Professional Documents
Culture Documents
Subsection 4A: Maintenance .................................................................................................... 4-3 Subsection 4B: Inspection ...................................................................................................... 4-37 Subsection 4C: Troubleshooting............................................................................................ 4-67
Revision 05.03
4-1
4-2
Revision 05.03
4-4
Revision 05.03
Figure 4.1_1250AC-681
Revision 04.10
Figure 4.2_1250AC-681
Revision 04.10
Figure 4.3_1250AC-681
Revision 04.10
Maintenance Checklist
Week beginning: ________________________
MAINTENANCE FUNCTION GREASE WASHPIPE PACKING GREASE UPPER SEAL RING (IF EQUIPPED) GREASE MUD SAVER VALVE (IF APPLICABLE) GREASE LWCV ACTUATOR (IF APPLICABLE) GREASE LINK TILT CYLINDER BUSHINGS CHECK INDICATOR ON HYDRAULIC FILTER * CHECK INDICATOR ON LUBE OIL FILTER * CHECK OIL LEVEL ON TOP DRIVE GEARBOX CHECK TOP DRIVE FOR LOOSE OR LEAKING HYDRAULIC FITTINGS OR COMPONENTS EXAMINE TOP DRIVE FOR LOOSE BOLTS, ETC. CHECK FLUID LEVEL IN BRAKE ACTUATOR(S) GREASE LINK SUPPORT GREASE BUW MAIN TUBES GREASE BUW GRIPPER CYLINDER
GREASE BUW GRIPPER HYD. SWIVEL FITTINGS
FREQ MON TUE WED THU 12 HRS 12 HRS 12 HRS Note 1 DAILY DAILY DAILY DAILY DAILY DAILY DAILY WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY WEEKLY MNTHLY MNTHLY MNTHLY MNTHLY MNTHLY 2 MTHS 6 MTHS 6 MTHS DAY: DAY: DAY: DAY: DAY: DAY: DAY: DAY: DAY: M M M M M M M M M TU TU TU TU TU TU TU TU TU W W W W W W W W W TH TH TH TH TH TH TH TH TH F F F F F F F F F SA SA SA SA SA SA SA SA SA
A B E
AA
C M N W X Z D G H
GREASE ROTARY MANIFOLD LIFT SPRINGS (MODEL 6027E ONLY) GREASE HANDLER LOCK CHECK & CLEAN LUBE SUCTION Y-STRAINER CHECK GEARCASE BREATHER EXAMINE BRAKE PADS FOR WEAR GREASE LUBE OIL PUMP CHECK OIL LEVEL IN HANDLER ROTATE GEARBOX CHECK OIL LEVEL IN TORQUE BOOST GEARBOX INSPECT BRUSHES ON DC MOTOR CHECK & CLEAN SPARK ARRESTOR SCREENS CHANGE OIL IN TOP DRIVE GEARBOX CHANGE OIL IN HANDLER ROTATE GEARBOX CHANGE OIL IN TOQUE BOOST GEARBOX
SU SU SU SU SU SU SU SU SU
BY: BY: BY: BY: BY: BY: BY: BY: BY: BY: BY: BY: BY: BY: BY: BY: BY:
J T V Y F P Q K L U R S
DATE DUE: DATE DUE: DATE DUE: DATE DUE: DATE DUE: DATE DUE: DATE DUE: DATE DUE:
CHECK OIL LEVEL IN RESERVOIR CHECK INDICATOR ON PRESSURE FILTER * CHECK INDICATOR ON RETURN FILTER * CHECK & CLEAN SUCTION Y-STRAINER
Note 1: Refer to manufacturers literature
HYDRAULIC POWER UNIT MAINTENANCE (IF APPLICABLE) DAILY DAILY DAILY BI-WKLY
* Change filter if indicator shows RED. This checklist is intended to be a guide ONLY. Please refer to Subsection 4A of this manual for more detailed instructions and specifications.
NOTE:
4-8
This checklist is coded to the alphabetical labels found on the Service and Maintenance Location Drawings.
Revision 05.03
Gear Oil
Ambient Temperature (C) A.G.M.A. Number Maximum Operating Temperature (C) CANRIG Top Drive Gear Oil Shell Lubricant Geartherm Arctic AS Geartherm Multigrade 150 ESSO* Lubricant Spartan EP 32 Spartan EP 32 Spartan EP 68 Spartan EP A/S Spartan EP 150 Spartan EP 220 Reductelf SP 68 Reductelf SP 100 Reductelf SP 150 Reductelf SP 220 ELF Lubricant CHEVRON Gear Compound EP
68 100
*Comparable products are available in the USA from the Exxon Corporation. Canrig Top Drives are designed to be used with ISO Industrial EP (Extreme Pressure) Gear Oils. Oils meeting AGMA specifications and grades shown in the above chart could be used in the Canrig Top Drive. See Lube and Maintenance for further information. For approval of a specific oil, contact Canrig Engineering Department.
Revision 05.03
4-9
Check bypass indicators daily. If indicator shows RED, change the filter element. Hydraulic element should be changed every 6 months. Lube element should be changed at every oil change.
4-10
Revision 05.03
Refer to Service and Maintenance Location Drawings in the Section for locations of the grease fittings.
Revision 05.03
4-11
US Gallons
4-6 10 10 10 12 12 18 10 10 10
Liters
15-22 38 38 38 45 45 68 38 38 38
* NOTE:
This optimum oil level is approximately to the bottom of the gearcase snout as viewed in the sight tube. The oil level should not be high enough to submerge the gears in the cluster assembly snout.
When operating a Canrig Top Drive unit in humid climates or when using corrosive drilling fluids (for example: high brine content) visually check the lubrication oil on a weekly basis for water contamination. Samples should also be taken for a visual examination. The gearcase can be drained by removing the drain plug in the bottom of the gearcase. Magnetic plugs are located on the bottom of the gearcase and in the Y-strainer to catch small metallic wear particles. An appreciable accumulation of such particles can be a clue to incipient bearing failure.
4-12
Revision 05.03
CAUTION:
Rotary Torque Boost Planetary Gearbox Canrig Part # M15-1001-010 Use Spartan EP GR68 gear oil or equivalent. Oil should be changed for the first time after 500 working hours. Subsequent changes should be done after every 2000 to 4000 hours or after 6 months. Check oil level monthly.
CAUTION:
Revision 05.03
4-13
Revision 05.03
Note:
For optimum performance, the mineral oil lubricant should be drained before using Canrig All-Season Gear Oil. Mixing products may reduce the effectiveness and advantages normally gained by using Canrig AllSeason Gear Oil.
Inspection Tests (Typical): SAE Grade Density, g/cm @ 15C Color, ASTM Flash Point, COC, C (F) Pour Point, C (F) Viscosity cP <150,000 (Brookfield) @ C (F) cSt @ 40C cSt @ 100C SUS @ 100F SUS @ 210F Viscosity Index Copper Corrosion, ASTM D130 Foam Test, ASTM D892 Non-Channeling, @ C (F) 75W-90 .090 8.0 205 (400) -45 (-49) -40 (-40) 125 17.0 642 87.8 149 Pass Pass < -50 (< -58)
4-16
Revision 05.03
Revision 05.03
4-17
WARNING: Cleaning solvents may be toxic and/or flammable. They can cause serious or fatal injury if used without proper precautions. For safety: 1. 2. 3. 4. 5. Do not inhale solvent fumes. Use solvents only in adequately ventilated areas. Avoid contact of solvent with skin. Do not expose solvent to flame or sparks. Observe caution statements issued by the manufacturer of the solvent.
4-18
Revision 05.03
Bearings, Housing, & Gearcase 1. For long term storage, use oil with strong adhesion properties (Esso Sebis K 68 or equivalent). 2. Fill to inch below the top of the gearcase sight glass with the proper oil, and run for 10 to 15 min before laying down the Top Drive. 3. If stored outside, rotate every month; if inside every three months.
Torque Boost & Handler Rotate Gear Boxes 1. After the top drive is rigged down, completely fill (through their breather ports) both gearboxes with gear oil containing a rust inhibitor additive.
Link Support 1. Bleed the pressure off while the top drive is still standing so the link support will settle to its lowest possible point. 2. Coat the upper section of the outer sleeve with rust inhibitor.
Link Tilt Cylinders 1. Fully retract the link tilt cylinders. 2. Spray pins and bushings with rust inhibitor.
Revision 05.03 4-19
Local Blower 1. Cover blower intake and outlet (where it mates to the drilling motor) as well as all drain holes with plastic and a wide adhesive waterproof tape. Quill 1. For extended storage it is recommended that the washpipe packing assembly be removed, cleaned, liberally coated with grease and reassembled to the Top Drive. 2. The tool joint should be cleaned, re-doped, and thread protector installed.
4-20
Revision 05.03
Revision 05.03
4-21
Pins 1. Coat all pins with rust inhibitor. Tensioning Cables 1. Unpin the tensioning cables from the cylinders and spray the thimbles with rust inhibitor. 2. Ensure that the cables are not kinked, pinched or under tension in any way.
Tensioning Cylinders 1. Retract the tensioning cylinders fully. Coat cylinder rod eye with rust inhibitor. Harpoon 1. Coat the latching mechanism with rust inhibitor. Junction Boxes 1. Ensure that all doors and strain reliefs are secured tightly, and holes left from the grasshopper leads (444 cables) are sealed. 2. Add moisture-absorbing pads inside each junction box.
4-22
Revision 05.03
Remote Blower 1. Cover both the intake and discharge ducts, as well as all drain holes. Crown Hanger 1. Coat all pins, bolts, and exposed metal areas with rust inhibitor. Rails 1. Coat with grease or rust inhibitor.
Revision 05.03
4-23
Air Conditioners 1. Cover the intake side to prevent dust and debris from clogging the fins. Grasshopper 1. Wrap all lugged leads. Ensure that all plugs capped tightly. Hydraulic System 1. Remove the breather from the HPU tank and replace it with a 1.5 in NPT plug. 2. Remove the drain plug from the catch tray to prevent water buildup.
4-24
Revision 05.03
Revision 05.03
4-25
6. Remove the air filter elements. Turn the engine at cranking speed with throttle control in fuel OFF position, and use a sprayer to add a mixture of 50% VCI-10 oil and 50% engine oil into the air intake or turbocharger inlet. Re-install the air filter elements. Completely enclose the elements with dark plastic bags and seal them with tape. Replace the air filter covers. Put tape over all openings to seal VCL vapors in the engine. NOTE: THIS IS CRITICAL TO PREVENT LOSS OF THE PROTECTIVE VAPORS.
7. Use a sprayer to put a mixture of 50% VCI-10 oil and 50% engine oil into the exhaust openings. Minimum application rate is 5.5 ml per liter (3 oz. Per 1000 cubic inches) of engine displacement. Seal exhaust pipe, including any drain holes in the muffler. 8. Remove the fuel from the secondary fuel filter housing or empty and re-install the fuel filter element to remove any dirt and water. Drain the fuel injection pump (sleeve
4-26 Revision 05.03
12. Under most conditions, it is best to remove the batteries and use them in another application, or put them in storage where they can be checked and electrically charged again when needed. If the batteries are not removed, wash the tops of the batteries until they are clean. Disconnect the battery terminals. Secure the cover over the batteries. 13. Loosen all fan, alternator belts, etc. 14. Attach a tag to the engine with a notation of the date that the unit was preserved. If the engine shows signs of corrosion at the check intervals repeat the protection procedure. It is not necessary to remove the preservative oil mixture before operating the engine. If a compartment under protection of VDL vapors is opened put more VCL mixture in to make up for the vapor loss.
Generators 1. When a generator is in storage, moisture condenses in the windings. To minimize condensation, when possible, store the generator in a dry storage area. Seal all openings with tape. 2. If a brush-type generator (SRCR) is to be in storage for a long time, lift the brushes off the slip ring to prevent damage to the slip ring by chemical action. Attach a tag to the generator stating that the brushes have been lifted. Note:
Revision 05.03
Before start-up of a generator use a megohmeter to check insulation resistance for moisture and/or foreign material.
4-27
Space heaters of the type used in the Top Drive drilling motor can be installed in the generator. These heaters heat the windings to remove moisture and should be connected at all times in high humidity conditions. Use a canvas enclosure around the generator and heating lamps to increase the ambient temperature. Make an opening in the top of the canvas to release the moisture. Send a low voltage current through the windings to increase the temperature of the windings to 85F. Note: If there is a possibility that insulation resistance has lowered to a dangerous level, contact Canrig or your nearest Caterpillar dealer.
4-28
Revision 05.03
Drilling Motor Before placing a stored motor in use: 1. Blow dust and dirt accumulation out of windings with clean, dry air. 2. (For DC motor applications only) Re-set the brushes. Visually inspect for spring corrosion, sticking brushes in brush holders, and general defects. 3. Check winding insulation continuity to ground with a 500 volt megger. If the megger reading is less than 2 megohms, the windings should be baked or dried until the moisture content is sufficiently reduced to raise the megger reading to 2 megohms. 4. An electrical source of heat is best for drying as it can be easily regulated and is clean. Proceed as follows: Remove the armature from the frame and remove bearings from the armature shaft. Heat the frame and armature until dried sufficiently to obtain the 2 megohm reading. Pack bearings with new grease. Refer to LUBRICATION AND MAINTENANCE RECOMMENDATIONS for the proper type and amount of grease. Reassemble the motor. If facilities are available, give the reassembled machine a running test to check bearings.
Revision 05.03
4-29
Top Drive Support Unit (TDSU) 1. Remove covers from intake sides of air conditioners. 2. Open valves on inlet side of HPU pumps 3. Unwrap all lugged leads on the grasshopper and check for cleanliness or damage. 4. Ensure all valves on HPU are open. 5. Remove NPT plug from breather port of HPU tank and install Canrig breather. 6. Check all terminal blocks for tightness
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently in this text, the matter should be referred to Canrig Drilling Technology Ltd.
4-30
Revision 05.03
When placing Canrig Top Drive Drilling Motors into storage, the following preparations should be undertaken to prevent damage to the equipment as a result of storage: 1. Machines should be placed on a pallet and stored indoors if possible. A clean, dry ambient temperature of 60F is preferred. In a high humidity environment, an ambient temperature of 70F is recommended. Every attempt should be made to avoid widely varying temperatures and high humidity. A protective cover acting as an umbrella should be used to prevent entrance of rain, dust, etc. 2. The drilling motors are equipped with AC space heaters (120VAC, 210W). These heaters should be energized to keep the internal machine temperature above ambient, preventing condensation and sweating. 3. All exposed machined steel parts and surfaces should be slushed. These areas are slushed prior to shipment from the factory, but should be examined for rust. Rust should be removed using fine abrasive paper, after the old slushing compound has been removed with mineral spirits. Methanol should be used to remove all residues. 4. Extreme care should be exercised not to damage critical machined surfaces such as the tapered shaft surface while removing rust. The surfaces should be reslushed with slush compound Kendell Grade 5, or the equivalent. 5. Brushes should be removed from their holders and clamped under the spring clips to prevent corrosion of the commutator surface as a result of moisture absorption caused by the carbon. 6. Do not completely seal the motor, but cover major vent areas with a waterproof shipping tape. Leave enough opening so that the machine can breathe i.e., moist air is not trapped. The intention is to prevent entrance of water, rust, small animals, but not to seal airtight. We do not recommend use of silica gel or dehydrating agents. 7. Since the lubricant drains from the top half of bearings during storage, this area is subject to corrosion. The shaft should be rotated periodically to redistribute a protective film. If stored inside, rotate every three months; if outside, every month. Before placing the machine back into service after prolonged storage (1 year or more) bearings should be inspected and repacked with new grease meeting the recommended GE lubrication specification. 8. The machine should be meggered when placed into storage and periodically while in storage (3 month intervals). Keep a record of the megger readings as a rapid decrease in insulation resistance indicates the machine condition is deteriorating and the storage conditions are inadequate. Before placing a stored motor back into storage, refer to the applicable instructions: REMOVING TOP DRIVE DRILLING MOTORS FROM STORAGE.
Revision 05.03 4-31
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not sufficiently for the purchasers purposes, the matter should be referred to Canrig.
4-32
Revision 05.03
All capscrews or fasteners permanently installed must be coated with Loctite 242 Threadlocker or the equivalent after insuring that the capscrew threads and mating thread are free of all dirt, oil and grease. This is a medium strength threadlocker that prevents rusting of all threads and prevents loosening due to vibration. This threadlocker can be sheared using normal hand tools.
All capscrews or fasteners that require periodic loosening to facilitate adjustment of components (tool joint clams, link tilt clamps, guide rails, etc.) should be coated with anti-seize thread compound 767 or the equivalent. When using capscrews with locknuts, use only Grade C Stover locknuts or equivalent. These can be identified visually by eight raised dots. These are re-usable, but new nuts are recommended after repeated removal and installation.
Hex Head Capscrew Socket Head Capscrew Size 1/4 5/16 3/8 7/16 1/2 9/16 198 3/4 7/8 1 1 1/8 1 1/4 Torque ft/lb 11 23 40 65 99 159 198 350 566 848 1245 1750 Torque N/m 15 31 54 88 134 216 268 475 767 1150 1688 2373
Plated Bolts or Machined Torque ft/lb 8 17 30 49 74 119 149 263 425 636 934 1313 Torque N/m 11 23 39 64 97 156 194 343 556 833 1222 1718
Flat Head Capscrews Button Head Capscrews Torque Torque ft/lb N/m 8 11 16 21 26 34 42 55 63 82 101 133 126 165 230 292 360 472 540 707 792 1037 1114 1458
Revision 05.03
4-33
Recommended Tools
FOR SERVICE AND MAINTENANCE OF A CANRIG TOP DRIVE Adjustable Wrenches: Assorted Pliers: Assorted Screwdrivers: Ball-driver Wrenches: Combination Wrenches: Dial Caliper Dial Indicator Drill Bit Set: Extractor Set Feeler Gauges Flashlight Gauge Adapter Hammer Hand Wrenches: Hex Bit Sockets: Hex Key Wrench Set: Inspection Mirror Lockwire Machinists File Kit Magnetic Base Magnetic Retrieval Tools: O-Ring Splicing Kit Pick Pinch Bar Pipe Wrenches: Pressure Gauge Punch and Chisel Set Seal and O-Ring Shackle, 5/8 Socket Set: Soldering Iron and Supplies Spinnaker Frame Stubs File Needle Taps, Bottoming: Taps, Pipe: T-Handle Hex Key Set: Utility Knife Wire Brush 6, 10 and 18 Needle Nose, Pliers, Side Cutters, Electricians Scissors 9mm, 13mm 1/4 to 1 1/2
1/16 to
5/8, 11/16, 7/8, 15/16, 1 3/8,Crowfoot Wrench, 15/16 3/8, 3/4 drive, 5/16 to 3/4 Imperial 1/16 to 3/8, Metric 1.5mm to 10mm
12, 18
4-34
Revision 05.03
Testing Procedure 1. Disconnect the power source. 2. Test the solenoid coil by attaching an ohmmeter (set to a low resistance range) across the coil terminals. A relatively low reading should be observed on the meter if the coil is good. Solenoid Manufacturer Vickers Rexroth Operating Voltage 24 VDC 120 VAC 24 VDC Approximate Resistance 19 ohms 32 ohms 35 ohms
It should not read zero ohms as this is an indication that the coil windings are shorted to each other, probably the result of melted insulation. If the ohmmeter reads infinity, it means that the coil is open and defective.
Revision 05.03
4-35
4-36
Revision 05.03
Revision 05.03
4-37
Inspection After Each Rig Move or Every 3 months (which ever comes first) Visually check the complete Torque Guide for any damage (i.e. bending or cracking). Visually check the integrity of all of the Torque Guide turnbuckles, pins, spherical bushings and flange connection bolts. (If applicable.) Visually check all the welds on the Torque Guide System including the harpoon for cracks. If suspicious cracks were found, a full Dry Magnetic Particle inspection must be
Revision 05.03
4-38
Revision 05.03
4-39
1000 Days Inspection The following major inspection is recommended every 1000 working days or at alternate intervals, which may be specified by regulatory authorities, operator policies, contractor policies or drilling conditions: 1. Disassemble the Top Drive unit. 2. Inspect all of the following hoisting load path components using magnetic particle techniques as specified on the Inspection Maps at the end of Section 4B: Quill Spindle Split Ring Upper link support Rotary manifold outer sleeve Housing Upper links Bail (if applicable) Block Interface Upper link pins (4) 3. Check all bearings, seals, seal running surfaces, gears and splines. Refurbish as necessary. 4. Inspect all the welds in the Torque Guide System using magnetic particle techniques as specified on the inspection maps at the end of Section 4B. 5. Inspect the end plates and lugs in the torque tubes for any damage and ensure that the lugs are properly aligned between sections. 6. Remove the motor and send to a qualified repair shop for inspection and repair if necessary. Refer to relevant Canrig and manufacturers literature for recommended procedures.
4-40
Revision 05.03
Revision 05.03
4-41
WF MPI
WF MPI
Fig. 1
Fig. 2
WF MPI
WF MPI
WF MPI
4-42
Revision 05.03
Fig. 1
Fig. 2
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03 4-43
WF MPI 100%
WF MPI 100%
Fig. 1
Fig. 2
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-44
Revision 05.03
Wet Fluorescent Magnetic Particle Areas Indicated with Arrows Fig. 1 Fig. 2
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709.Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-45
WF MPI 100% OF RADIUS ON BOTH EARS AND SURROUNDING AREA Fig. 1 Fig. 2
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C PSL 2. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-46 Revision 05.03
Fig. 1
Fig. 2
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-47
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C.
4-48
Revision 05.03
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-49
Procedure: Perform Wet Fluorescent Magnetic Particle Inspection on areas shown in accordance with ASTM E709. Acceptance criteria are as defined in API 8C. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-50
Revision 05.03
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-51
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-52
Revision 05.03
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-53
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-54
Revision 05.03
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-55
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-56
Revision 05.03
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-57
Procedure: Perform Die Penetrant Inspection on the entire pin (including the weld) in accordance with ASTM E165. Acceptance criteria are as defined in ASTM E165.
4-58
Revision 05.03
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-59
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-60
Revision 05.03
Procedure: Perform Dry Magnetic Particle Inspection on all in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
Revision 05.03
4-61
Procedure: Perform Dry Magnetic Particle Inspection on all welds shown in accordance with ASTM E709. Acceptance criteria are as defined in ASTM E709. All other areas not indicated shall be visually examined for damage and signs of fatigue.
4-62
Revision 05.03
Figure 4.5
MODEL 6027E 8035E, 1035E 1050E, 1250AC 1165E, 1265AC 1275AC SHIM PART # 966-26-1 681-11-1 681-11-1 681-11-1 681-11-1 INSPECTION FREQUENCY 2 3 months 4 6 months 4 6 months 4 6 months 4 6 months
Revision 05.03
4-63
Figure 4.6
4-64
Revision 05.03
Check Brake Calipers Brake calipers should be checked weekly. A function test should be done at this time. There should be a minimum gap of 0.06 between the brake pads and the disc. In addition to premature wear, dragging brake pads can also cause excessive heat build-up in the brake compartment. If the brake pads are dragging, the system may require bleeding to eliminate any trapped air. See Brake Bleeding Procedure.
Manual Brake Bleeding 1. The brake actuator should be bled first, and then the brake calipers. 2. Clean area around reservoir covers (2 on GE 752 and GE B20 motors, 1 on 761 motors). 3. Remove covers. 4. Fill reservoirs to indicated FULL level. Use only mineral base oil (hydraulic oil) in the brake reservoirs. Do not use brake fluid. Replace reservoir cover(s) but leave loose. 5. Put the Top Drive selector switch in the AUX position and start the HPU. 6. Cycle the brakes several times by operating the Brake switch at the Top Drive Console. 7. With the brake on and the HPU running, loosen the bleed screw on the component until there is no sign of air mixed with the oil. 8. Close the bleed screw. 9. Cycle the brake off and on. 10. Repeat the process until there is no air visible in the system. 11. Top off reservoirs to indicated FULL level and replace covers tightly.
Revision 05.03
4-65
4-66
Revision 05.03
Revision 05.03
4-67
Hydraulic Troubleshooting
Preliminary Procedure 1. Ensure pump is turned on and running at system pressure 2350 psi. (see note) 2. Ensure that there is power at the console. 3. Ensure that hydraulic lines are connected to the Top Drive. 4. Ensure that there is 2350 psi (see note) system pressure on the gauge at the Top Drive. 5. Ensure that there is 0 psi on the return pressure gauge at the Top Drive. 6. Read pressures at all applicable test points.
NOTE:
Pressures on individual Top Drive systems may vary. Consult the Hydraulic Drawings in the Drawings and Parts List section for exact pressures.
4-68
Revision 05.03
TRY MANUAL OVERRIDE, DOES ACTUATOR WORK? REPAIR MECHANICAL CONNECTION TO ACTUATOR SHAFT
REMOVE COUPLING BETWEEN VALVE AND ACTUATOR, TURN VALVE MANUALLY, IS VALVE SEIZED?
INSERT GAUGES ON TEST POINTS A & B, IS THERE 1500PSI ON GAUGE WHEN VALVE IS ACTIVATED? ELECTRICAL CONNECTION, WIRING / SOLENOID PROBLEM
REPAIR BALL VALVE DETACH HOSE AT ACTUATOR. IS THERE FLOW WHEN VALVE IS ACTIVATED?
ADJUST PRESSURE RELIEF VALVE SO PRESSURE IS 1500 PSI WHEN ACTUATOR IS STOPPED
CHANGE VALVE
REPAIR SEAL
PROBLEM SOLVED
4-69
Revision 05.03
FREE PIN
IS THE SOLENOID VALVE SHIFTING WITH THE SWITCH? INSERT GAUGES ON TEST POINTS A & B IS THERE 1200 PSI ON BOTH WHEN IN LOCK POSITION AND ON B IN UNLOCK POSITION?
ADJUST PRESSURE RELIEF VALVE SO PRESSURE IS 1200 PSI WILL VALVE ADJUST TO 1200
DETACH HOSE AT CYLINDER, IS THERE FLOW FROM A & B IN LOCK AND UNLOCK POSITION? DOES LOCK PIN WORK ?
REPLACE SEALS
4-70
Revision 05.03
CORRECT PROBLEM
INSERT GAUGES ON TEST POINTS A & B, IS THERE PRESSURE ALTERNATELY WHEN THE VALVE IS ACTIVATED UP/ DOWN?
TURN UP PRESSURE ON RELIEF VALVES OR CHANGE OUT FAULTY OR JAMMED RELIEF VALVE, DOES WRENCH MOVE?
INSERT GAUGES ON TEST POINTS ON ROTARY MANIFOLD (SEE SCHEMATIC) IS THERE PRESSURE WHEN THE VALVE IS ACTIVATED? CHECK FOR BLOCKED OR CRIMPED LINES TO ROTARY SEALS. DO ALL LINES HAVE FLOW?
PLUG LINES TO HYDRAULIC CYLINDER, IS THERE PRESSURE ON TEST POINT? PROBABLY LEAKING SEAL ON CYLINDER. BACK-UP WRECH SHOULD BE FULLY EXTENDED IN THIS CASE. REPAIR PISTON SEAL.
WITH PRESSURE @1500 PSI AND FLOW TO CYLINDER, BACK-UP WRENCH SHOULD TRAVEL UP/ DOWN. PROBLEM MAY BE A PLUGGED FITTING OR AN INTERNAL CYLINDER PROBLEM, REMOVE AND REPAIR.
4-71
Revision 05.03
RELIEF VALVE MAY BE SET TOO LOW OR MAY BE DAMAGED. TRY TO SET HIGHER OR REPLACE.
4-72
Revision 05.03
PROBLEM SOLVED
CHECK DIRECTIONAL VALVE OR LINES TO MANIFOLD. INSERT GAUGES ON TEST POINTS A & B. IS THERE SYSTEM PRESSURE ON GAUGE WHEN VALVE IS ACTIVATED?
TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE. DOES MOTOR ROTATE? WIRING CONNECTION OR SOLENOID PROBLEM.
OPEN UP FLOW CONTROLS. HAS FLOW INCREASED AT HOSES? CHECK FOR CRIMPED LINES, BLOCKAGE, ETC. RECONNECT HOSES AND ACTIVATE VALVE, DOES HANDLER ROTATE? PROBLEM SOLVED
CHANGE OUT MOTOR. DETACH 1 HOSE & CHECK LEAKAGE THRU MOTOR. IS LEAKAGE EXCESSIVE?
TRY LOCKING BACK-UP WRENCH ON QUILL NAD TURNING TRACTION MOTOR. THIS MAY FREE JAMMED ROTARY SEAL. AMPS REQUIRED TO ROTATE SHOULD BE LOW. IF EXCESSIVE, MAY BE INTERNAL MACHANICAL PROBLEMS. CONSULT CANRIG SERVICE DEPARTMENT.
Revision 05.03
4-73
TRY MANUAL OVERRIDE ON DIRECTIONAL VALVE. DOES BRAKE COME ON? DOES RESERVOIR HAVE OIL?
4-74
Revision 05.03
IS CYLINDER RETRACTING?
Revision 05.03
4-75
INSTALL TEST GAUGES ON CLUTCH TEST POINTS. DO YOU HAVE 500 PSI ON A WHEN VALVE OF & 500 PSI ON B WHEN VALVE ON?
INSTALL TEST GAUGES ON TORQUE BOOST TEST POINTS. DO YOU HAVE 2300 PSI ON B & 1075 PSI ON A WHEN VALVE ACTIVATED TO BREAKOUT/ MAKE-UP? (*1)
ADJUST PRESSURE REDUCING VALVE TO 500 PSI. CAN YOU GET 500 PSI?
OPEN VIEW HOLE IN BELL HOUSEING. CAN YOU SEE CLUTCH/ JAW ROTATE WHEN ENGAGED AND WHEN TORQUE SWITCH IS ACTIVATED? OPEN VIEW HOLE IN GEARCASE. CAN YOU SEE GEAR TURNING?
OPEN VIEW HOLE IN BELL HOUSING. CAN YOU SEE CLUTCH ENGAGE WHEN CLUTCH SWITCH IS ACTIVATED?
GEAR MAY BE SLIPPING ON SHAFT. REMOVE TORQUE BOOST ASSEMBLY AND REPAIR.
IF CLUTCH ENGAGES BUT WILL NOT ROTATE, CHECK HYDRAULIC MOTOR/ GEAR REDUCER FOR DAMAGE.
ELECTRICAL CONNECTION OR WIRING/ SOLENOID PROBLEM. IS THERE POWER AT VALVE? ADJUST PRESSURE REDUCING /OR RELIEF VALVES TO ACHIEVE REQUIRED PRESSURES. CAN YOU GET REQUIRED PRESSURE? (*2) CHANGE PRESSURE RELIEF/ RELIEF VALVES. CHANGE OUT HYDRAULIC MOTOR.
4-76
Revision 05.03
INSERT GAUGES ON TEST POINTS A & B. DO YOU HAVE 1000 PSI ON EXTEND PORT B WITH SOLENOID SHIFTED? (*1) DO YOU HAVE 1000 PSI ON RETRACT PORT A WITH SOLENOID NOT SHIFTED? (*1) MAY BE INTERNAL LEAKAGE IN ROTARY SEAL. IS THERE ANY PRESSURE ON PASSAGES NEXT TO EXTEND PASSAGE WITH PRESSURE WHEN IT SHOULD BE ZERO?
TRY TO INCREASE PRESSURE ON PRESSURE RELIEF VALVE. WILL PRESSURE INCREASE? OVERHAUL ROTARY SEAL. DOES GRIPPER CLOSE? CHANGE OUT PRESSURE RELIEF VALVE.
PROBLEM SOLVED
PROBLEM SOLVED
Revision 05.03
4-77
IF RETURN SIDE PRESSURE DOES NOT EQUAL 0 PSI THERE MAY BE LEAKAGE ACROSS SEALS. DISCONNECT EXTEND HOSE BETWEEN ROTARY SEAL & GRIPPER CYLINDER. IS THERE FLOW THERE WHILE CYLINDER IS STATIONARY?
INSTALL GAUGES ON TEST POINTS ON ROTARY SEAL. DOES A=2000 PSI, B=0? (*3)
ADJUST PRESSURE RELIEF VALVE UNTIL WORKING PRESSURE = 2000 PSI. DOES PRESSURE INCREASE?
REMOVE & REPLACE PRESSURE RELIEF VALVE. MAY BE A LEAKING ROTARY SEAL. REMOVE & REPLACE (*2) INSTALL GAUGES ON TEST POINTS A & B. DOES A=2000 PSI, B=0? WITH VALVE ACTIVATED, DOES B=2000 PSI, A=0? (*3) DOES GRIPPER OPEN?
PROBLEM SOLVED
*1 Install test points on A & B on manifold. B should read 1800 PSI when valve is actuated, A=0. With valve returned to spring position, (solenoid OFF) A should read 1800 PSI, B=0. *2 A temporary hose can be from valve bank to gripper cylinder to open the cylinder. Be cautious when rotating handler. *3 Pressure may vary, consult Hydraulic Schematic in the Drawings and Parts List section for actual pressure settings.
4-78
Revision 05.03
INSTALL TEST POINT A PORT ON MANIFOLD, INCREASE PRESSURE ON THE RELIEF VAVLE. DOES LINK TILT RETRACT FULLY?
PROBLEM SOLVED
LOAD MAY BE TOO GREAT FOR CYLINDERS. DO LINKS RETRACT FULLY WITH NO LOAD?
PROBLEM SOLVED
INSTALL TEST POINT GAUGES ON POINTS AT ROTARY MANIFOLD. DOES THE PRESSURE READ THE SAME AS AT A & B?
Revision 05.03
4-79
PRESSURE RELIEF VALVE SETTING IS TOO LOW, TURN UP PRESSURE. DOES LINK TILT STILL CREEP DOWN?
PROBLEM SOLVED
PROBLEM SOLVED
PROBLEM SOLVED
4-80
Revision 05.03
CHECK FOR BLOCKED OR CRIMPED HYDRAULIC LINES. ARE ALL LINES OK?
TRY TURNING IN THE PRESSURE REDUCING VALVE. DOES THE PRESSURE INCREASE?
PROBLEM SOLVED
CHECK THE LINK SUPPORT FOR MECHANICAL JAMMING. CHECK THE CYLINDERS FOR DAMAGE.
THERE MAY BE A LEAK IN THE ROTARY MANIFOLD SEALS. REPLACE THE SEALS.
THE RELIEF VALVE MAY BE SET TO LOW. TURN IN THE RELIEF VALVE. DOES THE PRESSURE INCREASE?
SET THE PRESSURE RELIEF VAVLE @ 2100 PSI. SET THE PRESSURE REDUCING VAVLE @ 1700 PSI. DOES THE LINK SUPPORT EXTEND?
PROBLEM SOLVED
PROBLEM SOLVED
Revision 05.03
4-81
PRESSURE SWITCH MAY NEED ADJUSTING. ADJUST TILL LIGHT GOES OUT.
ADJUST PRESSURE RELIEF VALVE UNTIL WORKING PRESSURE = 2000 PSI. DOES PRESSURE INCREASE?
ENSURE BALL VALVE IS OPEN ON THE SUCTION EXAMINE STRAINER FOR BLOCKAGE. IS OIL FLOWING TO THE PUMP?
4-82
Revision 05.03
AIR PURGE SWITCH MAY NEED ADJUSTING OR LINE TO SWITCH MAY BE BLOCKED.
Revision 05.03
4-83
Revision 05.03
4-84