MAINTENANCE

Top Drive System

DM1076-en Rev E
  

Copyright Warrior Manufacturing Ltd. 2011. All rights reserved.

  

Table of Contents

1 Overview...............................................................................................................................1
2 Inspection Categories and Schedules ...............................................................................3
2.1 Category 1 Inspection – Daily.........................................................................................3
2.2 Category 2 Inspection – Weekly or Rig Move.................................................................3
2.3 Category 3 Inspection – Monthly or 30 Working Days....................................................4
2.4 Category 4 Inspection – Quarterly or 90 Working Days .................................................4
2.5 Category 5 Inspection – 6 Months or 180 Working Days ...............................................4
2.6 Category 6 Inspection – 5 Years or 1000 Working Days................................................5
2.7 Jarring/Rough Drilling Inspection....................................................................................6
3 Lubrication ...........................................................................................................................7
3.1 Washpipe Packing ..........................................................................................................7
3.2 Upper Seal Carrier..........................................................................................................7
3.3 Main Housing..................................................................................................................8
3.3.1 Checking Oil Level...................................................................................................8
3.3.2 Changing the Oil......................................................................................................8
3.4 Mudsaver Valve Actuator................................................................................................8
3.5 Dual Ball Valve ...............................................................................................................8
3.6 Pump Drive (Diesel Powered HPU Only) .......................................................................9
3.6.1 Checking Oil Level...................................................................................................9
3.6.2 Changing Oil............................................................................................................9
4 Hydraulic System...............................................................................................................11
4.1 Hydraulic Fluid ..............................................................................................................11
4.1.1 Hydraulic Fluid Analysis Guidelines ......................................................................11
4.2 Venting Locations .........................................................................................................13
4.2.1 Auxiliary Hydraulic Return .....................................................................................13
4.2.2 Motor Case Flush ..................................................................................................14
4.3 Accumulator..................................................................................................................15
4.4 Hydraulic Motor – Top Drive .........................................................................................15
5 Procedures .........................................................................................................................16
5.1 Top Drive ......................................................................................................................16
5.1.1 How to Install the Washpipe Assembly .................................................................16
5.1.2 How to Change the Backup Wrench Gripper Dies ................................................17
5.1.3 How to Remove the Backup Wrench Scoping Cylinder ........................................18
5.1.4 How to Change the Main Housing Oil ...................................................................18

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5.2 Hydraulic Power Unit .................................................................................................... 20

5.2.1 How to Change the Hydraulic Filters (Canister Type) ........................................... 20
5.2.2 How to Change the Return Filter........................................................................... 20
5.2.3 How to Drain the Hydraulic Reservoir ................................................................... 21
5.2.4 How to Fill the Hydraulic Reservoir ....................................................................... 21
5.2.5 How to Flush the Hydraulic System ...................................................................... 22
Appendix A: ISO 4406 Oil Cleanliness Chart ......................................................................... 26
Appendix B: Wiring Color Code Charts.................................................................................. 27
Appendix C: Capscrew Torque Chart ..................................................................................... 29

Revision History
Revision Date
E 17 Nov-2011
D 24-Jun-2011
C 26-May-2011
B 06-May-2011
A 16-Nov-2010
Description
Added Jarring/Rough Drilling Inspection information
Added Appendix B: Wiring Color Code Charts.
Removed statement with NDE information in 2.5 - 6 month inspection
section.
Added oil level information in section 3.6.2.
Updated Lubrication images for washpipe packing and upper seal carrier
Added hydraulic fluid analysis section
Added content to section 3.3.2 Changing Oil
Updated section 4.1 Hydraulic Fluid
Updated Inspection Schedules
Added line to Category 3 inspection regarding electrical enclosures and
cable glands
Added Appendix C: Capscrew Torque Chart
Added new Category Inspections
Added Appendix A: ISO 4406 Oil Cleanliness Chart
Revised max pump drive oil level
Corrected numbering in section 3.6.2
Updated valve wording in section 5.2.5
Updated formatting
Added inspection items
Added 3.6 Pump Drive
Added 4.1 Hydraulic Fluid
Added 5.2.5 How to Flush the Hydraulic System
Initial release

This document applies to maintenance of the Top Drive System. Some images depicted in this manual may apply to
more than one model of equipment. As a result, your equipment may not look exactly as shown.

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1 Overview
Top drive performance, integrity and safe operation are based on continuous maintenance and
inspection. This document describes Warrior’s minimum requirements; drilling contractors may
implement their own inspection procedures based on local regulatory requirements.
Inspection and maintenance actions may be initiated based on but not limited to the following:
 specific time intervals
 measureable wear limits
 load cycle accumulation
 non-performance of equipment
 regulatory requirements

NOTE: In addition to scheduled maintenance, the load path and torque arrest
system may require additional inspection following periods of rough
drilling, jarring, pulling stuck pipe, running heavy casing strings or other
circumstances that can increase fatigue.
The existence of cracks can indicate severe deterioration and impending
failure. The detection and evaluation of cracks requires accurate inspection
methods. Only qualified personnel shall perform non-destructive testing
(NDT) inspections. They should be certified according to the ISO 9712
standard or by other recognized NDT certification programs or standards.
Prior to NDT inspection, parts should be free of foreign materials such as
paint, grease, oil, scale, etc.

Maintenance Top Drive System Page 1

  

Page 2 Top Drive System Maintenance

  

2 Inspection Categories and Schedules

2.1 Category 1 Inspection – Daily

This category involves observation of the equipment during normal operation for indications of
inadequate performance.
Inspect
Lubrication
Fasteners (capscrews, nuts,
lockwire)
Hydraulic filters
Hydraulic hoses and fittings
Hydraulic service loop
Electric service loop
Tool joint clamp
Safety cables
General overview of top drive
For
Adequate levels
Refer to the Lubrication section
Ensure that they are in place and torqued correctly
Check indicator lamps on HPU Control Panel for plugged
filter condition
Check visual indicators on filters for plugged filter condition
Inspect for leaks and tighten any fittings as required
Check the connections at each end of the loop
Check the connections at each end of the loop
Ensure the dies are set and the capscrews are torqued
correctly
Refer to the procedure How to Install the Tool Joint Clamp
in the Operation manual.
Ensure the cables are in place and in good condition
Inspect daily for any new or excessive damage or broken
components

2.2 Category 2 Inspection – Weekly or Rig Move

This comprises a Category 1 inspection PLUS additional inspections for corrosion,
deformation, loose or missing components, or visible cracks.
Inspect For
Hydraulic filters Press the LAMP TEST pushbutton on the HPU Control Panel
to check if any plugged filter indicator lamps are burned out
General overview of top drive Visually check for excessive damage or broken items
Torque reaction system Visually check for excessive damage or broken items

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2.3 Category 3 Inspection – Monthly or 30 Working Days

This comprises a Category 2 inspection PLUS additional inspections that should include
non-destructive testing (NDT) of critical areas.
This may involve some disassembly to access specific components to identify wear that
exceeds allowable limits and tolerances.
Inspect For
Pin and box connections: Perform wet fluorescent magnetic particle inspection
 quill (WFMPI) and dimensional inspection for damaged or cracked
 mud valve threads
 cross-over/saver sub
Rig saver Press the top drive Emergency Stop button and check to
(Diesel powered HPU only) ensure the rig saver activates
Electrical enclosures Open the enclosures and visually inspect for loose
Cable glands connections and water collecting
Ensure enclosure covers and cable glands are tight

2.4 Category 4 Inspection – Quarterly or 90 Working Days

This comprises a Category 3 inspection PLUS additional inspections and service to
examine and maintain the integrity of the oil.
Inspect For
Analysis of hydraulic fluid Sample for abnormalities:
 water and other impurities
Refer to 4.1.1 Hydraulic Fluid  metal particles
Analysis Guidelines o cleanliness to ISO 4406 19/17/14 or better
o refer to Appendix A: ISO 4406 Oil Cleanliness Chart
 acidity
 viscosity
Pump drive gearbox Drain and replace the lubricating oil
(Diesel powered HPU only) Refer to the Lubrication section for oil specifications

2.5 Category 5 Inspection – 6 Months or 180 Working Days

This comprises a Category 4 inspection PLUS additional service to maintain the integrity of
lubricating oil.
This may involve some disassembly to access specific components to identify wear that
exceeds allowable limits and tolerances.
Inspect For
Top Drive main housing Drain and replace the lubricating oil
Refer to section 3.3 Main Housing for oil specifications

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2.6 Category 6 Inspection – 5 Years or 1000 Working Days

This comprises a Category 5 inspection PLUS additional inspections to conduct NDT of all
load-path components. The top drive must be disassembled to the extent necessary to fully
inspect all load path components.
Inspect For
Load path components: Perform magnetic particle inspection (MPI) and/or wet
 spindle fluorescent magnetic particle inspection (WFMPI) on all load
 quill path items
 housing
 elevator links
 link support*
 split ring*
 collar*
 pins (housing / block)
 bail
 adapter links
(top drive / block)
 block sideplates
 block pins
 block shaft
Torque reaction components Perform magnetic particle inspection (MPI) on all
components
Bearings Check for wear and replace as required
Seals Check for wear and replace as required
Seal running surfaces Check for wear and replace as required
NORD-LOCK® washers Replace
Stover® lock nuts Replace
* Applies only to top drive models that have the Handler Rotate option

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2.7 Jarring/Rough Drilling Inspection

IMPORTANT: Warrior will void the warranty of any top drive and torque reaction
components that have been subjected to surface jarring.

Top drive equipment that has been subjected to down-hole jarring or other rough drilling
operations must be inspected as follows:
Inspect
If the weight was hanging from the
quill, inspect the following pin and
box connections:
 quill
 mud valve
 cross-over/saver sub
If the weight was hanging from the
elevators, inspect the following:
 spindle (accessible areas)
 link support*
 split ring*
 collar*
 bearing race
General overview of top drive
Fasteners (capscrews, nuts,
lockwire)
Hydraulic hoses and fittings
Hydraulic service loop
Electric service loop
Safety cables
Torque reaction system
Block adapter components
 housing (accessible areas)
 adapter links
 bail
 bail pins
* Applies only to top drive models that have the Handler Rotate option
For
Perform wet fluorescent magnetic particle inspection
(WFMPI) AND dimensional inspection for damaged or
cracked threads
Perform wet fluorescent magnetic particle inspection
(WFMPI) on all load path items
This inspection will involve partial disassembly of the
handler rotate assembly. Refer to the appropriate
drawings in the Parts Lists & Drawings section of the
top drive manual.
Inspect for any new or excessive damage or broken
components
Ensure they are in place and torqued correctly
Inspect for leaks and tighten any fittings as required
Check the connections at each end of the loop
Check the connections at each end of the loop
Ensure the cables are in place and in good condition
Visually check for excessive damage or broken items
Perform wet fluorescent magnetic particle inspection
(WFMPI) on all load path items
This inspection will involve partial disassembly of the
block interface. Refer to appropriate drawings in the
Parts Lists & Drawings section of the top drive manual.

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3 Lubrication

3.1 Washpipe Packing

Grease washpipe here

Frequency: Every 8 hours

Grease Specification: All-season synthetic

(NLGI #GCLB)

Figure 1: Washpipe Packing Grease Point

3.2 Upper Seal Carrier

Grease upper seal carrier here

Frequency: Every 8 hours

Grease Specification: All-season synthetic

(NLGI #GCLB)

Figure 2: Upper Seal Carrier Grease Point

Maintenance Top Drive System Page 7

  

3.3 Main Housing

3.3.1 Checking Oil Level

This port can be used to fill the housing

with oil. Refer to the Original Equipment
Manufacturer Literature section of the
manual binder for oil specifications.

Level indicator on the main housing.

Fill 1/2 to 2/3 full on sight glass.
Approximate capacity = 24 L (6.4 USG)

Frequency: Check level daily

Figure 3: Housing Lubrication

3.3.2 Changing the Oil

Recommended Oil Lubricant

Mobil SHC 630 Synthetic or approved equivalent

Under normal operating conditions, Warrior recommends changing the oil every 1000 hours or
6 months of service, whichever occurs first.
Refer to section 5.1.4 How to Change the Main Housing Oil for details.

3.4 Mudsaver Valve Actuator

Refer to the original equipment manufacturer for maintenance information.

3.5 Dual Ball Valve

Refer to the original equipment manufacturer for maintenance information.

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3.6 Pump Drive (Diesel Powered HPU Only)

3.6.1 Checking Oil Level

Dipstick

Level: Fill to MIN line

DO NOT overfill!

Frequency: Check oil level daily

Vent / Fill Port

Oil can be filled through this

port

Figure 4: Top of Pump Drive

3.6.2 Changing Oil

Recommended Oil Lubricant

Mobil SHC 630 Synthetic or approved equivalent

Under normal operating conditions, Warrior recommends changing the oil after 500 hours, or 3
months of service, whichever occurs first.

1. Stop the engine before attempting to check or replace the oil.

2. Drain the oil while the unit is still warm. Remove the drain plug located at the end of the
drainage hose and allow oil to drain through it. See Figure 5. Replace the drain plug once
the pump drive has been drained.
3. Pour new oil in through the vent / fill port at the top of the pump drive. Fill to MIN oil level on
the dipstick. DO NOT overfill. See Figure 4.

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Drainage Hose

Drain Plug

Figure 5: Pump Drive Drain

WARNING: Hot oil can cause severe burns. Use extreme care when removing
lubrication plugs and vents.

IMPORTANT: DO NOT over fill or under fill the oil, as this will result in overheating and
possible failure of the pump drive.

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4 Hydraulic System

4.1 Hydraulic Fluid

The approved hydraulic fluid for Warrior hydraulic top drives is Mobil SHC 526. The hydraulic
motor used on the top drive is sensitive to low viscosity, and synthetic fluid offers improved
thermal stability. If the approved synthetic fluid is not available in your area, contact Warrior for
options.

IMPORTANT: Hydraulic fluid must be tested regularly. Section 2.4 Category 4

Inspection – Quarterly or 90 Working Days calls for a hydraulic fluid
analysis. Refer to 4.1.1 Hydraulic Fluid Analysis Guidelines for details.

IMPORTANT: Product warranty is limited to the use of approved hydraulic fluid.

NOTE: Do not mix synthetic and mineral oil since the synthetic oil will form a
barrier on the moving parts that the mineral oil cannot penetrate. This can
cause a premature breakdown of fluid properties.

NOTE: Do not mix hydraulic oil from different manufacturers because their
respective additives may not be compatible.
If the hydraulic oil must be changed from one manufacturer to another, a
small amount of residual fluid is generally acceptable. See Procedure 5.2.5
How to Flush the Hydraulic System to ensure the system is fully flushed.

4.1.1 Hydraulic Fluid Analysis Guidelines

See also 2.4 Category 4 Inspection – Quarterly or 90 Working Days.

IMPORTANT: All fluid reports must be stored and copies will be required by Warrior
before any warranty claims can be considered.

1. Always sample new fluid prior to adding it to the system.

2. Fluid analysis reports should include the following as a minimum:
a) Particle Count
 Particle count should be ISO 4406 19/17/14 or better (refer to Appendix A: ISO 4406
Oil Cleanliness Chart).
 Mild contamination can be removed by running the kidney loop pump while
monitoring the condition of the return filter. Disconnect the auxiliary pressure coupler
(at the closest point to the HPU) and run the auxiliary motor until the contamination
level is within acceptable limits.

Maintenance Top Drive System Page 11

  

b) Water Content
 Water content should be less than 0.1%.
 Water can be present as dissolved, emulsified or free. The water saturation point of
the fluid drops as its temperature drops, resulting in an emulsion (fluid appears
cloudy) or bulk free water usually found in the lower level of the tank (check at the
drain valve).
 Fluid physical properties most affected by water content are:
o viscosity
o lubricity and load-carrying characteristics
o power transfer characteristics (compressibility)
c) Total Acid Number (TAN)
 Comparing the TAN (or AN) value of sampled fluid to the original base sample will
give an indication of depletion of the fluid additives and acidic contamination.
 Once the additives have been depleted, oxidation of the fluid will occur.
 Fluid must be replaced if the TAN shows an increase from base of approx 2.5x or if a
significant rise occurs.
d) Viscosity
 Test at 40ºC and 100ºC. Checking the viscosity at both temperatures will allow the
plotting of viscosity at the operating temperature of the system.
 Viscosity of the fluid must be within 98% of the base sample.

WARNING: The operating viscosity must never drop below 20 cSt or catastrophic
damage to the top drive motor will occur.

e) Metals
 Typical acceptable trace wear metals are:
Metal Parts per Million (PPM)
Iron (Fe) 30
Tin (Sn) 10
Nickel (Ni) 2
Lead (Pb) 15
Chromium (Cr) 10
Aluminium (Al) 10
Copper (Cu) 50
Molybdenum (Mo) 5

 These metal traces can increase during operation. Monitor for any significant rise in
levels which might indicate components are about to fail or have been damaged.
 Silicon (Si) is a contaminant and is very abrasive. Change the fluid if its
concentration exceeds 10 PPM.
 Phosphorous (P) and Zinc (Zn) are lubricants. Monitor for any significant rise or fall
from base levels.

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3. Fluid samples may be taken from the hot oil shuttle test point on the HPU when the system
shows shuttle flow. This port is labeled HOS-T. See Figure 6.

HOS-T port

Figure 6: Hot Oil Shuttle Test Point

4.2 Venting Locations

4.2.1 Auxiliary Hydraulic Return

Refer to the hydraulic schematic for the relief setting. If the return pressure exceeds the relief
setting, the hydraulic oil will vent to the atmosphere.

Hydraulic Relief Valve

Figure 7: Top Drive Hydraulics – Driller’s Side View

WARNING: Continued venting to atmosphere indicates a serious hydraulic failure.

Check the return lines before continuing top drive operations.

Maintenance Top Drive System Page 13

  

4.2.2 Motor Case Flush

Refer to the hydraulic schematic for the relief setting. If case pressure exceeds the relief setting,
the hydraulic oil will vent to the atmosphere.

Hydraulic Relief Valve

Figure 8: Top Drive Hydraulics – Off Driller’s Side View

WARNING: Continued venting to atmosphere indicates a serious hydraulic failure.

Check the return lines before continuing top drive operations.

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4.3 Accumulator
The accumulator is pre-charged with nitrogen (N2) gas at 190 PSI.
Refer to the original equipment manufacturer literature for proper operation and maintenance
procedures.

DANGER: Accumulator and connecting lines may be pressurized. Failure to follow

the manufacturer’s instructions can cause rapid discharging of gas or
hydraulic fluids which can result in serious injury or death.

Accumulator

Figure 9: Top Drive Hydraulics – Driller’s Side View

4.4 Hydraulic Motor – Top Drive

Refer to the original equipment manufacturer literature for all lubrication and maintenance
recommendations.

Maintenance Top Drive System Page 15

  

5 Procedures

5.1 Top Drive

5.1.1 How to Install the Washpipe Assembly

Refer to Mud Flow Assembly and Washpipe Assembly drawings.

The washpipe assembly is installed as a complete unit (complete with upper and lower packing
housings, washpipe, seals and packing). This unit bolts into place within the bonnet area.
4. Place the washpipe assembly into position as shown.
5. Install capscrews through upper packing housing into the bonnet.
6. Install capscrews through the lower packing housing into the quill adapter.
7. Ensure the capscrews are torqued as indicated in the Mud Flow Assembly drawing.
To remove the washpipe, reverse the above procedure.
Once the washpipe assembly is removed, the washpipe and/or the packing set can be changed
individually. The Washpipe Assembly drawing shows the correct orientation of the seals,
spacers, and other components.

Bonnet

Upper Packing Housing

Capscrew

Washpipe

Lower Packing Housing

Capscrew

Quill Adapter

Figure 10: Washpipe Assembly

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5.1.2 How to Change the Backup Wrench Gripper Dies

Refer to the Backup Wrench (BUW) Assembly drawing.

1. Extend the backup wrench so that it clears the lower well control valve and/or saver sub.
2. Ensure that the well bore is covered to ensure the dies do not fall downhole.
3. The backup wrench cylinder may be extended into the open area if required to help gain
access to the dies from the bottom.
4. Remove the top die retainer bolts.
5. Slide the dies upward. Use a screwdriver or pry bar and a hammer as required.
6. Slide new dies into the grooves by lightly tapping them with a hammer.
7. Re-install the die retainer bolts.

Die Holder, Cylinder Side

Die Retainer Bolts

Dovetail Grooves for Dies

Die Holder, Fixed Side

Figure 11: Backup Wrench Gripper Assembly

Maintenance Top Drive System Page 17

  

5.1.3 How to Remove the Backup Wrench Scoping Cylinder

Refer to the Backup Wrench Assembly and/or the Scoping Tube Assembly drawings.
1. Remove the backup wrench (BUW) from the top drive.
2. Undo the safety cable that attaches the inner tube to the outer tube.
3. Remove the stop pin.
4. Remove the 3/4 in. cap screws that connect the scoping tube to the gripper housing. Detach
the gripper.
5. Disconnect the hydraulic hoses.
6. Detach the spring plate by removing 2X 5/8-11 UNC nuts and 2X 1/2-13 UNC cap screws.
7. Pull the scoping cylinder rod end out of the inner guide tube until the cylinder pin is
accessible. Remove the pin.
8. Remove the top pin from the cylinder.
9. Replace the cylinder.
10. Re-assemble in the opposite order.

5.1.4 How to Change the Main Housing Oil

See also section 3.3 Main Housing for more information.

Under normal operating conditions, Warrior recommends changing the oil every 1000 hours or
6 months of service, whichever occurs first.

Recommended Oil Lubricant

Mobil SHC 630 Synthetic or equivalent

1. Remove the drain plug from the bottom of the housing.

Use an appropriate receptacle to capture the oil as it drains (24 L/6.4 USG).

Drain Plug

Figure 12: Drain Plug (Non-Handler Rotate) Figure 13: Drain Plug (Handler Rotate)

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2. For handler rotate models only:

a) Unbolt the lower seal carrier (12 bolts total) and lower it so that it rests on the split ring
collar.
Any remaining oil in the casing will drain.
Inspect for any foreign material in this area. Clean as required.

Lower Seal Carrier

Split Ring Collar

Figure 14: Lower Seal Carrier Bolts

b) Clean the lower seal carrier and visually inspect the condition of the O-ring.
c) Carefully lift the lower seal carrier into place and reinstall the bolts.

CAUTION: Ensure that the O-ring is seated correctly before reinstalling the lower
seal carrier. If it is out of place the O-ring could be damaged.

3. Replace the drain plug(s).

4. Refill the oil to the recommended level. Refer to section 3.3.1 Checking Oil Level.
5. Dispose of the used oil according to local regulatory requirements.

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5.2 Hydraulic Power Unit

Refer to the HPU-Manifold Assembly and/or the HPU Assembly drawings.

5.2.1 How to Change the Hydraulic Filters (Canister Type)

1. Shut down the HPU.

2. Close the suction valve (3 in.) and closed loop ball valves (4 X 1-1/4 in.) on the HPU.
3. Disconnect the 2 in. closed loop hoses at the HPU.
4. Remove the small bleed plug from the top of the filter canister.
5. Place a drain pan under the filter inlet fitting.
6. Remove the small drain plug from the filter inlet fitting and fully drain canister.
7. Loosen the canister using a wrench applied to the hex located at the top of the canister.
8. Spin the canister or canister cap (depending on the filter type) off the threads by hand – it’s
heavy – and set it down.
9. Pull the filter element from the filter head and dispose in accordance with local regulations.
10. Clean the canister and apply anti-seize to the canister threads.
11. Place a new element in the filter head and push to locate seals.
12. Lower the canister over the element or replace the canister cap and hand tighten the
threads.
13. Use the wrench to tighten the canister or cap.
14. Install the drain and bleed plugs.
15. Repeat for all canisters.
16. Open all ball valves and start the HPU (run at idle only).
17. Crack the bleed plugs on the top of the canisters. Bleed off the air until fluid flows, then
tighten the plugs.

5.2.2 How to Change the Return Filter

1. Disconnect the return (1 in.) and flush (1-1/4 in.) hoses at the HPU.
2. Loosen the six bolts holding the cap on the return filter.
3. Remove the filter lid.
4. Pull the filter out of the housing.
5. Install new filter and replace lid gasket.
6. Install the lid and tighten the bolts.
7. Reconnect the return and flush hoses.

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5.2.3 How to Drain the Hydraulic Reservoir

1. Fit suitable hoses to all reservoir drain fittings.

2. Open the ball valve(s).
3. Remove the reservoir breather.
4. Drain fluid into a suitable container and dispose of old oil in accordance with local
regulations.
5. Once the reservoir is drained, close the ball valves and replace the fitting caps and breather.

5.2.4 How to Fill the Hydraulic Reservoir

1. Clean the top of the oil barrel before opening.

2. Disconnect the return (1 in.) and flush (1-1/4 in.) hoses at the HPU.
3. Install a suitable barrel pump and open the ball valve to the cooler.
4. Fill the reservoir to level indicated on the reservoir sight glass.
5. When the oil level is correct, close the ball valve and reconnect the return and flush hoses.
Refer to the Original Equipment Manufacturer Literature section for hydraulic fluid
specifications.

Maintenance Top Drive System Page 21

  

5.2.5 How to Flush the Hydraulic System

1. Shut down the HPU.

WARNING: Discharge the accumulator hydraulic side prior to any maintenance or

repair work.

2. Remove the return filter, remove the plastic fill line from the hose barb, and open the ball
valve allowing the oil from the cooler to drain into the reservoir.
3. Drain the reservoir into a suitable container and dispose of old oil in accordance with local
regulations.
4. Undo the quick disconnects from the hose reel or mast piping.
5. Disconnect the hydraulic hoses at the HPU.
a. Option 1 – Systems having hard connections at the HPU skid:
Disconnect all 5 jumper lines from the HPU skid. See Figure 15.

Figure 15: HPU Hose Connections

(Hard connections at the HPU skid shown)

b. Option 2 – Systems having quick disconnects at the HPU skid:

Remove the quick disconnects from the HPU ends of all 5 jumper lines.
6. Remove the top lid from the HPU reservoir. Place the ends of all 5 jumper lines into the top
reservoir opening and securely fasten them into place.
7. Reconnect the quick disconnects to the hose reel or mast piping.
8. Stretch the service loop out fully and connect to the top drive using the quick disconnects.
9. Raise the top drive above the service loop hang off level.

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Top Drive

Service Loop Hang Off

Service Loops

HPU

Figure 16: Service Loop Setup

10. Put on all necessary fall arrest equipment, then climb to the top drive.
11. Remove the valve cover and valve cartridge shown on Figure 17. Crack all fittings indicated
on Figure 17 and Figure 18.

DANGER
Watch for
trapped pressure
Valve
Open
Cover and
Accumulator
Valve
line here
Cartridge

Figure 17: Accumulator and Valve Cartridge

Maintenance Top Drive System Page 23

  

Open Aux Pressure

line here

Open Aux Return

Open Flush line here
line here

Figure 18: Top Drive Auxiliary Hydraulic Lines

12. Raise the top drive to the crown.

13. When all the oil has stopped flowing out of the service loop into the reservoir, drain the
reservoir.
14. Bring the top drive down to floor level and reinstall the cartridge valve and valve cover.
Retighten all fittings.
15. Place a suitable catch container at the end of the 2 in. hard lines shown on Figure 15.
16. Remove the top of the filter bowls and the filters. Open the ball valves to allow the filters, hot
oil manifold, and lines to drain into the container.
17. Remove the case flush lines, suction lines, and 1-1/4 in. high pressure lines from the pumps.
Drain all the oil into a suitable container.
18. Remove the hot oil shuttle and auxiliary return lines from the hydraulic cooler. Drain all the
oil into a suitable container.
19. Reassemble the filters and close the filter drain ball valves. Reattach and tighten all
connections and reconnect all 5 jumper lines to the HPU hard connections. Reinstall the top
lid on the HPU reservoir. Make sure all connections are tight.
20. Clean up all oil around the unit. Drain any remaining oil from the reservoir and plug all
drains.
21. Fill the reservoir with 3-1/2 barrels of new hydraulic oil.
22. Disconnect the forward and reverse lines from the top drive and connect to each other.

IMPORTANT: A responsible technician must be available to monitor the HPU at all

times during the flushing process. The technician should be able to
identify any noises in a hydraulic system that relate to cavitation or
aeration of the pumps. If either noise occurs, hit E-stop immediately and
add more oil to the system.

23. Ensure that all suction valves are open.

Page 24 Top Drive System Maintenance

  

24. Turn the TOP DRIVE switch on the operator’s console to the AUX position. Let the auxiliary
pump run for 30 minutes. Activate all top drive auxiliary functions repeatedly.
25. Turn the TOP DRIVE switch on the operator’s console to the ENABLE position. Move the
drill throttle to approximately 10% of full throttle to allow the oil to flow through the 2 in.
hoses. Let the main pump run for 10 minutes.
26. Turn the TOP DRIVE switch on the operator’s console to the OFF position. Hook the 2 in.
lines, auxiliary, and flush lines to the top drive quick disconnects.
27. Turn the TOP DRIVE switch on the operator’s console to the ENABLE position. Rotate the
top drive forward at 10 RPM for 20 minutes.
28. Turn the TOP DRIVE switch on the operator’s console to the OFF position. Follow the drain
procedure steps 1 – 20.
29. Repeat steps 21 – 27, except fill the reservoir to level indicated on the reservoir sight glass.
30. After step 27 has been completed for the second time, check the hydraulic oil level in the
HPU reservoir and add oil as required.
31. Commence drilling operations.

Maintenance Top Drive System Page 25

  

Appendix A: ISO 4406 Oil Cleanliness Chart

ISO 4406 Code 2,500,000

28
1,300,000
27
Cleanliness levels are defined by three 640,000
26
numbers divided by slashes (/). These 320,000
25
numbers correspond to 4, 6, and 14 micron, in 160,000
24
that order. 80,000
23
40,000
Each number refers to an ISO Range Code, 22
which is determined by the number of particles 20,000
21
for that size (4, 6, & 14 µm) and larger present 10,000
20
in 1 ml of fluid. Each range is double the range 5,000 19 19
below it. 2,500 18
1,300 17 17
Refer to the chart to see the actual ranges.
640 16
320 15
160 14 14
80 13
40 12
20 11
10 10
5 9
2.5 8
1.3 7
0.64 6
0.32 5
0.16 4
0.08 3
0.04 2
0.02
1
0.01
0
0.00
Example: 4µm 6µm 14µm

larger than 4µm = 3,255

larger than 6µm = 846
larger than 14µm = 94

ISO Code = 19 / 17 / 14

Page 26 Top Drive System Maintenance

  

Appendix B: Wiring Color Code Charts

Bostrig™ Cable, J-Box Wiring
ICEA Method 1, Table E-1
Colored insulation with contrasting ink tracers as required. Six different insulation colors and
four different colored ink tracers are used to provide positive identification through 21
conductors. The same identification sequence may be repeated for cables containing more than
21 conductors.
Conductor Background First Second Conductor Background First Second
No. or Base Tracer Tracer No. or Base Tracer Tracer
Color Color Color Color Color Color
1 Black ----- ----- 20 Red Green -----
2 White ----- ----- 21 Orange Green -----
3 Red ----- ----- 22 Black White Red
4 Green ----- ----- 23 White Black Red
5 Orange ----- ----- 24 Red Black White
6 Blue ----- ----- 25 Green Black White
7 White Black ----- 26 Orange Black White
8 Red Black ----- 27 Blue Black White
9 Green Black ----- 28 Black Red Green
10 Orange Black ----- 29 White Red Green
11 Blue Black ----- 30 Red Black Green
12 Black White ----- 31 Green Black Orange
13 Red White ----- 32 Orange Black Green
14 Green White ----- 33 Blue White Orange
15 Blue White ----- 34 Black White Orange
16 Black Red ----- 35 White Red Orange
17 White Red ----- 36 Orange White Blue
18 Orange Red ----- 37 White Red Blue
19 Blue Red -----

Maintenance Top Drive System Page 27

  

Service Loop Wiring (Perfect-A-Flex®)

ICEA Method 1, Table E-2
Colored insulation with contrasting ink tracers as required. Six different insulation colors and
four different colored ink tracers are used to provide positive identification through 21
conductors. The same identification sequence may be repeated for cables containing more than
21 conductors.
Conductor Base Spiral Strips Conductor Base Spiral Strips
No. Color No. Color
1 Black ----- 20 Yellow Blue
2 Red ----- 21 Brown Blue
3 Blue ----- 22 Black Orange
4 Orange ----- 23 Red Orange
5 Yellow ----- 24 Blue Orange
6 Brown ----- 25 Yellow Orange
7 Red Black 26 Brown Orange
8 Blue Black 27 Black Yellow
9 Orange Black 28 Red Yellow
10 Yellow Black 29 Blue Yellow
11 Brown Black 30 Orange Yellow
12 Black Red 31 Brown Yellow
13 Blue Red 32 Black Brown
14 Orange Red 33 Red Brown
15 Yellow Red 34 Blue Brown
16 Brown Red 35 Orange Brown
17 Black Blue 36 Yellow Brown
18 Red Blue 37 Blue Red and Black
19 Orange Blue
NOTE: Color code repeats after 36 conductors. No green or white conductors/stripes.

Bostrig™ Multi-Pair Communication Wiring

ICEA Method 9
Pair Identification
One conductor of each pair should be coded “white” or “black” and the other conductor should
be coded with any other contrasting color. Pairs should be identified in sequence by printed
numbers on at least one conductor in each pair, beginning with the number 1.
Pair Black White
1 One One
2 Two Two
3 Three Three
4 Four Four

Page 28 Top Drive System Maintenance

  

Appendix C: Capscrew Torque Chart

Document: Work Instruction Effective Date DW1020

Capscrew Torque Chart 11-Nov-11 Revision A

CAP SCREW TORQUE (ft-lb) TORQUE (N-m)

Threads Oil or Anti- Oil or
Size (in.) (per in.) Grade Loctite® seize Loctite® Anti-seize
1/4 20 8 9 6 13 9
1/4 28 8 11 7 14 10
5/16 18 8 19 13 25 17
5/16 24 8 21 14 28 19
3/8 16 8 33 22 45 30
3/8 24 8 38 25 51 34
7/16 14 8 55 35 75 48
7/16 20 8 60 39 80 53
1/2 13 8 80 55 110 75
1/2 20 8 90 60 125 85
5/8 11 8 160 110 220 145
5/8 18 8 180 120 245 165
3/4 10 8 285 190 385 260
3/4 16 8 315 210 430 285
7/8 9 8 455 305 620 415
7/8 14 8 505 335 680 455
1 8 8 685 455 925 620
1 12 8 750 500 1,015 675
1-1/8 7 8 980 645 1,320 875
1-1/8 12 8 1,100 725 1,480 980
1-1/4 7 8 1,380 920 1,860 1,240
1-1/4 12 8 1,520 1,020 2,060 1,380
1-3/8 6 8 1,800 1,200 2,440 1,620
1-3/8 12 8 2,050 1,360 2,800 1,840
1-1/2 6 8 2,400 1,600 3,250 2,160
1-1/2 12 8 2,700 1,780 3,650 2,420

Maintenance Top Drive System Page 29