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HMIS Maintenance Guide

1. CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 103 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX E SERVICE CHECKLISTS MAINTENANCE GUIDE WEEKLY CHECKLISTS Date Supervisor Rig Time Weekly Top Drive Inspect For Inspector All fasteners nuts bolts and lock wires correct location tightness Auxiliary manifold general condition Connection locking clamps correct location tightness Hydraulic fittings tightness leaks Grabber dies excessive wear Hydraulic connections and hoses on the oil leaks top drive Load collar adequate load ride height on the spring load ride height should be 3 8 1 2 if it is not contact TESCO s Maintenance and Service Group Mud saver valve actuator sleeve general condition disassemble clean grease coat with corrosion inhibitor and reinstall see How to Disassemble and Service the Roto Actuator on page 33 Motor termination boxes moisture terminal nut Robotics and sensor panels moisture tightness of wire terminations Gearbox lubrication filter cleanliness check filter bypass and magnetic plug Upper quill bearing preload proper preload see How to Check and Adjust Preload on page 40 Pipe handler rotation motors check for tightness Load collar springs damage breaks Weekly Swivel Inspect For Inspector Hammer unions damage dec
2. 15 Monthly Periodic Oil Reservoir Service 15 Annual Oil Reservoir Service eeeeeee ee ee cece tenet eee eee 16 Power Unit Cooling System Service 16 Daily Cooling System Service 16 Monthly Periodic Cooling System 5 16 CONTACT 1 877 CTESCO 77 250TONHMIS475HP WWW TESCOCORP COM INTL 713 359 7295 III WWW TESCOPARTS COM TABLE OF CONTENTS MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES 17 Top Drive Owner s 17 Guidelines for Component Inspectors c einne ee se en en en en en en en einne is 18 Load Path Components and Inspection Information 18 3Thireaded Connectioris usns Wik ahi ed ue ele e eb Ga Pe ee ee 28 Threaded Connection Inspection Frequency HMI 28 Torque Arrest System cado ach Ra vx Rmus that ae tae Bo as A E 28 Torque Arrest System Inspection Frequency 30 Pipe Handler Rotation System Inspection Frequency 31 CHAPTER 4 SERVICE PROCEDURES selle nnn 33 Introductlon musste arcu ln v og
3. 8 Monthly Periodic Service Loop Service Requirements 8 Torque Arrest System Service RequirementS c cocer eee eee 8 Daily Torque Arrest System Service 8 Weekly Torque Arrest System Service 9 Power Unit Prime Mover Service Requirements 9 Daily Prime Mover 9 Weekly Prime Mover 10 Monthly Periodic Prime Mover Service 10 Power Unit Pump Drive Service Requirements 12 Daily Pump Drive Service ic 4 2 x 5 2 d a I A S 12 Weekly Pump Drive 13 Monthly Periodic Pump Drive 13 Power Unit Filter Manifold Service Requirements 14 Daily Filter Manifold Service 0 0 0 ttt ttt 14 Monthly Periodic Filter Manifold Service 14 Power Unit Oil Reservoir Service RequirementS eee eee eee eee 15 Daily Oil Reservoir 5
4. C 3 Lower thrust surface C 4 Splines C 5 Load nut grooves 6 Quill pin end A B C also refer to Threaded Connections on page 28 Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 877 CTESCO 77 250TONHMIS475HP WWW TESCOCORP COM INTL 713 359 7295 21 WWW TESCOPARTS COM CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Figure 3 3 Load nut retainer and split collar HMI Frequency Operating Days and Inspection Type Point Every At At At At 60 250 500 750 1000 1 Load nut retainer shoulder 2 Entire load nut retainer 3 Split collar 4 Split collar grooves 5 6 Bottom plate A A A C not a load area Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 22 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION Figure 3 4 Mudsaver valve and actuator HMI 39000812 ai Frequency Operating Days and Inspection Type Point Name Every 60 At 250 At 500 At 750 At 1000 1 Top box connection A B C 2 Upper valve stem hole
5. nnn nent need 65 TOD DAVEE n T asl yes ted AP andrea eee ach Spade ebay dnt tig E EA Ven chee Aue eh i 66 Junction Boxes Auxiliary Panel 66 Main Drive bee XP Peggy DEG OHSAS ad rd Y 66 bad NUES cs Et c Ser eet te Y N EE esas cus 66 Cera 66 Elevators EHI nacre Sot a Does OR e c 67 Mudsaver Valve rl 67 SAVER SUDS uz b mtt emt uu etu ut ieu ett rete 67 Hose Storage Reel eec bc o eode Reb 68 Main Storage ae dne d e hx ax AS ha RR 68 Drillers Panel IDEE Rem ees tin ten Fais Rode eee Reece eg ee eg Ys 68 nterloCKS 1 ture tse Edge Au Led Bt A fo bre Aat ava iie 69 Torque Arrest System sas reae od way QRR RARA tk a ACAR ERA RR bea ek aed RT ha des 69 Torque Track 69 Torque Bushing Extend 69 Studs for Torque n 69 Hanging Sling 70 Torque Beam and c lt sieur aac epe I Red ae ai gn diana Rn E 70 P OWenUnit2 une des
6. 50 Remove the Load Nut 2 2 eee 51 Remove the Quill and Swivel 52 How to Assemble the Load 52 Install the Qui Lu 52 Install the Eoad NUt ees ang Ren tose eke Shobha asia eaa 53 Install the Mudsaver Valve 54 How to Disassemble and Assemble the Grabber 55 roduc iosa ne ede tud SER icai edie ak aet 56 How to Change the Grabber 56 How to Remove the Grabber Actuating 5 57 How to Reinstall the Grabber Actuating 15 57 CONTACT 1 877 TESCO 77 250TONHMIS475HP WWW TESCOCORP COM INTL 713 359 7295 IV WWW TESCOPARTS COM MAINTENANCE GUIDE TABLE OF CONTENTS How to Repair the Grabber Cylinder eee eee eee 58 How to Remove and Reinstall the Lower Grabber Leg 59 How to Change the HMI Gear 61 CHAPTER 6 LONG TERM PRESERVATION AND 65 VAR OA gb Ee ao wp oe D 65 Before System Shut Down aise s hide taaa
7. Additional Comments CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 96 WWW TESCOPARTS COM MAINTENANCE GUIDE ELEVATOR INSPECTION LOG APPENDIX D SAMPLE INSPECTION LOGS Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Date Days in Service Cumulative Inspected By Results Comments Next Service Due Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Additional Comments CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 97 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX SAMPLE INSPECTION LOGS MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 98 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS APPENDIX E SERVICE CHECKLISTS This Appendix contains examples of the following checklists Daily Checklist see also Maintenance and Service Schedules Weekly Checklist see also Maintenance and Service Schedules Monthly Checklist
8. C 3 Lower valve stem hole A B C 4 Lower box connection C 5 Length of valve body C Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 23 WWW TESCOPARTS COM CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Figure 3 5 Saver sub HMI 39000813r1 ai Frequency Operating Days and Inspection Type Point Name Every 60 At250 At 500 At750 At 1000 1 Upper seal face 2 Upper threads A B C 3 Lower seal face C 4 Lower threads C 5 Entire length of body C Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 877 TESCO 77 250TONHMIS475HP WWW TESCOCORP COM INTL 713 359 7295 24 WWW TESCOPARTS COM MAINTENANCE GUIDE Figure 3 6 Load collar HMI CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION Frequency Operating Days and Inspection Type Point Every At At At At 60 250 500 750 1000 1 Load collar ears A A B A B A B 2 Load shoulder check for cracks galling and heat damage 3 Complete load collar A C Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 8
9. on tahitian UN Lfd 70 Hydraulic Oil Storage 70 Air Oll Cooler 15 Soto te t tbt sot d Sette St Cu b cake De Cis br eel BB 71 Optional Stand Alone Plate 71 Auxiliary Oil P mp ise a e ee ee ed G R ee meme Red Re ri r ig og e do 71 Filter Manifolds tt tms cra hk ade tS o be e RURSUS ate aL ee ek AOE 71 Pump Drive and Main Hydraulic Pumps i eeeeeeeeee ee ee ee ee ee ee ee ee ee eee 71 Prime Moveis ase naaa tet eth ois ate Near uus viet ceed eens es Lena 72 Main Electrical Panel uos fees o ee t ede ik t e LT 72 General n i eia pe Pee we PR A RPP ie a IIT EIS Raus Eres 72 Storage Gontalriers sesarat PEDE E uer Hebdos utes Hatte hue ed yas 73 Container T 73 Container 2 alena dele Rae R E EA RE a Bee dead eRe TI 73 Container teet um err itt eec sees teens aue ter tein Cros eii ec e Ld 73 APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS 75 CONTACT 1 877 CTESCO 77 250TONHMIS475HP WWW TESCOCORP COM INTL 713 359 7295 V WWW TESCOPARTS COM TABLE OF CONTENTS MAINTENANCE GUIDE PUIPOSE d aut RU eit A as PA Altes Eo aen od 75 SE alo E go eos eost a Mae E 201 2 EA DE 75 Tables estesa D Corta E NET LAE
10. TESCO Maintenance Guide HMIS Top Drive System 250TON HMIS 475HP DOCUMENT NAME 880028 REv 9 MAINTENANCE GUIDE COPYRIGHT AND DISCLAIMER Tesco Corporation TESCO has made every effort to ensure that this document contains accurate and current information for the TESCO top drive however the document is intended to be used in conjunction with a complete training program and on site supervision and TESCO does not warrant or guarantee that the information contained herein is either complete or accurate in every respect and the reader hereby protects indemnifies and holds harmless Tesco Corporation together with its directors officers employees and agents from and against all liability for personal injury death or property damage to any person arising directly or indirectly from the use by the reader of the information contained in the document This equipment was filled at the factory with TESCO ULTREX M brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified TESCO ULTREX M is a trademark and TESCO is a registered trademark of Tesco Corporation Tesco Corporation O 2009 Contact Information Corporate Head Office 3993 W Sam Houston Parkway No Suite 100 Houston Texas 77043 USA www tescocorp com www tescoparts com Telephone 713 359 7000 Fax 713 359 7001 After Market
11. CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Weekly Pump Drive Service The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments mounting to prime mover Inspect For Breather filter cap cleanliness Mating bolts tightness Monthly Periodic Pump Drive Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Inspect For Pump shaft splines and adapters wear correct lubrication refer to TESCO s fluid specifications for hydraulic units EM000039 EM000041 EM000042 Pump drive oil cleanliness change as required do not over fill excess oil causes heat build up refer to TESCO s fluid specifications for hydraulic units EM000039 EM000041 EM000042 itis best to change the oil immediately after equipment operation when the oil is warm Hydraulic fittings tightness CONTACT 1 877 TESCO 77
12. The grabber might require disassembly and repair if the following problems occur The grabber will not open or close even though electrical and hydraulic circuits are operating normally The grabber will not hold the required pressure A hydraulic oil leak is detected How to Change the Grabber Dies It is easiest to perform this procedure if the drill pipe is disconnected and the saver sub is removed however grabber dies can be changed with the drill pipe connected to the saver sub if required small parts If possible use the EXTEND function to move the bot tom of the grabber away from hole center Cover all exposed areas around well center to prevent parts from falling through the table Caution This procedure requires the removal and replacement of ber is partially closed Do not allow the grabber to close fully Caution It is easier to access the grabber dies and bolts if the grab 1 Remove the lower die keeper plates 2 and the retaining bolts 2 per plate 2 Use a long pin punch or similar tool to tap the dies downward and out of the die holder blocks Remove spacers if used Use a film of grease or pipe dope to lubricate the new dies 5 Install the new dies and spacers Note Select dies and spacers that are appropriate for the drill pipe in use Refer to Appendix B Tool Joint Usage Chart 6 Install the die keeper plates Note Torque the retaining bolts to 100 ft lb CONTACT 1
13. 3 10 11 12 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Install the die holder plate on the end of the grabber cylinder Torque the retainer plate bolts to 40 ft lb Slide the cylinder assembly into the clamping box Note Ensure that the port extensions are oriented upward Install the retraction place and piston retaining bolts 2 and torque the bolts to 100 ft lb Install the port extensions 2 Invert the clamping box Note Place the clamping box on wooden blocks to protect port extensions Install the dies keeper plates and die keeper bolts Secure all drilled bolts in place with lockwire Slide the clamping box into the outer torquing box Install the retraction pins 2 and secure them in place with lock wire Connect the grabber open close hydraulic lines Reset the grabber height For more information refer to How to Reset the Grabber Height on page 37 250TON HMIS 475HP WWW TESCOCORP COM 57 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How to Repair the Grabber Cylinder This procedure assumes that the grabber cylinder has been removed from the clamping box Refer to Appendix B Tool Joint Usage Chart to determine which dies and spacers to use for the tool joint in use 1 Remove the die holder plate from the cylinder assembly 2 Use the gland nut spanner supplied by TESCO to remove the brass gland nut from the end of the cylinder Pull
14. 60 Figure 5 4 Gear ratio configuration 61 CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 vil WWW TESCOPARTS COM LIST OF FIGURES MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 Vill WWW TESCOPARTS COM MAINTENANCE GUIDE LIST OF TABLES LIST OF TABLES Table 1 1 Where to find more information c c c 1 Tabl 331 Inspection types uu rok n tente utt ul OR RR She Re tn SA 19 Table A 1 Standardtorques a c c c 76 Table A 2 Special fastener torques 77 Table A 3 B7 5 77 Table A 4 Thread engagements 78 Table B 1 Tool joint usage 79 CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 IX WWW TESCOPARTS COM LIST OF TABLES MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 X WWW TESCOPARTS COM CHAPTER 1 ABOUT THIS DOCUMENT MAINTENANCE GUIDE This document contains information on how to service and maintain your HMIS Top Drive System T
15. CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES DRIVE OWNER S GUIDELINES The integrity performance and safe operation of TESCO s top drives depend on sound maintenance and inspection of all load path torque arrest system and critical components This chapter describes TESCO s minimum recommended inspection schedule including the following recommended reporting format for third party inspections recommended minimum inspection frequency for each load path torque arrest system or critical component specific areas of concern for each component Caution In addition to the schedule suggested here all load path torque arrest system and critical components must be inspected following rough drilling excessive jarring or any other exceptional circumstance that might increase fatigue failure When you receive inspection reports file them in accordance with procedures in your operating area Itis critical that you maintain complete inspection and service records for all load path torque arrest system and other critical components information must be used in conjunction with a regular inspection and maintenance program as defined in Chapter 2 Maintenance and Service Schedules Caution This guide addresses MPI and WFMPI testing only This TESCO will not assume responsibility or liability for any component product or material that has been repaired rebuilt welded or heat treated ou
16. HMI S Advanced Performance Multi Grade Gear Oil 80W 90 731140 HS Advanced Performance Multi Grade Gear Oil 80W 90 731140 HC Advanced Performance Multi Grade Gear Oil 80W 90 731140 HCI Advanced Performance Multi Grade Gear Oil 80W 90 731140 HXI Advanced Performance Multi Grade Gear Oil 80W 90 731140 Fluid Description TESCO Part Pump Drives All TESCO Manufactured Description ECI 900 1350 Synthetic Multi Grade Gear Oil 75W 90 731136 EMI 450 Synthetic Multi Grade Gear Oil 75W 90 731136 EMI 400 Synthetic Multi Grade Gear Oil 75W 90 731136 EXI Synthetic Multi Grade Gear Oil 75W 90 731136 EMI 400 H amp P Advanced Performance Gear and Bearing Oil ISO 220 731133 Fluid Description TESCO Part All TESCO Hydraulic Systems Advanced Formula Single Weight Motor Oil SAE 40 731135 All Swivels Fluid Description TESCO Part Advanced Performance Gear and Bearing Oil ISO 220 731133 Advanced Performance Multi Grade Gear Oil 80W 90 731140 Fluid Description either can be used TESCO Part Advanced Performance Hydraulic Oil ISO 68 731143 Drives Grease for All TESCO Top Biodegradeable Hydraulic Oil ISO 68 Fluid Description either can be used 731138 TESCO Part NLGI 1 cold weather 48 tubes 731142 48T NLGI 2 hot weather 48 tubes 731141 48T CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP WWW TESCOCORP COM
17. for sign of overheating Comments Notes CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 101 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX E SERVICE CHECKLISTS MAINTENANCE GUIDE Daily Prime Mover Inspect For Inspector All hoses and belts leaks tightness Exhaust system routing loose clamps and bolts check visually Oil level low idle oil level check for leaks Coolant level correct level Oil pressure correct operating range consult the manufacturer s service and maintenance documentation for your prime mover module Operating fuel pressure adequate pressure consult the manufacturer s service and maintenance documentation for your prime mover module Air filter restriction indicator consult the manufacturer s service and maintenance documentation for your prime mover module Rig saver confirm correct position open Radiator clogging debris Caution Never use high pressure spray to clean the radiator Pressure can bend and damage the cooling fins Never spray a hot radiator with cold water Always stop the engine before cleaning the radiator Daily Pump Drive Inspect For Inspector Oil level adequate oil level fill if required Oil system leaks Cooling system excessive dirt general condition check the heat exchanger Pump drive lubrication sys
18. of Full Torque 100 100 100 100 90 100 100 100 80 100 100 100 70 100 100 100 60 90 100 100 50 70 100 100 40 60 75 100 30 45 60 75 20 30 40 55 Engagement as a of the bolt diameter Values represent the percentage of torque from Table 1 Engagement does not include chamfer or incomplete threads Engagements of less than one bolt diameter in tapped holes shall not be used without the engineer s approval CONTACT 1 877 TESCO 77 250TON HMIS 475HP INTL 713 359 7295 78 MAINTENANCE GUIDE WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX B TOOL JOINT USAGE CHART APPENDIX B TOOL JOINT USAGE CHART Use the following chart to configure the grabber and grabber dies to accommodate the current drill pipe Table B 1 Tool joint usage chart Tool Joint O D TESCO Part 3 1 8 in 6 5 8 in 3051 Description Die holder 1047 Socket head capscrew 1 2 13UNC x 2 1 2 in 3054 Bottom keeper plate 8378 Top die retainer plate 3725 Hex head capscrew 3 8 16UNC x 1 in 1045 Socket head capscrew 1 2 13UNC x 1 in 6654 Spacer 9070 Tong die 1 in thick x 1 1 4 in wide x 5 7 8 in long 4891 opt Tong die 1 in thick x 1 1 4 in wide x 3 7 8 in long 3055 opt 4 in 7 1 2 in 3051 Die spacer Die holder 1047 Socket head capscrew 1 2 13UNC x 2 1 2 in 3054 Botto
19. A g 6178 Z 5692 gt C 6178 i NS ms i 1i xL Idler SOK Trunion gt Trunnion ail Trunion Idler Shaft Retainer a Idler 5691 7 6265 eene Kk Shaft Sh 5691 E m d amp Motor Hydraulic Motor Manifold Motor Flange Motor Pilot Counter Bore 3900027210 ai CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 61 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE Use the following procedure to move the idler gear and change pinion gear from 21T 1 64 1 to 28T 2 19 1 1 Drain all of the oil from the gearbox Note If you replace the oil ensure that all waste oil is correctly disposed of 2 Remove the motor and manifold as a single unit To remove the motor and manifold you must remove the six bolts that hold the motor in place Label all control hoses disconnect and put protective covers on all hose ends 3 Remove the 21 T pinion gear from the motor pilot bore of the gearbox is not moved out of alignment when you remove the Caution Ensure that the bearing below the pinion gear in the base A pinion gear 4 Inspect the lower bore area for metal deposits or debris If you find dirt or debris thoroughly clean the gearbox 5 Remove the retainer plate for the 1 64 1 trunnion idler pin from the bottom of the gearbox 6 Remove the 2 19 1 idler bore plugs from the top and bottom
20. CAT I Protected electronic control circuits control power 24 volt DC The fuses on the 24 volt secondary side of the control transformer are 20 amps FUSE MAIN POWER 480 3 PHASE L1 L2 L3 Manufacture Bullet Type 80 Amp CSA Type D HRCI R Dual Element Class RK 5 Current Limiting Listed Fuse DL 93 91 CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 81 WWW TESCOPARTS COM APPENDIX FUSES FOR THE CONTROL TRANSFORMER MAINTENANCE GUIDE FUSE 120 VOLT L1 L2 amp AC 15 L1 Power Supply to 15 amp breakers for AC 15 Primary side of control transformer AC 4 Receptacles e 3 Lights Type 250 VAC 30 amp e IR 10 kA OMT 30 L2 Control power to Auxiliary pump Circulation pump Cooling Fan Type Edison Fast Acting MOL 8 amp 250 VAC IR 200 amp 125 VAC IR 10 kA AC 15 24 VDC Power Supply Input Type BAF 10 250 VAC IR 200 amp 125 VAC IR 10 kA FUSE 24 VDC POWER SUPPLY OUTPUT Type Buss AGC 20 32 volt 20 amp FUSE 24 VDC POWER SUPPLY TO TORQUE CIRCUIT Type Edison Fast Acting MOL 1 amp 250 VAC IR 100 amp 125 VAC IR 10 kA CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 82 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX C FUSES FOR THE CONTROL TRANSFORMER CONTROL POWER SUPPLY NAMEPLATE INFORMATION Type Custom Rectifier Level I ACME Electric Power Products Gr
21. INTL 713 359 7295 15 WWW TESCOPARTS COM CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE Annual Oil Reservoir Service Replace the tank screen filters at least once every operating year POWER UNIT COOLING SYSTEM SERVICE REQUIREMENTS Daily Cooling System Service The following visual checks should be performed at least once every operating day More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Air oil cooler leaks correct fan operation Note Set the fan switch to manual before you check operation fan cleanliness correct hot oil shuttle flow Note if the unit is operating check the flow meter on the opposite side of the electrical panel Water oil cooler if installed leaks or damage check visually All sides including under leaks complete visual inspection Cooler core debris blockages Hydraulic hoses and connections leaks tightness Monthly Periodic Cooling System Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All mounting bolts and fittings tightness CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 16 WWW TESCOPARTS COM MAINTENANCE GUIDE
22. and Better Ways to The Bottom are trademarks of Tesco Corporation Tesco Corporation June 2007 POD Due to ongoing product development all specifications are subject to change without notice Asia Pacific Latin America Jakarta Indonesia Buenos Aires Argentina Email APBU_sales tescocorp com Email LABU_sales tescocorp com China Middle East amp Africa Chaoyang District Beijing Dubai UAE Email CHINA_sales tescocorp com Email MABU_sales tescocorp com Europe Russia United States Canada Ll H Aberdeen UK Houston Texas Calgary Alberta Email EURO_sales tescocorp com Email NABU_sales tescocorp com TESCO tescocorp conm Better Ways to The Botto m CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 121 WWW TESCOPARTS COM APPENDIX F TESCO ULTREX LUBRICANTS MAINTENANCE GUIDE E ULTREX EL ESI Synthetic Blend Grease TESCO NLCI 2 Hot Weathe BULLETIN 87200 e Superior protection for equipment against heavy loads dirt dust water and heat PRODUCT OF CHOICE FOR EXTREME APPLICATIONS rovides Superior Equipment Protection for TESCO Mud Saver Valves Patented Synthetic Blend Calcium Sulfonate Grease Protects and Stays in Place Under Severe Load Conditions Contains High Concentraion of Moly and Graphite to educe Heat Friction and Abrasive Wear Lasts 2 to 5 Times Longer Than Conventional Greases Superior Water Resistance won t wash out during o
23. and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Position the actuator on top of the wooden blocks on the grabber Ensure that the actuator and valve are either both open or both closed Ensure that the actuator and valve are oriented in the same way as they were when removed See Figure 4 1 Danger If the orientation is not correct the valve will not open when required This causes a serious safety hazard Figure 4 1 Actuator valve orientation Align the valve sockets before sliding the actuator over the valve CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 34 WWW TESCOPARTS COM MAINTENANCE GUIDE 9 10 12 13 14 15 16 17 18 19 CHAPTER 4 SERVICE PROCEDURES Slowly raise the grabber to move the actuator to the correct position The actuator should slide smoothly onto the double ball valve Install four brass shims 0 010 in or a 0 010 in feeler gauge between the body of the mud valve and the actuator Note The shims help to align the valve and actuator concentrically during assembly Coat all locking pins and setscrews with a thin coat of anti seize compound Install the locking pins springs and setscrews as follows a Put all locking pins spring and setscrews in place b Turn the setscrews until they meet the springs but d
24. load collar 5 mudsaver valve 5 prime mover 10 service loop 8 service loop components 8 swivel 6 swivel hammer unions 6 swivel oil level 6 top drive 5 torque arrest system 9 urethane capture blocks 8 water pump 10 weep hole plugs 10 weekly service pump drive 13 service loop 8 top drive 5 weep hole plugs inspection 10 wet fluorescent magnetic particle inspection 28 WFMPI inspection 28 WFMPI testing 28 WWW TESCOCORP COM WWW TESCOPARTS COM
25. see also Maintenance and Service Schedules Six Month Checklist Daily Top Drive Report The Daily Top Drive Report exists in booklet form and can be ordered from TESCO IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 99 WWW TESCOPARTS COM APPENDIX E SERVICE CHECKLISTS DAILY CHECKLISTS MAINTENANCE GUIDE Date Supervisor Rig Time Daily Top Drive Inspect For Inspector Gearbox oil correct oil level Hydraulic hoses and connections at the top drive Grabber dies excessive wear Mudsaver valve lower ball manually operate the valve to check function Saver sub threads excessive wear Swivel oil level correct level Grabber check and reset grabber height Lubricate With Inspector Grease nipples on the EXTEND cylinder 4 if applicable EP2 multi purpose grease Lower bearing retainer of gearbox grease ports EP2 multi purpose grease Upper bearing retainer of gearbox grease ports 2 EP2 multi purpose grease Grease ports on the load collar 1 EP2 multi purpose grease LINK TILT cylinders 4 EP2 multi purpose grease Grease ports on the eleva
26. 1 in repeat this procedure to adjust the grabber height 11 When the correct distance is achieved install all safety devices CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 37 WWW TESCOPARTS COM CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How TO SET THE PRESSURE RELIEF VALVE FOR THE AUXILIARY SYSTEM Perform this procedure as part of monthly power unit maintenance The pressure relief valve for the auxiliary system is located on the hydraulic oil cooler 1 2 3 4 5 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Set the AUX PUMP switch at the driller s panel to ON Set the GRABBER switch to OPEN Loosen the lock nut on the adjustment screw of the relief valve Unscrew the lock nut a few turns but do not remove it Adjust the set screw on the relief valve until the pressure gauge near the relief valve reads 1 900 psi min 2 000 psi max Figure 4 4 Auxiliary relief valve Note Some Tesco top drives are equipped with a secondary auxiliary relief at the auxiliary manifold This is used to warm the oil in the lines for cold climate applications If your top drive is equipped with this secondary relief valve set the main tank relief valve to 150 200 psi higher than the top drive relief valve The top drive relief valve should be set to 2 000 psi 50 Tighten the lock nut Set the GRABBER switch to neutral Set the AUX PUMP switch to OFF 250TON HMIS 475HP WWW TES
27. 113 WWW TESCOPARTS COM APPENDIX F TESCO ULTREX LUBRICANTS MAINTENANCE GUIDE OIL LUBRICANTS E ULTREX EH Semi Synthetic Multi Grade Gear Oil BULLETIN 81400e Superior protection against leaking seals dry starts water contamination oxidation and foaming UP TO 4 TIMES LONGER LIFE rovides Superior Equipment Protection for all TESCO Hydraulic Top Drive Gear Boxes and the EX 600 Gear Box Helps Eliminate Dry Start Wear Prevents Seals from Leaking Prevents Rust and Corrosion Displaces Water for Easy Drainage Controls Foaming Lowers Operating Temperature and Resists Oxidation to Prolong Oil Life Wide Temperature Range up to 149 C 300 F 80W 90 flows down to 26 C 15 F Meets or Exceeds the Following Performance Requirements All API GL 3 GL 4 and GL5 most GLA and GL 2 applications Military Specification MIL PRF 2105E 1 Viscosity Ranges 4EP SEP and 6 EP Mack Truck GO A through GO H applies to 80 90 Rockwell Standard 0 76 applies to 804 90 KW Dart specifications applies to 80 90 Part Number Order Information 5 USgal 19 L Pail 731140 19L 55 USgal 208 L Drum 731140 208L 330 USgal 1248L Tote 8731140 1248L CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 114 WWW TESCOPARTS COM MAINTENANCE GUIDE ULTREX SEMI SYNTHETIC MULTI GRADE GEAR OIL 80W 90 USED FOR paraffin
28. A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS Table A 2 Special fastener torques Fastener Description Minimum Mild Steel ft lbs High Strength Steel ft lbs E t dox ded Dry Lubricated Dry Lubricated UNBRAKO 5 16 in 18 UNRC 3 8 in 27 20 35 26 UNBRAKO 1 2 in 13 UNRC 1 2 in 118 88 154 115 UNBRAKO 5 8 in 11 UNRC 5 8 in 217 162 283 212 Special fasteners shall be used only in critical locations or special applications Thread engagement is based on the minimum class 2B tapped threads in mild steel capable of developing bolt tension 8096 of bolt yield When using hardened steel washers on mild steel use torque values for high strength steel Table A 3 B7 Stud torques Stud Size Dry ft lbs Lubricated ft lbs 1 2 in 3 UNC 85 64 5 8 in 11 UNC 175 131 3 4 in 10 UNC 300 225 7 8 in 9 UNC 450 338 1 in 8 UNC 680 510 1 1 8 in 7 UNC 880 660 1 1 4 in 7 UNC 1260 945 1 3 8 in 6 UNC 1700 1275 1 1 2 in 8 UN 2300 1725 Recommended torques are based on bolt tensions of approximately 75 of stud yield strength CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 77 WWW TESCOPARTS COM APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS Table A 4 Thread engagements Material Aluminum Mild Steel High Strength Steel Engagement of Full Torque of Full Torque
29. INTL 713 359 7295 250TON HMIS 475HP WWW TESCOCORP COM 13 WWW TESCOPARTS COM CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE POWER UNIT FILTER MANIFOLD SERVICE REQUIREMENTS Daily Filter Manifold Service The following visual checks should be performed at least once every operating day More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Filter housing and manifold leaks Charge pressure differential correct differential pressure one gauge on the inlet and one gauge maximum differential is 100 psi if differen the outlet of the charge pressure manifold tial is greater than 100 psi replace the fil ter elements use the manufacturer s recommended fil ter element Hydraulic hoses and connections leaks tightness Monthly Periodic Filter Manifold Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Oil filters closed loop cleanliness oil filters should be replaced as indicated by oil analysis or every 4 000 operating hours use the manufacturer s recommended fil ter Oil filters tank cleanliness oil filters should be replaced every 900 operating hours or as indicated by the canister
30. INTL 713 359 7295 250TON HMIS 475HP 109 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX E SERVICE CHECKLISTS Monthly Pump Drive MAINTENANCE GUIDE Inspect For Inspector Pump shaft splines and adapters wear correct lubrication refer to Tesco s fluid specifications for hydraulic units EM000039 EM000041 EM000042 Pump drive oil cleanliness change as required do not over fill excess oil causes heat build up refer to Tesco s fluid specifications for hydraulic units EM000039 EM000041 EM000042 itis bestto change the oil immediately after equipment operation when the oil is warm Monthly Filter Manifold Inspect For Inspector Oil filters closed loop cleanliness oil filters should be replaced as indicated by oil analysis or every 4 000 operating hours use the manufacturer s recommended filter Oil filters tank cleanliness oil filters should be replaced every 900 operating hours or as indicated by the canister dirt alarms use the manufacturer s recommended filter Monthly Oil Reservoir Inspect For Inspector Return oil tank filter correct connections inspect visually Filter canister correct bolt correct torque Tank all sides including underneath leaks Monthly Cooling System Inspect For Inspector All mounting bolts and fittings tightness Comments Notes CONTACT 1
31. Order the Daily Top Drive Report booklet from TESCO TESCO Hydraulic Top Drive Daily x cialis Report Date Operator Job Location Current Depth A Weather Temp F Date Start of Well Job Start Date Days Remaining I ps Pom Pm Pn ws rill Range Switch Setting Set Torque Max Torque Rs Rsm s Lowco Hinoj ee _ __ eem I MT L1 Charge Flow fr chart Flow Total Loop Flow meters Pump Case Drain Drin Om apm Drillers Loop Gauge Swash Plate Pres psi Rosemount Reading Torque fr chart Charge Pressure psi lout lout Oil Temp Water Cool lout lou Oil Temp After Modine Ii Auxiliary Set Pressure Auxiliary Pump Flow RPM Oil Pressure F Main Loop Flow Meters gpm emperature CF Tank Temperature Loop Temp Shuttle Lube Flow Lube Temp Coolant Temperature Lube Pressure Coolant Pressure Total Engine Hours 24 00 Engine Hours Last Oil Change Engine Hours Last Oil Change Next Oil Change Due Engine Hours Next Oil Change Due Engine Hours Sample Taken Oil Change amt Sample Taken Oil Change ves nooo Top Drive Swivel Operating Days Since 500 Day Re certification In shop Major Rebuild of all Components in Top Drive Days Sin
32. SERVICE LIFE AMSOIL Synthetic Automatic Transmission Fluid is recommended for use up to 50 000 miles under severe service and up to 100 000 miles under normal service or according to the vehicle manufacturer recommended intervals whichever is longer AMSOIL recommends thoroughly draining the transmission and flushing with new AMSOIL ATF to achieve a minimum 90 purity of new transmission fluid Drain intervals may be extended fur ther with oil analysis As defined by the vehicle or transmission manufacturer HEALTH amp SAFETY This product is not expected to cause health concerns when used for the intended application and according to the recommendations in the Material Safety Data Sheet MSDS MSDS s are available upon request at 715 392 7101 or via the Internet at www AMSOIL com Keep Out of Reach of Children Don t pollute Return used oil to collection centers MSIE G 173 7 07 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX F TESCO ULTREX LUBRICANTS MAINTENANCE GUIDE GREASE LUBRICANTS bail ULTREX E Synthetic Blend Grease NLGI 1 Cold Weather BULLETIN 871008 Superior protection for equipment against heavy loads dirt dust water and heat PRODUCT OF CHOICE FOR EXTREME APPLICATIONS rovides Superior Equipment Protection for TESCO Mud Saver Valves Patented Synthetic Blend Calcium Sulfonate Grease Protects and Stays in Place Under Severe Load Conditions Contains High Concentrati
33. Sales and Service Contact Toll Free North America 1 877 TESCO 77 International 713 359 7295 CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 1 WWW TESCOPARTS COM REVISION INFORMATION MAINTENANCE GUIDE Revision Information Version Date Description of Changes Rev A June 2004 HMI model general engineering review with updates and additions for 2004 Rev B March 2005 All models updated the Service Checklist Appendix to reflect information in the Maintenance and Service Schedules chapter updated the Mudsaver Valve and Actuator Inspection chapter Rev C June 2005 All models added information about how to adjust the preload when the top drive is installed in the derrick HMI model added information on how to perform three separate preload checks for the HMI top drive units separated non destructive testing images from text to conform with TESCO technical documentation standards Rev D May 2006 HMI model updated non destructive testing and inspection schedules as per ICD HLR 020 Rev 4 February 2007 Added note about checking gauges and fluid levels to Maintenance and Service Schedules chapter as per ECN 133 0001 Updated version numbering from alphabetic to numeric Rev 5 March 2007 Updated Non Destructive Testing and Inspection Schedules chapter as per ECN 122 0017 Rev 6 June 2007 Updated Non Destructive Testing and Inspection Schedules chapter as per ECN 122 0025 add
34. base Check the bowl seal and replace it if necessary Remove the cover and cover seal Clean the mating surface and replace the cover seal if required Reassemble the filter and ensure that all moving parts rotate freely Start the engine and monitor the filter connections and joints for leaks 250TON HMIS 475HP WWW TESCOCORP COM 46 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How TO PERFORM A COOLANT ANALYSIS ENGINE 1 Ensure that you have a coolant test kit available Note These are available from the equipment manufacturer 2 Ensure that your test area is clean and free of contaminants 3 Using the test kit and supplied instructions evaluate the coolant fluid for the following Nitrite concentration If nitrite concentration is inadequate system corrosion can occur Glycol concentration If glycol concentration is inadequate freezing or boil over can occur any inhibitor or anti freeze additives Never introduce unapproved Caution Consult the manufacturer s documentation before you use additives sealer additives for example into the coolant system How TO CHECK THE SPLINES ON THE PUMP SHAFT Note This procedure takes several hours to perform Pump shaft splines can only be inspected when an extended period of downtime is anticipated mended by your Safety or Loss Prevention Department before you Caution Always perform correct lock out procedures as recom attempt this proce
35. combinations of gear types Can be added as make up oil to other GL 5 Automatic universal C 3 fluid combined transmissions Truck transmissions that only allow the use of GL 1 gear oil motor oil Spicer Dana or Fuller transmissions Tesco Corporation June 2007 POD Due Asia Pacific Jakarta Indonesia Email APBU_sales tescocorp com Il specifications are subject to change without notice Latin America Buenos Aires Argentina Email LABU_sales tescocorp com tescocorp com CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 115 China Middle East amp Africa Chaoyang District Beijing Dubai UAE Email CHINA_sales tescocorp com Email MABU_sales tescocorp com Europe Russia United States Canada E H Aberdeen UK Houston Texas Calgary Alberta Email EURO_sales tescocorp com Email NABU_sales tescocorp com TES c Better Ways to The Botto m WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX F TESCO ULTREX LUBRICANTS MAINTENANCE GUIDE EE ULTREX fl H Hydraulic Oil BULLETIN 85200e Superior protection against leaking seals contaminants pump wear and erratic operation HYDRAULIC OIL OF CHOICE FOR ALMOST EVERY SINGLE GRADE APPLICATION ovides Superior Equipment Protection for TESCO Standard Open amp Closed Loop Hydraulic Systems Controls Seal Swell to Help Prevent Seals from Leaking Highly Resistant to Oxidation Controls Water and
36. dirty environments Graphite Layered solid that provides added protection at high temperatures and improves lubrication in wet conditions PHYSICAL PROPERTIES PROPERTIES GREEN 1 Penetration ASTM D 217 313 Multistroke penetration ASTM D 217 325 Wheel bearing leakage ASTM D 1263 NA Water washout ASTM D 1264 lt 0 2 Pressure Oil separation ASTM D 1742 0 5 Four ball Index ASTM D 2596 101 Four ball weld ASTM D 2596 1000 Four ball wear scar ASTM D 2596 0 41 Timken method ASTM D 2509 60 Rust test ASTM D 1743 Passed Copper corrosion ASTM D 130 1B Low Temperature Limit 28 20 F Dropping Point ASTM D 2265 302 C 575 F High Temperature Limit 260 C 500 Base Oil Viscosity 40 C 104 F 110 87 USED FOR Heavy industrial equipment exposed to high low temperatures high speed wheel bearings anti friction bearings open gears turbine pumps paper and pulp mills steel mills chemical plants and waste water plants construction equipment sewage treatment plants irrigation equipment non domestic water pumps wet mining scroll saws kiln cars high speed wheel bearings boat trailer bearings sleeve bearings chassis utility trucks buses sea going vessels coastal and wharf equipment inland waterway applications NOT FOR Any application with a continuous temperature exceeding 260 C 500 F intermittently without monitored lubrication TESCO ULTREX
37. filter manifold daily service 14 filter manifold monthly service 14 filter manifold service requirements 14 function light pressure switch 39 G gear ratio configuration 61 gear ratio change 61 gearbox lubrication schematics 1 WWW TESCOCORP COM WWW TESCOPARTS COM INDEX gearbox oil monthly inspection 6 grabber change grabber dies 56 service actuating piston 57 grabber actuating piston reinstallation 57 grabber actuating piston removal 57 grabber chain weekly inspection 5 grabber cylinder repair 58 grabber dies daily inspection 3 grabber dies weekly inspection 5 grabber dies changing 56 grabber disassembly and assembly 55 grabber height daily inspection 3 grabber height reset 37 grabber leg reinstall 59 remove 59 grabber leg service 59 grabber monthly inspection 6 grabber service 55 grabber storage 66 guidelines for component inspectors 18 H hanging assembly storage 70 high strength fasteners torque standards 75 113 hinge pins monthly lubrication 6 hydraulic fittings monthly inspection 6 hydraulic oil analysis 45 hydraulic oil tank storage 70 hydraulic schematics 1 information where to find more 1 inspection guidelines 18 inspection types 19 install the top drive 1 interlocks storage 69 J junction boxes storage 66 L link tilt cylinders daily lubrication 4 load collar weekly inspection 5 load nut inspection 22 load nut installation 53 load nut s
38. hex head 3 8 in x 1 1 2 in Die holder retainer for 1 2 in shims Shim 1 2 in Tong die 1 in thick x 1 1 4 in wide x 5 in long Break away tab Die retainer 3 1 2 in 6 5 8 in Cap screw hex head 3 8 in x 1 1 2 in Die holder retainer Tong die 1 in thick x 1 1 4 in wide x 5 in long Break away tab Die retainer CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP Cap screw hex head 3 8 in x 1 in WWW TESCOCORP COM 80 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX C FUSES FOR THE CONTROL TRANSFORMER APPENDIX C FUSES FOR THE CONTROL TRANSFORMER throughout the Tesco top drive components ONLY qualified personnel should install maintain and or troubleshoot the electrical systems A severe safety hazard exists for personnel not accustomed to or familiar with electrical hazards and procedures N Danger Electrical voltages of different potentials are used GENERAL The electrical protection requirements for the primary and secondary of this transformer will be clearly marked in an area close to the fuse locations This will be on the Plexiglas barrier The information will indicate the following Type Voltage Rating Current Rating Interrupting Rating CAT II Power supply to control power transformer and receptacle outlet circuits 120 volt AC The fuses on the 120 volt primary side of the control transformer are 10 amps
39. lower the grabber Install the mudsaver die lock clamp and retainer ring Use a die lock clamp to install the saver sub into the mudsaver valve Note For more information refer to the Operations Guide for your unit 250TON HMIS 475HP WWW TESCOCORP COM 54 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How TO DISASSEMBLE AND ASSEMBLE THE GRABBER Figure 5 2 HMI grabber box components He S Seal Alignment Grabber Cylinder Die Holder Retainer Plate Top Die Holder Retainer Tong Dies Safety Wired p 2 A A Die Holder Breakaway Tabs Inner Die Holder Safety Wired W Blue Loctite 242 Retracting Pins Grabber Close Safety Wired Safety Wired Blue Loctite 242 Grabber Open Tordue Box 39000751r0 ai 250TON HMIS 475HP CONTACT 1 877 TESCO 77 55 INTL 713 359 7295 Tong Dies Die Holder i Breakaway Tabs Inner Die Holder Top Die Holder Retainer f oc 3 em Clamping Box Retracting Plate WWW TESCOCORP COM WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE Introduction This section contains the procedures that explain how to disassemble and assemble the grabber components How to Change the Grabber Dies How to Remove Service and Reinstall the Grabber Actuating Piston How to Remove and Reinstall the Grabber Leg
40. of monthly top drive maintenance Use a pin located on the back side of the grabber leg to adjust the height You can use one of several pin locators to position the grabber leg Figure 4 3 Grabber position Height adjustment pin positions on the back of the grabber leg Bottom seal face 1 i Top of dies Before You Start Measure the distance from the top of the grabber die to the lower seal face of the saver sub Note This measurement should be 1 in If the distance is not 1 in adjust the grabber height by changing the pin locations as follows 1 Open the hinged pin retainer on the upper grabber leg 2 Lower the top drive until the grabber is resting on the floor 3 Adjust the height of the top drive so that the weight of the grabber leg is removed from the height adjustment pin 4 Remove the height adjustment pin 5 Lower or raise the top drive to obtain the required lin dimension see Figure 4 3 6 Find the closest aligned holes between the grabber leg spring and the grabber leg If no holes align raise the top drive slightly until two holes align 7 Insert the height adjustment pin 8 When the height adjustment pin is in place raise the top drive to transfer weight back onto the grabber leg spring 9 Push up and down on the grabber leg Note This ensures the leg floats on the spring and comes to rest in the proper position 10 Measure the die sub distance again Note If the distance is not
41. of the gearbox Note At the top of the gearbox this is a frost plug at the bottom it is a blank plate 7 Remove the retainer plate for the trunnion idler and immediately install a thread protecting bolt into the tapped idler pin hole Caution These threads are important for correct gear installation Do not damage these threads Remove the idler pin and replace both O rings 9 Move the idler gear to align with the bore position of the 2 19 1 trunnion idler pin 10 Apply lubrication to the idler bearings Note This will help maintain alignment when you install the idler pin 11 Install a long bolt or ready rod in the idler pin 12 Pull the pin into the 2 19 1 gearbox bore Caution Do not misalign the bearing set in the idler gear 13 Secure the pin with the retaining plate for the idler pin 14 Install the 2 19 1 pinion gear Caution Do not misalign the bearings the pinion bore 15 Install the idler bore plug in the 1 64 1 position top of gearbox 16 Apply silicone to the frost plug CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 62 WWW TESCOPARTS COM MAINTENANCE GUIDE 17 18 19 20 CONTACT 1 877 TESCO 77 INTL 713 359 7295 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Replace the O ring on the trunnion bore plug and install the plug in the 1 64 1 position bottom of the gearbox Replace the O ring on the motor pilot flange and apply silicon
42. quill preload must be adjusted To decrease end play in the quill increase the preload you must remove shims from the shim pack Use the following calculation to determine how many shims to remove observed quill end play in 0 000 in 0 010 in the thickness of shims to be removed Sample Calculation If the quill end play is 0 019 in then 0 019 in 0 010 in 0 029 in 0 002 Between 0 027 to 0 031 in of shims must be removed to adjust the preload to the correct force How TO PERFORM A HYDRAULIC OIL ANALYSIS Hydraulic oil analysis is part of periodic power unit maintenance Note Test ports for the hydraulic oil are located at the closed loop filter manifold 1 Ensure that the oil is warm and recently circulated Note If the oil is cold or has been static particulate will settle to the bottom of the tank and you will not get an accurate sample 2 Ensure that you have a small clean sample bottle ready Note If the oil sample is contaminated with debris or grime the analysis will be inaccurate Shut off the power unit Install a tee and valve at the filter manifold at the driller s gauge port Start the power unit Set the PUMPS REV FWD switch to FWD and use a low flow rate Open the valve at the filter manifold and allow the oil to flow for several seconds DOA AN Ur m s Collect a sample from the running stream of oil Note Ensure that you do not allow outside dirt or contaminants into the sample bott
43. the first bolt to line up the bottom retainer plate with the outer retainer and top plate Insert the remaining bolts Note Torque the bolts in a cross pattern gradually increasing the torque on all bolts to 140 ft lb Secure all bolts with lockwire 250TON HMIS 475HP WWW TESCOCORP COM 53 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE Install the Mudsaver Valve Before you can perform this procedure the quill must be fully installed as per previous procedures CONTACT 1 877 TESCO 77 INTL 713 359 7295 1 10 11 12 Reduce SET and MAX TORQUE values to levels much lower than what is required for normal operations Apply thread dope to the mudsaver valve and the quill pin Lift the mudsaver valve and start the mudsaver quill connection by hand Screw the mudsaver quill connection together by hand Caution Do not use the top drive to make the connection this can damage the valve threads Manually reset the grabber height so that it closes on the mudsaver valve At the driller s panel set the GRABBER switch to CLOSE it should close on the mudsaver valve Set the MODE switch to CONN and set the PUMPS REV FWD switch to FWD Push and hold the MAX TORQUE button Note Use the Bosch control valve on the filter manifold of the power unit to increase MAX TORQUE to the desired make up torque Release the MAX TORQUE button when desired torque is achieved Open and
44. to minimize distortion Fasteners shall be tightened using intermediate torque settings of 4096 and 75 of values in the tables fasteners must be made up snug prior to starting the tightening sequence 4 Fastener torques for bolting dissimilar materials must be based on the torque requirements for the lower strength material U N O 5 Fasteners and holes should be free of burrs or damage Damaged threads must be repaired using the appropriate tooling to ensure a free and smooth assembly 6 When thread locking compound is used holes and fasteners should be cleaned free of oil or grease and the compound should be applied in conformance with manufacturer s recommendations 7 Allowable bolt tension and torque based on bolt thread engagement must be in accordance with Table 4 U N O 8 Special fasteners must be installed and torqued in accordance with Table 2 9 When threadlock is used fasteners must be torqued in accordance with Table 1 Table 2 and Table 3 using the Lubricated Torque data U N O CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 75 WWW TESCOPARTS COM APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS MAINTENANCE GUIDE 10 For torque values for B7 studs with 2H nuts see Table 3 11 Lubricated fasteners must have oil or thread locking compound applied to the threads only 12 Where metals with strongly varying electromotive properties are bolted together such
45. unless otherwise specified DRIVE SERVICE REQUIREMENTS Daily Top Drive Service Requirements Inspection Perform the following visual inspection at least once every operating day More frequent inspections might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Gearbox oil level correct gearbox oil level halfway up sight glass Hydraulic hoses and connections at the top drive leaks Grabber dies excessive wear Mudsaver valve lower ball manually operate the valve to check function Saver sub threads excessive wear Swivel oil level see Figure 2 1 on page 4 correct level Grabber check and reset grabber height see How to Reset the Grabber Height on page 37 CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 3 WWW TESCOPARTS COM CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Figure 2 1 HMI swivel oil level Lubrication MAINTENANCE GUIDE The following lubrication should be performed at least once every operating day More frequent lubrication might be required if you are operating the top drive in harsh or demanding drilling environments IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX l
46. weekly inspection 6 swivel inspection 20 21 swivel oil level daily inspection 3 swivel oil level weekly inspection 6 swivel weekly inspection 6 swivel yoke daily lubrication 5 T tank filters replacement 16 T bar daily inspection 8 T bar storage 70 testing inspection schedules 17 threaded connections inspection 28 threaded connections testing 28 tool joint usage chart 79 top drive daily inspection 3 daily lubrication 4 daily service 3 monthly lubrication 6 monthly service 6 weekly inspection 5 weekly service 5 top drive gearbox oil daily inspection 3 100 top drive lubrication points 7 top drive storage 66 torque arrest system CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 128 MAINTENANCE GUIDE long term storage 69 service requirements 8 torque arrest system daily inspection 8 torque arrest system MPI testing 28 torque arrest system weekly inspection 9 torque beam daily inspection 8 torque beam storage 70 torque bushing daily inspection 8 torque bushing storage 69 torque standards for high strength fasteners 75 113 torque track daily inspection 8 torque track storage 69 tripping operations 1 U urethane capture blocks weekly inspection 8 V valves monthly inspection 8 water pump inspection 10 water oil cooler inspection 16 weekly inspection counter balance system 5 fasteners 5 fluid quick couplers 8 grabber chain 5 grabber dies 5
47. will support the weight of the mudsaver valve Open the grabber to release the mudsaver valve Install a valve handling nubbin and remove the mudsaver valve Refer to the Rig Out Procedures as described in the Installation Guide for your unit 250TON HMIS 475HP WWW TESCOCORP COM 50 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Remove the Load Nut Before you can perform this procedure the upper and lower quill collars must be removed and the quill must be connected to a lifting apparatus 1 gt SO 5A co CONTACT 1 877 TESCO 77 INTL 713 359 7295 Use the lifting apparatus to lower the quill approximately 12 in 0 3 m Note You have to lower the quill before you can access the load nut Caution The outside diameter of the quill increases below the lower groove on the collar Monitor this section of the quill when you lower the quill as it will not pass through the rotary seal Do not allow the weight of the quill to rest on the rotary seal Remove the snap rings from the locking pin s on the load nut Remove the locking pins Pry the top debris o ring out of its groove in the load nut and slide it up the quill Remove the lock wires from the load nut bolts 8 Remove all the bolts on the load nut Slide the bolt retainer off the bottom of the quill Gently tap the outer retainer to expose the inner split collars Remove the inner split collars from th
48. 13 359 7295 250TON HMIS 475HP 28 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION Figure 3 9 Non destructive testing for the standard torque arrest system HMI Driver s Side Wear Pad N C _ Off Driver s 39000271 ai CONTACT 1 877 TESCO 77 INTL 713 359 7295 Back Wear Pad Torque Track Studs amp Nuts Connectors Torque Track Side Wear Pad Gear Box lt HE gt Bm Z x s lt ia Torque Bushing Bolts amp Nuts Torque Track Torque Beam T Bar Extend Frame Bolts Upper amp Lower Clevis s W Bolts Nuts amp Pins 250TON HMIS 475HP 29 Redi Rod Nuts amp Washers Torque Beam Clamp Bars Torque Beam Clamp Plate amp Bolts WWW TESCOCORP COM WWW TESCOPARTS COM Torque Arrest System Inspection Frequency HMI CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Frequency Operating Days and Inspection Type Name At At At At 250 500 750 1000 Bolts gearbox to extend frame mount A A A Replace Complete extend frame mounts A A A C Extend frame A A A C Extend arms A A B A Torque bushing front plate A A A Torque bushing side plates A A A Torque bushing bolts nuts A A A Replace Torque track connectors A A A Torque track mounting plate on bottom A A B A section inclu
49. 2 EP2 multi purpose grease Wash pipe port 1 EP2 multi purpose grease Swivel yoke hinge pins 2 EP2 multi purpose grease Upper bearing retainer 1 EP2 multi purpose grease Lower bearing retainer 2 EP2 multi purpose grease Weekly Top Drive Service The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For CONTACT 1 877 TESCO 77 INTL 713 359 7295 All fasteners nuts bolts and lock wires correct location tightness Connection locking clamps correct location tightness Counter balance system correct installation and function Grabber dies excessive wear Hydraulic hoses and connections on the top oil leaks deformation drive Load collar adequate load ride height on the spring load ride height should be 3 8 to 1 2 in if it is not contact TESCO s Maintenance and Service Group Mudsaver valve lower ball correct function manually operate to confirm function Safety chain on the grabber leg broken components loose wires 250TON HMIS 475HP 5 WWW TESCOCORP COM WWW TESCOPARTS COM CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE Swivel Inspection Requirements The following inspection should be performed at least once every operating week if the top
50. 4 SERVICE PROCEDURES MAINTENANCE GUIDE CONTACT 1 877 TESCO 77 10 11 12 13 14 15 16 Set the ELEVATOR switch driller s panel to OPEN and push and hold the ELEVATOR SAFTEY OPEN button Note This will send 1 500 psi hydraulic pressure to the needle valve on the counter balance manifold Slowly open the needle valve and allow the hydraulic oil to charge the counter balance system Monitor the counter balance cushion by watching the gap that develops between the swivel bail and the block hook Continue to charge the system until the gap is 1 1 2 to 2 in the yoke pin should now be located in the center of the slotted eye of the link Close the needle valve Shut off the auxiliary pump Note This will allow the oil pressure in the auxiliary system to decrease Set the ELEVATOR switch to OPEN then to CLOSE This will relieve any pressure in the system Remove the elevator hydraulic hose from the counter balance manifold Caution If you disconnect a quick coupler while there is pressure in the system it will be extremely difficult to reconnect the coupler Figure 4 2 Counter balance cushion height Weight off Weight on 39000299r0 ai 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 36 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How TO RESET THE GRABBER HEIGHT Use this procedure to reset the grabber height Perform this procedure as part
51. 40 kg 75 C 1200 rpm 1 Brookfield Viscosity cP ASTM D 2983 APPLICATIONS AMSOIL Synthetic Universal Automatic Transmission Fluid is completely compatible with other synthetic and petroleum automatic transmission fluids AMSOIL ATF is a universal multi functional fluid that greatly reduces the need for specialized fluid inventories and the possibilities of misapplication AMSOIL ATF is recommended for transmission hydraulic and other applications requiring any of the following specifications GM DEXRON Il III amp VI Ford MERCON MERCON V amp SP e Chrysler ATF through ATF 4 Honda Z1 Not for use in CVT transmissions Toyota Type T amp T IV Mitsubishi Hyundai Diamond SP II amp III Allison C 3 C 4 Caterpillar TO 2 Voith G607 G1363 ZF TE ML 14A 14B 14C Mercedes Benz 236 1 236 2 236 6 236 7 236 9 BMW 7045E 1 amp 2 e JWS 3309 e LT 71141 ESSO e Nissan Matic D J amp K e Vickers 1 2865 amp M 2950S Excellent for power steering units that use ATF Not for use in CVT transmissions AMSOIL products and Dealership information are available from your local AMSOIL Dealer AMSOIL INC Superior WI 54880 715 392 7101 Fax 715 392 5225 715 392 5267 Printed in U S A Copyright 2007 CONTACT 1 877 TESCO 77 INTL 713 359 7295 119 250TON HMIS 475HP 6 8 32 4 172 11 0 220 428 53 63 hr ASTM D 4172B 0 44 20 C 1245 40 C 9087
52. 76 APPENDIX TOOL JOINT USAGE 79 APPENDIX C FUSES FOR THE CONTROL TRANSFORMER 81 General bassa ss e tb Beene eae eee ette LM E tL aer 81 Fuse Main Power 480 VAC Phase 1 12 13 81 Euse 120 volt E1 E2 amp AC 15 wie Mie oe be ase acer bearr aos Cae aha ER Seg abi 82 Fuse 24 VDC PowerSupplyOutpUt cc ccc en ee en en nine ee ee einne innis 82 Fuse 24 VDC Power Supply to Torque CircUit nee ee ee ee eee ee 82 Control Power Supply Nameplate lnformatioN c c ccc 83 APPENDIX D SAMPLE INSPECTION LOGS 89 Quill IMS PSCtion va Sue der Ad eae nentur t heh abe aed he er seo Rr RR e RAD HR S etn C end VR 90 Integrated Swivel Inspection Log 91 Load Nut Retainer and Split Collar Inspection Log 92 Mudsaver Valve Inspection Log 93 Saver Sub Inspection Log hei gk rhe dt wale eek ead eS 94 Load Collar Inspection Log siocair irriserva AE ta CSE EE San IRI et 95 Elevator Links Inspection Log 222 240432 034490 10041004 1402 RR 96 Elevator Inspection Log sa su darru d ia ng AH EE IR HH hh 97 APPENDIX E SERVICE CHECKL
53. 77 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 25 WWW TESCOPARTS COM CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Figure 3 7 Elevator links bails HMI Frequency Operating Days and Inspection Type Point Name Every 250 At 1000 1 Entire length of link A B 2 Top eye load collar eye A B 3 Bottom eye elevator eye A B 4 Length between the eyes A B Refer to Table 3 1 on page 19 for inspection type details As recommended by equipment manufacturer CONTACT 1 877 TESCO 77 0o 250TON HMIS 475HP CW TESCOCORP COM INTL 713 359 7295 26 WWW TESCOPARTS COM MAINTENANCE GUIDE Figure 3 8 Elevators HMI CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION Frequency Operating Days and Inspection Type Point Name At 250 1 Main hinge pin 2 Primary latch 3 Secondary latch 4 Elevator link ears 5 Elevator body 6 Latch pins 7 Elevator inserts 8 Insert grooves top and bottom Ensure the insert does not fall out Refer to Table 3 1 on page 19 for inspection type details As recommended by equipment manufacturer CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP WWW TESCOCORP COM 27 WWW TESCOPARTS COM CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES THREADED CONNECTI
54. 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 110 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS SIX MONTH CHECKLIST Date Supervisor Rig Time The six month checklist repeats many of the tests and inspections required in the weekly and monthly checklists Complete the regular weekly and monthly checklist requirements and perform the following additional tests and inspections Inspection Point Notes Data Actions Inspector Power building dust dirt clean if required use dry air or vacuum Driller s panel replace desiccant packs Top drive robotics junction box replace desiccant packs Load path components MPI and WMPI tests Drive pump motor amps Top drive circulation pump motor amps Heat pump motor amps Chiller circulation pump motor high amps ambient Chiller compressors amps Chiller condenser fan high ambient amps Lubrication Lubricate With Inspector Top and bottom motor bearings Shell Cyprina Grease RA Worm drive bearings EP2 multi purpose grease Slewing bearing EP2 multi purpose grease Comments CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 111 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX E SERVICE CHECKLISTS CONTACT 1 877 TESCO 77 INTL 713 359 7295 DAILY TOP DRIVE REPORT
55. 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 56 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS How to Remove the Grabber Actuating Piston The grabber must be empty before you can perform this procedure Caution This procedure requires the removal and replacement of small parts If possible use the EXTEND function to move the bot tom of the grabber away from hole center Cover all exposed areas around well center to prevent parts from falling through the table Cut the lock wires on the lower grabber retractor pins Remove the retractor pins 2 Label the grabber open and grabber close hydraulic hoses then remove them Cap the hoses Caution Ensure that the GRABBER switch is in the neutral position and the auxiliary pump is shut off Slide the complete clamping box assembly out of the torquing box Remove the piston retaining bolts 2 and the retraction plate from the clamping box Remove the hydraulic extension ports 2 Slide the cylinder assembly out of the clamping box You do not need to remove the die and die holder at this time Repair or replace the piston or seals as required Note If you are replacing the piston assembly then you must remove the die holder and install it onto the new piston How to Reinstall the Grabber Actuating Piston The following procedure assumes that all grabber cylinder components are assembled 1 2
56. A A A C Lower grabber leg A A A C Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 32 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES INTRODUCTION The service procedures described in this chapter are an extension of the service activities discussed in Maintenance and Service Schedules How TO DISASSEMBLE AND SERVICE THE ROTO ACTUATOR This procedure is performed as part of monthly top drive maintenance This procedure explains how to clean the internal bore of the actuator and the outer diameter of the mud valve body If you need to replace a seal or if any other type of service is required refer to the manufacturer s service manual 1 2 3 4 5 10 11 12 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Remove the hydraulic lines for the mud valve open valve close circuit Plug and cap the hydraulic line terminations to prevent dirt accumulation Remove the actuator stop bracket Remove the internal snap rings on the hex drive shaft Remove the hex drives 2 Note The strip kit contains a slide hammer for this purpose Loosen the upper and lower hose clamps Note It is easier to loosen them until they can be repositioned above the locator pins than to try to remove them entirely Loosen all setscrews except 2 by 1 2 turn Note Leave two opposing screws tight to hold the ac
57. ANCE AND SERVICE SCHEDULES Weekly Torque Arrest System Service Requirements The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All bolts and threaded rods damage or decay tightness Torque track hanging assembly damage close visual inspection is required Torque bushing liner or torque arrest wear the bushing liner must be replaced beam liners before the liner mounting bolts come in contact with the torque tube Torque bushing clearance amount of clearance it might be necessary to remove a torque bushing shim if there is more than 1 4 in clearance between the torque bushing and the torque tube or if there is excessive torque bushing movement Torque track stabilization components cracks or loose fasteners close visual inspection is required POWER UNIT PRIME MOVER SERVICE REQUIREMENTS Daily Prime Mover Service The following visual checks should be performed at least once every operating day More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX
58. COCORP COM 38 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How TO SET THE FUNCTION LIGHT PRESSURE SWITCH FOR THE AUXILIARY SYSTEM Perform this procedure as part of monthly power unit maintenance CONTACT 1 877 TESCO 77 INTL 713 359 7295 Note The function light pressure switch for the auxiliary system should be set to 800 psi It is easier if two people perform this procedure Set the AUX PUMP switch to ON Set the GRABBER switch to OPEN Note Leave the switch in the OPEN position This allows system pressure to build Use the relief valve setscrew to reduce the auxiliary pressure relief setting to 800 psi Use the adjustment wheel on the pressure switch to adjust the pressure switch until the AUX PUMP ON indicator light on the driller s panel illuminates Note You might have to have someone stand at the driller s panel to monitor the light If no assistance is available use a digital multi meter as follows a Disconnect the wires at the junction box for the pressure switch b Attach a digital multi meter DMM in Q ohm range to the wires from the switch c Adjust the wheel on the switch until the switch closes Note The DMM will switch from O L overload to 000 1 0 2 which indicates a short circuit d Ensure the auxiliary system is at 800 psi e Re install the wires f Close the junction box Reset the auxiliary relief valve to the operating setting Note
59. ESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Main Storage Reel 1 An FY TI Perform the following for all hose ends and quick couplers clean and inspect apply a thin coat of grease wrap with corrosion inhibitor tape check the rubber seals within the hammer unions ensure the isolation valves are closed Grease the bearings on the storage reel saddle Ensure that protective caps are installed on all hose connections Grease the drive chain on the storage reel Remove the hydraulic control for the storage reel Store the hydraulic control in the top drive shipping container or other sheltered location Perform the following steps for the 37C conductor cables 2 1 2 3 4 Spool the 225 ft cable onto a shipping reel Spool the 160 ft pigtail onto a power cable post Spray the connector ends with light oil Wrap the connectors with corrosion inhibitor tape DRILLER S PANEL CONTACT 1 877 TESCO 77 INTL 713 359 7295 SD 907 DON Uv BR C ON Open the driller s panel Check for moisture or damage Clean the interior Verify that all wire terminals are torqued to specification Install a new desiccant bag Clean all the connectors Spray the ends of the connectors with light oil Wrap all of the connectors with corrosion inhibi
60. I inspection 28 MPI testing pipe handler rotation system 31 torque arrest system 30 MPI testing for torque arrest 28 mudsaver storage 67 mudsaver valve actuator daily lubrication 4 mudsaver valve daily inspection 3 mudsaver valve installation 54 mudsaver valve weekly inspection 5 N non destructive testing torque arrest system 28 non destructive testing schedules 17 oil analysis hydraulic 45 oil filter centrifugal 46 oil level inspection 9 oil pressure inspection 9 oil reservoir annual service 16 oil reservoir daily service 15 oil reservoir monthly service 15 oil reservoir service requirements 15 operating pressure inspection 9 options and spares parts lists 1 periodic magnetic particle inspection 28 power unit service requirements 12 power unit storage 70 preload inspection 6 pre operational checklists 1 prime mover daily inspection 9 prime mover daily service 9 prime mover monthly inspection 10 prime mover monthly service 10 CONTACT 1 877 TESCO 77 INTL 713 359 7295 INDEX prime mover service requirements 9 prime mover weekly inspection 10 pump drive daily service 12 pump drive monthly service 13 pump drive oil inspection 13 pump drive weekly service 13 pump shaft inspection 13 pump shaft splines service 47 Q quick couplers service loop 8 quill installation 52 quill preload 40 quill preload calculation 45 quill preload inspection 6
61. ISTS 000 cece eee ee eee eee eens 99 Daily lt GHECKIISIS ea oett ahead eigen Ziska RU E 100 Weekly Checklists tl 104 Monthly ChecklistSss steep Meee ted VIE RE ada ihe Sane ia DA SA e oy aad 107 Six Month Checklists fede ete ls eles b e ol toh 111 Daily Top Drive Report pa are dd A dA teen 8 L ms 112 APPENDIX F TESCO ULTREX LUBRICANTS 113 QuickReferenceGUuid c c ccc ccc ee ee ee ee ee ee ee ee ee ee ee en 113 eon Fir wet Grad dO hac Aaah nad Ah Ie Meads hina A D ASS E a Mudd dated 114 Grease Lubricants 2 oett ea S Choin dd d 120 INDEX oct Saree Sw Oe ee dex Yel d UE YE ee ee VES 125 CONTACT 1 877 TESCO 77 250TONHMIS475HP WWW TESCOCORP COM INTL 713 359 7295 VI WWW TESCOPARTS COM MAINTENANCE GUIDE LIST OF FIGURES LIST OF FIGURES Figure 2 1 HMI swivel oil 4 Figure 2 2 Lubrication points for the Top Drive 2 2 2 22222 7 Figure 2 3 D2P oil level engine not running 12 Figure 2 4 Oil tariklevel ir a a Ely Xv Live e lE VE MSS a 15 Figure 3 1 Swivel 20 Fig re 3 2 Quill FIMD ueter
62. ONS MAINTENANCE GUIDE All threaded connections listed in the following table must be subjected periodically to wet fluorescent magnetic particle inspection WFMPI by a qualified inspector Each piece should be inspected for surface defects Also an inspection of threads should be conducted in accordance with the following schedule Note Any part of an operating day should be considered one day performed following any episode of rough drilling excessive Caution All inspections listed in the following table should be jarring or any other exceptional circumstance that might increase fatigue failure Operator discretion is critical in determining when this testing should occur Threaded Connection Inspection Frequency HMI pin X pin connections lower threads and seal face require daily visual inspection Description Minimum Frequency Inspection Type Mud saver stabbing valve 60 operating days WFMPI box X box connections Saver sub 60 operating days WFMPI Frequency 7 the number of operating days TORQUE ARREST SYSTEM components of the torque arrest system must be subjected to periodic magnetic particle inspection MPI by a qualified inspector Each piece should be inspected for surface defects according to the following schedule Any part of an operating day should be considered one day Removal of paint may be required for inspection CONTACT 1 877 TESCO 77 INTL 7
63. Other Contaminants Controls Foaming Prevents Rust and Corrosion Prevents Pump and Cylinder Wear Ideal for Use with Vane Pumps Piston Pumps Gear Pumps Meets or Exceeds the Following Performance Requirements Dennison Abex HF 1 HF 2 HF O Vickers 286 5 and M 2950 S Ford M6C32 GMLH Specs 04 06 03 KB AWYG 32 Parsons AMCA AW Hydraulic DIN 51524 part 2 Part Number Order Information 5 gal 20 L Pail 731143 20L 55 gal 208 L Drum 731143 208L CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 116 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX F TESCO ULTREX LUBRICANTS ULTREX SEMI SYNTHETIC MULTI GRADE GEAR OIL 80W 90 PHYSICAL PROPERTIES PROPERTIES Weight Per Gallon Lbs Viscosity CST 40 C 104 F 100 C 212 F Viscosity SUS 40 C 104 F 100 C 212 F Viscosity Index Flash Point Pour Point Operating Range USED FOR paraffin base gear oils NOT FOR TESCO ULTREX and Better Ways to The Bottom are trademarks of Tesco Corporation Extreme Pressure EP Agents Oxidation Inhibitors Shock Load Reducers Seal Conditioners Sp Leak Inhibitors Most seal leaks occur because many oils cause seals to shrink Special agents provide controlle Viscosity Index Improvers Mai Max Continuous Operating Temperature ATOTAL ADDITIVE PACKAGE THAT SETS IT APART FROM ALL OTHER GEAR OIL
64. PECTION LOG APPENDIX D SAMPLE INSPECTION LOGS Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Serial Inspection Date Days in Service Cumulative Inspected By Results Comments Next Service Due Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Additional Comments CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 95 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX SAMPLE INSPECTION LOGS MAINTENANCE GUIDE ELEVATOR LINKS INSPECTION LOG Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Inspection Days in Service Next Service Serial Date Cumulative Inspected By Results Comments Due Good Condition 0 Repaired 0 Replaced Good Condition Q Repaired Replaced C Good Condition Repaired Replaced Good Condition Repaired Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced
65. S ADDITIVES Premium Grade Base Oil maintain better lubricity Adhesive and Cohesive Polymers Keeps oil on gears during high speed operations and during idle periods Tackiness Agents Rust and Corrosion Inhibitors a 5 prevent mechanical wear stress fractures and dry starts ier on equipment surfaces to prevent chemical wear eat seeking additive w occur under loads nimize the stress vibration and cha operations shions impact to mi ring start sto ecial compo bring the seals back to their normal size Demulsifiers Separates water from oil to keep metal surfaces dry Allows excess water to be drained from equipment and vents conditions Eliminate the need to switch oil grades in different seasons a Extends service life of the lubricant by retarding the oxidation or breakdown process q er that can occur under heavy loads and tain full viscosity over a wider temperature range to ensure full protection in fluctuating Superior grade highly refined base oil resists oxidation and high temperature breakdown to Hel Blocks out corrosive elements such as acids water condensate and steam by forming a protective ba H ch Increases the ability of the lubricant to prevent the extreme wear that nds that soften and condition seals to keep them from hardening and cracking swell to Anti Foam Agents Withstand agitation and heat without
66. SCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 59 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE Figure 5 3 HMI grabber assembly HMI Gearbox Safety Safety Wired Wired Upper Grabber Leg Safety Wired aP 27 5 Roto Actuator Stop 1 Lower Grabber Leg B S E 9 Grabber Safety Chain X Grabber Safety Wired Typ 10 places Safety Wired Typ 6 places Safety Wired 39000752r0 ai CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 60 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS How TO CHANGE THE HMI GEAR RATIO Figure 5 4 Gear ratio configuration Set up for the 2 19 1 Set up for the 1 64 1 Gear Ratio Gear Ratio Pinion Gear qu Upper Bearing F gt 0686 amp O ring 0592 2 19 1 1 64 1 Gear Pinion Gear 3769 3770 Idler Bore Idler B Plug 5113 Plug 5113 Pinion Gear _ Lower Bearing DIR EN 686 Ne CT O ring 5797 ua lt Sue Idler Gear 5655 iz JA O Ring Idler Gear 4040 5655 AEO lt a Pinion Gear 4 VAA SRK pot owe ft NAT Retainer 4924 a ip y yy t pco bheir vi F Jao Z ID IX hi O Ring ms LM 4040 Je di Idler Trunnion E22 O Rings QE Bore Plug Co Rings
67. See How to Set the Pressure Relief Valve for the Auxiliary System on page 38 for more information Operate any hydraulic function to confirm that the indicator light is operating correctly 250TON HMIS 475HP WWW TESCOCORP COM 39 WWW TESCOPARTS COM CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How TO CHECK AND ADJUST PRELOAD When the top drive is manufactured TESCO adjusts the preload for the quill upper bearing by placing a shim pack between the top bearing retainer and the gearbox When the retainer bolts on the top bearing are torqued this exerts a clamping force on the quill upper bearing and thrust bearing This force prevents the quill from exhibiting end play during operation of the top drive Preload is measured in 0 000 of an inch The ideal preload is 0 008 0 010 in Over time bearing and component wear will reduce the preload If the preload 15 reduced too much quill end play will result Even the smallest amount of end play will result in damage to the bearings and mating components For this reason quill end play should be checked every month or after any severe operating events such as jarring or rough drilling Figure 4 5 Description of preload 1 Dial gauge 2 Upper quill hub bearing 3 Shim pack 4 Preload Preload is the amount of compression between the upper and lower quill hub bearings increase the preload remove shims To decrease the preload add shims 5 Gearbox 6 Low
68. TIVE PACKAGE THAT SETS IT APART FROM ALL OTHER GREASES ADDITIVES Calcium Sulfonate Base Extremely water resistant heavier than water to resist washouts even in submerged environments Withstands high heat and provides additional extreme pressure protection under heavy loads Adhesive and Cohesive Polymers Tackiness Agents Highly elastic polymers hold grease together and in place to prevent the entry of contaminants squeeze out channeling and sling off Rust and Corrosion Inhibitors jocks out corrosive elements such as acids water condensate and steam by forming a protective barrier on equipment surfaces to prevent chemical wear Extreme Pressure EP Agents Heat seeking additive which increases the ability of the lubricant to prevent the extreme wear that can occur under loads Anti Wear Agents Forms a lubricant film on metal surfaces in the presence of heavy loads and high temperatures events cold welding Oxidation Inhibitors Extends service life of the lubricant by retarding the oxidation or breakdown process Shock Load Reducers Cushions impact to minimize the stress vibration and chatter that can occur under heavy loads and during start stop operations Friction Reducers ates out on metal surfaces to prevent friction and wear under heavy loads Molybdenum Disulfide Layered solid lubricant that plates on metal surfaces to provide excellent protection against wear on heavily loaded surfaces and in dusty
69. able 1 1 Where to find more information For information on Refer to system components System Description installing the top drive rig up procedure commissioning pre operational checklists rig out procedure Installation Guide setting torque and speed driller s panel function and operating descriptions making connections drilling ahead tripping Stuck pipe Operations Guide TESCO manufactured parts and part numbers Parts List electrical schematics hydraulic schematics cooling schematics gearbox lubrication schematics System schematics available options and spares TESCO Representative CONTACT 1 877 TESCO 77 250TON HMIS 475HP INTL 713 359 7295 1 WWW TESCOCORP COM WWW TESCOPARTS COM CHAPTER 1 ABOUT THIS DOCUMENT MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 2 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Note To ensure the equipment operates properly and to prevent downtime check the pressure and temperature gauges all fluid levels and flow meters daily IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants
70. as steel and aluminum thread locking compounds should be applied to limit the effects of galvanic corrosion 13 A minimum of two full threads should project above any nut or locknut installed on a stud or as part of a bolted connection Additional length is allowed to install safety pines or cotter pins to prevent fasteners from falling into overhead equip ment TABLES Table A 1 Standard torques Material Aluminum ft lbs Mild Steel ft lbs High Strength Steel ft lbs Size Dry Lubricated Dry Lubricated Dry Lubricated 1 4 in 20 UNC 9 7 10 8 12 9 5 16 in 18 UNC 16 12 19 15 25 19 3 8 in 16 UNC 33 25 40 30 45 34 7 16 in 14 UNC 47 36 57 43 70 53 1 2 in 13 UNC 86 64 100 75 110 83 9 16 in 12 UNC 118 88 141 106 160 120 5 8 in 11 UNC 163 122 195 146 220 165 3 4 in 10 UNC 278 209 333 250 400 300 7 8 in 9 UNC 436 327 523 393 645 484 1 in 8 UNC 667 500 800 600 970 728 1 1 8 in 7 UNC 950 713 1142 856 1370 1028 1 1 4 in 7 UNC 1317 988 1575 1181 1900 1425 1 1 2 in 6 UNC 2283 1713 2742 2056 3200 2400 Recommended torques are based on bolt tensions of approximately 80 of the yield strength and a minimum of one bolt diameter class 2B thread engagement in the material or bolt head bearing pressures whichever is less CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 76 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX
71. ay and tightness Swivel oil level correct level CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 104 WWW TESCOPARTS COM MAINTENANCE GUIDE Weekly Service Loop APPENDIX E SERVICE CHECKLISTS Inspect For Inspector All service loop components damage excessive wear Urethane capture blocks hose placement tightness at top drive and roller saddle Fluid quick couplers auxiliary and damage or decay tightness cooling All cable connections tightness power sensor robotics and ground cables Weekly Torque Arrest System Inspect For Inspector All bolts and threaded rods damage or decay tightness Torque track hanging assembly damage close visual inspection is required Torque bushing liners or torque arrest wear the bushing liner must be replaced before the beam liners liner mounting bolts come in contact with the torque tube Torque bushing clearance amount of clearance it might be necessary to remove a torque bushing shim if there is more than 1 4 in clearance between the torque bushing and the torque tube or if there is excessive torque bushing movement Torque track stabilization components cracks or loose fasteners close visual inspection is required Weekly Power Module Inspect For Inspector Air filters on the heat pump cleanliness filters can be washed Air filters on the door fan and chopper c
72. base gear oils NOT FOR ADDITIVES Premium Grade Base Oil Adhesive and Cohesive Polymers Tackiness Agents Rust and Corrosion Inhibitors Extreme Pressure EP Agents Oxidation Inhibitors Shock Load Reducers APPENDIX F TESCO ULTREX LUBRICANTS Superior grade maintain better lubricity Helps prevent mechanical wear stress locks ou arrier on equipment surfaces to prevel Heat seeking additive which increases can occur under loads Extends service life of the lu Cushions impact to mini ricant by eeps oil on gears during high speed opera corrosive elements such as aci ize the stress vi TESCO ULTREX and Better Ways to The Bottom are trademarks of Tesco Corporation A TOTAL ADDITIVE PACKAGE THAT SETS IT APART FROM ALL OTHER GEAR OILS ighly refined base oil resists oxidation and high temperature breakdown to ac a eta ds water condensate bration and chatter that can occur under heavy loads and ions and during idle periods res and dry starts d steam by forming a protective emical wear ility of the lubricant to prevent the extreme wear that ing the oxidation or breakdown process during start stop operations Seal Conditioners Special compounds that soften and condition seals to Keep them from hardening and cracking Leak Inhibitors lost seal leaks occur because many oils cause seals to s
73. ce Last Spline Check Total Pump Drive Hours 24 00 Operating Days Since 60 Day Load path M P I Inspection of all Oilfield Connections in TD Load path Oil Change Engine Hours Gearbox al Deol Saver Sub in Service ser serial numbered equipment Comments Document any changes in overhead White Copy Business Unit Office Pink Copy Issuer Critical Information Binder Copyright Tesco Corporation 2004 881034 RevB Last Updated May 05 250TON HMIS 475HP 112 MAINTENANCE GUIDE WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX F TESCO ULTREX LUBRICANTS APPENDIX F TESCO ULTREX LUBRICANTS QUICK REFERENCE GUIDE Engine s Component Description Fluid Description TESCO Part Drive s Component Gear Boxes Hydraulic Top 60 Series Detroit Advanced Formula Synthetic Blend Motor Oil SAE 15W 40 731134 12 V 2000 Series Detroit Advanced Formula Synthetic Blend Motor Oil SAE 15W 40 731134 16 V 2000 Series Detroit Advanced Formula Synthetic Blend Motor Oil SAE 15W 40 731134 All CAT Engines Advanced Formula Synthetic Blend Motor Oil SAE 15W 40 731134 12 V 92 Detroit Advanced Formula Single Weight Motor Oil SAE 40 731135 16 V 92 Detroit Advanced Formula Single Weight Motor Oil SAE 40 731135 Fluid Description TESCO Part Drive s Component Gear Boxes Electric Top Description
74. chematics 1 cooling system daily service 16 cooling system monthly inspection 16 cooling system monthly service 16 cooling system service requirements 16 counter balance height 35 counter balance system monthly inspection 6 counter balance system weekly inspection 5 D daily inspection air oil cooler 16 coolant level 9 exhaust system 9 grabber dies 3 grabber height 3 mudsaver valve 3 oil level 9 oil pressure 9 operating pressure 9 prime mover 9 radiator 10 rig saver 10 saver sub 3 swivel oil level 3 top drive 3 CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP INDEX top drive gearbox oil 3 100 top drive hoses and connections 3 torque arrest system 8 water oil cooler 16 daily lubrication elevator 4 link tilt cylinders 4 mudsaver valve actuator 4 swivel 5 swivel yoke 5 top drive 4 daily service cooling system 16 filter manifold 14 oil reservoir 15 prime mover 9 pump drive 12 swivel 5 top drive 3 disassembly assembly instructions 49 drill ahead 1 driller s panel functions 1 driller s panel storage 68 drive belts inspection 10 E electrical schematics 1 elevator daily lubrication 4 elevator links inspection 26 elevator storage 67 elevators inspection 27 engine coolant analysis 47 engine oil filter 46 exhaust system inspection 9 extend frame monthly lubrication 6 extend frame storage 69 F fasteners weekly inspection 5
75. de all bolt holes Torque track studs nuts A A A Replace T bar A A B A T bar clamp bolts A A A Replace T bar extension A A A T bar clamp plate A A A Torque beam A A A Torque beam clamp bar A A A Redi rod nuts torque arrest system A A A Connection to the derrick leg A A A Torque track A A A Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 30 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION PIPE HANDLER ROTATION SYSTEM INSPECTION FREQUENCY Figure 3 10 Other non destructive testing HMI xe F a Gearbox Grabber Leg Bolts Typ 12 places er gt Upp Grabber Leg fons gt Lower Grabber Leg Clamping Box Torque Box Bolts Typ 10 places 3 Torque Box 3900027012 ai CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 31 WWW TESCOPARTS COM CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Frequency Operating Days and Inspection Type Name Every At At At At 60 250 500 750 1000 Torque box A A A C Clamping box A A A C Torque box bolts A A A Replace Grabber bolts A A A Replace Gearbox grabber leg bolts Replace Upper grabber leg
76. dirt alarms use the manufacturer s recommended fil ter Hydraulic fittings tightness CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 14 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES POWER UNIT OIL RESERVOIR SERVICE REQUIREMENTS Daily Oil Reservoir Service The following visual checks should be performed at least once every operating day More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Reservoir and area leaks Return oil tank filters dirt inspect the dirt alarm and replace the filter if required Low oil level shutoff equipment correct connection inspect visually Tank oil See Figure 2 4 correct operating level Hydraulic hoses and connections leaks tightness Figure 2 4 Oil tank level Monthly Periodic Oil Reservoir Service The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Return oil tank filter correct connections inspect visually Filter canister correct bolt correct torque Tank all sides including underneath leaks Hydraulic fittings tightness CONTACT 1 877 CTESCO 77 250TONHMIS475HP WWW TESCOCORP COM
77. drive is equipped with the optional swivel More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Hammer unions damage decay and tightness Swivel oil level correct level Monthly Periodic Top Drive Service The following visual checks should be performed at least once every operating month or as indicated in the following table More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Inspect For Gearbox oil abnormalities take samples to test for water metal particles etc every 900 operating hours Hydraulic fittings tightness Roto actuator sleeve general condition disassemble clean grease coat with corrosion inhibitor and reinstall see How to Disassemble and Service the Roto Actuator on page 33 Grabber correct grabber height check and reset grabber height see How to Reset the Grabber Height on page 37 Counter balance system correct cushion height see How to Set the Counter Balance Cushion Height on page 35 Sensor panel moisture tightness of wire terminati
78. dure 1 Close the isolation valves to isolate the hydraulic lines that go to the pump drive 2 Shut off the suction valve s to the pump s D If you must remove the hydraulic hoses from the pumps ensure the ends of the hoses are protected from dirt and grime Loosen the hold down nuts studs for the pump Using a soft sling create a basket sling for the pump Attach the sling to an overhead lifting device aN Hoist the sling until the weight of the pump is supported with the lifting device Note Do not lift the pump Hoist it only enough to support the pump weight 8 Pull the pump backwards to disengage the pump spline connection Note Move the pump back far enough to get a good view of the splines and internal components 9 Remove and inspect the pump adaptor plate Replace it if necessary 10 Ensure that there is residual oil between the pump and the pump adapter Caution If these areas inspect the lubrication hoses pump until the problem is located Inadequate lubrication will cause severe equipment damage 11 Check all load areas for spline deterioration CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 47 WWW TESCOPARTS COM CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE 12 When inspection is complete reinstall the pumps in their original position 13 Torque all hold down bolts to 350 ft lb When you restart the unit check the oil supp
79. e Quill 1 Clean and inspect the quill connections Note The mudsaver valve must be removed before you can inspect the lower connection Coat all connections with thread compound or preservative grease Wrap all connections with corrosion inhibitor tape Load Nut If you remove the quill service the load nut as follows 1 Clean and inspect all parts of the load nut 2 Coat all segments with light oil then reinstall 3 Applya coat of grease to the outside of the load nut particularly the load shoulder Grabber Leg Remove the grabber leg Apply a liberal coat of grease to the sliding section of the lower leg Apply grease or anti seize compound to all pin pockets and threads Reinstall the grabber leg gt Remove the grabber cylinder from the grabber assembly See How to Remove the Grabber Actuating Piston on page 57 Remove the die holder plates and dies 7 Inspect and clean all die holder plates and dies CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 66 WWW TESCOPARTS COM MAINTENANCE GUIDE 8 9 CHAPTER 6 LONG TERM PRESERVATION AND STORAGE Apply grease or anti seize compound to all die holder plates and dies Reassemble the grabber components 10 Coat the entire torque box with a light film of grease 11 Install the grabber cylinder in the grabber assembly Elevators 1 2 so enn no R Remove the elevator inserts Use a wire b
80. e loop hoses and cables from the top drive The top drive must be fully functional for you to disassemble the load path 1 2 10 12 13 14 15 16 17 18 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Put the top drive into its shipping stand Move the top drive to a firm level location where you have the following overhead hoisting equipment enough overhead clearance so that you can remove the quill If you want to remove the saver sub loosen and remove it now Loosen and remove the mudsaver quill die lock clamp Remove the hydraulic hoses for the open and close circuits for the mudsaver valve Position the grabber so that it will close on the mudsaver valve Note Use the pin set on the back of the grabber leg to change the position of the grabber Place blocks between the valve actuator and the grabber When the grabber is in position on the mudsaver valve set the GRABBER switch to CLOSE Clear all tools from the quill area Set the MODE switch to CONN Set the PUMPS REV FWD switch to REV With the grabber closed on the mudsaver valve press and hold the BREAKOUT button Break out the mudsaver valve and allow the quill to unscrew the connection Caution Relieve tension on the connection by lowering the grabber in small increments as the connection unscrews When the connection is unscrewed lower the grabber and the mudsaver valve Verify that the blocks that you installed earlier
81. e quill Note This exposes the groove profile of the quill Slide the top plate of the load shoulder off the quill Note The locking pins on the top plate prevent the load nut from rotating on the quill 250TON HMIS 475HP WWW TESCOCORP COM 51 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE Remove the Quill and Swivel Body The quill and swivel body cannot be removed until the quill collars and the load nut have been removed The quill must be connected to a lifting apparatus 1 IN Remove the lockwires from the bolts on the quill drive hub Note These bolts combined with the drive hub hold the quill in the quill gear Remove the socket head bolts 12 Note The quill is now free Secure the quill and swivel body by running a sling through the yoke of the swivel Note If you removed the yoke and links wrap a soft sling around the bail pins in the side of the swivel Hoist the swivel body and quill out of the gearbox Caution The lifting apparatus must be rated for 6 000 Ib If the drive bushing of the quill will not separate from the drive hub use the jacking screws 2 on the top of the drive hub to separate them How TO ASSEMBLE THE LOAD PATH Use the following procedures to assemble the load path nstall the Quill nstall the Load Nut Connect the Mudsaver Valve Install the Quill Inspect clean and deburr the following components before you reassemble t
82. e to the space plate Replace the motor and manifold assembly Replace the gearbox oil Note Refer to fluid specification EM000042 for information on what lubricants can be used in this application 250TON HMIS 475HP WWW TESCOCORP COM 63 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 64 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 6 LONG TERM PRESERVATION AND STORAGE INTRODUCTION Use the following guidelines whenever you place a TESCO top drive into long term storage Before you begin these procedures ensure that all necessary unit maintenance is complete and the unit is fully functional If all repairs cannot be completed ensure that you create the following a detailed list of maintenance repair requirements a complete list of parts required BEFORE SYSTEM SHUT DOWN Before you shut down the top drive system do the following 1 Add corrosion inhibitor to the gearbox Most oil inhibitors require some mixing with the base oil Prepare the corrosion inhibitor according to the manufacturer s instruction 2 Test the cooling system for inhibitor levels If fluid without inhibitor has been added additional inhibitor should be added now 3 Check the cooling fluid If the system will be stored at temperatures below 0 Celsius ensure the prime mo
83. ed sentence about accordance with API 8C ISO 13535 Rev 7 October 2007 Added caution symbols to all Warning Caution and Danger notes Added more safety warnings Rev 8 November 2007 New revision to remove CE ATEX standards from manual Rev 9 May 2009 Added TESCO ULTREX recommendations and updated the footer to contain contact information CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 Il WWW TESCOPARTS COM MAINTENANCE GUIDE TABLE OF CONTENTS TABLE OF CONTENTS LIST OF FIGURES 26 Sess ege tani ad odds e was Pro tee hes eo ois Vil LISTUOF TABLES 27 oot 2 ks Sa dde icem sed Saut IX CHAPTER 1 ABOUT THIS DOCUMENT ccc ccc 1 CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES 3 Top Drive Service Requirements see ee ee nee ee ee ee ns ns nos en rn 3 Daily Top Drive Service RequirementS ee ee ee ee ee ee ee tenes 3 Swivel LubricationRequirementS c c c ee ee ns ns 5 Weekly Top Drive Service 5 Swivel Inspection Requirements 6 Monthly Periodic Top Drive 6 Service Loop Service RequirementS c c cec ccc crecer ere 8 Weekly Service Loop Service
84. er quill hub bearing 7 Quill 8 Protective block 9 Bottle jack or grabber CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 40 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How to Check for Quill Hub End Play When the Top Drive is Installed in the Derrick This procedure describes only one method for checking the quill endplay when the top drive is in the derrick If you are not sure if your method will be effective contact a qualified TESCO representative 1 Secure the top drive in the mast Pin the torque bushing to the track or support the top drive mainframe directly in the mast with slings tugger line hoists come a longs or other supports Note Whichever method you use to secure the top drive in the mast make sure the travelling blocks and the counter balance are not supporting any weight from the top drive When the top drive is secure the weight of the swivel and quill should be supported by the top drive gearbox and should rest on the lower bearing in the gearbox top drive is not supported by the counter balance system Discon nect the counter balance system or lower the travelling equipment enough so that the counter balance system is slack Caution It is critical that all top drive weight is off the quill and the 2 Mount a dial indicator gauge on the quill with the stem contacting a point on the bottom face of the lower bearing retainer 3 Selec
85. erial number for the replacement part Next Service Due Enter the hours or days of service when the component requires its next inspection Additional Comments Enter additional information as required CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP WWW TESCOCORP COM 89 WWW TESCOPARTS COM APPENDIX SAMPLE INSPECTION LOGS MAINTENANCE GUIDE QUILL INSPECTION LOG Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Inspection Days in Service Next Service Serial Date Cumulative Inspected By Results Comments Due Good Condition 0 Repaired 0 Replaced Good Condition Q Repaired Replaced C Good Condition Repaired Replaced Good Condition Repaired Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Additional Comments CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 90 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX D SAMPLE INSPECTION LOGS INTEGRATED SWIVEL INSPECTION LOG Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Inspection Days in Service Next Service Serial Date Cumulative Inspected By Results Comments Due Good Cond
86. ers if applicable wear damage Wash pipe leakage Load collar correct spacing between load collar and load nut CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 107 WWW TESCOPARTS COM APPENDIX E SERVICE CHECKLISTS MAINTENANCE GUIDE Inspect For Inspector Mud valve lower ball manually operate to ensure correct function Hammer union on Kelly Hose integrity and tightness Grabber drawworks and mud valve mud function test pump interlocks Auxiliary manifold general condition Lubricate With Inspector Hinge pins and extend frame spray with penetrating oil WD 40 or spray lithium Monthly Service Loop Inspect For Wire terminals in the driller s panel tightness All multi conductor connections moisture dirt open and check then spray with electrical cleaner moisture dispersant Main service cable connectors cleanliness open clean reinstall All hoses leaks damage Threads isolation valves damage loose parts Monthly Auxiliary Hydraulic Power Unit Inspect For Inspector Auxiliary system pressure relief correct setting Auxiliary system function light pressure correct setting switch Auxiliary hydraulic filter cleanliness inspect and change Auxiliary hydraulic fluid complete fluid analysis every 900 operating hours Monthly Power Module Danger Do not
87. es tenete a sha daha doe Ie rec o tae 21 Figure 3 3 Load nut retainer and split collar 1 22 Figure 3 4 Mudsaver valve and actuator 23 Figure 3 5 Saver sub 24 Figure 3 6 Load collar HMI 27 2 22 2067202 E ER 0 R 0 R RER RR R R Ih 25 Figure 3 7 Elevator links bails 26 Figure 3 8 Elevators HM z 54 ac 34 d 2 4 2 3 5A d 2 27 Figure 3 9 Non destructive testing for the standard torque arrest system 29 Figure 3 10 Other non destructive testing 31 Figure 4 1 Actuator valve 34 Figure 4 2 Counter balance cushion 36 Figure 4 3 Grabber 5 37 Figure 4 4 Auxiliary relief valve 38 Figure4 5 Descriptionofpreload c c tenn eens 40 Figure 5 1 Load path componentS c c c ccc cec 49 Figure 5 2 HMI grabber box compOnents es 55 Figure 5 3 HMI grabber assembly
88. et the switch Function Light Pressure Switch for the Auxiliary System on page 39 Auxiliary system pressure relief valve correct setting see How to Set the Pressure Relief Valve for the Auxiliary System on page 38 CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 11 WWW TESCOPARTS COM CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE POWER UNIT PUMP DRIVE SERVICE REQUIREMENTS Daily Pump Drive Service The following visual checks should be performed at least once every operating day More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Inspect For Oil level adequate oil level fill if required Oil system leaks Cooling system excessive dirt general condition check the heat exchanger Pump drive lubrication system correct lubrication of the pump splines check at the oil filler cap Hydraulic hoses and connections leaks tightness Figure 2 3 D2P oil level engine not running CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 12 WWW TESCOPARTS COM MAINTENANCE GUIDE
89. even in submerged environments Withstands high heat and provides additional extreme pressure protection under heavy loads ighly elastic polymers hold grease together and in place to prevent the entry of contaminants Squeeze out channeling and sling off Rust and Corrosion Inhibitors locks out corrosive elements such as acids water condensate and steam by forming a protective barrier on equipment surfaces to prevent chemical wear I Adhesive and Cohesive Polymers Tackiness Agents B Extreme Pressure EP Agents Heat seeking additive which increases the ability of the lubricant to prevent the extreme wear that can occur under loads Anti Wear Agents Forms a lubricant film on metal surfaces in the presence of heavy loads and high temperatures events cold welding Oxidation Inhibitors Extends service life of the lubricant by retarding the oxidation or breakdown process Shock Load Reducers Cushions impact to minimize the stress vibration and chatter that can occur under heavy loads and during start stop operations Friction Reducers lates out on metal surfaces to prevent friction and wear under heavy loads Molybdenum Disulfide Layered solid lubricant that plates on metal surfaces to provide excellent protection against wear on heavily loaded surfaces and in dusty dirty environments Graphite Layered solid that provides added protection at high temperatures and imp
90. factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Inspect For Battery if applicable correct electrolyte level evidence of corrosion Water pump seal drain evidence of leaks Weep hole plugs correct placement evidence of leaks Fan hub correct lubrication see the appropriate Engineering Memo document for lubrication specifications Universal joint on the drive shaft correct lubrication grease if required do not over lubricate or this can damage the seals Monthly Periodic Prime Mover Service The following visual checks or procedures should be performed at least every operating month or according to the schedule below More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Electrical control panels dirt moisture replace desiccant packs Radiator cap damage or corrosion Drive belts correct tension cracks and erosion Air starter filter cleanliness clean as required CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP WWW TESCOCORP COM 10 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Inspect For Crankcase oil and fi
91. forming foam contaminants Reduce pressure levels on seals 80W 90 75 Copper Corrosion ASTM D 130 76 78 3 Hours 121 C 250 F Pass 1B 78 Thermal Oxidation Stability Test 1 60 Pass 819 0 Falex Load ASTM 3233 Failure Load 27 2kg 60lbs 893 Film Strength Four Ball Method ASTM D 2783 315 10 Weld Load 315kg 694lbs 229 C 445 F Load Wear Index 57 27 C 16 6 F Wear Scar Diameter ASTM D 4172 0 28mm 011in 60 C 320 F 49 C 300 F to 26 C 15 F Differentials Limited Slip Differentials Simple Manual Transmissions Axles Power Dividers Gear Trains Bronze Gears up to 93 3 C 200 F and Gear Boxes including enclosed gears of spur type hypoid spiral bevel worm herringbone helical planetary and unusual combinations of gear types Can be added as make up oil to other GL 5 Automatic universal C 3 fluid combined transmissions Truck transmissions that only allow the use of GL 1 gear oil motor oil Spicer Dana Fuller transmissions Tesco Corporation June 2007 POD Due to ongoing product development all specifications are subject ta change without notice Asia Pacific Jakarta Indonesia Email APBU_sales tescocorp com Latin America Buenos Aires Argentina Email LABU_sales tescocorp com Les cue orp oo m CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 117 China Middle East amp Africa Chaoyang District Beijing Dubai UAE Email CHINA_sales tescoc
92. g the top drive handling frame on blocks 3 Ensure that the grabber is fully supported from beneath Note The weight of the leg is approximately 400 Ib 181 kg 4 Remove and cap the grabber open and grabber close hydraulic lines Note Label all hoses to make it easier to reinstall them correctly 5 If possible hoist the top drive off the grabber leg Note If it is not possible to hoist the top drive use a manual chain fall to support the weight of the grabber leg Remove the support blocks and lower the leg to the ground Remove the height adjustment pins to release the grabber leg Remove the grabber leg assembly from the working area Repair the components as required Reinstall the Lower Grabber Leg 1 Position the grabber leg below the top drive 2 If possible lower the top drive and allow the grabber leg to travel into the upper grabber leg If the top drive cannot be lowered raise the grabber leg into position using manual chain fall or similar device Caution Be careful while inserting the grabber leg so that no dam age occurs to the cylinder or hydraulic lines Carefully monitor the spring assembly 3 When the grabber leg is in position insert the height adjustment pin 4 Adjust the height of the grabber as described in How to Reset the Grabber Height on page 37 Install the grabber leg safety chain Install the hydraulic lines for the GRABBER OPEN and GRABBER CLOSE circuits CONTACT 1 877 TE
93. he battery terminals and coat them with grease b Check the electrolyte level of the battery c Ensure battery is fully charged prior to storage Seal all crank case breathers and wrap them with corrosion inhibitor tape Wrap the alternator if equipped in an airtight bag that contains desiccant packs Ensure the bag is completely sealed Wrap the ECM modules if equipped in an airtight bag that contains desiccant packs Ensure the bags are completely sealed 10 Spray the engine air starter with light penetrating oil 11 Coat the connection for the air line with grease Main Electrical Panel 1 2 3 4 General Uo ees ae Nr CONTACT 1 877 TESCO 77 INTL 713 359 7295 Open the panel and check for moisture Replace all desiccant packs Seal the door and wrap the seam with corrosion inhibitor tape Spray light inhibitor oil on all external switch points Clean and inspect all electrical connections Spray all electrical connections with light oil Wrap all cable ends with corrosion inhibitor tape Grease all hose end unions Install protective caps 250TON HMIS 475HP WWW TESCOCORP COM 72 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 6 LONG TERM PRESERVATION AND STORAGE STORAGE CONTAINERS When the final inspection is complete all equipment should be placed in shipping containers All shipping containers should be stored in a cool dry place Equipment can be efficiently stored in the following configu
94. he load path quill threads load nut profiles drive bushing and drive spacer bolts load nut components 1 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Ensure all required maintenance for the gearbox and swivel body is completed before you perform this procedure Ensure the quill is clean Ensure the lower quill connection is properly protected use a lifting nubbin or other suitable protection Lightly grease the quill splines and drive bushing areas IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified 250TON HMIS 475HP WWW TESCOCORP COM 52 WWW TESCOPARTS COM MAINTENANCE GUIDE uu 10 11 12 13 14 15 16 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Ensure the dowel pins are installed in the drive hub of the gearbox Ensure the load collar is in place Install the gear drive bushing and spacers onto the quill Ensure that the radial location bushing for the quill gear is properly installed and that it uses a spiral lock retaining ring Note These are located at the bottom of the drive hub Hoist the swivel and quill gear above the gearbox Note Use a lifting device rated for at least 6 000 Ib Ensure the top drive stand 15 on a solid and level surface Slowly lowe
95. hrink Special agents provide controlled swell to ring the seals back to their normal size Demulsifiers Separates water from oil to keep metal surfaces dry Allows excess water to be drained from equipment Anti Foam Agents Withstand agitation and heat without forming foam contaminants Reduce pressure levels on seals and vents Viscosity Index Improvers Maintain full viscosity over a wider temperature range to ensure full protection in fluctuating conditions Eliminate the need to switch oil grades in different seasons PHYSICAL PROPERTIES PROPERTIES 80W 90 Weight Per Gallon Lbs 75 Copper Corrosion ASTM D 130 Viscosity CST 40 C 104 F 76 78 3 Hours 121 C 250 F Pass 1B 100 C 212 F 78 Thermal Oxidation Stability Test L 60 Pass Viscosity SUS 40 C 104 F 8190 Falex Load ASTM 3233 Failure Load 27 2kg 60165 100 C 212 F 89 3 Film Strength Four Ball Method ASTM D 2783 315 Viscosity Index 10 Weld Load 315kg 694165 Flash Point 229 C 445 Load Wear Index 57 Pour Point 27 16 6 Wear Scar Diameter ASTM D 4172 0 28mm 0Min Max Continuous Operating Temperature 60 C 320 F Operating Range 49 C 300 F to 26 C 15 F Differentials Limited Slip Differentials Simple Manual Transmissions Axles Power Dividers Gear Trains Bronze Gears up to 93 3 C 200 F and Gear Boxes including enclosed gears of spur type hypoid spiral bevel worm herringbone helical planetary and unusual
96. ifications for correct inhibitor concentration Close all valves Apply a light coat of grease to all valve stems Seal all tank breather ports Apply a light coat of grease to hose end connectors Wrap hose ends with corrosion inhibitor tape Open the terminal boxes for the tank thermostat on the forward side of the tank Check the boxes for moisture Place a desiccant bag in each box 10 Apply anti seize compound to the cover bolts and reinstall the covers 11 Grease the cover seal to prevent moisture from entering CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP WWW TESCOCORP COM 70 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 6 LONG TERM PRESERVATION AND STORAGE Air Oil Cooler 1 Clean the cooler Caution The cooler fins are easily damaged Use extreme care dur A ing cleaning 2 Check for visible damage and repair if required 3 Prepare the cooler unit for storage Note If the unit will be stored in a shipping container no further preparation is required Note If the unit will be exposed to the elements during storage fabricate a cooler cover using tarps plywood or other available materials Optional Stand Alone Plate Exchanger 1 Open the unions to the water side of the cooler 2 Ensure that the inside is dry 3 If the unit has been operated using seawater flush with fresh water 4 Apply a light coat of grease to all unions and reinstall the caps Auxiliary Oil Pump O
97. ing retainer Install a soft sling in the bonnet of the top drive Use overhead equipment to gently hoist and lower the top drive 4 Monitor the dial gauge for movement Values on the dial gauge should be within acceptable preload parameters new bearings 0 008 to 0 010 in used bearings 0 000 to 0 005 in 5 Ifthe dial gauge indicates movement outside acceptable parameters test the quill to quill gear drive bushing endplay first to isolate the actual endplay location See Check the Quill to Quill Gear Drive Bushing Drive Spacer Endplay on page 44 6 Ifthe test for quill to quill gear drive bushing preload indicates no endplay then adjust the gearbox preload a Unbolt the bearing retainer b Remove the required number of shims that are located under the upper bearing retainer See Sample Calculation on page 45 c Reinstall the bearing retainer CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 42 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES Check the Swivel Bearing Preload 1 Remove the wash pipe from the bonnet 2 Install a magnetic base dial gauge Note Attach the magnetic base to the bonnet so that the needle rests on the quill 3 Install a soft sling in the bonnet of the top drive Use overhead equipment to gently hoist and lower the top drive Monitor the dial gauge for movement Values on the dial gauge should be within acceptable preload
98. ition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Additional Comments CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 91 WWW TESCOPARTS COM APPENDIX SAMPLE INSPECTION LOGS MAINTENANCE GUIDE LOAD NUT RETAINER AND SPLIT COLLAR INSPECTION LOG Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Inspection Days in Service Next Service Serial Date Cumulative Inspected By Results Comments Bilis Good Condition 0 Repaired 0 Replaced Good Condition Repaired Replaced Good Condition Repaired Replaced Good Condition Repaired Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Additional Comments CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 92 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX D SAMPLE INSPECTION LOGS MUDSAVER VALVE INSPECTION LOG Top Drive Number Service Facility Service Activation Date Top Drive Ty
99. le 9 Submit for analysis according to laboratory instructions Note When submitting oil for analysis include any information that may assist the lab in conducting the analysis For example list any recent component changes or equipment problems If you have any questions regarding the results or would like assistance contact TESCO technical support CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 45 WWW TESCOPARTS COM CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How TO SERVICE THE CENTRIFUGAL OIL FILTER ENGINE This procedure is performed as part of periodic power unit maintenance CONTACT 1 877 TESCO 77 INTL 713 359 7295 1 2 3 4 5 6 D 10 11 12 13 14 15 Shut off the engine and wait until the centrifuge in the oil filter stops spinning Remove the filter cover Lift the centrifuge turbine assembly slightly and hold Allow oil to drain out of the hoses Loosen the bowl nut until the face of the nut extends beyond the bushing face Strike the face of the nut to separate the centrifuge bowl from the turbine base Note Do not strike the nut with any hard object the palm of your hand will work Remove the bowl nut completely Remove the bowl and baffle screen Remove the accumulated dirt from the centrifuge bowl Note Use an implement that will not damage the bowl Wipe the bowl with solvent after you remove the debris Clean the baffle and turbine
100. leanliness filters can be washed module Ventilation louvers cleanliness obstructions restrictions Cooling ducts cleanliness obstructions restrictions Weekly Prime Mover Inspect For Inspector Battery if applicable correct electrolyte level evidence of corrosion Water pump seal drain evidence of leaks Weep hole plugs correct placement evidence of leaks Fan hub correct lubrication see the appropriate Engineering Memo document for lubrication specifications CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 105 WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX E SERVICE CHECKLISTS MAINTENANCE GUIDE Inspect For Inspector Universal joint on the drive shaft correct lubrication grease if required do not over lubricate or this can damage the seals Weekly Pump Drive Inspect For Inspector Breather filter cap cleanliness Mating bolts mounting to prime mover __ tightness Weekly Auxiliary Hydraulic Power Unit Service Inspect For Inspector Electric motor and hydraulic pump Unnatural noise Comments Notes CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 106 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS MONTHLY CHECKLISTS Date Supervisor Rig Time Monthly T
101. lers for the EXTEND mechanism Apply a thin coat of grease to all quick couplers Wrap the quick couplers with corrosion inhibitor tape se IA V UTR t Inspect the liner of the torque bushing for wear Note Replace the liner prior to storage if required Studs for Torque Track Clean and grease CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 69 WWW TESCOPARTS COM CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE Hanging Sling Assembly 1 2 Clean and inspect the hanging sling assembly Apply a thin film of grease to the entire assembly including cables and cable clamps Torque Beam and T Bar SN CUM dis Clean and inspect the T bar Apply a thin film of grease to the entire T bar Clean and inspect the T bar clamp on the torque beam Apply grease to the inside of the clamp plates Apply anti seize compound to all bolts Reinstall the clamp Apply a thin coat of grease to the threaded rods of the clamp Note Apply grease to the entire length of rods POWER UNIT IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Hydraulic Oil Storage Tank 1 Oe 2 bha Add oil inhibitor to the tank Note Check the manufacturer s spec
102. lter cleanliness these filters should be changed use recommended OEM filters refer to the every 300 operating hours refer to the prime mover manual for frequency equipment service manual for the correct oil a complete oil analysis should be conducted every third oil change 900 operating hours Note It is best to change the oil immediately after equipment operation when the current oil is warm Radiator and heat exchanger cleanliness inspect and clean every 300 operating hours Caution Never use high pressure spray to clean the radiator Pressure can bend and damage the cooling fins Never spray a hot radiator with cold water Always stop the engine before cleaning the radiator Hydraulic fittings tightness Fuel filters primary and secondary use cleanliness inspect periodically replace recommended OEM filters according to manufacturer s specifications Note More frequent replacement might be required where the fuel supply quality is poor Exhaust system carbon build up also use rig up or operational downtime to inspect bolts and flanges Centrifugal oil filter if equipped cleanliness service every 900 operating hours or according to manufacturer s specifications Cooling system filter cleanliness replace every 900 operating hours Coolant perform a coolant analysis every 900 operating hours replace as required Auxiliary system function light pressure correct setting see How to S
103. lubricants unless otherwise specified Inspect For All hose connections and belts leaks tightness Exhaust system routing loose clamps and bolts check visually Oil level low idle oil level check for leaks Coolant level correct level Oil pressure correct operating range consult the manufacturer s service and maintenance documentation for your prime mover module Operating fuel pressure adequate pressure consult the manufacturer s service and maintenance documentation for your prime mover module CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 9 WWW TESCOPARTS COM CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE Inspect For Air filter restriction indicator consult the manufacturer s service and maintenance documentation for your prime mover module Rig saver confirm correct position open Radiator clogging debris Caution Never use high pressure spray to clean the radiator Pressure can bend and damage the cooling fins Never spray a hot radiator with cold water Always stop the engine before cleaning the radiator Weekly Prime Mover Service The following visual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments IMPORTANT This equipment was filled at the
104. ly to each pump drive as follows 14 Start the pump drive 15 Allow the lubrication pump to circulate for one minute 16 Slightly loosen the lubrication line to each pump adapter plate 17 Ensure that each line has adequate oil flow Note The volume of flow should be low but continuous If a line does not exhibit correct flow shut down and completely remove the line Inspect the line for clogs pump failure or filter problems if a filter is present CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 48 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS Figure 5 1 Load path components Typ 12 places Safety wired ie 226 1 ae l ee Quill Gear Spacer 2 sl DO T Drive Hub Typical 10 places Die Lock Clamp A nen ap Z gt Debris O Ring gt EZ Y Outer Retainer spit Cale E se n Load Shoulder Top Plate Bolt Retainer DU r Load Nut Bolt Typ 8 places 3900075010 ai CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 49 WWW TESCOPARTS COM CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS MAINTENANCE GUIDE How TO DISASSEMBLE THE LOAD PATH Use the following procedures to disassemble the load path Break Out the Load Path Remove the Load Nut Remove the Quill and Swivel Body Break Out the Load Path Perform the following steps before you disconnect the servic
105. m keeper plate 8378 Top die retainer plate 3725 Hex head capscrew 3 8 16UNC x 1 in 1045 Socket head capscrew 1 2 13UNC x 1 in 6654 Spacer 1676 Tong die 1 2 in thick x 1 1 4 in wide x 5 7 8 in 2526 opt Tong die 1 2 in thick x 1 1 4 in wide x 3 7 8 in 3055 opt 5 in 8 1 2 in 3051 Die spacer Die holder standard 1044 Socket head capscrew 1 2 13UNC x 1 in 3054 Bottom keeper plate 1045 Socket head capscrew 1 2 13UNC x 1 in 1676 Tong die 1 2 in thick x 1 1 4 in wide x 5 7 8 in 2526 opt Tong die 1 2 in thick x 1 1 4 in wide x 3 7 8 in 3055 opt 8 1 2 in 8 3 4 in 8760 Die spacer Die holder 1045 Socket head capscrew 1 2 13UNC x 1 in 7443 Shim 1 8 in 1676 Tong die 1 2 in thick x 1 1 4 in wide x 5 7 8 in 2526 opt Tong die 1 2 in thick x 1 1 4 in wide x 3 7 8 in 3055 opt CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP Die spacer WWW TESCOCORP COM 79 WWW TESCOPARTS COM APPENDIX TOOL JOINT USAGE CHART Table B 1 Tool joint usage chart Tool Joint O D TESCO Part 2 7 8 in 4 in MAINTENANCE GUIDE Description Die holder retainer for 1 2 in shims Shim 1 2 in Tong die 1 in thick x 1 1 4 in wide x 5 in long Break away tab Die retainer 3 1 4 in 4 1 2 in Cap screw
106. ness clean as required Crankcase oil and filter use recommended OEM filters refer to the prime mover manual for frequency cleanliness these filters should be changed every 300 operating hours refer to the equipment service manual for the correct oil a complete oil analysis should be conducted every third oil change 900 operating hours Note It is best to change the oil immediately after equipment operation when the current oil is warm Radiator and heat exchanger cleanliness inspect and clean every 300 operating hours Caution Never use high pressure spray to clean the radiator Pressure can bend and damage the cooling fins Never spray a hot radiator with cold water Always stop the engine before cleaning the radiator Fuel filters primary and secondary use recommended OEM filters cleanliness inspect periodically replace according to manufacturer s specifications Note More frequent replacement might be required where the fuel supply quality is poor Exhaust system carbon build up also use rig up or operational downtime to inspect bolts and flanges Centrifugal oil filter if equipped cleanliness service every 900 operating hours or according to manufacturer s specifications Cooling system filter cleanliness replace every 900 operating hours Coolant perform a coolant analysis every 900 operating hours replace as required CONTACT 1 877 TESCO 77
107. o TESCO Engineering for disposition Return to a TESCO authorized service centre for complete dimensional visual WFMPI MPI inspection for recertification Upon completion of Type C inspection the inspection schedule starts at zero operating days CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP WWW TESCOCORP COM 19 WWW TESCOPARTS COM CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE Figure 3 1 Swivel HMI Frequency Operating Days and Inspection Type At 250 At 500 At 750 At 1000 1 Hook contact point A B A B A B 2 Swivel yoke A A A 3 Swivel yoke pin holes A B A B A B 4 Yoke pins A B A B A B 5 Swivel links A A A C 6 Swivel link yoke pin holes A B 7 Swivel link swivel pin holes A B A B A B 8 Swivel pins A B A B A B 9 Swivel body pin holes A B A B A B C 10 Swivel body A A A C Refer to Table 3 1 on page 19 for inspection type details CONTACT 1 877 TESCO 77 250TONHMIS475HP WWW TESCOCORP COM INTL 713 359 7295 20 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION Figure 3 2 Quill HMI Frequency Operating Days and Inspection Type Point Name Every At At At At 60 250 500 750 1000 1 Threads and bore A A A 2 Upper thrust surface
108. o not tighten them c Start the locking pins Install the hex drives 2 Install the snap rings into snap ring grooves Tighten all setscrews evenly to 100 ft lb Install a hose clamp over the locking pins Remove the brass centering shims Lower the grabber Remove the wooden blocks Rotate the quill with the top drive to position the locking mechanism to accept the stop bracket of the actuator Install the stop bracket Connect the hydraulic lines for the mud valve open valve close circuit Test the actuator to confirm that it is working correctly How TO SET THE COUNTER BALANCE CUSHION HEIGHT Perform this procedure as part of monthly top drive maintenance Ensure the top drive is positioned at the racking platform before you start this procedure 1 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Connect the hose quick coupler for the elevator to the charge fitting for the counter balance system Shut off the auxiliary pump Set the ELEVATOR switch at the driller s panel to CLOSE Open the needle valve on the counter balance manifold Note This relieves all pressure on the counter balance system Check the nitrogen pressure and adjust if required Note The nitrogen pressure must be 800 psi Ensure the counter balance relief valve is set at 1 200 psi Close the needle valve on the counter balance manifold Start the auxiliary pump 250TON HMIS 475HP WWW TESCOCORP COM 35 WWW TESCOPARTS COM CHAPTER
109. on of Moly and Graphite to Reduce Heat Friction and Abrasive Wear Lasts 2 to 5 Times Longer Than Conventional Greases Superior Water Resistance Won t Wash Out During Operation Even When Totally Submerged Bearing Speeds Up to 20 000RPM s Reduces Grease Inventory to Save Money Wide Operating Temperature Range NLIGI 1 remains effective to 204 C 400 F continuous and 260 C 500 F ntermittent With Monitored Lubrication and Down to 28 C 20 F Meets or Exceeds the Following Performance Requirements US Steel Mill Grease Specifications Roll Neck Grease Req No 340 Extreme Pressure Grease Req No 350 Extra duty EP Grease Req No 352 Extreme Temp Reg No 355 370 amp 372 Ball and Roller Bearing Req No 371 Mill Utility Grease Req No 375 Military Spec MIL G 23549C Federal Specification VV G 632a CASE 251H EP Caterpillar MPG Chrysler MS 3551E General Motors Specification GM 6031 M DIN51 825 DIN 51 818 a Part Number Order Information ase Lot 48Tubes 731142 48T Bulk 181 4 kg 400 Ib Drum Bulk 54 4 kg 120 Ib Keg Bulk 15 8 kg 35 Ib Pail 731142 400LB 731142 120LB 731142 35LB CONTACT 1 877 TESCO 77 250TON HMIS 475HP INTL 713 359 7295 120 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX F TESCO ULTREX LUBRICANTS ULTREX SYNTHETIC BLEND GREASE NLGI 4 ATOTAL ADDI
110. ons Quill hub preload correct preload see How to Check and Adjust Preload on page 40 The following lubrication should be performed at least once every operating month More frequent lubrication might be required if you are operating the top drive in harsh or demanding drilling environments Lubricate With Hinge pins and extend frame if applicable spray with penetrating oil WD 40 or spray lithium CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 6 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Figure 2 2 Lubrication points for the Top Drive 5 e Swivel Yoke Washpipe lt le bh me 1 E 2 lt Z if Swivel Pin 1 4 CY X FEN C K JL lt Pin Seal Housing 2 Extend Frame Hinge Pins Typical PH VA C EME VA CINA CCX DECAT NA TEGA X OT t t oo ders One each end 4 Mud Saver Valve DN RUN Upper amp Quill Bushing 1 Fata rers ae Elevator Hinge Pin 1 Elevator Handle Pin 2 One at each end of pin 39000268 ai CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 7 WWW TESCOPARTS COM CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES MAINTENANCE GUIDE SERVICE LooP SERVICE REQUIREMENTS Weekly Service Loop Service Requirements The following vis
111. op Drive Inspect For Inspector Gearbox oil abnormalities take samples to test for water metal particles etc every 900 operating hours Grabber correct grabber height check and reset grabber height Roto actuator sleeve general condition disassemble clean grease coat with corrosion inhibitor and reinstall see How to Disassemble and Service the Roto Actuator on page 33 Grabber dies excessive wear Sensor panel moisture tightness of wire terminations Quill hub preload correct preload 11 station manifold general condition leaks All fasteners nuts bolts and lock wires correct location tightness Top Drive hydraulic connections and oil leaks deformation hoses Saver sub threads excessive thread wear seal face condition Connection locking clamps correct location tightness Grabber leg safety chain shackles broken components lock wires Pipe bumper motor guard dents or bends that may indicate bolt damage Counter balance system ensure proper function setup cushion height pressure and hose integrity Hammer union on Kelly hose integrity and tightness Grabber drawworks and mud valve mud function test pump interlocks Gearbox lubrication system hoses oil leaks adequate circulation press 60 120 psi Motor cooling fan function test unnatural noises Torque wear liners if applicable wear damage Block support wear lin
112. orp com Email MABU_sales tescocorp com Europe Russia United States Canada E Aberdeen UK Houston Texas Calgary Alberta Email FURO_sales tescocorp com Email NABU_sales tescocorp com TES c Better Ways to The Botta m WWW TESCOCORP COM WWW TESCOPARTS COM APPENDIX F TESCO ULTREX LUBRICANTS MAINTENANCE GUIDE The First fr St Synthetic Universal Autor Transmission Fluid For Outstanding Performance in Transmissions Power Steering and Hydraulic Applications PRODUCT DESCRIPTION AMSOIL Synthetic Automatic Transmission Fluid ATF exceeds the performance requirements for domestic and foreign automatic appe transmission fluid applications AMSOIL ATF provides automatic transmissions power steering units and hydraulic equipment with excellent lubricating protection and better performance over a wider temperature range than conventional automatic transmission fluids Resists Oxidation and Thermal Degradation AMSOIL ATF resists thermal and oxidative degradation better than systems In tests designed to measure wear conventional transmission fluids protecting clutches planetary characteristics under severe service and gears valves pumps and seals from damaging sludge and varnish high pressure operating conditions AMSOIL deposits AMSOIL ATF helps prevent component overheating and ATF far exceeds the requirements of ensures cooler smoother transmission operation hydraulic equipment manufacturers Provides L
113. oup Standard Power 500 B 24H 0002 101943 01 115 230 volt 50 60 Hz e 24 v 20 OA DC EIA 413974440 G CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 83 WWW TESCOPARTS COM APPENDIX FUSES FOR THE CONTROL TRANSFORMER MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 84 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX D SAMPLE INSPECTION LOGS APPENDIX D SAMPLE INSPECTION LOGS The following pages contain examples of inspection logs It is important to keep detailed inspection records for all load path and torque arrest system components Please use the following pages as a guide Use this log to schedule and track inspections for each load path component In this field Do this Serial Number Record the component serial number Inspection Date Enter the date of the most recent component inspection Days in Service Enter the cumulative hours or days of service the component has been in service on the date of inspection Inspected By Enter the name of the company that performed the inspection Note Attach a copy of the inspection results to this inspection log Results Comments Summarize the test results and note any special action taken in the Additional Comments section at the bottom of the page If a component is replaced include the s
114. ow Temperature Protection Extends Orain Intervals AMSOIL ATF outperforms petroleum fluids in low temperature fluidity AMSOIL ATF is a stable formulation that In fact AMSOIL ATF offers twice the cold temperature fluidity required lasts longer in service than conventional by current automatic transmission fluid specifications AMSOIL ATF ATFs It maintains its viscosity friction and provides easier starting faster warm ups smoother shifting and lubricating properties for extended periods of time even under severe conditions AMSOIL ATF maximizes transmission performance and service life while reducing maintenance costs through longer drain intervals HIGH TEMPERATURE FLUID LIFE TEST Turbo Hydromatic Oxidation Test THOT 1 1 1 1 DEXRON I OXIDATION TEST REQUIREMENT 450 HOURS RESISTS OXIDATION TWO TIMES LONGER THAN REQUIRED FOR CONVENTIONAL ATF AMSOIL SYNTHETIC ATF 900 HOURS CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 118 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX F TESCO ULTREX LUBRICANTS TYPICAL TECHNICAL PROPERTIES AMSOIL Synthetic Universal Automatic Transmission Fluid ATF Kinematic Viscosity 100 C cSt ASTM D 445 Kinematic Viscosity 40 C cSt ASTM D 445 Viscosity Index ASTM D 2270 Noack Volatility weight loss ASTM D 5800 Flash Point C F ASTM D 92 Pour Point C F ASTM D 97 Four Ball Wear Test Scar in mm
115. parameters new bearings 0 003 in used bearings 0 001 to 0 003 in 6 Ifthe values are outside acceptable preload parameters adjust the preload a Remove the bolts that attach the bonnet upper bearing retainer to the swivel housing b Remove the required number of shims See Sample Calculation on page 45 c Reattach the bonnet upper bearing retainer to the swivel housing CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 43 WWW TESCOPARTS COM CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE Check the Quill to Quill Gear Drive Bushing Drive Spacer Endplay 1 Check that the quill drive hub to quill hub bolts are tight 2 Install a dial gauge on the quill between the swivel and the gearbox Note Attach the magnetic base to the quill such that the needle rests on the quill gear drive bushing Install a soft sling in the bonnet of the top drive Use overhead equipment to gently hoist and lower the top drive Monitor the dial gauge for movement There should be no movement mu p If there is movement this indicates that the spacer is not the correct size Contact TESCO as the spacer will have to be removed and resized CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 44 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 4 SERVICE PROCEDURES How to Calculate the Preload Adjustment If the previous procedure reveals any amount of quill end play the
116. pe Location Other Inspection Days in Service Next Service Serial Date Cumulative Inspected By Results Comments Due Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Additional Comments CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 93 WWW TESCOPARTS COM APPENDIX SAMPLE INSPECTION LOGS MAINTENANCE GUIDE SAVER SUB INSPECTION LOG Top Drive Number Service Facility Service Activation Date Top Drive Type Location Other Inspection Days in Service Next Service Serial Date Cumulative Inspected By Results Comments Due Good Condition 0 Repaired 0 Replaced Good Condition Q Repaired Replaced C Good Condition Repaired Replaced Good Condition Repaired Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Good Condition 0 Repaired 0 Replaced Additional Comments CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 94 WWW TESCOPARTS COM MAINTENANCE GUIDE LOAD COLLAR INS
117. pen the electrical junction box Ensure the box is clean and dry Apply a light coat of grease to the sealing surface of the cover plate Coat all bolts with an anti seize compound and reinstall the bolts Remove the coupler cover plate Spray light penetrating oil onto the coupler SA we m wm EB Reinstall the cover plates Filter Manifold 1 Remove the caps on the hammer union 2 Lightly grease the caps and reinstall them 3 Apply a light grease to all filter caps and relief plugs Pump Drive and Main Hydraulic Pumps 1 Apply light grease to all unpainted metal parts to protect against corrosion 2 Apply grease to the threads of all mounting studs 3 Add corrosion inhibitor to the pump drive oil Note Check the manufacturer s specifications for correct inhibitor concentration 4 Sealand cover all breather ports and vents CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 71 WWW TESCOPARTS COM CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE Prime Mover 1 o lt A Ta 9 Add corrosion inhibitor oil to the engine crankcase Note Check the manufacturer s specifications for correct inhibitor concentration Change the oil and the filter Service and protect the radiator Note See Air Oil Cooler on page 71 for more information Grease all belt tensioners and pulleys Perform the following battery maintenance if required and if equipped a Remove t
118. peration even when totally submerged Bearing Speeds Up to 20 000RPMS Reduces Grease Inventory to Save Money Wide Operating Temperature Range NLIGI 2 Remains Effective To 204 C 400 F Continuous And 260 C S00 F ntermittent With Monitored Lubrication And Down To 23 C 94 u Meets or Exceeds the Following Performance Requirements US Steel Mill Grease Specifications Roll Neck Grease Reg No 340 Extreme Pressure Grease Req No 350 Extra duty EP Grease Req No 352 Extreme Temp Req No 355 370 amp 372 Ball and Roller Bearing Req No 371 Mill Utility Grease Req No 375 Military Spec MIL G 23549C Federal Specification VV G 632a CASE 251H EP Caterpillar MPG Chrysler MS 3551E General Motors Specification GM 6031 M DIN 51825 DIN 51818 Part Number Order Information Case Lot 48 Tubes 31141 48T Bulk 181 4 kg 420 Ib Drum 731141 400LB Bulk 54 4 kg 120 Ib Keg 731141 12018 Bulk 15 8 kg 35 Ib Pail 731141 35LB CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 122 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX F TESCO ULTREX LUBRICANTS ULTREX SYNTHETIC BLEND GREASE NLGI 2 A TOTAL ADDITIVE PACKAGE THAT SETS IT APART FROM ALL OTHER GREASES ADDITIVES Calcium Sulfonate Base Extremely water resistant heavier than water to resist washouts
119. perform the following checks unless the main breaker panel is disconnected and locked out Danger Only qualified personnel should perform the A following maintenance activities Inspect For Inspector All wire terminal screws tightness All bolted connections on both the tightness incoming and outgoing waterfall CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 108 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX E SERVICE CHECKLISTS Inspect For Inspector Input and output power connections correct position and tightness Electrical connections for the main drive correct torque component Critical These connections must be torqued to specification Severe component damage can result if they are over tightened IGBT s and related bus works correct torque Critical These connections must be torqued to specification Severe component damage can result if they are over tightened Cooling connectors tightness All external power connections to the top cleanliness moisture these should be drive from the mechanical module disassembled sprayed with electrical cleaner moisture dispersant and reconnected Monthly Prime Mover Inspect For Inspector Electrical control panels dirt moisture replace desiccant packs Radiator cap damage or corrosion Drive belts correct tension cracks and erosion Air starter filter cleanli
120. quill storage 66 R radiator inspection 10 rig out rig saver inspection 10 rig up roto actuator disassemble 33 reassemble 34 service 33 S safety chain inspection 5 sample inspection logs 89 saver sub daily inspection 3 saver subs storage 67 schedule non destructive testing 17 sensor panel monthly inspection 6 service loop monthly inspection 8 service requirements 8 weekly requirements 8 service loop components weekly inspection 8 service loop hoses monthly inspection 8 service loop quick couplers weekly inspection 8 service loop weekly inspection 8 service procedures 33 auxiliary function light 39 auxiliary pressure relief 38 calculate preload adjustment 45 centrifugal oil filter 46 coolant analysis 47 counter balance height 35 hydraulic oil analysis 45 pump shaft splines 47 250TON HMIS 475HP WWW TESCOCORP COM WWW TESCOPARTS COM INDEX quill preload 40 reset grabber height 37 roto actuator 33 service requirements cooling system 16 filter manifold 14 oil reservoir 15 power unit 12 prime mover 9 service loop 8 torque arrest system 8 set torque and speed 1 six month checklist 111 six month inspection top drive 111 spline inspection 13 splines pump shaft 47 split collar inspection 22 storage junction boxes 66 storage preparation 65 stuck pipe 1 studs storage 69 swivel daily service 5 swivel daily lubrication 5 swivel hammer unions
121. r the quill through the quill drive gear When the quill drive gear is close to the top of the drive hub rotate the drive gear to align it with the dowel pins Lower the quill until the dowels are visible at the top of the drive hub If required reset the jacking set screws 2 These are located on top of the drive bushing hub Put a drop of blue Loctite thread fastener in each hole and install socket head cap screws Note Torque bolts in a cross pattern gradually increasing the torque on all bolts to 140 ft lb Secure all bolts in place with lock wire Install the Load Nut The swivel body and quill must be in place before you can perform this procedure 1 2 3 4 A 10 11 12 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Raise the top plate of the load shoulder into position with the bevel side facing up Loosely install the locking pins This will hold the top plate in position Ensure the quill profile is clean Coat the quill profile area with a light coat of anti seize compound or rust inhibitor oil Ensure the inner segments of the split collar are clean Install the inner segments of the split collar on the quill Note Tap the segments with a non marking hammer to seat them Ensure the outer retainer is clean and coated with a light film of rust inhibitor oil or anti seize compound Slide the outer retainer onto the split collar segments Slide the bottom plate into position Use
122. ration Container 1 power unit Container 2 top drive assorted small items multi conductor cables Container 3 torque arrest system components cable storage reel CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 73 WWW TESCOPARTS COM CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 74 WWW TESCOPARTS COM MAINTENANCE GUIDE APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS APPENDIX A TORQUE STANDARDS FOR HIGH STRENGTH FASTENERS The following information originated from the Standards document STD0015 PURPOSE This Standard should be used as a guideline for all fasteners used in production where the torque values are not specified on the Engineering documentation and drawings All TESCO Standards on fasteners should be adhered to as non conformance can lead to the following low quality products rework cost warranty claims late delivery customer dissatisfaction lower production STANDARDS 1 Allcapscrews bolts and nuts have to be Grade 8 or equivalent unless noted other wise U N O 2 Fasteners must be torqued in accordance with tables 1 2 and 3 U N O Torques should be applied smoothly and with a calibrated wrench 3 Multiple fastener arrays must be made up evenly using an appropriate torque sequence
123. roduct development all specifications are subject to change without notice Asia Pacific Latin America Jakarta Indonesia Buenos Aires Argentina Email APBU_sales tescocorp com Email LABU_sales tescocorp com China Middle East amp Africa Chaoyang District Beijing ubai UAE Email CHINA_sales tescocorp com Email MABU_sales tescocorp com Europe Russia United States Canada m E Aberdeen UK Houston Texas Calgary Alberta Email EURO_sales tescocorp com Email NABU_sales tescocorp com TESCO tescocorp com Better Ways to The Botto m CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 123 WWW TESCOPARTS COM APPENDIX F TESCO ULTREX LUBRICANTS MAINTENANCE GUIDE This page has been left blank intentionally CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 124 WWW TESCOPARTS COM MAINTENANCE GUIDE INDEX A actuating piston grabber 57 actuator lubrication 4 actuator sleeve monthly inspection 6 actuator valve orientation 34 air starter filter inspection 10 air oil cooler inspection 16 annual inspection tank screen filters 16 annual service oil reservoir 16 assembly and disassembly instructions 49 auxiliary pressure relief 38 auxiliary system function light pressure switch 39 C cable reel storage 68 chart tool joint usage 79 commissioning 1 component inspection guidelines 18 coolant analysis 47 coolant level inspection 9 cooling s
124. roves lubrication in wet conditions PHYSICAL PROPERTIES PROPERTIES GREEN 2 Penetration ASTM D 217 288 Multistroke penetration ASTM D 217 295 Wheel bearing leakage ASTM D 1263 3 Water washout ASTM D 1264 lt 01 Pressure Oil separation ASTM 0 1742 0 02 Four ball Index ASTM D 2596 101 Four ball weld ASTM D 2596 1000 Four ball wear scar ASTM D 2596 0 344 Timken method ASTM D 2509 70 Rust test ASTM D 1743 Passed Copper corrosion ASTM D 130 1B Low Temperature Limit 23 C 9 4F Dropping Point ASTM D 2265 302 C 575 High Temperature Limit 260 500 Base Oil Viscosity 40 C 104 F 110 87 USED FOR Heavy industrial equipment exposed to high low temperatures high speed wheel bearings anti friction bearings open gears turbine pumps paper and pulp mills steel mills chemical plants and waste water plants construction equipment sewage treatment plants irrigation equipment non domestic water pumps wet mining scroll saws kiln cars high speed wheel bearings boat trailer bearings sleeve bearings chassis utility trucks buses sea going vessels coastal and wharf equipment inland waterway applications NOT FOR Any application with a continuous temperature exceeding 260 C or 500 intermittently without monitored lubrication TESCO ULTREX and Better Ways to The Bottom are trademarks of Tesco Corporation Tesco Corporation June 2007 POD Due to ongning p
125. rush to clean and brush the inserts Apply a thin coat of grease or anti seize compound to the inside of the elevators and all sides of the inserts Apply anti seize compound to all stop bolts Install the elevator inserts Operate the elevators and thoroughly grease the body and hinge Apply grease to the exposed rod shafts of the elevator operating cylinders Grease all retainer bolts on the elevator link s Mudsaver Valve Sog cV uU Uo gt Eo E c Remove the actuator Clean and inspect the threads on the mudsaver valve Clean the inside of the valve Manually close the valve Pour oil into the ball of the valve Operate the valve Repeat steps 4 6 for both sides of both balls Apply liberal amounts of thread dope to all connections Use a wire brush to clean and brush the outside of the valve Apply grease to the valve stem area and valve body Clean and inspect the actuator Grease the inside of the actuator Reinstall the actuator on the mudsaver valve Note Use anti seize compound on all fasteners and hex nuts Saver Subs 1 2 CONTACT 1 877 TESCO 77 INTL 713 359 7295 Clean and inspect all threads Apply pipe dope and install thread protectors 250TON HMIS 475HP WWW TESCOCORP COM 67 WWW TESCOPARTS COM CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE HOSE STORAGE REEL IMPORTANT This equipment was filled at the factory with T
126. t a bottle jack that is appropriate for the combined swivel and quill weight of the top drive If combined quill and swivel weight is less than 5000 Ib then a 5 ton bottle jack is recommended If combined quill and swivel weight exceeds 5000 Ib then a 7 1 2 ton bottle jack is recommended Caution Ensure the bottle jack is rated appropriately for the load Caution Use blocking and suitable protection to prevent damage to the connection and grabber 4 Insert the bottle jack between the grabber box and the end of the quill Note For an HMI top drive where the grabber is supported by a spring insert blocking between the top of the elevators and the underside of the grabber so that you can apply load to the quill Use the bottle jack to hoist the quill Monitor the dial gauge for movement Hoist the quill several times to confirm endplay readings 7 Remove shims as required to eliminate endplay CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 41 WWW TESCOPARTS COM CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE How to Check and Adjust HMI Specific Preloads There are three preload checks that must be performed for HMI top drive units gearbox bearing preload swivel bearing preload quill to quill gear drive bushing spacer preload Check the Gearbox Bearing Endplay 1 Install a magnetic base dial gauge on the quill Note Put the magnetic end on the quill and the needle on the bear
127. tem correct lubrication of the pump splines check at the oil filler cap Daily Filter Manifold Inspect For Inspector Filter housing and manifold leaks Charge pressure differential correct differential pressure one gauge on the inlet and one gauge on maximum differential is 100 psi if differential is the outlet of the charge pressure greater than 100 psi replace the filter elements manifold use the manufacturer s recommended filter ele ment CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 102 WWW TESCOPARTS COM MAINTENANCE GUIDE Daily Oil Reservoir APPENDIX E SERVICE CHECKLISTS Inspect For Inspector Reservoir and area leaks Return oil tank filters dirt inspect the dirt alarm and replace the filter if required Low oil level shutoff equipment correct connection inspect visually Tank oil correct operating level Daily Cooling System Inspect For Inspector Air oil cooler leaks correct fan operation Note Set the fan switch to manual before you check operation fan cleanliness correct hot oil shuttle flow Note if the unit is operating check the flow meter on the opposite side of the electrical panel Water oil cooler if installed leaks or damage check visually All sides including under leaks complete visual inspection Cooler core debris blockages Comments Notes
128. th a photograph or illustration indicating all cracks or damage points confirmation that all indicated inspection areas have been checked LOAD PATH COMPONENTS AND INSPECTION INFORMATION This chapter contains illustrations of all components in the top drive load path Each illustration indicates the inspection points for the specific component It also describes any special considerations that must be addressed when inspecting the component It 15 critical that all components of the load path be subjected to periodic magnetic particle inspection MPI by a qualified inspector Each piece should be inspected for surface defects according to the schedules that follow Note Any part of an operating day should be considered one day Removal of paint might be required for inspection CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 18 WWW TESCOPARTS COM MAINTENANCE GUIDE Inspection Types CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION The three inspection types are outlined in Table 3 1 Table 3 1 Inspection types Inspection Type Description A Visually inspect for If a crack is suspected perform local paint strip and MPI inspection All cracked components should be referred to TESCO Engineering for disposition wear deformation cracks corrosion galling heat damage other irregularities Perform MPI or WFMPI for cracks All cracked components should be referred t
129. the piston out of the cylinder Replace the seals and inspect the cylinder for internal damage Note Use a fine emery cloth or a fine grit cylinder hone to remove small surface defects 5 Install new gland seals as required Caution Exercise caution when you reassemble this component The piston open close ports can damage the gland seals 6 Assemble the piston components Note Ensure that all bolts and O rings are coated with light grease before assembly 7 Actuate the cylinder with oil to purge the air from the cylinder Danger Air in the cylinder will act as an accumulator Accumulation of pressure can cause injury when the piston is tested 8 Pressure test the piston assembly to 2 000 psi on both the open and close side of the circuit CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 58 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS How to Remove and Reinstall the Lower Grabber Leg Remove the Lower Grabber Leg 1 Remove the safety chain from the back of the lower grabber leg 2 Prepare the leg for removal according to one of the following conditions If the top drive can be hoisted off of the grabber leg then lower the grabber to the end of its travel stroke and use blocks to support it If the top drive cannot be hoisted ensure that there is enough clearance below the top drive to remove the grabber leg This might require settin
130. tor 3 EP2 multi purpose grease Elevator hinge pin 1 EP2 multi purpose grease Mudsaver valve actuator 3 Metalon EP1 5 TESCO Part 2996 Swivel link pins 2 if applicable EP2 multi purpose grease Wash pipe 1 EP2 multi purpose grease CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 100 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE Daily Torque Arrest System APPENDIX E SERVICE CHECKLISTS Inspect For Inspector All connections damage or decay All overhead equipment T bar torque beam damage or decay torque track torque bushing Daily Auxiliary Hydraulic Power Unit Inspect For Inspector Auxiliary hydraulic oil tank correct oil level Coolant tank correct coolant level Modine air exchanger radiator cleanliness Cooling coil on the Trane chiller cleanliness All flow meters reporting correct flow Daily Power Module Inspect For Inspector All panels and floor coolant leaks Drive components Caution Condensation in the drive components can cause severe damage if not immediately addressed moisture Indicator lights correct function replace if required VFD Blower proper operation Door fan proper operation Chopper fan proper operation Selection switch ESD push button correct function replace if required Braking register module
131. tor tape Store the driller s panel in the top drive shipping container or other sheltered location 250TON HMIS 475HP WWW TESCOCORP COM 68 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 6 LONG TERM PRESERVATION AND STORAGE Interlocks Clean all interlock valves Spray the valves with light oil Clean all of the connectors Spray the ends of the connector with light oil Be IN ou Wrap all of the connectors with corrosion inhibitor tape TORQUE ARREST SYSTEM IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Torque Track Assembly Clean and inspect all sections of the torque track Use a wire brush on the end connection points of all torque track sections Clean and dry the ends of the track sections Apply a thin coat of grease to the ends of the track sections Install protective end caps Coat all bolts and studs with anti seize compound Di Im QU Apply paint or corrosion inhibitor to any bare spots along the length of the torque tracks Torque Bushing Extend Frame Clean and inspect all pin sockets Apply a thin coat of grease to all pin sockets Wrap all pin sockets with corrosion inhibitor tape Grease the ends of all cylinder pivots and the exposed cylinder rods Clean the hydraulic quick coup
132. torage 66 load nut removing 51 load path assembly 52 load nut 53 CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 126 MAINTENANCE GUIDE mudsaver valve 54 quill 52 load path components 49 load path disassembly 50 break out 50 load nut 51 quill 52 swivel body 52 load path inspection 18 logs sample inspection 89 long term storage 65 before shut down 65 driller s panel 68 elevators 67 extend frame 69 grabber leg 66 hanging assembly 70 hydraulic oil tank 70 interlocks 69 load nut 66 main cable reel 68 mudsaver 67 power unit 70 quill 66 saver subs 67 studs 69 T bar 70 top drive 66 torque arrest system 69 torque beam 70 torque bushing 69 torque tracks 69 lubrication points top drive 7 M make connections 1 monthly checklists 107 monthly inspection air starter filter 10 aux system function light switch 11 cooling system 16 counter balance system 6 drive belts 10 gearbox oil 6 grabber 6 hydraulic fitting 6 prime mover 10 pump drive oil 13 pump shaft 13 quill preload 6 roto actuator sleeve 6 sensor panel 6 service loop 8 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE service loop hoses 8 service loop threads and valves 8 top drive 107 monthly lubrication extend frame 6 hinge pins 6 top drive 6 monthly service cooling system 16 filter manifold 14 oil reservoir 15 prime mover 10 pump drive 13 top drive 6 MP
133. tside of TESCO facilities CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 17 WWW TESCOPARTS COM CHAPTER 3 NON DESTRUCTIVE TESTING AND INSPECTION SCHEDULES MAINTENANCE GUIDE GUIDELINES FOR COMPONENT INSPECTORS Only qualified personnel can inspect load path torque arrest system and critical components Inspectors must use only fully operational regularly maintained testing equipment To ensure accurate test results each component must be thoroughly cleaned before inspection In some cases removal of paint is required Visual and magnetic particle inspection shall be conducted in accordance with API 8C ISO 13535 If you are inspecting a TESCO load path torque arrest system or critical component you must provide the top drive owner with the following information General information for each component tested type of test or inspection performed MPI WFMPI etc type of equipment used to perform the testing operating conditions name and type of inspecting company name and signature of the inspector date of inspection Inspection results for each component tested part description name size etc serial number of the inspected part exact location of all points of damage measured from a recognizable point of reference including the following cracks excessive wear deformation corrosion erosion all dimensions for all cracks length depth wid
134. tuator in place until you are ready to remove it Remove the connection locking clamp for the saver sub Remove the saver sub Visually inspect the lower portion of the valve body for raised die marks Note Any raised spots will impede the removal of the actuator Buff them smooth to ensure smooth removal Place wooden blocks on top of the grabber Note These blocks will support the actuator during the next part of this procedure Raise the grabber to support the weight of the actuator 250TON HMIS 475HP WWW TESCOCORP COM 33 WWW TESCOPARTS COM CHAPTER 4 SERVICE PROCEDURES MAINTENANCE GUIDE 13 14 15 16 17 18 Remove all setscrews 8 and springs 8 Remove the locator pins 8 using the slide hammer if required Note The actuator is now separated from the double ball valve Before you continue note the orientation of the actuator in relation to the double ball valve Lower the grabber Remove the actuator from the double ball valve Note The strip kit includes two lifting handles for moving the actuator These handles screw into any of the locking pin locations Clean the internal bore of the actuator and the outer diameter of the mud valve body Re assembly 1 IN Lightly grease the internal bore of the actuator and the outer diameter of the mud valve body IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance
135. ual checks should be performed at least once every operating week More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All service loop components damage excessive wear Urethane capture blocks hose placement tightness at top drive and roller saddle Fluid quick couplers auxiliary hydraulics damage or decay tightness Monthly Periodic Service Loop Service Requirements The following visual checks should be performed at least once every operating month More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For Wire terminals in the driller s panel tightness All hoses leaks damage Threads isolation valves damage loose parts TORQUE ARREST SYSTEM SERVICE REQUIREMENTS Daily Torque Arrest System Service Requirements The following visual checks should be performed at least once every operating day More frequent inspection might be required if you are operating the top drive in harsh or demanding drilling environments Inspect For All connections damage or decay All overhead equipment T bar torque damage or decay beam torque track torque bushing CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 8 WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 2 MAINTEN
136. ubricants unless otherwise specified Lubricate With Shots Grease nipples on the EXTEND EP2 multi purpose grease 2 each cylinder 4 Lower bearing retainer of gearbox EP2 multi purpose grease 2 each grease ports 2 Upper bearing retainer of gearbox EP2 multi purpose grease 2 each grease ports 2 Grease ports on the load collar 1 EP2 multi purpose grease 5 each LINK TILT cylinders 4 per side 8 2 multi purpose grease 2 each total Grease ports on the elevator 3 EP2 multi purpose grease 3 each Mudsaver valve actuator 3 Mystik J76 TESCO Part Fill grease reservoir 4409 or Metalon EP1 5 TESCO Part 2996 CONTACT 1 877 TESCO 77 INTL 713 359 7295 250TON HMIS 475HP 4 WWW TESCOCORP COM WWW TESCOPARTS COM MAINTENANCE GUIDE CHAPTER 2 MAINTENANCE AND SERVICE SCHEDULES Swivel Lubrication Requirements The following lubrication should be performed at least once every operating day if the top drive is equipped with the optional swivel More frequent lubrication might be required if you are operating the top drive in harsh or demanding drilling environments IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Lubricate With Ports on the swivel link hinge points
137. uu euet Serie a Sete te die ei fen 33 How to Disassemble and Service the Roto Actuator 33 How to Set the Counter Balance Cushion Height 35 How to Reset the Grabber Height 37 How to Set the Pressure Relief Valve for the Auxiliary 38 How to Set the Function Light Pressure Switch for the Auxiliary System 39 How to Check and Adjust 40 How to Check for Quill Hub End Play When the Top Drive is Installed in the Derrick 41 How to Check and Adjust HMI Specific 42 How to Calculate the Preload 45 How to Perform a Hydraulic Oil 51 5 45 How to Service the Centrifugal Oil Filter 46 How to Perform a Coolant Analysis 47 How to Check theSplinesonthePumpShaft c c eee eee eee 47 CHAPTER 5 DISASSEMBLY AND ASSEMBLY INSTRUCTIONS 49 How to Disassemble the Load 50 Break Out the Load Path 0 0 0 ccc e
138. ver cooling fluid level is at full If required add GDX Diesel anti freeze If necessary drain the cooling system and replace the cooling fluid 4 Determine if you will need to perform a load path inspection before you re start the unit If an inspection will be required ensure that all load path connections are broken out now This will allow you or another inspector to inspect the top drive system without having to supply power to the unit The following procedures assume that the top drive system has already been correctly decommissioned as described in the Rig Out Procedures section of the Installation Guide for your unit CONTACT 1 877 TESCO 77 250TON HMIS 475HP WWW TESCOCORP COM INTL 713 359 7295 65 WWW TESCOPARTS COM CHAPTER 6 LONG TERM PRESERVATION AND STORAGE MAINTENANCE GUIDE TOP DRIVE IMPORTANT This equipment was filled at the factory with TESCO ULTREX brand fluids and greases To ensure maximum performance and to avoid cross contamination we strongly recommend the continued usage of TESCO ULTREX lubricants unless otherwise specified Junction Boxes Auxiliary Panel Open the motor sensor junction box Check for moisture Install a new desiccant pack Tighten all wire terminals in the junction box Uode a oe Close and reseal the junction box When these procedures are complete seal all junction boxes with corrosion inhibitor tape Also ensure that all breather openings are sealed Main Driv

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