure correct orientation when reinstalling them.
If there are problems shifting from one gear to the other, use the
following procedure to shift the gears:
1. Turn the drive stem with chain tongs to make sure the gear
mesh aligns properly. Do not turn the DC motor while
shifting gears.
2. Insert two 3/8" bolts in the threaded holes on the bottom of
the shafts while shifting the gears and use a bar to turn the
shaft in the proper direction. Do not shear the bolts.
Eccentric shaft rotation direction is the same as the shifter
input shaft when shifting into gear.
3. If the shift input mechanism slips when attempting to shift
gears, use a torque wrench to check the torque of the shifter
when the clutch begins to slip. If the torque is less than 65 ft
lb, use the torque setting procedure on the following page to
adjust the clutch.
Gearbox oil must be drained before removing clutch.

The factory setting of the clutch is 45 ft lb. Increase the torque if
problems persist.
4. Remove the 3" inspection plugs on the rear of the gear case
and make sure the compound gears are free to turn with the
unit in neutral. If the gears cannot turn, it is an indication of
a larger problem (i.e., contaminants in gears, damaged
bearings, etc.).
24
September 16, 1996
Torque setting procedure

Use the following procedure to set the torque limit clutch to 4550 ft lb:
1. Attach any torque indicator to the output stub (Figure 4).
2. Hold the body and determine the current torque setting.
3. Remove the snap ring and locking plate.
4. Use a 5/8" open end wrench to turn the nut clockwise to
increase torque, or to turn the nut counterclockwise to
decrease the torque.
5. Check the resulting torque and repeat the above steps if more
adjustment is necessary.
6. Replace the locking plate and snap ring.
Other gearbox lubrication and maintenance

considerations
Keep the bottom of the eccentric gear shafts clean and free of
corrosion, paint or other contaminants. Keep this area lightly
lubricated with oil.
Contaminant build up or corrosion around the upper end of
the eccentric shafts can cause persistent shifting problems.
Install sealed caps on the top of the shaft to correct the
problem. There are two ways to install sealed caps. One way
requires shop installation during top drive overhaul.
There is a kit for field installation (P/N 97926). It consists of a
rubber gasket, a sealing cap and a stud which threads into an
existing tapped hole in the top of the eccentric shaft. The stud
holds the cap on top of the gear case and keeps contaminants
away from the shaft. It also adds a secondary seal between the oil
in the gearbox and the DC motor cooling air path.
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.
25
September 16, 1996
Figure 4. Torque setting procedure

26
September 16, 1996
Oil capacity
The TDS 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 1020 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 gear case.
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 gear
case, only 5-6 gallons of oil at the bottom of the gear case actually
drains. Oil 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.
27
September 16, 1996
Lubricating the DC motor

The upper motor armature bearings have grease points located on
the brake adapter plate attached to the top of the 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 two
ounce by weight Shell Cyprina RA. Lubricate the commutator
(brake) end bearing every 1,500 hours, or six months, with two
ounce by weight Shell Cyprina RA.
28
Excessive lubrication of electric motors can cause motor failure due to

shorting or heat buildup from grease coming in contact with the field
windings.
September 16, 1996
Lubricating the rotating head

Apply grease daily at the five fittings. Inspect for seal leakage
around the lower bearing retainer weekly.
Grease
Fittings
Grease
Fitting
Grease
Fittings
Figure 5. Lubricating the rotating head
29
September 16, 1996
Lubricating the link adapter

Apply grease to the four fittings weekly.
650 Ton
Solid Body Elevator
2 Grease Fittings on front,
2 Grease Fittings opposite.
(4 places total)
Figure 6. Lubricating the Link Adapter
30
September 16, 1996
Lubricating the torque wrench

Apply grease to the six fittings daily. Inspect the stabbing for
excessive wear or cracks. Replace as necessary.
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 5).
Lubricate weekly. Inspect the guide ring periodically for wear or
damage and replace as necessary.
Grease Fittings
2 places as shown
and 2 places
opposite side.
(4 Total)
Figure 5. Lubricating the master bushing wear guide
31
September 16, 1996
Lubricating the Varco BNC drill pipe

elevator
Apply grease to the seven grease fittings on the BNC elevator each
trip, 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 8. Lubricating the BNC drill pipe elevator
32
September 16, 1996
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 10 fittingslubricate all 10 each trip.
Lubricating the safety valve actuator

Apply grease to the six fittings on the actuator arms daily. Check
for worn components and operate the valve to verify correct
adjustment weekly.
33
September 16, 1996
Lubricating the upper IBOP safety valve

Lubricate the upper IBOP daily at the lubrication fittings located
directly below the actuator cranks in the recessed counter bores.
Refer to the IBOP Service Manual included in this manual for
complete IBOP lubrication instructions.
Open
Position
Closed
Position
Actuator
Shell
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 9. Lubricating the IBOP actuator
34
September 16, 1996
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
10). Check guide rollers weekly for cracks or excessive axial or
radial play and replace as necessary. Lubricate the hinges (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, perform 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. Re-grease 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.
There are two grease points for the motor trunnions, one at each
bottom corner of the motor frame (Figure 11). Lubricate these
weekly.
35
September 16, 1996
Lubricate the wash pipe packing daily with the mud pump off.
Check the filter gauge on the pressure filter daily with the
hydraulic power on to determine the condition of the filter
element. Replace the element when a bypass condition is
indicated.
Do not weld or torch cut on or near the motor frame without

removing hydraulic accumulators.
5
2
1
Lubrication
Manifold (4)
4
3
Figure 10. Guide dolly assembly (with hinges rear half)

36
September 16, 1996
Figure 11. Motor frame/guide dolly assembly (with hinges front)

37
September 16, 1996
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.
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.
38
September 16, 1996
Lubrication schedule
Frequency
Daily
Daily
Daily
Daily
Daily
Daily
Each trip
Each trip
Each trip
Each trip
Each trip
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
Weekly
750 hrs/90 days
1500 hrs/6 mos.
Monthly
Monthly
3 months
3 months
3 months
Lubricant Number
Location
code*
of points
Torque wrench
1
6
Gearbox oil (check level)
2
1
Rotating head
1
5
Safety valve actuator cranks
1
2
Hydraulic pressure filter
4
Upper quill shaft bearings
1
1
BNC drill pipe elevator
1
7
PS-16 power slip
1
8
RBS
1
17
RBS stabbing head
1
10
Guide dolly rollers
1
20
Gearbox (shift gears)
Dolly motor trunnions
1
2
Air filter/regulator/lubricator
IBOP actuator arms
1
6
Link adapter
1
4
Elevator support
1
7
Master bushing wear guide
1
4
Link tilt (check condition)
Main shaft spline
1
1
GE motor pinion bearing
3
GE motor commutator bearing
3
Motor frame/dolly hinges
1
4
Cooling system cleaning
AC blower motor
1
2
Change gearbox oil
2
1
Gear oil filter/suction strainer
1
*See lubricant specification table

Check condition and replace as necessary
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.
39
September 16, 1996
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:
Damage the gearbox due to reduced oil flow
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 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 transmission operating properly:
40
September 16, 1996
Minimum Ambient
Temperature
F
(C)
Below 20
(-6)
20-60
(-616)
45-85
(730)
Above 70
(21)
Oil Type Required
Varco Part Number
See Note Below*

2EP, ISO 68
4EP, ISO 150
6EP, ISO 320
See Note Below*

56004-1
56004-BSC
56004-2
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 engineering.
If the oil temperature rises above 200F, 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 engineering.
41
42

Avi-Motive
Lidok EP2
Chevron
Exxon
Lidok EP1
Avi-Motive W
Below -20C
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
2
-
Mobil
Shell
Statoil
Texaco
Total
Union
NGL1
AGMA
ISO Viscosity
Grade
-
Unoba EP1
Multis EP1
Multifak EP1
Uniway EP1N
Alvania EP1
Mobilux EP1
Gulf Crown EP32 Gulf Crown EP31
MP grease
Castrol
Gulf
Above -20
Ambient
temperature
range
Above 21C
Carter EP 150
Meropa 150
Loadway EP150
Omala 150
MobilGear 629
EP Lube HD150
Spartan EP150
NL Gear 150
Alpha -150
Carter EP 68
Meropa 68
Statoil
Omala 68
MobilGear 626
EP Lube HD68
Spartan EP68
NL Gear 68
Alpha LS-68
-6 to 16C
320
6EP
150
4EP
I66
2EP
Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP
Carter EP 320
Meropa 320
Loadway EP320
Omala 320
MobilGear 632
EP Lube HD320
Alpha LS-320
Alpha LS-320
Alpha LS-320
7 to 30C
Gear Oil
General Purpose Grease
Lube Code and Description

3
Cyprina RA
All
temperatures
Motor Grease
Tellus 32
DTE 24
Harmony 32AW
Nuto H32
AW Hyd oil 32
Hyspin AWS-32
-15 to 75C
45
Unax AW46
Azolla ZS 46
Rando oil HD46
32
Unax AW32
Azolla ZS 32
Rando oil HD32
Hydraway HMA 46 Hydraway HMA 32
Tellus 46
DTE 25
Harmony 46AW
Nuto H46
AW Hyd oil 46
Hyspin AWS-46
-10 to 85C
Hydraulic Oil
September 16, 1996
PH-60 Lubrication and

Maintenance Guide
500 Ton Capacity
See the Service Manual for more detail
Weekly
Rotating Head
Positioning Roller
Apply two pumps
Hydraulic Link Tilt

Apply
two pumps per
grease fitting
(8 places)
Weekly
Weekly
500 Ton Rotating Head
Apply two pumps per grease fitting
(4 places)
Weekly
Support Shaft
Apply general purpose grease
at the contact point between
the shaft and frame
Weekly
Weekly
Grease Lubrication Schedule

Description
Pneumatic
Link Tilt
Check condition of the air
bladder, the pivot pin and the stops
Points Frequency
Rotating Head Positioning Roller
Weekly
Weekly
500 Ton Link Adapter
Weekly
Hydraulic Link Tilt
Weekly
Link Adapter Wear Shoe
Daily
IBOP Actuator Cranks
Daily
Upper IBOP Valve
Weekly
IBOP Actuator Arms
Weekly
Weekly
IBOP Actuator Cam Followers
Weekly
Link Spreader (if equipped)
Weekly
Torque Tube Clevis Pins
Daily
Upper IBOP Valve

Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps
Clamp Body Cylinder Trunnion
Weekly
Clamp Body
Weekly
Support Shaft
Weekly
Elevator Link Eyes
Weekly
Recommended Lubricants
Manufacturer
Daily
IBOP
Actuator Cranks
Apply one pump per grease fitting
(2 places, 1 each side)
Replace plug
before operating
Above -20 C
(Above -4F)
Weekly
N/R
MP Grease
Avi-Motive W
Avi-Motive

Lidok EP1
Lidok EP2
Gulf Crown EP31
Gulf Crown EP32
Mobil
Mobilux EP1
Mobilux EP2
Daily
Shell
Alvania EP1
Alvania EP2
Statoil
Uniway EP1N
Uniway EP2N

Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2
Union
Unoba EP1
Unoba EP2
Weekly
Clamp Body
N/R
N/R
Gulf
Viscosity Index
NGLI
AGMA
Weekly
IBOP Actuator
Cam Followers
(2 places, one each side)
Weekly
(Below -4F)
Exxon
Link Adapter
Wear Shoe
(4 places)
IBOP Actuator Arms

Below -20 C
Chevron
Daily
Weekly
Ambient Temperature Range
Castrol
500 Ton
Link Adapter
(2 places)
Clamp Body
Cylinder Trunnion
Apply two pumps
per grease fitting
General Condition Checks

Description
Frequency
Check for missing lockwire
Daily
Check for loose or broken parts
Daily
Check for missing cotter pins
Daily
Check for hydraulic and air leaks
Daily
Check for wear on tong dies and guide flippers
Daily
Weekly
Elevator Link Eyes
Pipe Dope
Test IBOPs for leakage (in place)
Weekly
Check for proper rotation of

the IBOP actuator cam followers
Daily
Check condition of the air bladder, stops,

and pivot pin on the pneumatic link tilt
See the other side for the

PH-60 650/750 Ton Capacity
Weekly
Varco P/N
126732

Maintenance Guide
650/750 Ton Capacity
650/750 Ton Powered Rotating Head
Hydraulic Link Tilt
Rotating Head Bull Gear

Brush with grease
Apply
two pumps per
grease fitting
(8 places)
Weekly
Weekly
Weekly
650/750 Ton
Rotating Head
Apply two pumps
per grease fitting
(5 places)
Weekly
PH-60
Support Shaft
Apply general purpose
grease at the contact
point between
the shaft and frame
Weekly
Weekly

(5 places)
650/750 Ton
Link Adapter
Apply two pumps
per grease fitting
(4 places)

Description
Points Frequency
Weekly
650/750 Ton Rotating Head
Weekly
Weekly
Powered Rotating Head Bull Gear
Weekly
650/750 Ton Link Adapter
Weekly
Hydraulic Link Tilt
Weekly
Daily
Daily
Upper IBOP Valve
Weekly
IBOP Actuator Arms
Weekly
Daily
Weekly
Weekly

Daily
Weekly
Clamp Body
Weekly
Pneumatic Link Tilt

Check condition of the air bladder,
the pivot pin and the stops
Daily
(4 places)
Weekly
Elevator Link Eyes
Weekly
Weekly
Upper IBOP Valve

Remove 1/4" NPT plug, install grease fitting
Apply ten pumps
Replace plug
before operating
Below -20 C
Above -20 C
N/R
MP Grease
Avi-Motive W
Avi-Motive
Lidok EP1
Lidok EP2
Gulf Crown EP31
Gulf Crown EP32
Mobil
Mobilux EP1
Mobilux EP2
Shell
Alvania EP1
Alvania EP2
Daily
Statoil
Uniway EP1N
Uniway EP2N
Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2

Union
Unoba EP1
Unoba EP2
Weekly
N/R
N/R
Clamp Body
Exxon
Gulf
Weekly
Clamp Body
Cylinder
Trunnion
Apply two pumps
per grease fitting
Weekly
(Below -4F)
Chevron
Link Spreader
(if equipped)
Apply two pumps
per grease fitting

Castrol
Upper IBOP
Actuator
Cam Followers
Apply two pumps
per grease fitting
Weekly
Support Shaft
Manufacturer
Weekly
(Above -4F)
IBOP Actuator Arms

Viscosity Index
NGLI
AGMA

Description
Frequency
Daily
Daily
Daily
Daily
Daily
Weekly

Daily

Weekly
Weekly

PH-60 500 Ton Capacity
Elevator Link Eyes

Pipe Dope
Varco P/N
126732

Maintenance Guide
500 Ton Capacity
Weekly
Hydraulic Link Tilt
Apply
two pumps per
grease fitting
(8 places)
Weekly
Rotating Head
Positioning Roller
Apply two pumps

(4 places)
Weekly
Weekly
PH-85 Support Shaft
Apply general purpose grease
at the contact point between
the shaft and frame
Weekly
Weekly

Description
Pneumatic
Link Tilt
Check condition of the air
bladder, the pivot pin and the stops
500 Ton
Link Adapter
Apply two pumps
per grease fitting
(2 places)
Points Frequency
Rotating Head Positioning Roller
Weekly
Weekly
500 Ton Link Adapter
Daily
Daily
Weekly
IBOP
Actuator Cranks
Link Adapter
Wear Shoe
Apply two pumps
per grease fitting
(4 places)
Hydraulic Link Tilt
Weekly
Daily
Daily
Upper IBOP Valve
Weekly
IBOP Actuator Arms
Weekly
Weekly
Weekly
Weekly
Weekly
Daily
Upper IBOP Valve

Remove 1/4" NPT plug,
install grease fitting
Apply ten pumps
IBOP Actuator
Cam Followers
Apply two pumps
per grease fitting
(2 places, one each side)
Weekly
Clamp Body
Weekly
Support Shaft
Weekly
Elevator Link Eyes
Weekly
Replace plug
before operating
Weekly
Weekly
Manufacturer
IBOP Actuator Arms

Link Spreader
(if equipped)
Apply two pumps
per grease fitting

Below -20 C
Above -20 C
(Below -4F)
(Above -4F)
N/R
MP Grease
Avi-Motive W
Avi-Motive
Lidok EP1
Lidok EP2
Gulf Crown EP31
Gulf Crown EP32
Daily
Mobil
Mobilux EP1
Mobilux EP2
Shell
Alvania EP1
Alvania EP2
Statoil
Uniway EP1N
Uniway EP2N

Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2
Union
Unoba EP1
Unoba EP2
N/R
N/R
Castrol
Chevron
Exxon
Gulf
Weekly
Clamp Body
Cylinder Trunnion
Apply two pumps
per grease fitting
Viscosity Index
NGLI
AGMA
Weekly

Description
Frequency
Clamp Body
Daily
Daily
Daily
Daily
Daily
Weekly
Weekly
Elevator Link Eyes

Daily
Pipe Dope


PH-85 650/750 Ton Capacity
Weekly
Varco P/N
126731

Maintenance Guide
650/750 Ton Capacity
Hydraulic Link Tilt
Rotating Head Bull Gear

Brush with grease
Apply
two pumps per
grease fitting
(8 places)
Weekly
Weekly
Weekly
650/750 Ton
Rotating Head
Apply two pumps
per grease fitting
(5 places)
Weekly
PH-85
Support Shaft
Apply general purpose
grease at the contact
point between
the shaft and frame
Weekly
Weekly

(5 places)
650/750 Ton
Link Adapter
Apply two pumps
per grease fitting
(4 places)

Description
Points Frequency
650/750 Ton Rotating Head
Weekly
Weekly
Weekly
Powered Rotating Head Bull Gear
Weekly
Pneumatic Link Tilt

Check condition of the air bladder,
the pivot pin and the stops
650/750 Ton Link Adapter
Weekly
Hydraulic Link Tilt
Weekly
Daily
Daily
Upper IBOP Valve
Weekly
IBOP Actuator Arms
Weekly
Weekly
Daily
Weekly
Daily

Weekly
Clamp Body
Weekly
Weekly
Elevator Link Eyes
Weekly
Manufacturer
Upper IBOP
Actuator
Cam Followers
Apply two pumps
Daily
(4 places)
Weekly
Support Shaft
Weekly
Upper IBOP Valve

Remove 1/4" NPT plug, install grease fitting
Apply ten pumps
Replace plug
before operating
Weekly
Link Spreader
(if equipped)
Apply two pumps
per grease fitting
Weekly
Clamp Body
Cylinder
Trunnion
Apply two pumps
per grease fitting

Below -20 C
Above -20 C
(Below -4F)
(Above -4F)
N/R
MP Grease
Avi-Motive W
Avi-Motive
Lidok EP1
Lidok EP2
Gulf Crown EP31
Gulf Crown EP32
Mobil
Mobilux EP1
Mobilux EP2
Shell
Alvania EP1
Alvania EP2
Statoil
Uniway EP1N
Uniway EP2N
Texaco
Multifak EP1
Multifak EP2
Total
Multis EP1
Multis EP2
Union
Unoba EP1
Unoba EP2
Weekly
N/R
N/R
Clamp Body
Castrol
Chevron
Exxon
Gulf
Weekly
IBOP Actuator Arms
Daily
Viscosity Index
NGLI
AGMA

Description
Frequency
Daily
Daily
Daily
Daily
Daily
Weekly

Daily

Weekly
Weekly

PH-85 500 Ton Capacity
Elevator Link Eyes

Pipe Dope
Varco P/N
126731
TDS-4H Lubrication
and Maintenance Guide
For more detail see the
TDS-4H Service Manual
See the other side of this chart for the
TDS-4S Lubrication and Maintenance Guide

Description
Swing Guide Dolly
Monthly
Swing Guide Dolly Hinges
(4 places, 2 each hinge)
Frequency
Daily
Daily
Daily
Daily
Check condition of the oil and hydraulic filter gauges
Daily
Check the gear oil levels
Daily
Check for cracks and excessive axial or radial play

on the guide dolly rollers and replace as necessary
Daily
Retract Guide Dolly

(28 places, 7 each manifold)
Weekly
Bail Pins
Weekly
Monthly
Motor Trunnions
Apply two pumps
per grease fitting
Weekly
Swing Guide Dolly
Apply two pumps
per grease fitting
(20 places, 5 each manifold,
if equipped)
Hydraulic
Filter
(Actual location
may vary)
See the manufacturers

documentation for Swivel
lubrication information

Description
Points Frequency
Bail Pins
Weekly
Upper Bearing
Weekly
Motor Trunnions
Monthly
Monthly
Swing Guide Dolly (Grease Fittings on Manifolds)
20
Weekly
Non-Swing Guide Dolly (Grease Fittings on Manifolds)
20
Weekly
Retract Guide Dolly (Grease Fittings on Manifolds)
28
Weekly
Gear Oil
Filter
(Actual location
may vary)
See lubrication section of the TDS-4H service manual for lubrication of electric motors
Gear Oil Lubrication Schedule

Description
Frequency
Replace the Gearbox Oil and Perform an Oil Analysis
3 Months
Replace the Gearbox Oil Filter
3 Months
LO
Oil viscosity should be adjusted based on expected ambient conditions for next three months
Mfr.
Grease
Gear Oil
Gear Oil Fill
Monthly

Below -20C
Above -20C
N/R
Avi-Motive W
Lidok EP1
Gulf Crown EP31
Mobilux EP1
Alvania EP1
Uniway EP1N
Multifak EP1
Multis EP1
Unoba EP1
MP Grease
Avi-Motive
Lidok EP2
Gulf Crown EP32
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
(Below -4F)
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
(Above -4F)
-6 to 16C
(20 to 60F)
7 to 30C
(45 to 85F)
Above 21C
Viscosity Index
NGLI
AGMA
ISO
Viscosity
Grade
1
N/R
N/R
2
N/R
N/R
N/R
2EP
68
N/R
4EP
150
Motor Trunnions
Apply two pumps
per grease fitting
(Above 70F)
Alpha LS-68
Alpha LS-150
Alpha LS-320
NL Gear 68
NL Gear 150
NL Gear 320
Spartan EP68
Spartan EP150
Spartan EP320
EP Lube HD68
EP Lube HD150
EP Lube HD320
MobilGear 626
MobilGear 629
MobilGear 632
Omala 68
Omala 150
Omala 320
Loadway EP68
Loadway EP150
Loadway EP320
Meropa 68
Meropa 150
Meropa 320
Carter EP 68
Carter EP 150
Carter EP 320
N/R
6EP
320
Weekly
Upper Bearing
Apply two pumps
per grease fitting
Refer to the
TDS-4H Service Manual
or the
Pipehandler Lubrication
for maintenance and
lubrication of the
Rotating Head
Gear Oil Sight Gage

Check with Top Drive
OFF
Gear Oil Drain
and Sample Valve
Varco P/N
127052
TDS-4S Lubrication
TDS-4S Service Manual
See the other side of this chart for the
TDS-4H Lubrication and Maintenance Guide

Swing Guide Dolly
Description
Monthly
Swing Guide
Dolly Hinges
Apply two pumps
per grease fitting
(4 places, 2 each hinge)
Frequency
Daily
Daily
Daily
Daily
Check the washpipe assembly for leaks
Daily
Check condition of the oil and hydraulic filter gauges
Daily
Check the gear oil levels
Daily
Check for cracks and excessive axial or radial play

on the guide dolly rollers and replace as necessary
Daily
Retract Guide Dolly

(28 places, 7 each manifold)
Weekly
Upper Bonnet Seals
Apply one pump of
general purpose grease
Using hand pump only
Washpipe Assembly
Apply three pumps of
general purpose grease
at beginning of tour
Mud pumps OFF
Weekly
Daily
Monthly
Motor Trunnions
Apply two pumps
per grease fitting
Weekly
Swing Guide Dolly
Apply two pumps
per grease fitting
(20 places, 5 each manifold,
if equipped)
Hydraulic
Filter
(Actual location
may vary)

Description
Points Frequency
Washpipe Assembly
Daily
Upper Bonnet Seal
Weekly
Bail Pins
Weekly
Motor Trunnions
Monthly
Monthly
Swing Guide Dolly (Grease Fittings on Manifolds)
20
Weekly
Non-Swing Guide Dolly (Grease Fittings on Manifolds)
20
Weekly
Retract Guide Dolly (Grease Fittings on Manifolds)
28
Weekly
Gear Oil
Filter
(Actual location
may vary)
See lubrication section of the TDS-4S service manual for lubrication of electric motors
Gear Oil Lubrication Schedule

Description
Frequency
Replace the Gearbox Oil and Perform an Oil Analysis
3 Months
Replace the Gearbox Oil Filter
3 Months
LO
Oil viscosity should be adjusted based on expected ambient conditions for next three months
Mfr.
Grease
Gear Oil

Below -20C
Above -20C
N/R
Avi-Motive W
Lidok EP1
Gulf Crown EP31
Mobilux EP1
Alvania EP1
Uniway EP1N
Multifak EP1
Multis EP1
Unoba EP1
MP Grease
Avi-Motive
Lidok EP2
Gulf Crown EP32
Mobilux EP2
Alvania EP2
Uniway EP2N
Multifak EP2
Multis EP2
Unoba EP2
(Below -4F)
Castrol
Chevron
Exxon
Gulf
Mobil
Shell
Statoil
Texaco
Total
Union
(Above -4F)
-6 to 16C
(20 to 60F)
Gear Oil Fill

7 to 30C
(45 to 85F)
Above 21C
(Above 70F)
Alpha LS-68
Alpha LS-150
Alpha LS-320
NL Gear 68
NL Gear 150
NL Gear 320
Spartan EP68
Spartan EP150
Spartan EP320
EP Lube HD68
EP Lube HD150
EP Lube HD320
MobilGear 626
MobilGear 629
MobilGear 632
Omala 68
Omala 150
Omala 320
Loadway EP68
Loadway EP150
Loadway EP320
Meropa 68
Meropa 150
Meropa 320
Carter EP 68
Carter EP 150
Carter EP 320
Viscosity Index
NGLI
AGMA
ISO
Viscosity
Grade
1
N/R
N/R
2
N/R
N/R
N/R
2EP
68
N/R
4EP
150
N/R
6EP
320
Weekly
Bail Pins
Apply two pumps
per grease fitting
Monthly
Refer to the
TDS-4S Service Manual
or the
Pipehandler Lubrication
for maintenance and
lubrication of the
Rotating Head
Gear Oil
Sight Gage
Check with Top Drive
OFF
Gear Oil Drain
and Sample Valve
Motor Trunnions
Apply two pumps
per grease fitting
Varco P/N
127052
Varco Wash Pipe Assembly Guide

See the Top Drive Service Manual for more detail
Lubrication Schedule
Description
Lubricant
Packing Box
Apply 3 pumps of multipurpose

lithium-based or high temperature
moly-based grease (do not mix
lubricants)
3" Bore
4" Bore
123290 &
123290-1000
123440 &
123440-750
Frequency
Each Tour
or
Twice Daily
Rotate the mainshaft at approximately 50 rpm for 1 to 2 minutes

before turning on the mud pumps
Regular greasing will increase packing seal and wash pipe life
3" Bore Packing Kits

Part #'s
Contents
Comments
123290-PK
(Standard)
(1) Packing Set 123292-2

(2) O-Rings 51300-348-F
(1) Grease Fitting 53219-1
Nitrile/Cotton, Pressure
rated at 5,000 psi
(Use with Wash Pipe
123289 or 123289-TC)
123290-PK-1
(High Pressure)

(2) O-Rings 51300-348-F
Nitrile/Armide, Pressure
rated at 10,000 psi
(Use with Wash Pipe
123289-TC only)
Special Tools
Wash Pipe Wrench
O-Ring
51300-348-F
O-Ring
51300-359-F
Snap Ring
123562
Snap Ring
123634
Holding Ring
123288
Holding Ring
123437
Packing Seal
(5 per Set)
123292-2 or
123292-3
Packing Seal
(5 per Set)
123584-2 or
123584-3
Wash Pipe
Nut
123284
Wash Pipe
Nut
123431
Wash Pipe
123289
*123289-TC
Wash Pipe
123438
*123438-TC
* Tungsten Coated
* Tungsten Coated
3" Bore
Wash Pipe Wrench
30150084
Recommended for proper
tightening of the wash pipe
nut and packing box
4" Bore Packing Kits

Part #'s
Contents
Comments
123440-PK
(Standard)

(2) O-Rings 51300-359-F
Nitrile/Cotton, Pressure
rated at 5,000 psi
(Use with Wash Pipe
123438 or 123438-TC)
123440-PK-1
(High Pressure)

(2) O-Rings 51300-359-F
Nitrile/Armide, Pressure
rated at 7,500 psi
(Use with Wash Pipe
123438-TC only)
Reassembly Procedure
Checklist
With the packing box upside down, assemble the packing seals and
spacers into the packing box using care to line-up the upper spacer
slot with the dowel pin
Hand pack all seals with multipurpose lithium-based or high
temperature moly-based grease using care not to grease the
outside diameter of the spacers
Install the socket head dog nose screw, ensuring that the screw nose
is fully engaged in the groove of the lower spacer
Install the wash pipe nut onto the wash pipe

Grease the packing seal and install into the holding ring
using care not to grease the outside diameter of the holding ring
Install the packing seal and holding ring over the slotted end
of the wash pipe
The wash pipe should be

replaced when any measurable
wear or grooving is present
Packing Box
123563
Packing Box
123626
Install the grease fitting and turn the packing box upright
Install the wash pipe into the packing box assembly (slotted end up)
4" Bore
Wash Pipe Wrench
141481
Grease
Fitting
53219-1
Socket Head
Dog Nose Screw
123564
If the packing box is properly

tightened, and a leak is still present, do
not attempt to eliminate the leak with additional
hammering (See Installation Procedure)
Grease
Fitting
53219-1
Socket Head
Dog Nose Screw
123564
Typical Assembly View
Install the snap ring
Install the upper and lower o-rings using grease to hold them in place
Compress the assembly to the length of the wash pipe
Installation Procedure
Checklist
Install the wash pipe assembly on the Top Drive and hand tighten
the wash pipe nut and packing box (apply pipe dope to the threads)
Long-Arm
Allen Wrench
53303-14
Long-Arm
Allen Wrench
53303-14
Upper Spacer
123285
Upper Spacer
123434
Manually rotate the mainshaft 1 or 2 revolutions to seat

and align the pipe in the packing box
Set the Top Drive brake
Tighten the packing box first with the wash pipe wrench or by
hammering a few blows on every other lug, releasing the brake,
turning the mainshaft and reseting the brake with each blow
(the packing box should tighten at approximately 3/4 turn or
advance 1/4 inch from the hand tightened position)
Tighten the wash pipe nut next with the wash pipe wrench or by
hammering gently on a lug (the wash pipe nut should tighten at
approximately 1/4 turn or advance 1/10 inch from the hand
tightened position)
Middle Spacer
123286
Middle Spacer
123435
Middle Spacer
123286
Middle Spacer
123435
Lower Spacer
123287
Lower Spacer
123436
O-Ring
51300-348-F
O-Ring
51300-359-F
The wash pipe nut and

the packing box have
left-handed threads
Dowel
Pin
Slide the
wash pipe nut
and the packing box
together for installation
Hand pack all seals

with multipurpose
lithium-based or
high temperature
moly-based grease
completely filling
the void
Apply 6 to 8 pumps of multipurpose lithium-based or high

temperature moly-based grease to the grease fitting
Rotate the Top Drive at approximately 50 rpm for 1 minute
without mud pumps
Turn on the mud pumps and check for leaks (if leaks occur,
disassemble and repeat all previous steps)
If leaks continue, see the Top Drive service manual for inspection
of alignment and runout of mating parts.
Varco P/N
128844
Ensure that the nose of the

socket head dog nose screw
is fully engaged in the groove of
the lower spacer
Upper IBOP
Break-out Procedure
PH-85 Pipehandler Service Manual
Step 1
A. Breakout saver sub and lower IBOP the normal
way using PH-85 pipe handler.
B. Tilt links with elevator to mouse hole or remove.
C. Tie up links with cable to Top Drive (safety).
D. Hang the RTBS intensifier assembly on guard of
PH-85. Connect (2) 1/4" hoses to line body on
PH-85 manifold, connect the 1/2" hose to the
TDS brake by disconnecting the existing brake
hose at the brake drum, and hook up rig air to
(A1) location on the intensifier assembly.
Step 2
A. Hoist RTBS with the shackle on the end of the
stem and place and secure RTBS on rotary table,
remove shackle.
B. Lock rotary table.
C. Lock main shaft with
TDS brake, switch valve
handle to horizontal
position and adjust air
pressure to 175 psi.
Step 3
A. Stab PH-85 over RTBS & lower it to line up with
top of yellow area.
B. Select "MAKE-UP" mode (reverse from normal).
C. Screw the PRV valve on PH-85 manifold all
the way in
D. Push "TORQUE WRENCH" button
on VDC. PH-85 will rise, clamp on
RTBS, and break out upper IBOP.
It will stroke back down
when the button is
released. Repeat until
IBOP is loose.
(Note: IBOP valve
should breakout @
approximately
2500 psi)
Step 4
A. Raise TDS/PH-85 until stabbing guide clears the
top of RTBS.
B. Place drive ring over RTBS
shoulder with square boss
engaged with drive ring.
RTBS
Intensifier
Assembly
Tie-up
Cable
Upper IBOP
Valve
PH-85
Lower
IBOP
Adjust Air
Pressure
To 175 Psi
Intensifier
Adjustment
Torque Tube
Saver
Sub
Drive Ring
Yellow
Area
RTBS
Intensifier
Assembly
RTBS (Rotary
Table Back-up
Structure)
Step 5
A. Swing PH-85 back with tugger line.
B. Install thread protector in IBOP valve and lower
TDS/PH-85 so splines are engaged.
C. Tie up PH-85 with cable and leave tugger line
slack (safety).
D. Unlock TDS main shaft and spin out upper IBOP
until it is separated from main shaft
E. Raise TDS/PH-85.
F. Screw in lifting plug
to upper IBOP.
G. Remove upper IBOP
with shell.
150
125
Handle
Shown in
Horizontal
Lock Position
Lock Rotary Table
Top of Rotary
Table and Deck
RTBS
Intensifier Assembly
Step 6
A. Install thread protector in replacement
upper IBOP.
B. Position replacement upper IBOP with shell over
RTBS and drive ring.
C. Lower TDS/main shaft slowly into new upper
IBOP, (PH-85 swung out) while spinning main
shaft until upper IBOP connection is shouldered.
D. Lock main shaft again.
Secure To
Pad Eye On
GE Motor
Step 7
A. Raise TDS/PH-85 above RTBS, remove thread
protector. Remove drive ring.
B. Release tie-up cable (Ref 5B), stab PH-85 over
RTBS and lower it to yellow area as shown
C. Switch PH-85 valve to "BREAK OUT" mode
(reverse from normal).
D. Push "TORQUE WRENCH" button on VDC,
PH-85 will rise, clamp on RTBS
and make-upupper IBOP
to desired torque
indicated by pressure
gauge on RTBS
intensifier assy panel
and stroke back down.
Note: make up torque
91,000 lb-ft = 2,150 psi)
175
200
75
225
25
250
10
275
1500
1750
300
1000
2000
0
750
2250
500
2500
250
2750
3000
To Release Brake
Move Handle To
Vertical Position
Tie-up
Cable
New
Upper
IBOP
Lifting
Plug
Lifting
Plug
Old
Upper
IBOP
Yellow
Area
Step
7D
Top of Rotary
Table and Deck
Varco P/N
30150095
Step 8
A. Remove RTBS from rotary table.
B. Unlock main shaft and rotary table.
C. Disconnect rig air to intensifier assy, disconnect
(2) 1/4" hoses and the 1/2" hose from the TDS
brake drum. Reconnect the brake hose from
TDS manifold.
D. Readjust the PRV valve to its original setting.
E. Remove the RTBS intensifier assembly
and store away.
F. Reinstall lower IBOP and saver sub
in the normal way using
the PH-85.
G. Release the links (Ref 1C).
100
1250
Engaged
On Square
Boss

Montrose Scotland
TOP DRIVE
Training Manual
Inspection
Maintenance
Inspection
Swinging out the TDS for
maintenance
Varco 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
the engineering drawings for information specific to your rig
configuration):
1. If you have a retract system, operate the switch on the drillers
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.
4-9
Current date
On some rigs, it may be necessary to secure the traveling block

frame to the guide dolly frame using chain and/or rope.
5. Turn 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.
Unlatching the hook from the 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
movement of these assemblies.
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 180 and secure the motor assembly to the
derrick with chain and/or rope.
4-10
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.
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.
2. 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.
3. 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.
4. Secure the motor frame to the guide dolly with the two
swing-out bolts opposite the hinges.
5. Connect the mud hose to the S-tube.
6. Connect the air intake hose.
7. Hook the counterbalance system pear links onto the ears of
the hook or block.
8. Turn on the hydraulic power unit and bleed air out of the
system.
9. Adjust the hydraulics as outlined later in this section.
4-11
Current date
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.
The DC motor has a complete manufacturers instruction manual

for your reference provided as a separate book in this manual.
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 mufflers
with simple pipe elbows.
4-12
Derrick termination kit air filter/

regulator/lubricators
Top drives that rely on rig air to power link tilt, upper IBOP,
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.
Varco supplies a filter/regulator/lubricator in the derrick installation

kit and recommends installing it at the fingerboard level in the
derrick. Improperly adjusted regulators can cause poor device
performance at reduced pressures, or valve and cylinder seals and Oring extrusion at excessive pressures.
Inspect the entire filter/regulator/lubricator monthly for damage
to the filter bowl, overall body, or inlet and outlet fittings.
Replace any damaged, corroded, or improperly functioning
components.
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 100200 SSU at 100F (ISO 32/34).
Do not use fluids such as Marvel Mystery Oil, motor oil, or

Dextron II in the lubricator. Swollen seals may result.
4-13
Current date
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 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.
Inspect the link tilt intermediate stop and adjustment device

for overall integrity weekly. Replace the components if there is
excessive looseness of the threaded rod in the threaded hole of
the pivot arm (refer to the figure in the Air Actuator
Replacement procedure later in this book). An indication 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 replacement can result in injury to rig
personnel.
Drill stem load-carrying

components
Because the drill stem load carrying components are critical,
Varco recommends performing the following procedures and
inspections on a regular basis.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes (Figure 4-1). Compare the measurements
with the Wear Chart (Figure 4-1) to determine the current
strength of the elevator links. The capacity of the links equals the
capacity of the weakest link.
4-14
Upper
Eye
(Hook)
Wear Chart - Forged Links

Lower
Upper
Eye
Eye
Dimension Dimension
A
C
,,,,
,,,,
,,,,
,,,,
Capacity
(per set)
in Tons
B = 3 1/2 in., 350-Ton

5 in.
4 13/16 in.
4 5/8 in.
4 7/16 in.
2 3/4 in.
2 9/16 in.
2 3/8 in.
2 3/16 in.
350
300
225
175
,,,
,,,
,,,
,,,
B = 4 1/2 in., 500-Ton

6 in.
5 3/4 in.
5 1/2 in.
5 1/4 in.
3 1/2 in.
3 1/4 in.
3 in.
2 3/4 in.
500
420
325
250
B = 6 1/4 in., 750-Ton

7 1/2 in.
7 1/4 in.
7 in.
6 3/4 in.
7 1/2 in.
7 1/4 in.
7 in.
6 3/4 in.
350
300
225
175
To determine the strength of worn links,

measure (with calipers) the amount of eye
wear and compare the measurements
with the above Wear Chart to find the
current capacity. The capacity of the set of
links is determined by the weakest link.
,,,,
,,,,
,,,,
A
Lower
Eye
(Elevator)
Figure 4-1. Visual inspection of elevator links
4-15
Current date
Landing collar
Disassemble and inspect the landing collar every six months.

Use the following procedure to disassemble the landing collar
(Figure 2-4 in the Installation and Commissioning book) for
inspection:
1. Disconnect the top drive from the drill string.
2. Remove the IBOPs and pipehandler.
3. Raise the solid body elevator to expose the landing collar
retainer.
4. Straighten the retainer tabs.
5. Slide the retainer ring above the split landing collar halves.
6. Drive out one roll pin.
7. Remove the landing collar halves.
8. Slide the retainer off the drive stem.
After disassembly, inspect all landing collar parts for wear,
damage, or corrosion. Check for:
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
Radial grooves on the inside diameter of the retainer shell
Missing tabs from the retainer shell
Wear or corrosion induced pitting on the retainer shell
shoulder
Wear, corrosion, or fatigue cracks on the inside or outside
diameter of the landing 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 1/8 in.
Evidence of wear, corrosion or fatigue cracks on the safety
links
4-16
Replace the appropriate part(s) if any of the above conditions

exist. Use the following procedure to reassemble the landing
collar:
1. Replace the existing O-ring in the retainer shell.
2. Grease the inside diameter of the retainer shell.
3. Slide the retainer onto the drive stem above the landing collar
grooves.
4. Install one new roll pin and safety links on the split landing
collar halves.
5. Coat the landing collar halves with a generous amount of
water resistant grease.
6. Place the landing collar halves on the drive stem with 15
taper closest to the top drive.
7. Drive in the remaining roll pin.
8. Slide the retainer shell over the landing collar halves.
9. Use a hammer and drift to bend all 32 retainer tabs to secure
the retainer shell.
10. Coat the retainer shell and drive stem with a generous
amount of water resistant grease to prevent corrosion.
11. Reinstall the IBOPs and pipehandler.
4-17
Current date
Drive stem
Regularly inspect and measure the drive stem/mainshaft for wear.

Remove the drive stem/mainshaft from service if bore wear is
greater than the dimensions shown in Figure 4-2.
Determine inspection frequency according to API Recommended
Practice 8B, Section 2 for power swivels and power subs.
Varco 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 5T1 to identify and define imperfections found
during inspections.
Figure 4-2. 500-ton drive stem minimum bore wear dimensions
4-18
Use the following API recommended guidelines (Figure 4-3) to

determine the tensile load bearing capacities of the drive stem
landing collar.
Figure 4-3. 500-ton drive stem landing collar tensile dimensions
4-19
September 16, 1996
Main shaft
Regularly inspect and measure the drive stem/main shaft for wear.
Remove the main shaft 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.
Varco 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 5T1 to identify and define imperfections found
during inspections.
* See Figure 3
Figure 2. TDS-4H 650-ton minimum bore wear dimensions
18
September 16, 1996
Use the following API recommended guidelines (Figure 3) to

determine the tensile load bearing capacities of the drive stem/
main shaft landing collar.
Figure 3. 650-Ton drive stem /main shaft landing collar, tensile dimensions
19
Current date
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 in. 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 1/8 in. deep. Larger defects or any
crack indications are cause for replacing the suspect component.
These components are:
Drive stem/main shaft (lower portion)
Landing collar
Upper and lower IBOP
350-ton BNC drill pipe elevator
Link adapter
Saver and spacer subs
Power subs
Power swivels
Elevator links
4-20
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
subsurface irregularity can also compromise a components
integrity.
Details on magnetic particle and ultrasonic inspection procedures
are in the following publications:
I.A.D.C.
Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection of

Steel Forgings
ASTM E-709 Std. Recommended Practice for Magnetic Particle
ASTM A-388 Std. Practice for Ultrasonic Examination of
Heavy Steel Forgings
Safety valves inspection procedures (IBOP)
Upper and lower safety valves, because of their internal 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 IBOP
Service Manual included as a separate book in this manual.
4-21

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Varco Technical Education Centre

Varco Technical Education Centre

Training Manual June 99

Derrick electrical termination kit

Training Manual June 99

3/8" OVER FULL LENGTH

10' 6" +0"/-4"

Figure 1. General rail installation data

Training Manual June 99

ELECTRICAL SERVICE LOOP **

73 FT. MUD HOSE

83 FT. HYD, AIR & WATER

TYPICAL EQUIPMENT STACK-UP

Figure 2. Derrick services/general installation data

Training Manual June 99

Rail Loading with TDS in Setback position

Rail Loading while Drilling - 38,000 FT LBS for TDS-3S,

Figure 3. General installation data

Rail Loading with TDS in Setback position

Rail Loading while Drilling - 60,000 FT LBS

Figure 1c. General installation data (cont.)

Training Manual June 99

Figure 4. Typical cabling diagram

The cable requirements, depending on options selected are:

SCR room to transfer panel

Transfer panel to derrick J-box

#6AWG/2C (Shunt only)

SCR Room to transfer panel

AC Power to hydraulic pumps

AC Power to water pumps

Transfer panel to derrick J-box

Transfer panel to RBS unit

Transfer panel to drillers console

Transfer panel to derrick J-box

Transfer panel to SCR console

Purge control system (not shown)

Purge control unit to transfer panel

Purge control unit to transfer panel

Transfer panel to derrick J-box

Terminate the J-boxes per the electrical schematic. Follow

Training Manual June 99

Training Manual June 99

September 16, 1996

Refer to the engineering drawings to install the TDS.

Unless a new or recently-overhauled swivel is used, the old bail

Generally, a swivel saver sub is not used unless a crossover sub is

TDS-4H Installation and commissiioning

September 16, 1996

Figure 3. Swivel assembly

TDS-4H Installation and commissioning

September 16, 1996

On some configurations it may be necessary to remove the upper

TDS-4H Installation and commissiioning

September 16, 1996

Safety Link (4)

Figure 4. Landing collar installation

TDS-4H Installation and commissioning

September 16, 1996

TDS-4H Installation and commissiioning

September 16, 1996

Figure 5. Counterbalance system