Service Manual Top Drive System: TDS-4S

TDS-4S
Top Drive System

Service Manual
SM00620
Revision B
March 8, 2001
ii TDS-4S Contents
Contents
Book 1 – Description
Preface/Manual conventions
Safety information ........................................................... 1-5
Directional references ...................................................... 1-6
Manual layout.................................................................. 1-6
Chapter 1 Introduction
General description .......................................................... 1-7
Chapter 2 Major component description

Motor housing assembly ................................................ 1-19
Drilling motor ......................................................... 1-20
Two speed transmission ........................................... 1-20
Integrated swivel bail and swivel washpipe ............... 1-22
Standard rotating head ............................................. 1-24
Powered rotating head ............................................. 1-26
Rotating head controls ....................................... 1-26
Cooling systems ............................................................. 1-28
Local blower ............................................................ 1-28
Closed loop .............................................................. 1-30
Remote blower ......................................................... 1-32
Guide dolly assemblies ................................................... 1-34
Motor alignment system ................................................ 1-37
Pipehandler .................................................................... 1-38
Link adapter ............................................................ 1-39
Safety valves (IBOP) ................................................ 1-40
Saver and crossover subs..................................... 1-40
Safety valve actuator ................................................. 1-40
Torque wrench ........................................................ 1-42
TDS-4S Contents iii

March 8, 2001
Link tilt mechanisms ................................................ 1-45

Standard and extended reach pneumatic
link tilt mechanisms ........................................... 1-45
Hydraulic link tilt mechanism ........................... 1-48
Link tilt controls .......................................... 1-48
Elevator links ................................................................. 1-50
Counterbalance system .................................................. 1-51
TDS Control System (TDCS) ....................................... 1-53
Varco Driller’s control and instrumentation
Console (VDC) ....................................................... 1-53
Transfer control panel .............................................. 1-54
Purge control system ................................................ 1-54
Service loops .................................................................. 1-55
Derrick electrical termination kit ................................... 1-56
Auxiliary equipment ...................................................... 1-57
Master bushing ID wear guide ................................. 1-58
Swiveling drill collar dolly ........................................ 1-59
Wireline adapter ...................................................... 1-60
Crown height indicator ............................................ 1-62
Chapter 3 Specifications
Drilling motor ......................................................... 1-65
Main gearbox lube system ........................................ 1-65
Cooling systems ....................................................... 1-66
Local blower ...................................................... 1-66
Derrick mounted remote blower ........................ 1-66
Closed loop ........................................................ 1-66
Guide dollies ............................................................ 1-67
Pipehandler .............................................................. 1-67
Service loop kits ....................................................... 1-68
Power loop (non-regulated areas) ....................... 1-68
Control loop ...................................................... 1-68
Fluid loop .......................................................... 1-69
Electrical equipment accessories ............................... 1-70
API Class I, Division II -N.E.C. ........................ 1-70
European standard zone 2 area-EExd ................. 1-70
iv TDS-4S Contents
Book 2 – Installation and Commissioning
Manual layout.................................................................. 2-6
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9
Installation ................................................................. 2-9
Wiring ..................................................................... 2-13
Plumbing ....................................................................... 2-15
Hydraulic................................................................. 2-15
Air ........................................................................... 2-15
Water....................................................................... 2-15
Rig-up procedure ........................................................... 2-16
Motor alignment cylinder system ................................... 2-22
Driller’s controls and instrumentation ........................... 2-23
Varco Driller’s Console (VDC)................................ 2-23
Throttle and torque limit controls ........................... 2-23
Wiring ..................................................................... 2-23
Service loops .................................................................. 2-24
Installation ............................................................... 2-24
Electrical loop .................................................... 2-25
Fluids loop ......................................................... 2-25
Air loop ....................................................... 2-26
Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29
Long term TDS storage procedures................................ 2-32
Returning the TDS to service after storage ..................... 2-33
TDS-4S Contents v
March 8, 2001
Book 3 – Operation
Manual layout .................................................................. 3-6
Chapter 1 Operating procedures

Start-up procedure ........................................................... 3-7
Stalling the DC motor ..................................................... 3-8
Changing transmission speeds .......................................... 3-9
Pipehandler operation .................................................... 3-11
Controls............................................................. 3-12
ROTATING HEAD LEFT/RIGHT switch ..... 3-12
AUTO STOP/FREE ROTATE switch ............ 3-12
Torque wrench ........................................................ 3-16
Changing drill string sizes ........................................ 3-19
PH-85 ............................................................... 3-19
PH-60d ............................................................. 3-19
Torque values for load carrying components ............ 3-20
Drilling ahead ................................................................ 3-21
Drilling ahead with triples ....................................... 3-21
Drilling ahead with singles ....................................... 3-24
Drilling ahead on a semi .......................................... 3-26
Tripping ........................................................................ 3-28
Reaming out .................................................................. 3-29
Well control procedures ................................................. 3-31
Running casing .............................................................. 3-32
Handling bottom hole assemblies .................................. 3-32
Post jarring operations ................................................... 3-34
vi TDS-4S Contents
Book 4 – Maintenance and Troubleshooting
Manual layout.................................................................. 4-8
Chapter 1 Maintenance
Inspection ........................................................................ 4-9
TDS swing out procedure .......................................... 4-9
DC drilling motor ................................................... 4-12
Motor alignment cylinder ........................................ 4-12
Air exhaust muffler .................................................. 4-12
Derrick termination kit air filter/regulator/
lubricators ................................................................ 4-13
Pipehandler .............................................................. 4-14
Nondestructive Examination (NDE) ....................... 4-14
Visual inspection................................................ 4-14
Landing collar .............................................. 4-16
Drive stem ................................................... 4-18
Magnetic Particle Inspection (MPI) ................... 4-20
Ultrasonic Inspection ......................................... 4-21
Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
Lubricating the motor and motor support
bonnet assembly............................................................. 4-23
Gearbox ................................................................... 4-23
Torque setting procedure ................................... 4-25
Other gearbox lubrication and
maintenance considerations ............................... 4-27
Initial oil change period ........................................... 4-27
Oil capacity.............................................................. 4-28
Lubricating the DC motor ....................................... 4-29
Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31
Lubricating the link adapter ........................................... 4-32
Lubricating the torque wrench ....................................... 4-33
Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Contents vii

March 8, 2001
Lubricating the safety valve actuator .............................. 4-34

Lubricating the upper safety valve (IBOP) ..................... 4-35
Lubricating the guide dolly assembly ............................. 4-36
Lubricating the bail pins ................................................ 4-41
Lubricating the cooling system ....................................... 4-42
Lubrication schedule ...................................................... 4-44
Lubricant specifications ................................................. 4-45
Adjustment procedures .................................................. 4-49
Adjusting the torque wrench .................................... 4-49
Adjusting the upper safety valve (IBOP)
and safety valve actuator system ............................... 4-52
Adjusting the counterbalance system ........................ 4-52
Adjusting the motor alignment cylinder system ....... 4-54
Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62
Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62
Replacing the torque wrench
clamping piston seal ..................................... 4-68
Replacing the standard rotating head
glyd rings ........................................................... 4-71
Replacing the powered rotating head
glyd rings ........................................................... 4-75
Replacing the standard or extended reach
link tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81
Front jaw ........................................................... 4-81
Rear jaw ............................................................. 4-81
Removing the jaws ................................................... 4-82
Front jaw ........................................................... 4-82
Rear jaw ............................................................. 4-82
Upper safety valve (IBOP) ....................................... 4-82
Lower safety valve (IBOP) ....................................... 4-82
Removing the motor assembly
from the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motor
and motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87
Local blower cooling system assembly/disassembly ... 4-89
Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95
Safety wiring tips ..................................................... 4-97
viii TDS-4S Contents

Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-99
Troubleshooting the motor alignment cylinder ...... 4-100
Troubleshooting the drilling motor and guide dolly ..... 4-101
Troubleshooting the motor air brake ..................... 4-101
Troubleshooting the retract guide dolly ................. 4-101
Troubleshooting the transmission .......................... 4-102
Troubleshooting the oil pump ............................... 4-103
Troubleshooting the cooling system ....................... 4-104
Troubleshooting the pipehandler ................................. 4-106
Troubleshooting the torque wrench ....................... 4-106
Troubleshooting the safety valve actuator............... 4-108
Troubleshooting the link tilt .................................. 4-108
Troubleshooting the pipehandler at the
counterbalance manifold ........................................ 4-109
Troubleshooting the crown height indicator .......... 4-110
Six-gang air valve assembly illustration ................... 4-111
Book 4 – TDS-4S Control System

Maintenance and troubleshooting/
checkout procedures ........................................................ 5-7
TDS-4S Contents ix
March 8, 2001
x TDS-4S Contents
TDS-4S
Top Drive
Drilling
System
Description
SM00620-1
Rev. B
March 8, 2001
1-2 TDS-4S Description

Contents
Manual layout.................................................................. 1-6
Chapter 1 Introduction
Chapter 2 Major component description

Motor housing assembly ................................................ 1-19
Drilling motor ......................................................... 1-20
Two speed transmission ........................................... 1-20
Integrated swivel bail and swivel washpipe ............... 1-22
Rotating head controls ....................................... 1-26
Cooling systems ............................................................. 1-28
Local blower ............................................................ 1-28
Closed loop .............................................................. 1-30
Remote blower ......................................................... 1-32
Guide dolly assemblies ................................................... 1-34
Motor alignment system ................................................ 1-37
Pipehandler .................................................................... 1-38
Link adapter ............................................................ 1-39
Saver and crossover subs..................................... 1-40
Safety valve actuator ................................................. 1-40
Torque wrench ........................................................ 1-42
Link tilt mechanisms................................................ 1-45
link tilt mechanisms ........................................... 1-45
Hydraulic link tilt mechanism ........................... 1-48
Link tilt controls .......................................... 1-48
Elevator links ................................................................. 1-50
TDS-4S Description 1-3

March 8, 2001
TDS Control System (TDCS) ....................................... 1-53

Varco Driller’s control and instrumentation
Console (VDC) ....................................................... 1-53
Transfer control panel .............................................. 1-54
Purge control system ................................................ 1-54
Service loops .................................................................. 1-55
Derrick electrical termination kit ................................... 1-56
Auxiliary equipment ...................................................... 1-57
Master bushing ID wear guide ................................. 1-58
Swiveling drill collar dolly ........................................ 1-59
Wireline adapter ...................................................... 1-60
Crown height indicator ............................................ 1-62
Chapter 3 Specifications
Drilling motor ......................................................... 1-65
Main gearbox lube system ........................................ 1-65
Cooling systems ....................................................... 1-66
Local blower ...................................................... 1-66
Derrick mounted remote blower ........................ 1-66
Closed loop ........................................................ 1-66
Guide dollies ............................................................ 1-67
Pipehandler .............................................................. 1-67
Service loop kits ....................................................... 1-68
Power loop (non-regulated areas) ....................... 1-68
Control loop ...................................................... 1-68
Fluid loop .......................................................... 1-69
Electrical equipment accessories ............................... 1-70
API Class I, Division II -N.E.C. ........................ 1-70
European standard zone 2 area-EExd ................. 1-70

Preface
Manual conventions
Safety information
Information pertaining to possible personnel injury and
equipment damage appears throughout this manual and is
formatted to draw the reader’s attention to important
information, a warning, or a caution note. See the examples
below and pay close attention to these important advisories.
z Indicates advisories for operational or servicing procedures

involving little or no risk of personnel injury or equipment
damage.
e Indicates advisories involving a risk of equipment damage.
n Indicates advisories involving a definite risk of injury to rig

personnel.
Avoid personnel injury and equipment damage by reading this

manual and related documents before operating, inspecting, or
servicing the equipment.

March 8, 2001
Directional references
References to the right or left and front or back of components
described in this manual assume the perspective of the Top Drive
Drilling System (TDS-4S), standing behind the TDS-4S as it
faces well center.
Manual layout
This binder contains several separate books that you can remove
individually for convenience.

Chapter 1
Introduction
General description
Oil well drilling with a rotary table, kelly drive bushing, and a 45
ft. kelly was the industry standard for years. For decades, drillers
extended the drill string with the “making-a-single-connection”
process using the rotary table, kelly, pipe tongs, drawworks
cathead, master bushing, bowls, and slips. This method of
handling pipe and joint makeup remained unchanged, apart from
minor improvements such as kelly spinners, until the advent of
top drive drilling systems.
Varco produces several Top Drive Drilling Systems (TDS) to
rotate the drill string and allow adding entire 93 ft. stands of pipe,
eliminating two thirds of the conventional single-pipe drilling
connections. This manual describes the function and
maintenance of the TDS-4S, which integrates the drill pipe
connection handling and drive systems with the drilling swivel.
The TDS (Figures 1-1 and 1-2) provides the rotating power of a
conventional rotary table drive while eliminating the need to
“pick up” the cumbersome swivel/kelly combination. The TDS
does not interfere with the existing conventional equipment. It
allows tripping, circulation, rotation, and the running of casing as
well as providing 90 ft. back reaming capabilities to reduce the
chance of stuck pipe.

March 8, 2001
Guide Dolly
Assembly
Motor Housing
Assembly
LO
Pipehandler Assembly
Figure 1-1. Typical TDS-4S overall view

The TDS integrated swivel bail connects directly to a drilling
hook. Connecting the TDS integrated swivel bail directly to the
traveling block or motion compensator frame can eliminate the
drilling hook and shorten the TDS working height further.
Integrated Swivel Bail

Counterbalance
Cylinder (2)
Gooseneck
Air Brake
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(Disengaged)
Rotating Head
Lower Gearcase
Main Shaft/Drive Stem
Figure 1-2. TDS-4S motor and swivel housing assembly

March 8, 2001
The integrated drive stem functions as the main output shaft

driving the drill string. The electric drilling motor and
transmission, located next to the stem, rotates the stem.
The DC motor bolts to an upper assembly of the gearcase,
called the motor support bonnet.
The motor frame/guide dolly attaches to the motor housing
assembly. The entire assembly moves vertically on two rails
installed in the derrick. The vertical rails react the motor torque
during drilling operations and keeps the TDS positioned over
wellcenter.
The pipehandler assembly (Figures 1-3 and 1-4) can make or
break drill pipe at any height in the derrick.

Rotating Head
(Part of the Motor Housing Assembly)
Link Adapter
Torque Arrestor (4) (Also know as: Solid Body Elevator)
(Landing Collar Inside
on Main Shaft/Drive Stem)
Hydraulic/Pneumatic
Link Tilt
Upper IBOP
Valve Actuator
Splined Upper
IBOP Valve
Lower IBOP Valve
(Inside Torque Tube)
Torque Wrench
350-Ton 108 in. Link (2)

(Optional Varco Equipment)
Manually or
Remotely Operated
Drill Pipe Elevator
Figure 1-3. Typical 650-Ton, PH-85 pipehandler assembly

March 8, 2001
Torque Arrestor (4)

650-Ton
Rotating Head
(Part of Motor
Housing Assembly)
Link Adapter
(Also known as
Solid Body Elevator)
(Landing Collar Inside
On Main Shaft/Drive Stem)
Pneumatic Link Tilt

Safety Valve Actuator
Lower IBOP Valve

(Inside Torque Tube)
Splined Upper
IBOP Valve
Torque Wrench
108 in.
350-Ton Links
Manually or Remotely
Operated Drill Pipe Elevator
Figure 1-4. 650-Ton, PH-60d pipehandler assembly

Internal Blow Out Preventor (IBOP) valves connect to the end of
the drive stem (Figure 1-5). The driller can close the upper IBOP
at any position in the derrick from the driller’s control console. A
second, lower IBOP can be manually closed and sent downhole
while controlling a kick.
Main Shaft/
Drive Stem
Link Adapter
(Also known as
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Crank Assembly (2)
Actuator Arm (2) Safety Valve

Actuator Shell
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Figure 1-5. Safety valves (IBOPs) and actuator assembly

March 8, 2001
The drive stem passes through the link adapter. The torque
arrestors keep the link adapter above the landing collar on the
drive stem when drilling (Figures 1-6, 1-7 and 1-8). When
hoisting, the link adapter is pulled down onto the landing collar
due to the added weight of the drill string. This directs the
hoisting load through the drive stem, motor housing assembly,
and swivel bail.
The fluid service loop provides the hydraulic, pneumatic power,
and optional cooling water services to the TDS. The electric
service loops provide DC power and AC power/control.
A drill pipe elevator hangs from a pair of conventional links that
attach to the link adapter. Actuating the link tilt swings the
elevator out to facilitate picking up pipe.
The Major component description chapter of this book describes
each of these assemblies. Subsequent books provide more
information on the equipment specific to your rig configuration.

Rotating Head
(Part of Motor Housing Assembly)
Link Adapter
(Also known as
Torque
Arrestors (4)
Figure 1-6. 650-Ton rotating head, link adapter and torque arrestors

March 8, 2001
650/500-Ton
Hydraulic/Pneumatic Link Tilt Rotating Head
(Part of
Motor Housing
Assembly)
650/500-Ton
Link Adapter
(Also known as
Solid Body
Elevator)
Torque
Arrestor
650-Ton: (4)
500-Ton: (2)
Link Adapter
Support Plate
Upper
IBOP Valve
108 in.
350-Ton Safety Valve
Links Actuator
(Optional
Varco Equipment)
Torque Wrench
Lower
IBOP Valve
Manually or Remotely Operated

Drill Pipe Elevator Saver Sub
Figure 1-7. 650-Ton, PH-85 pipehandler in relation to other TDS assemblies

650-Ton
Pneumatic Link Tilt Rotating Head
(Part of Motor
Housing
Assembly)
650-Ton
Link Adapter
(Also known as
Solid Body
Elevator)
Torque
Arrestor (4)
Link Adapter
Support Plate
Upper
IBOP Valve
108 in.
350-Ton
Safety Valve
Links
Actuator
(Optional
Varco Torque Wrench
Equipment)
Lower
IBOP Valve
Manually or Remotely Operated

Saver Sub
Drill Pipe Elevator
Figure 1-8. 650-Ton, PH-60d pipehandler in relation to other TDS assemblies

March 8, 2001

Chapter 2
Major component
description
Motor housing assembly

The motor housing assembly is composed of the following:
❏ Drilling motor and brake

❏ Two speed transmission
❏ Rotating head
❏ Integrated swivel and washpipe

March 8, 2001
Drilling motor
The drilling motor on the TDS is a 1,100 hp DC drilling motor.
Mechanically, the motor features a double-ended armature shaft
and thrust bearings for vertical operation.
There is an air brake on the motor to hold torque in the drill
string to assist in directional work. It is remotely operated by a
solenoid valve. Please refer to the specifications included later in
this book for additional details.
Two speed transmission

The two speed transmission consists of the following major
components:
❏ Bull gears – 96 tooth, 2.0 diametral pitch

❏ High range compound gears – 27 tooth and 30 tooth
❏ Low range compound gears – 23 tooth and 40 tooth
❏ Motor pinion gears – 21 tooth
❏ Geneva transmission shifter mechanism (Figure 1-9)
❏ Main body and lower gearcase
❏ Main shaft/drive stem
❏ Bonnet
❏ Swivel bearing
The compound gears mount to their eccentric shafts with a two-
row, full complement roller bearing on one end and a spherical
roller bearing on the other end.

Rotating Head
Assembly
Shifter
Input Shaft
HI LO
External
HI / LO
Indicator
Compound
Gear Shafts
Bottom View
High Gear Low Gear

Eccentric Shaft Eccentric Shaft
(Engaged) (Disengaged)
Geneva Shifter Input

Mechanism
Top View
Figure 1-9. Transmission/geneva mechanism

March 8, 2001
Lubrication to the bearings and gear meshes is force fed by an

electrically driven gear pump externally mounted on the gearcase
(Figure 1-10). The lower gearcase is a heavy duty steel casting,
fully ribbed for added heat dissipation.
The transmission shifts gears by rotating two vertical compound
gear eccentric shafts. The two compound shafts (high and low)
are supported on heavy trunnions between the main body and
lower gearcase halves. As the shafts rotate (less than one-half
turn), the compound gears go into or out of mesh with both the
motor pinion gear and the bull gear because the support shaft
center axes are offset or eccentric.
Each compound shaft carries a large, internally splined geneva
slave. A common geneva master sequentially unlocks, rotates, and
locks both gears. The master rotates using a reduction gear set
with a vertical manual input shaft. It carries its own latching
mechanism and provides the security of a double lock on the
compound shafts.
A 1 in. male hex at the bottom of the transmission case (Figure
1-9), rotates the input shaft. After pushing inward on the male
hex, it takes five turns of the input shaft to unlock both gear sets,
rotate the engaged gear set to full disengagement, rotate the
disengaged gear set into full engagement, and lock both gear sets
in their proper positions with positive stops in the locked
position. An external indicator shows the gear range selection.
Integrated swivel bail and swivel

washpipe
The integrated swivel bail is a bearing assembly that allows
transfer of the rotating load to the lifting components
(Figure 1-2).
The swivel washpipe is a rotating seal that allows mud to flow to
the rotating drill string.

Lower Radial Motor Pinion
Shaft Bearing Gears
Side View
Bull
Gears
Inlet Compound Shafts (Not Visible)
Bull Gears
Motor Pinion
Gears
LEGEND
Pressure Tap
Fabricated
Bottom View Drilled
Figure 1-10. Transmission lubrication system

March 8, 2001
Standard rotating head

The standard rotating head allows transferring pneumatic and
hydraulic pressure from stationary ports on the drilling motor
housing to rotating ports on the rotating head (Figure 1-11). It
features two hydraulic passages, three pneumatic passages, and
two spare passages capable of transferring either pneumatic or
hydraulic fluid (all are rated at 2,500 psi).
The rotating head assembly consists of:
❏ Stationary flange
❏ Eight rotary glyd rings
❏ Swivel block
❏ Cam
❏ Auto-return cylinder
❏ Cam follower
❏ Swivel block locking mechanism
The hydraulic and air lines for the various pipehandler functions
(air link tilt, torque wrench, etc.) run from their respective
solenoid valves to the stationary flange. The fluids travel from the
flange to the swivel block via sealed rotating passages. The glyd
rings maintain the seal between the passages.
Additional hoses connect the ports in the swivel block to the
corresponding devices (link tilt, etc.). The swivel block rotates
relative to the flange without twisting or damaging any hoses.
There is also a lug for mounting the torque wrench hanger and
holes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom of
the gearcase with the drive stem running through the center.
There is also an auto-return cylinder mounted on the stationary
flange. The auto-return cylinder is hydraulically connected to the
counterbalance manifold. The rod end of the cylinder connects to
a cam follower assembly that tracks the cam mounted to the
swivel block.

Cam Stationary Flange
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location
Glyd Ring (8) Swivel Block
Torque Wrench Hanger

(Lug not shown)
Figure 1-11. Standard 650-Ton rotating head assembly

March 8, 2001
Powered rotating head

The 10-port powered rotating head (Figure 1-12) allows
transferring pneumatic and hydraulic pressure from stationary
ports on the drilling motor housing to rotating ports on the
rotating head. It features three hydraulic passages, five pneumatic
passages, and two spare passages capable of transferring either
pneumatic or hydraulic fluid (all are rated at 2,000 psi).
The rotating head assembly consists of the following components:
❏ Stationary flange
❏ Eleven rotary glyd rings
❏ Swivel block
❏ Bull gear
❏ Hydraulic motor assembly
❏ Proximity sensor and adjustable targets
The hydraulic and air lines for the various pipehandler functions
(hydraulic link tilt, torque wrench, etc.) run from their respective
solenoid valves to the stationary flange. The fluids travel from the
flange to the swivel block via sealed rotating passages. The glyd
rings maintain the seal between the passages.
Additional hoses connect the ports in the swivel block to the
corresponding devices (link tilt, etc.). The swivel block rotates
relative to the flange without twisting or damaging any hoses.
There is also a lug for mounting the torque wrench hanger and
holes for attaching the torque arrestors on the swivel block.
The rotating head stationary flange bolts directly to the bottom of
the gearcase with the drive stem running through the center.
The hydraulic motor assembly mounts to the swivel flange which
engages a compound gear, driven by a pinion gear on the
hydraulic motor shaft. Two switches on the driller’s control panel
control the hydraulic motor.
Rotating head controls

The powered rotating head has two switches. The ROTATING
HEAD LEFT/RIGHT switch rotates the rotating head, pipe
handler, and link tilt to the right or left (same direction as the
drill string). The AUTO STOP/FREE ROTATE switch controls
the powered rotating head operating mode.

Stationary
Flange
Rotary Glyd
Ring (11)
Torque Arrestor
Hanger
Bull Gear
Swivel Block
Hydraulic Motor
Assembly
H1
S1
A1
RE
A3
PRESSU
H1
H3
A2
S2
A5
A4
H2
S2
A4
A1
A5
A2
H3
A3
H2 S1
Figure 1-12. Powered rotating head assembly

March 8, 2001
Cooling systems
Local blower
The local blower cooling system with an optional extended intake
provides local cooling air to the drilling motor (Figure 1-13). It
receives air approximately 27 ft. above the rig floor at the lowest
point of the motor’s travel.
An explosion-proof 20 hp, 3,450 rpm AC electrical motor
directly drives the impeller in the blower housing. An optional
flexible duct connects the blower housing to the extended intake
mounted on the traveling equipment.
Two spark arrestor assemblies are mounted on the exhaust ports
of the upper gearcase. These components hinder the egress of any
air born sparks from the DC motor.

Axial Fan
20 hp Transmission
Blower Motor Cooler
Locking Key
Oil Fittings (2)

Blower Housing
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
Flex Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Spark Arrestor
Figure 1-13. Typical local blower cooling system

March 8, 2001
Closed loop
The closed loop cooling system (Figure 1-14) consists of two air/
water heat exchangers cooled by twin blowers driven by a double
ended AC motor. Ducting directs air out the motor exhaust port
to the heat exchangers and back to the blower inlets. The heat
exchangers are built from Cupro-Nickel tubes and the headers are
pressure tested to 250 psi.
The system requires a supply of liquid coolant (sea water, chilled
fresh water or glycol) at 100 gpm at a maximum inlet
temperature of 90°F.
Purge air at a rate of 70 scfm per motor at 1.0 psig is also required
to provide positive system pressure, and a purge control system
(refer to TDS Control System information provided later in this
chapter) monitors system pressure to insure safe operation.

Dual Shaft
20 hp AC
Blower Motor
Blower Mount/
Brake Cover
Blower
Housing (2)
Impeller (2)
8 in. Flex
Connection (2)
Blower Inlet (2)
Water
Connections
DC to Motor
Exhaust Port on
Upper Gear Case
Inspection
Cover
GE
Drilling Motor
Heat Exchanger (2)
Figure 1-14. Typical closed loop cooling system

March 8, 2001
Remote blower
The remote blower motor cooling system consists of a motor and
pressure blower mounted in the derrick at racking board level
(Figure 1-15). Air is drawn in from outside the wind wall,
through a flexible duct into the top of the drilling motor, and
exits through spark arrestors attached to the air outlets of the
motor.
A pressure switch monitors the motor air inlet pressure to verify
blower operation. The contacts of the pressure switch are usually
wired into the SCR assignment logic for the drilling motor.
A moisture separator is attached to the blower inlet duct to
prevent water from entering the motor.

Air Inlet
40 hp Explosion Proof
Electric Motor (AC)
and Centrifugal
Pressure Blower
Wind Wall
Racking Platform
at Racking Board Level
Rigid Cooling Duct
Spark Arrestor
Motor Dolly Assembly

86' Flex Air Duct
Figure 1-15. Typical remote blower cooling system

March 8, 2001
Guide dolly assemblies

The guide dolly assembly transmits the drilling torque reaction to
the guide rails keep the TDS positioned over wellcenter and can
provide a method for setting the entire unit aside for maintenance
or to allow rig operation without the TDS if necessary.
The standard guide dolly assembly consists of two frames
connected by hinges on the pivot side and hold-down bolts on
the other (Figure 1-16).
Non-swing retract guide dollies use hold-down bolts (swing bolts)
on both sides (Figure 1-17). One frame attaches to the motor
housing assembly and includes attachment points for the service
loops and rotary hose. The other frame includes the guide rollers
and remains in the guide rails during all normal operations.
Centralized lubrication manifolds provide roller lubrication.

Motor Frame
Guide Dolly Frame
Hinge Pin (2)
Hold-down Bolt
(Swing Bolt) (2)
Figure 1-16. Typical swing guide dolly assembly

March 8, 2001
Upper Stabilizer Arm

Motor Frame
Guide Dolly
Frame
Retract
Cylinder
Lower
Extend/Retract
Arm
LEGEND
Intermediate
Extended Mode
Frame Retracted Mode
45.0"
Figure 1-17. Typical retract guide dolly assembly

Motor alignment system
The motor alignment system consists of a duplex cylinder,
hydraulic accumulator, pressure reducing valve manifold, and
related hardware.
The duplex cylinder attaches between the bottom of the lower
gearcase and the motor frame. It connects to an accumulator
circuit located on the guide dolly. The accumulator is charged
with nitrogen and maintained at a predetermined pressure setting
by the alignment cylinder manifold. Figure 1-18 shows the motor
alignment cylinder installed in a typical motor frame.
The duplex cylinder maintains a wellcenter orientation for the
swivel stem when disconnected from the drill sting, while
allowing the motor housing assembly to float slightly about its
trunnions.
Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)
Figure 1-18. Motor alignment cylinder

March 8, 2001
Pipehandler
The main components of the pipehandler include the following
(Figures 1-3 and 1-4):
❏ Link adapter
❏ Safety valves (Upper and Lower IBOPs)
❏ IBOP valve actuator
❏ Torque wrench
❏ Link tilt mechanism
The pipehandler provides two basic functions for the TDS:
❏ Tripping 93 ft. drilling pipe stands

❏ Providing up to 85,000 ft lb torque for makeup and
break-out of connections at any height in the derrick
(the PH-60d provides up to 60,000 ft lb torque)
The pipehandler can be configured for various tool joint
connections. It includes a link adapter and a special-purpose
Varco torque wrench assembly. It also incorporates a remote
IBOP valve actuator and link tilt mechanism.
When not in use, the pipehandler remains stationary and free
from the drill string passing through it. When tripping or
performing bottom hole operations, the pipehandler is free to
rotate 360°, emulating the action of a standard hook.

Link adapter
The link adapter (solid body elevator) and the elevator links
(Figures 1-7 and 1-8), working in conjunction with the torque
arrestors, transfer the hoisting loads to the drive stem.
The drive stem is free to rotate inside the link adapter while
drilling. The link adapter does not rotate with the drive stem
because torque arrestors raise the link adapter up off the load
supporting landing collar located on the drive stem.
When hoisting loads, springs inside the torque arrestors compess
to transfer the load to the drive stem by pulling the link adapter
down onto the landing collar. The link adapter rotates with the
rotating head–which is required for tripping operations.
The torque arrestors contain compression springs capable of
supporting any stand of drill pipe in the full up position.

March 8, 2001
Safety valves (IBOP)

The Varco pipehandler includes two Internal Blowout Preventor
safety valves (IBOPs) to provide blowout prevention. For detailed
descriptions, installation, operation, maintenance, and parts
information, refer to the IBOP Service Manual.
Saver and crossover subs

Each pipehandler ships with two saver subs and one crossover
sub. Saver subs (Figures 1-7 and 1-8) are dual pin subs used to
preserve the threads on the lower IBOP and provide a pin for the
box end of the drill string. Saver sub threads can be recut to a
minimum shoulder-to-shoulder length of 5 in. before the sub
must be discarded.
The crossover sub converts the lower IBOP pin to a box
connection for well control procedures with standard pipe.
e Saver subs are load bearing components in the TDS and must be
inspected periodically along with other load bearing components.
Refer to the Maintenance and Troubleshooting book for more
information.
Safety valve actuator

The remotely operated upper IBOP valve actuator allows upper
IBOP actuation at any height in the derrick.
The upper IBOP actuator system consists of the following:
❏ Two pneumatic air cylinders

❏ Two actuator arms
❏ Actuator shell
❏ Two crank assemblies
❏ Two pneumatic solenoid valves
Double-acting air cylinders move the actuator arm. The actuator
arm connects to the valve actuator shell and moves the actuator
shell up or down (Figure 1-19). A slot in the actuator shell
engages the crank assemblies, which opens or closes the IBOP.
The air cylinders are operated remotely by a solenoid valve
controlled by an electrical switch at the VDC.

Main Shaft/
Drive Stem
Link Adapter
(Also known as
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Crank Assembly (2)

Actuator Shell
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Figure 1-19. Safety valve actuator system

March 8, 2001
Torque wrench
The torque wrench provides a means for making and breaking
out connections with the drive stem.
The torque wrench assembly consists of the following
components (Figures 1-20 and 1-21):
❏ Hanger
❏ Torque tube
❏ Torque tube guide ring
❏ Two torque cylinders
❏ Two clamping jaws
❏ Two clamping pistons
❏ Control manifold
❏ Lift cylinder
❏ Two stop tubes
❏ Stabbing guide
❏ IBOP actuator cylinders and arms
A hanger attached to the rotating head supports the torque
wrench. The torque wrench has two torque cylinders connected
to the torque tube.
The clamping jaw contains a 10 in. diameter clamping piston for
gripping the box end of the drill pipe. On the lower section of the
upper IBOP, a female spline engages the mating male spline on
the lower IBOP contained inside the torque tube.
When actuated, the torque wrench rises and engages the splines
on the upper IBOP. It then receives sequenced pressure to clamp
the clamping piston on the box connection. After the clamping
pressure develops, another sequence valve automatically opens
and directs pressure to the torque cylinders. The torque cylinders
can rotate up to 25° while developing a maximum torque of
85,000 ft lb (60,000 ft lb for PH-60d).
One electrical push button on the VDC controls the entire torque
wrench operation. The driller simply holds the button down until
the connection is made or broken. The driller then releases the
button to allow the unit to automatically recycle to the ready
position. A two-position, air piloted hydraulic valve located on
the counterbalance manifold controls the cycle.
The torque wrench can also make up or break out the saver sub
or the lower IBOP. A manually operated valve on the rear of the
pipehandler selects either the make up or break out function.
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
IBOP Actuator
Air Cylinders
Lift Cylinder
IBOP
Actuator Arms
Torque Tube
V Stop Tube (2)

a
r
Clamping Jaw c
(Inside Clamp Body) o
Control Manifold
(Hidden)
Torque Cylinder (2)

Stabbing Guide
Clamping Piston
(Inside Clamp
Body Cylinder)
Guide Ring
(Not Visible)
Figure 1-20. PH-85 torque wrench assembly

March 8, 2001
IBOP Actuator
Hoses (Air)
Hanger
Torque Wrench
Hoses (Hydraulic)
Lift Cylinder
IBOP Actuator
Air Cylinders
IBOP
Actuator Arms
Torque Tube
Stop Tube (2)
Clamping Jaws
(Inside Clamp Body) Control Manifold
(Hidden)
Torque Cylinder (2)

Stabbing Guide
Clamping Piston
(Inside Clamp
Body Cylinder)
Guide Ring
(Not Visible)
Figure 1-21. PH-60d torque wrench assembly

Link tilt mechanisms

link tilt mechanisms
The standard (Figure 1-22) and extended reach (Figure 1-23) link
tilt assembly allows:
❏ The elevators to move off of well center to pick up a stand in

the mousehole.
❏ The derrickman to handle pipe more easily.
The link tilt assembly mounts on the front of the solid body
elevator (link adapter). This assembly consists of a pivoting lifting
frame connected to the drilling elevator links with chains and
clamps. A switch on the VDC controls a pneumatic solenoid
valve that inflates an air spring within the lifting frame. Inflating
the air spring pivots the frame upward, tilting the links outward.
Extended reach link tilt mechanisms have two air springs and
extend 76 in. A standard reach link tilt will extend links 52 in.
Both reaches are based on 108 in. elevator links.
An adjustable intermediate stop mechanism provides clearance
between the drill pipe elevator and the monkey board to assist the
derrickman in racking operations.

March 8, 2001
Lifting Frame
Intermediate
Stop
Air
Actuator
D/P Elevator
Link Clamp
Intermediate
Stop Release
Figure 1-22. Standard pneumatic link tilt mechanism

Lifting
Frame
Double Air
Actuator
D/P Elevator
Intermediate Link Clamp
Stop
Intermediate
Stop Release
Figure 1-23. Extended reach pneumatic link tilt mechanism

March 8, 2001
Hydraulic link tilt mechanism

The hydraulic link tilt assembly (Figure 1-24) provides lateral
movement of the drill pipe elevator to a position above the
mousehole or toward the monkeyboard.
The link tilt assembly mounts on the front of the link adapter
(solid body elevator). The link tilt uses dual hydraulic cylinders.
Full link tilt extension moves drill pipe approximately 78 in. from
well center, based on 108 in. links. During operation, the
operator can stop link tilt movement at any position and hold the
supported load in place.
The link tilt also enables retracting the open drill pipe elevator
from the drill pipe while drilling, tripping, and adding stands
(available only on PH-85 models).
Link tilt controls

The link tilt is controlled by a four-position switch. The positions
are RETRACT, FLOAT, HOLD, and EXTEND.
RETRACT
In the RETRACT position, the elevator backs away from well
center.
FLOAT
FLOAT returns the elevators to well center from the retracted or
extended position. A 1/2-second delay is programmed into the
FLOAT function to allow the control switch to travel from the
RETRACT position to the HOLD position without activating
the FLOAT.
HOLD
This setting holds the position of the elevators extended or
retracted.
EXTEND
This setting extends the elevator forward to the mousehole
through wellcenter.

Hydraulic
Link Tilt with
Passive Stop
Passive
Stop
Assembly
(2)
Cylinder
Assembly
(2)
Link
Tilt Arm
Hydraulic
Link Tilt with
Intermediate Stop
Intermediate Stop
Stop Adjuster
Figure 1-24. Hydraulic link tilt

March 8, 2001
Elevator links
Varco elevator links attach to the link adapter and support the
drill pipe elevator. Elevator link options include:
❏ 108 in., 350-Ton elevator links

❏ 132 in., 350-Ton elevator links
❏ 180 in., 500-Ton elevator links (special long links for running
casing, providing 120 in. of clearance for cementing heads)

Counterbalance system
The counterbalance system prevents damage to tool joint threads
while making or breaking connections with the TDS. It provides
cushioned stroke similar to that provided by the hook.
The counterbalance system prevents damage to the threads of the
saver sub and drill pipe by offsetting the weight of the top drive
while stabbing into a connection. The system (Figure 1-27)
consists primarily of two hydraulic cylinders, a counterbalance
manifold, and two hydraulic accumulators. The hydraulic
cylinder assemblies connect the integrated swivel bail and the
traveling equipment (hook, block, becket, hook adapter, etc.).
When properly adjusted, the counterbalance system supports all
but about 800 lb of the weight of the top drive over a full 8 to
10 in. of travel.
The system also incorporates a complete backup. The two
accumulators, constantly maintained at system pressure, are
always able to provide pressure to the counterbalance cylinders if
the HPU is “off ” or non-operational for any reason. For normal
operation, however, the HPU is “on” when using the torque
wrench for breaking out the top drive at the floor and is left on
while making up the next stand.
When adding a stand to the string during drilling operations, the
driller takes a stand in the elevators and stabs it into the box in
the rotary table. The driller continues to lower the TDS until the
saver sub touches the box of the new stand. At this point, only
about 800 lb load is on the saver sub/drill pipe connection. The
counterbalance cylinders support the remainder of the TDS
weight. The driller then spins in and torques up the connection
with the pipehandler assembly and is ready to drill ahead.
Note that the driller does not have to do anything extra to get the
counterbalance system to function properly. It is a pre-adjusted
system. Once drilling resumes, the HPU can be turned off and
restarted again for breaking out the connection at the floor after
drilling the stand down.

March 8, 2001
Stabbing Mode:
Top Drive Lowered Past Thread Contact
Guide Dolly
Assembly
18,970 lb 18,970 lb
Hydraulic
Cylinders (2)
Hydraulic
Accumulators (2)
38,750 lb
Typical System Weight
Counterbalance
Manifold
810 lb
Weight on Threads
Hydraulic Fluids
Power Supply Service Loop
Rig Floor
Figure 1-27. Counterbalance system

TDS Control System (TDCS)
The TDS Control System (TDCS) provides the driller with a
control console that operates all of the TDS functions. The
components of the TDCS include:
❏ Varco Driller’s control and instrumentation Console (VDC)
❏ Transfer control panel (TP)
❏ Purge control system for closed loop cooling systems
Varco Driller’s control and

instrumentation Console (VDC)
The Varco driller’s control and instrumentation Console (VDC)
consists of a torque meter, an RPM meter and various switches
and indicator lights. The basic TDS control functions are:
❏ Link tilt
❏ Remotely controlled upper IBOP valve
❏ Motor brake
❏ Motor spin-torque control
❏ Makeup torque limit
❏ Transfer switch (TDS/ROT)
The existing rotary table controls adjust motor speed, torque and
direction while drilling. A typical VDC also contains indicator
lights for determining the status of:
❏ The brake
❏ The remotely controlled upper IBOP valve
❏ The oil pump
❏ Blower pressure loss
❏ Cooling air temperature
❏ The purge system(s)
Optional controls and status indicator lights are available. Refer
to Engineering Drawing 98952 for VDC configurations.

March 8, 2001
Transfer control panel

The TDS operates from the same SCR as the rotary table.
The Transfer control panel switches power between them.
This electrical enclosure contains the DC contacts, the
programmable controller, the auxiliary AC components
and the rig instrumentation interfaces for recording torque
and speed of the TDS.
The DC power cables running from the SCR to the rotary table
motor are disconnected from the rotary table and connect to the
transfer panel. New cables run from the TP to the rotary table
motor and to the racking board junction boxes for the TDS.
The transfer panel has a purge control system for use in a
hazardous area (Zone 2 or Class 1, Div. 2). If the panel is in the
SCR room, a purge system is not required.
The panel is compatible with all currently installed SCR systems
and is configured at installation for the SCR it will control. Logic
and alarm functions are connected to the TDS by programming
the transfer panel’s Programmable Logic Controller (PLC) to
operate the rig’s existing systems. Similarly, TDS interlocks and
limits, such as spin-up and makeup speeds, are programmed into
the PLC and are the same for all installations.
Purge control system

The transfer panel, VDC, and TDS closed loop cooling system
have separate purge systems. All systems provide positive internal
pressure to prevent hazardous gases from entering areas of
potential ignition in Zone 2 or Class 1, Div. 2 hazardous areas.
Pressure switches in the protection units monitor the pressure and
provide an alarm signal in the event of purge pressure loss.
Prior to starting an unpurged system, the purge control unit
purges the system for a specific time interval sufficient to remove
any trapped hazardous gas. Status lights on the VDC indicate to
the driller correct purge pressure, loss of purge and system
purging. If purge pressure loss alarms and indicators are ignored
for a preset time interval, the isolation unit can be set to shut
down the TDS.

Service loops
The service loops transfer the required electric and fluid services
between the derrick service standpipes and junction boxes, and
the corresponding junction boxes and fluid connections located
on the TDS. There are two kinds of loops: one containing the
electric cables, and one containing air, hydraulic and water lines
(water lines included only on units with a closed loop cooling
system).
The power electrical loop contains four 646 MCM DC power
cables, one 2/0 AWG drilling motor ground cable. The other
electrical service loop contains a composite cable consisting of:
❏ 26 14 AWG conductors for auxiliary features

❏ 4 8 AWG conductors for blower motor
❏ 2 5 AWG conductors for series motor field supply
❏ 2 14 AWG shielded pairs for the RPM pickup signal
The power and ground cables are spiral wound and potted inside
a protective cover with 7 1/2 in. mounting flanges at each end.
The composit cable is pathed in its own smaller service loop. This
allows for easy changeout of either the power loop or the
composit loop in the event of a failure.
The TDS can use optional dual electrical service loops in order to
meet certain regulatory agency requirements for power cable
current carrying capacity.
The fluids loop can consists of any combination of the following:
❏ 3 3/4 in. diameter hoses for hydraulic supplies

(one is a spare)
❏ 2 1/2 in. diameter hoses for air supply (one is a spare)
❏ 1 1 in. diameter hoses for purge supply
❏ 2 1 1/4 in. diameter hoses for cooling water
(closed loop cooling systems only)
❏ 2 1 in. diameter hoses for retract cylinder supply and return
❏ Additional 7-conductor, 20 AWG cables as required

March 8, 2001
Derrick electrical termination kit

This kit consists of all the necessary electrical junction boxes
attached to a bulkhead mounting plate, which is then mounted in
the derrick to connect the rig electric supplies to the service loop.
There are several J-box configurations, depending upon which
electrical system is ordered. Each configuration complies with
specific electrical codes and regulatory agency requirements
throughout the world.

Auxiliary equipment
Auxiliary equipment is compatible with all TDS models. All of
the equipment is selected or adapted for your specific rig. Below is
a list of auxiliary equipment available:
❏ Master bushing ID wear guide

❏ Swiveling drill collar dolly
❏ Wireline adapter
❏ Crown height indicator
❏ Driller’s recorder tranducer kit

March 8, 2001
Master bushing ID wear guide

The master bushing ID wear guide centers the rotating drill
string and protects the master bushing while drilling ahead
(Figure 1-26). It hinges open for removal or when setting
manual slips. The bushings can be changed out to accomodate
different size drill pipe.
Figure 1-26. Master bushing ID wear guide

Swiveling drill collar dolly
The swiveling drill collar dolly (Figure 1-27) allows the drill collar
elevators to turn freely when handling bottom hole assemblies.
The drill collar dolly’s upset, which latches in the standard drill
pipe elevator, mounts on a bearing which allows it to swivel even
under load. A shoulder elevator is suspended from the
“perfection” links (or a second drill pipe elevator if lifting subs are
used). The collars can be walked in or out with the elevator
turning on the drill collar dolly.
Drill Pipe
Elevator
Drill Collar
Dolly
A
100 TON
VARCO
Perfection
Links (36")
;;
;;; ;;
;;; ;;;
;;;
91 in.
Square
Shoulder
Elevator
Lifting
Sub
37 in.
Drill
8 in. Collar
View A-A
Figure 1-27. Swiveling drill collar dolly

March 8, 2001
Wireline adapter
The wireline adapter (Figures 1-28 and 1-29) attaches to the
pipehandler and prevents wireline from interfering and damaging
pipe and TDS components. It can be used with a lubricator held
in the elevators by using 180 in. casing elevator links.
42.52 in.
26.0 in.
23.1 in.
Typical Section through Sheave
Figure 1-28. Typical PH-85 wireline adapter

View A-A
9/16 in. Max.
Wire Rope Dia.
Top Drive
Torque Wrench
Torque Wrench Guard

(remove for installation)
20 in. Dia.
Sheave
Elevator Links
(180 in. long-
Customer furnished)
Lubricator
Wireline Adapter installs in

place of Torque Wrench
To Mud Manifold Guard using existing Pins
Elevator Links
(180 in. or longer-
Customer furnished)
View A-A
Figure 1-29. Typical PH-60d wireline adapter

March 8, 2001
Crown height indicator

The crown height position indicator is a self-contained electronic
instrument which determines the position of the traveling
equipment with respect to the derrick crown. The system contains
four major subassemblies:
❏ A metal target typically located on the Varco block dolly

assembly
❏ Two hinged sensor bracket assemblies located on the rear of
the guide track
❏ A sensor junction box located in the derrick near the above
bracket assemblies
❏ A crown height indicator control box, or an integral control
in the driller’s control and instrumentation console
The Crown Height Indicator Control (CHIC) control box
(Figure 1-30) contains three indicator lights and an electronic
printed circuit board. Two of the indicators display the position
of the top of the traveling equipment relative to the crown. The
third indicator displays system power status.
The yellow indicator on the CHIC control box illuminates when
the top of the traveling equipment is within ten feet of the crown.
The red indicator illuminates when the traveling equipment is
within five feet of the crown. When the traveling equipment is
within two feet of the crown both indicators flash alternately. The
green indicator illuminates when correct DC system power is
available. This indicator also contains a push-to-test button which
simulates the 2 ft. position.
The integral crown height indicator controls on the VDC are
identical to the separate control box.

CROWN CLEARANCE
2 FEET IBOP BRAKE
WHEN FLASHING CLOSE ON
R
5 FEET
IBOP BRAKE
CLOSE OPEN OFF ON
Y
10 FEET
TORQ. WRENCH LINK TILT
ACTIVE/TEST PUSH & PULL OFF ON
Integrated Controls
IBOP BRAKE CROWN CLEARANCE

CLOSE ON 2 FEET WHEN FLASHING
Purge Air in R
5 FEET
IBOP BRAKE
CLOSE OPEN OFF ON
Y
10 FEET
Purge Air out

TORQ. WRENCH LINK TILT G to Protection Unit
PUSH & PULL OFF ON
ACTIVE/TEST
VDC
Independent
Controls
Figure 1-30. Typical CHIC control box

March 8, 2001

Chapter 3
Specifications
Drilling motor
Horsepower: 1,100
Maximum stall time at full power is generally about 10 seconds.
Refer to the Operation book for details.
Main gearbox lube system

Provides lubrication to both the primary gear set and swivel
bearing. It includes explosion proof 5 hp AC motor/pump
combination, filter/strainer, pressure loss sensor, and oil level sight
glass. The TDS-4S main gearbox lube system holds approximately
20 gallons (refer to the Maintenance and Troubleshooting book for
details on oil capacity and adding oil to the gearbox).

March 8, 2001
Cooling systems
Local blower *
Flow 3,200 cfm
Blower motor 20 hp
Typical voltage 220/460 VAC, 3-phase, 60 Hz
Speed 3,450 rpm
Spark arrestors Standard style, BASEEFA
approved type available
Derrick mounted remote blower *

Flow 3,200 cfm
Blower motor 40 hp
Speed 3,450 rpm
Spark arrestors Standard style, BASEEFA
approved type available
* These systems include an additional oil cooler/heat exchanger

mounted on top of the gearcase on the TDS.
Closed loop
Flow 3,200 cfm
Blower motor 20 hp
Speed 3,450 rpm
Heat exchanger 220,000 BTU/Hr.
for GE motor
Cooling water supply 50 gpm at 250 foot head,
measured at rig floor
Oil cooler 6 gpm
Max. inlet temp 90°F

Guide dollies
Standard rail setback 30, 39 or 48 in.
(Wellcenter to centerline of rails)
Standard rail spacing 62, 66 or 72 in.
(Centerline of rails)
Recommended rail sizes W12x53 (land masts),
or W14x74, W14x90
Roller size 6 in. flange and 6 in. side
Frame material ASTM A-500/A-36 steel
or equivalent
Pipehandler
Break-out torque PH-85 and PH-85H = 85,000 ft lb
PH-60d = 60,000 ft lb
Hydraulic pressure 2,000 psi maximum
Hydraulic flow 30 to 35 gpm
Air pressure 90 psi minimum

March 8, 2001
Service loop kits
Power loop (non-regulated areas)

646 mcm 4 (each)
Standard length 86 ft. (flange to flange)
Diameter 5 in. ID SAE 100-R2
hose outer jacket
Power cable voltage 2,000 maximum (each)
Ground cable 2/0 conductor tinned copper
ground
Control composite loop

26 conductor, 14 guage
2 pair, 14 guage twisted and shielded
1 pair, 6 gauge twisted and shielded

Fluid loop
z Not all hoses are required for all configurations.

Overall length of assembly 86 ft. (flange to flange)
Hydraulic pressure or return hose (3 total)

Size 3/4 in. ID, SAE 100-R9
Maximum working pressure 3,000 psi
Air supply hose (2 each)

Size 1/2 in. ID, SAE 100-R2
Working pressure 150 psi
Purge air supply hose (2 each)

Size 1 in. ID, SAE 100-R2
Water hose (2)

Size 1 1/4 in. ID, SAE 100-R2
Retract hoses (2)

Size 1 in. ID, SAE 100-R2

March 8, 2001
Electrical equipment accessories
API Class I, Division II -N.E.C.

Derrick J-boxes (2 each) Cast aluminum,
explosion proof
Motor J-boxes (2 each) Cast aluminum,
explosion proof
Solenoid valves (6 each) 1/2 in., 4-way, 2 position
Pressure switches (2 each) 6 in. of H2O sensor
Motor space heaters (2 each) 2 - 200 watt, 110 volt
VDC/instrument kit Various switches
Torque meter (0 - 1,500 Amps)
RPM meter (0 - 350 rpm)
European standard zone 2 area-EExd

Derrick J-boxes (2 each) Stainless steel
Motor J-boxes (2 each) Stainless steel
Solenoid valves (6 each) 1/2 in., 4-way, 2 position
Pressure switches (2 each) 6 in. of H2O sensor
Motor space heaters (2 each) 2 - 200 watt, 220 volt

TDS-4S TOP DRIVE DRILLING SYSTEM
Drill Pipe Torque Vs. Speed GE 752 High Torque Series Motor
60,000
58,200
INTERMITTENT
55,000
1,130 HP LIMIT
50,000 50,900
CONTINUOUS
LOW GEAR
45,000
40,000 160 RPM
37,200 INTERMITTENT
TORQUE, CONTINUOUS (ft lb)
1,130 HP LIMIT
35,000
32,500 CONTINUOUS
30,000
25,000
HIGH GEAR
20,000
15,000
12,000 ft lb
10,000
5,000 ft lb
5,000
120 190
0
0 50 100 150 200 250 300
RPM
CONTINUOUS TORQUE VALUES ARE BASED ON 1250 ARMATURE AMPS
INTERMITTENT TORQUE VALUES ARE BASED ON STALL AT 1400 AMPS
WITH A 7 SEC. MAX. DURATION
JUNE 3, 1991 A.N.

March 8, 2001
TDS-4S TOP DRIVE DRILLING SYSTEM

Drill Pipe Torque Vs. Speed GE 752 High Torque Shunt Motor
55,000
50,000 50,100
INTERMITTENT
45,000 45,500
CONTINUOUS LOW GEAR
40,000
TORQUE, CONTINUOUS (ft lb)
35,000
32,000 INTERMITTENT
30,000
29,100 CONTINUOUS
HIGH GEAR
25,000
20,000
Reduced Field
Required in this Area
15,000
10,000
5,000
130 RPM 205 RPM
0
0 50 100 150 200 250 300
RPM
Continuous Torque Values are based on 1250 Armature Amps.
Intermittent Torque Values are based on stall at 1400 Amps with a 7 second maximum duration.
Reduced Field area is based on a 30 Amps Field.

TDS-4S
Top Drive
Drilling
System
Installation and
Commissioning
SM00620-2
October 20, 1998
2-2 TDS-4S Installation and Commissioning

Contents
Manual layout.................................................................. 2-6
Chapter 1 Preparation
Preinstallation checklist.................................................... 2-7
Chapter 2 Installation
Derrick electrical termination kit ..................................... 2-9
Installation ................................................................. 2-9
Wiring ..................................................................... 2-13
Plumbing ....................................................................... 2-15
Hydraulic................................................................. 2-15
Air ........................................................................... 2-15
Water....................................................................... 2-15
Rig-up procedure ........................................................... 2-16
Motor alignment cylinder system ................................... 2-22
Driller’s controls and instrumentation ........................... 2-23
Varco Driller’s Console (VDC)................................ 2-23
Throttle and torque limit controls ........................... 2-23
Wiring ..................................................................... 2-23
Service loops .................................................................. 2-24
Installation ............................................................... 2-24
Electrical loop .................................................... 2-25
Fluids loop ......................................................... 2-25
Air loop ....................................................... 2-26
Retract loop ....................................................... 2-27
Chapter 3 Commissioning
Checkout procedures ..................................................... 2-29
Long term TDS storage procedures................................ 2-32
Returning the TDS to service after storage ..................... 2-33
TDS-4S Installation and Commissioning 2-3

October 20, 1998

Preface
Manual conventions
Safety information

damage.

personnel.


October 20, 1998
faces well center.
Manual layout

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

October 20, 1998

Chapter 2
Installation
Derrick electrical termination kit
Installation
Refer to Figures 2-1, 2-2, and 2-3 for typical mounting
dimensions of the plate assembly. Mount it at racking board
height within 15 ft. of the service loop support bracket.
Remember to provide convenient access for wiring and
maintenance.
Usually, mounting the plate so that the J-box is four to five feet
above the walk-around and near the service loop support bracket
is adequate. If a walk-around does not exist, then construct a
work platform to allow access to the J-boxes. Manufacture
appropriate brackets and clamps to attach the plate to the derrick
structure.

October 20, 1998
± 1/4 in.
Over Full Length CL Rail
CL Rail ± 3/8 in. Over Full Length
± 1/8 in. Within 25 ft. of Floor
CL Rail CL Rail
C
L Well Center
± 3/8 in. Over Full Length
± 1/8 in. Within 25 ft. of Floor
C
L Well Center
TDS Back
Operational Clearance Between Top Drive
And Nearest Girt or Fastline Should Be 3 in. Minimum
Guide Rails
Nearest Girt
Splice
Clearance Splice Plates
or Bolts Are
Not Permissible
on Inside
Surfaces
of Beam
Dolly Overhang
Maximum Rail Support Spacing

16 ft. for W12x53 Rails
25 ft. for W14x74 Rails
6" Rail Stop
Guide Splice Dolly

Dolly Rail Clear Overhang
Size
Config. Inches
10 ft. 6 in. +0/-4 in. 39 x 66 W14 x 90 3.3 0

48 x 62 W14 x 90 3.3 0
30 x 72 W12 x 90 3.3 1.6
30 x 72 W14 x 90 2.3 0.5
Drill Floor
CL Well Center
Figure 2-1. General rail installation data

Clearance Hole For Instrument
.75 in. Dia. Bolt (4 Places) J-Box **
36.0 in.
Motor J-Box **
Electrical Supply*
48.0 in.
Filter/Regulator
Lubrication Assembly** 800 lb Load
B
18.0 in.
Must Support
4,000 lb
Control Service Loop**
B Electrical Service Loop**
Hydraulic Fluids Service Loop**

Air Standpipes 36.0 in.
Standpipes To Be 1 1/2 in.
To Be 1 1/2 in. Sch 40 Pipe*
Sch 80 Pipe*
Water Standpipes View A-A
A To Be 2 in.
Sch 40 Pipe* Typical Service
Loop Termination
86 ft.
Service A
Loops
Gussets *
75 ft.
Mud
Hose
Ref
Service Loop
73 ft. Mud Hose Bracket**
Connection
Existing Girt *
5500 lb Load
View B-B
83 ft. Hydraulic, Air and Water
Standpipe Height and
Service Loop Bracket Location
10 ft. 6 in.
+0/-4 in. 7 ft. Ref * Customer Supplied
** Varco Supplied
Typical Equipment Stack-Up
Figure 2-2. Derrick services/general installation data

October 20, 1998
Motor Frame
Setback
Rails
L
P
L
9 ft. 3 in. TDS-3S
10 ft. 3 in. TDS-4S,
TDS-8S 7 ft. TDS-3S
8 ft. TDS-4S,
TDS-6S, TDS-8S
P
L
Rail Stops
L
42,600 lb for a typical TDS-3S
Rail Loading with TDS in Setback position

Load P - lb
Rail Spacing TDS-3S TDS-4S, TDS-8S
39 in. x 66 in. 18,600 18,900
48 in. x 62 in. 18,600 18,900
30 in. x 72 in. 17,500 17,800
Rail Loading while Drilling - 38,000 ft lb for TDS-3S,

60,000 ft lb for TDS-4S, 68,000 ft lb for TDS-6S,
34,000 ft lb for TDS-7S and 62,250 ft lb for TDS-8S.
Load L - lb
Rail Spacing TDS-3S TDS-4S, TDS-8S TDS-6S TDS-7S
39 in. x 66 in. 3450 5450 -- 3090

48 in. x 62 in. 3680 5800 -- 3290
30 in. x 72 in. 3170 5000 -- 2840
91/101 in. x 108 in. -- 3330 3780 --
Figure 2-3. General installation data

Wiring
The electrical installation requires routing power to the transfer
panel and then to the TDS through the service loops (Figure 2-4).
In addition, control cables are required between the service loop,
the transfer panel, the SCR, the TDS Varco Driller’s Console
(VDC), the SCR’s driller’s console, the hydraulic and water
pumps and the drilling recorder.
Derrick
Power
J-Box
#6AWG/2C*
#12AWG/20C
Shunt Field Derrick
#10AWG/4C
#16AWG/10C #14AWG/2 Pr Shld AC
Transfer Panel J-Box
#6AWG/2C*
Shunt Field
Service Loop
(4)646MCM*
Top
SCR
Drive
Room
System
#14AWG/2 Pr Shld
#14AWG/2 Pr Shld
#14AWG/37C
#12AWG/20C
#12AWG/20C
#16AWG/10C
#12AWG/20C
#12AWG/3C
#12AWG/3C
#10AWG/4C
E/P
Torq #6AWG/2C*
Existing
Power
AC Rotary
Cables
Power Table
RBS
E/P Controls
RPM
#12AWG/3C
#10AWG/4C
#10AWG/4C
#6AWG/4C
#6AWG/4C
#16AWG/10C
#16AWG/10C
TDS Existing
Driller’s Console Driller’s Console
HYD HYD
Pump Pump Water Water
#1 #2 Pump Pump
#1 #2
#16AWG/10C
#16AWG/10C
Figure 2-4. Typical cabling diagram

October 20, 1998
The cable requirements, depending on options selected are:

Cable Runs
646MCM (4 Shunt) SCR room to transfer panel
(8 Series) Transfer panel to derrick J-box
Transfer panel to rotary
#6AWG/2C (Shunt only) SCR Room to transfer panel
Transfer panel to derrick J-box
Transfer panel to rotary
#6AWG/4C AC Power to hydraulic pumps
#10AWG/4C AC Power to water pumps
AC Power to transfer panel
#12AWG/20C Transfer panel to existing driller’s console
Transfer panel to hydraulic pumps
Transfer panel to water pumps
#12AWG/3C Transfer panel to RBS unit
Transfer panel to VDC
RBS unit to VDC
#14AWG/37C Transfer panel to VDC
#14AWG/2PR SHLD Transfer panel to derrick J-box
Transfer panel to VDC
Transfer panel to drilling recorder
#16AWG/10C Transfer panel to SCR console
Transfer panel to SCR room
Hydraulic pumps to transfer panel
Water pumps to transfer panel
Purge control system (not shown)
#12AWG/3C Purge control unit to transfer panel
Isolation unit to floor air control unit
Transfer panel protection unit to isolation unit
#16AWG/10C Purge control unit to transfer panel
VDC protection unit to isolation unit
#14AWG/2PR SHLD Transfer panel to derrick J-box
Terminate the J-boxes per the electrical schematic. Follow

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

October 20, 1998
Rig-up procedure
z Refer to the engineering drawings to install the TDS.

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

roller brackets from the dolly to allow the unit to engage the
guide rails.
3. Once the TDS is fully engaged on the guide rails, install the
stops at the bottom of the guide rails and lower the TDS onto
the stops.
4. Slide the link adapter onto the drive stem and support it up
against the rotating head with adequate rigging and an air
winch. Be certain that the link tilt mounting bosses are
opposite from the torque wrench mounting clevis on the
rotating head.
5. Slide the landing collar retainer onto the drive stem as shown
in Figure 2-5. Install the O-ring in the uppermost groove on
the stem. Load the O-ring and remaining grooves with a
waterproof grease. Place the split landing collar around the
grooves of the drive stem, and drive in the remaining roll pin.
Grease the OD liberally. Wipe off excess grease.
6. Use the installation procedure in the IBOP Service Manual to
install the pipehandler assembly.
7. Use the pipehandler to tighten the connection between the
lower IBOP/saver sub assembly to the upper IBOP.

O-Ring
Roll Pin (4)
Split Landing
Collar (2)
Drive Stem
Safety Link (4)
Figure 2-5. Installing the landing collar
8. Use the four bolts, lock washers and safety wire provided to
install this assembly to the link adapter. Connect the opposite
end of the hose to the quick disconnect on the rotating head
assembly.
9. Install the elevator links and drill pipe elevator. Attach the
link tilt clamps to the bails (U-bolts on the inside). There
should be about 1/2 in. slack in the chains.

October 20, 1998
10. Install the counterbalance system as illustrated in Figure 2-6.

When using chain, use the following procedure to determine
the chain length required:
a. Install pear links to ears on hook-block.
b. With the hook supporting the TDS, measure the distance
from the point of contact inside the pear link to the top
of the mounting lug on the integrated swivel bail.
c. Subtract 37 1/4 in. from the measurement in step b.
d. Cut the chain to the length obtained in step c.
The tolerance is: +3 1/4 in. or -0 in.
e. Assemble remaining components and install per
Figures 2-6 and 2-7.
11. Attach the service loops to the bracket on the TDS dolly
frame. Using the cable clamps provided on the motor support
bonnet, route the electrical cables over the gear box and into
the J-boxes. The front guard folds down for access to the J-
boxes.
Use the electrical schematic (refer to the engineering
drawings) to make the connections. Be certain that the cables
are securely tied or clamped to the structure along their
length. Route the hoses to the bulkhead and plug in the quick
disconnects. Follow the stamped code numbers to confirm
each type, and identify spares.
12. Attach the S-tube to the swivel gooseneck and the side of the
motor frame as follows:
a. Make up the upper union just before clamping the
S-tube to the side of the motor frame.
b. Install the drill pipe rubber onto the S-tube aligned with
the mounting saddle on the frame.
c. Attach the mud hose to the bottom connection of the
S-tube.
d. Position the 20° S-tube elbow on the bottom of the
S-tube to adjust the hanging direction of mud hose.
13. Remove the exhaust duct shipping covers from the spark
arrestors on the air exhaust duct at each side of the DC
motor. Save the covers for use during future shipping or
storage.

Pear Link
Connecting
Link
Hydraulic
Accumulator
(Inside Motor Frame)
Motor Frame
and Guide Dolly
Counterbalance Assembly
Cylinder Assembly
(2)
Counterbalance
Counterbalance Lug Manifold
(Bolted to Bail) (On Guide Dolly)
Integrated
Swivel Bail
Figure 2-6. Typical counterbalance assembly

October 20, 1998
Loop Assembly
Guide Assembly
Cylinder Assembly
Hose Assemblies
Hydraulic Accumulator
(Inside Dolly Tube)
Counterbalance Swivel Bail

Operation Switch
Figure 2-7. Optional counterbalance assembly with parking system
n Never operate the top drive with the exhaust duct covers
attached to the spark arrestors on the air exhaust ducts.
Doing so severely restricts air flow through the motor, causing
overheating and potential damage. They can also fall off
during operation and injure personnel working below.
Attach the covers only during shipping and storage.

Counterbalance system
Figures 2-6 and 2-7 illustrates the installation arrangement for
this system. Please see the Maintenance and Troubleshooting book
for the adjustment procedures.
This assembly is pre-charged when it is shipped by land or water
transport. When this assembly is shipped by air freight, it must be
pre-charged according to the instructions in the Maintenance and
Troubleshooting book.

October 20, 1998
Motor alignment cylinder system

Figure 2-8 shows the motor alignment cylinder installed on a
typical motor frame.
The split shipping brace, shown exploded from the cylinder rod,
is only removed after unit is fully installed. If the brace is removed
before the hydraulic system is powered, the motor will tend to
rotate on its trunnions.
If the cylinder is removed for service, use the three bleed holes
(located along the top of the cylinder barrel) to remove trapped
air from the cylinder before operating the unit. Refer to the
Maintenance and Troubleshooting book for the adjustment
procedure.
Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)

Driller’s controls and instrumentation
The controls and instrumentation described in the following
sections are, or must be, supplied for operation of the TDS
system.
Varco Driller’s Console (VDC)

Mount the VDC within easy reach and in plain view of the driller
while he is operating the drawworks brake and clutches. The
gauges must be easily seen by the driller during drilling
operations. Provide appropriate cable glands for the electric
cables.
Throttle and torque limit controls

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

by Varco should be aware that Varco systems are specifically
designed with operational interlocks and safety devices to
prevent possible injury to personnel or damage to the system.
Other systems must meet Varco requirements. Varco highly
recommends the use of its system as it is specifically made for
use with the TDS.

October 20, 1998
Service loops
Installation
Install the service loops as follows:
1. Fabricate the appropriate brackets and clamps to attach the
service loop mounting bracket to the derrick structure.
2. Place the service loop derrick mounting bracket at the height
specified on the derrick interface drawing provided in the
engineering drawings. Locate the bracket on the side of the
derrick adjacent to the hinges on the TDS and as far as
practical toward the corner where the guide rail bracing is
attached. The bracket must be located far enough from the
corner to insure the loops do not catch under the guide rails
during operations, but far enough back to provide clearance
for tong lines, the stabbing board, tugger lines, etc.
3. Do not unpack the service loops from the shipping protective
crate until they are ready to hang in the derrick. Lift the
service loops onto the rig floor (still in the crates) and then
remove them from the crates with the lifting eyes provided.
e Use care in lifting gear rigging so as not to damage electrical

conductors. Use lifting eyes only. Do not bend the service loops tighter
than a three foot bend radius. Tighter bends damage the loops.
4. Attach a sling to the TDS end of the service loop and lift
using the lifting eyes only. Allow enough room for the 86 ft.
service loop to hang and untwist.
5. Use the lifting eyes to pull the derrick end of the loop
through the V-door and attach it to the air tugger. Hoist this
end of the loop into the derrick while slacking off at the crane
end. Do not drag the loop on any sharp areas on the derrick.
Disconnect the crane from the sling and continue hoisting the
loop into the derrick.
6. Check that the derrick end of the loop is hanging toward the
crown. Attach the derrick end to the derrick service loop bracket
and hold in place with flange clamps (Figures 2-2).

7. Pick up the TDS end of the loops and attach them to the
service loop bracket at the bottom of the motor frame.
8. Complete the terminations of the two loops as outlined in the
following sections.
Electrical loop
1. Connect the pre-terminated wire ends at the motor J-boxes
using the appropriate glands. Refer to the electrical schematic
provided to ensure proper terminal block assignments.
2 Cut wires and cables to length and terminate them at the
derrick end to attach them to the derrick J-boxes.
Terminal ends and lugs are supplied, but proper assembly
equipment (crimping pliers, wire strippers, and hydraulic crimper
for the DC power lugs with the correct dies for the cable) must be
provided by the installer. Installation practices should comply
with applicable electrical codes (i.e., NEC, etc.).
Fluids loop
1. Before connecting the hoses from the service loop, be certain
that the service stand pipes have been flushed free of any
contamination.
z Use only 10 wt. hydraulic oil or non-detergent motor oil as a

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

October 20, 1998
3. Connect the service loop to the standpipes, noting the codes

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

elevator, attach the airlines from the air-operated elevators to the
spare port S1 on the rotating head whenever possible. Port S1 is
located next to the hydraulic return port in the rotating head.
Port S2 is next to the hydraulic press port.
Install a pressure relief valve on the elevator and set at 200 psi.

Retract loop
If your rig is equipped with a retract guide dolly, attach the retract
loop to the derrick mounting brackets as follows:
z There are four separate service loops needed for a TDS with
retractable dollies: two electrical loops, a fluids loop, and a retract
system loop. The electrical and fluids service loops attach to the
derrick service loop mounting bracket, the retract loop attaches to
the retract system service loop bracket.
1. Lift the crate containing the retract system service loop onto
the rig floor.
2. Uncrate the service loop.
3. Attach an air winch to the lifting eyes on the derrick end
(derrick end has 8 ft. of hose extending beyond the flange)
and hoist to the retract system mounting bracket.
4. Attach the service loop flange to the mounting bracket with
the hardware provided. Ensure that the service loop hangs
straight in the derrick without any twists or kinks.
e Use only 10 wt. hydraulic oil or non-detergent motor oil as a

lubricant in the air system. Use of any other type of oil (i.e. Marvel
Mystery Oil, etc.) or synthetic additive will cause the seals in the air
valves to swell and cease to function.
5. Connect the retract service loop hydraulic and pneumatic
hoses to the derrick standpipes.
e Before connecting the hoses from the service loop, be certain that the
standpipes have been flushed free of any contamination.

October 20, 1998

Chapter 3
Commissioning
Checkout procedures
1. Turn on the hydraulic and air power and check for leaks.
Repair as required.
2. Turn on the electric power (driller’s controls only).
3. Check the function of switches and solenoids. There is an
audible click when each solenoid is actuated.
4. Actuate the link tilt. Be sure that it operates smoothly and the
elevator reaches a joint in the mousehole.
5. Adjust the intermediate stop so that the elevator clears the
monkeyboard when actuated. Refer to the Maintenance and
Troubleshooting book if a problem occurs.
6. Actuate the motor brake. There is a loud sound as the air
escapes when the brake releases.
7. Move the Make/Break valve located on the manifold at the back
of the pipehandler torque wrench to the BREAK position.
8. Turn on the hydraulic power supply and adjust the pressure
reducing valve (also located on the torque wrench manifold)
to the appropriate pressure for the lower IBOP connection.

October 20, 1998
9. Return the Make/Break valve to the MAKE position.

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

and that no binding occurs as the valve will fail prematurely (wash
out) if it does not open and close fully.
16. Verify that the indicator light on the VDC lights up when the
IBOP valve is closed.
17. Assign the TDS at the driller’s console and check that the
blower operates.
18. Advance the throttle and be sure that the motor is operating
properly in both directions.
19. Calibrate the Torque meter and RPM meter.
20. With the Hydraulic Power Unit (HPU) off, bleed down the
TDS accumulators (HYD SIDE, not gas side).
21. Remove the split shipping brace (Figure 2-7) from the motor
alignment cylinder.
22. Open the two flow control valves 1-1/2 turns off their seats.
23. Set a joint of drill pipe in the slips.

24. Bring the TDS down as if stabbing the saver sub into the box.
The pin and box should be in alignment. If adjustment is
necessary, use the following procedure:
a. Measure how far and in what direction (toward or away
from the rails) the pin must move to line up with the drill
pipe box.
b. Turn off the HPU and bleed down the cylinder
accumulator (open the needle valve on the back of the
manifold). This allows the motor alignment cylinder to
relax and the motor to rotate on its trunnions until the
integrated swivel bail contacts the motor support bonnet.
c. Loosen the lock tab and jam nut on the cylinder clevis.
d. With a wrench tightened on the cylinder rod flats, screw
the rod into or out of the clevis, in the same direction the
saver sub pin is to be moved.
e. Secure the jam nut and lock tab.
f. The nominal position of the two cylinder flow control
valves is 1-1/2 turn off their seats. If you experience heavy
drill pipe vibration, first attempt to control it with non-
rotating stabilizers if the casing shoe is close to the surface.
If motor movement becomes excessive due to continued
vibration, (more than 1/2 in. of total cylinder stroke)
close the flow controls to 3/4 turn off their seats.

October 20, 1998
Long term TDS storage procedures

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

Returning the TDS to service after storage
Before placing the TDS back into service, verify the following
items:
1. Remove all rust preventive and any corrosion that may have
taken place, taking special care with all load carrying
components.
2. Follow the procedure in the drilling motor service manual.
To verify the condition of the motor, take note of the
following:
a. Blow out all dust and dirt that may have accumulated in
the windings with clean, dry air.
b. Visually inspect for spring corrosion, sticking brushes and
general defects.
c. Remove the brushes from holders, inspect and replace
them as necessary prior to operation.
d. Check the winding insulation continuity to ground with
a 1,000 volt megger. If the reading is less than two
MOhms, bake the winding until the moisture content is
sufficiently reduced to produce an acceptable reading.
3. Perform a complete system test and adjustment as detailed in
the next section.

October 20, 1998

TDS-4S
Top Drive
Drilling
System
Operation
SM00620-3
October 20, 1998
3-2 TDS-4S Operation

Contents
Manual layout.................................................................. 3-6
Chapter 1 Operating procedures

Start-up procedure ........................................................... 3-7
Stalling the DC motor ..................................................... 3-8
Changing transmission speeds .......................................... 3-9
Pipehandler operation .................................................... 3-11
Controls............................................................. 3-12
ROTATING HEAD LEFT/RIGHT switch ..... 3-12
AUTO STOP/FREE ROTATE switch ............ 3-12
Torque wrench ........................................................ 3-16
Changing drill string sizes ........................................ 3-19
PH-85 ............................................................... 3-19
PH-60d ............................................................. 3-19
Torque values for load carrying components ............ 3-20
Drilling ahead ................................................................ 3-21
Drilling ahead with triples ....................................... 3-21
Drilling ahead with singles ....................................... 3-24
Drilling ahead on a semi .......................................... 3-26
Tripping ........................................................................ 3-28
Reaming out .................................................................. 3-29
Well control procedures ................................................. 3-31
Running casing .............................................................. 3-32
Handling bottom hole assemblies .................................. 3-32
Post jarring operations ................................................... 3-34
TDS-4S Operation 3-3

October 20, 1998

Preface
Manual conventions
Safety information

damage.

personnel.


October 20, 1998
faces well center.
Manual layout

Chapter 1
Operating procedures
Start-up procedure
Use the following procedure to start up the TDS:
1. Place the blower/oil pump switch in the AUTO position.
2. Place the hydraulic power unit (HPU) switch in the PLC
position.
3. Place the water pumps switch in the PLC position.
4. Place the motor space heater switch in the ON position.
5. Place the top drive/rotary table (TDS/ROT) lockout switch
in the TDS position.
6. Assign a SCR.

October 20, 1998
Stalling the DC motor
e The brake on the top end of the TDS drilling motor armature shaft is
a static, or parking brake. It is not a running or dynamic brake. It is
not intended to, nor is it capable of, slip-releasing the wind-up torque
in the drill string. Using the brake to slip-release the drill string
wind-up torque causes the brake to heat up and can destroy the brake
lining.
When the TDS motor brake holds the down-hole torque, Varco
recommends using the following procedure to safely release the
torque in the string:
1. Use the hand throttle to develop motor torque equal to the
wind-up torque held by the parking brake.
2. Release the parking brake.
3. Reduce the drill current, reducing motor torque, as the drill
string slowly releases the wind-up torque.
4. Turn the hand throttle off and reset the drill current to the
normal operating position after the pipe unwinds completely.
e Do not leave the top drive DC motor stalled in a high torque

condition generally for more than 10 seconds (refer to the following
table):
Amps Stall time (sec) Amps Stall time (sec)

280 240 900 25
470 90 1000 20
670 45 1200 15
820 30 1400 10

Changing transmission speeds
The transmission shifts gears by rotating two vertical compound
gear eccentric shafts (Figure 3-1). The two compound shafts (high
and low) are supported between the main body and lower gear
case halves on heavy trunnions. As the shafts rotate (less than one-
half turn), the compound gears go into or out of mesh with both
the motor pinion gear and the bull gear because the support shaft
center axes are offset or eccentric.
To change transmission speeds, use a 1 in. wrench to turn the
1 in. male hex, located on the well side of the guide dolly lower
cross members at the bottom of the transmission case, to rotate
the input shaft. It takes five turns of the input shaft to unlock
both gear sets, rotate the engaged gear set to full disengagement,
rotate the disengaged gear set into full engagement and lock both
gear sets in their proper positions with positive stops in the locked
position. An external indicator shows the gear range selection.
An optional remote gear shifter is available. It allows the operator
to change gears simply by turning a switch to select the desired
gear. Refer to the Remote Gear Shifter Supplement for more
information.

October 20, 1998
Rotating Head
Assembly
Shifter
Input Shaft
HI LO
External
HI / LO
Indicator
Compound
Gear Shafts
Bottom View
High Gear Low Gear

Eccentric Shaft Eccentric Shaft
(Engaged) (Disengaged)
Geneva Shifter Input

Mechanism
Top View
Figure 3-1. Transmission/geneva mechanism

Pipehandler operation
Standard rotating head

The perimeter of the rotating head cam (Figure 3-2) has an
indented area where the cam follower normally rests. When the
cam follower is in this indented area, the return cylinder rod is
fully retracted and hydraulic pressure inside the cylinder is at
equilibrium. When the swivel block and cam rotates to another
position along with the drill string, the ramp of the cam extends
the return cylinder rod, unbalancing hydraulic pressure in the
cylinder. When the elevator is released, the system automatically
returns to its pre-selected (indented) position (equilibrium).
To operate the swivel block locking mechanism, pull down the
locking lever, pulling the locking pin out of one of 24 locking
slots in the cam. With the locking lever in the vertical position,
manually rotate the swivel block to the desired position and
release the locking lever, setting the pin.
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location

(Lug not shown)
Figure 3-2. Standard 650-Ton rotating head assembly

October 20, 1998
Powered rotating head

The 10-port powered rotating head (Figure 3-3) functions as a
hydraulic slip ring. It provides ten hydraulic and pneumatic
passages between the stationary swivel flange and the rotating
swivel block and attached pipe handling equipment.
The powered rotating head is operated by controls on the driller’s
console. The driller can rotate the swivel block and attached pipe
handling equipment freely, or to a predesignated AUTO STOP
position. The position can be set by locating a target in the bull
gear on the rotating head, to align with the proximity sensor
mounted on the flange of the rotating head.
Controls
The powered rotating head is controlled by two switches.
ROTATING HEAD LEFT/RIGHT switch

This switch rotates the powered rotating head, pipe handler, and
link tilt to the right or left (same direction as the drill string).
Rotation only occurs when the switch is held in the RIGHT or
LEFT position. Rotation stops when the switch returns to the
center position.
z The ROTATING HEAD function is only active when the LINK

TILT switch is in the FLOAT position.
AUTO STOP/FREE ROTATE switch

This switch is in the AUTO STOP mode when the light is
illuminated (on). In the AUTO STOP mode, a proximity sensor
automatically stops rotating head rotation. The AUTO STOP
function is independent of the direction of rotation. Rotation
continues when the ROTATE switch returns to the center
position, then activated again. When the AUTO STOP/FREE
ROTATE light is off, the FREE ROTATE mode is active. In this
mode, the rotating head rotates as described in the ROTATING
LEFT/RIGHT section above.

Stationary
Flange
Rotary Glyd
Ring (11)
Torque Arrestor
Hanger
Bull Gear
Swivel Block
Hydraulic Motor
Assembly
H1
S1
A1
RE
A3
PRESSU
H1
H3
A2
S2
A5
A4
H2
S2
A4
A1
A5
A2
H3
A3
H2 S1
Figure 3-3. Powered rotating head assembly

October 20, 1998
Safety valves (IBOP)

Operating the switch on the VDC to the IBOP CLOSED
position causes the two actuator air cylinder rods to extend,
moving the arms and the actuator shell body upward (Figure 3-4).
This upward movement causes the crank assemblies to rotate 90°,
closing the upper IBOP.
Operating the switch to the OPEN position retracts the cylinder
rods, drawing the IBOP actuator shell downward-opening the
upper IBOP.
z Closing the manually operated lower IBOP requires an Allen

wrench.

Main Shaft/
Drive Stem
Link Adapter
(Also known as
Landing Collar
Upper IBOP
Valve Actuator
Air Cylinder (2)
Crank Assembly (2)

Actuator Shell
Upper IBOP
Torque Tube
Lower IBOP
Saver Sub
Drill Pipe
Figure 3-4. Safety valve actuator system

October 20, 1998
Torque wrench
The primary function of the TDS torque wrench is to breakout
the drill string from the saver sub before making a connection.
The torque wench can also make connections if necessary (i.e.,
when replacing the lower IBOP or saver sub, or while back-
reaming, or when adding a pup joint to the drill stem).
The torque wrench has a control manifold with the following
components (Figure 3-5):
❏ Hydraulic pressure gauge

❏ Control and sequencing valves
❏ Hydraulic hose inlet and outlet Quick Disconnects (QDs)
❏ Manual Make/Break directional valve
The Make/Break valve controls the torque wrench operating
direction (makeup/breakout) during operation.
A pressure reducing valve (PRV) on the control manifold allows
presetting the makeup torque (this valve is bypassed when the
torque wrench is in breakout mode).
When the driller actuates the torque wrench from the VDC, the
lifting cylinder rod retracts, raising the torque tube to engage the
splines on the upper IBOP. A sequenced signal from the control
manifold then operates the clamping piston, clamping the jaws
onto the drill string box connection. Then another sequenced
signal from the control manifold automatically
directs pressure to the torque cylinders, rotating the torque tube
up to 25° while developing a maximum torque of 85,000 ft lb
(65,000 ft lb on the PH-60d Pipehandler). The position of the
Make/Break valve on the control manifold determines the
direction that the torque tube rotates.
A two-position, air-piloted, hydraulic valve located on the
counterbalance manifold located on top of the TDS guide dolly
controls the entire sequenced cycle described above. A push
button switch on the VDC operates the hydraulic valve. The
driller holds the button down to makeup or breakout a
connection, and then releases the button to allow the torque
wrench to automatically recycle to the ready position. If the
torque developed on the first pass is insufficient, the driller simply
operates the button again.

Manually switch the Make/Break valve on the torque wrench to
the MAKE position to use the top drive torque wrench to make
connections. This allows the driller to initiate automatic torque
wrench sequences and repeat them until reaching the preset
makeup torque.
Make/Break
Valve
Recycle Clamp Torque

Sequence Sequence Sequence
Valve Valve Valve
Torque Wrench
Manifold
BREAK MAKE
Hydraulic
Pressure
Return
RECYCLE CLAMP TORQUE

PRV 50 60
40
70
1000 1500
30
Hydraulic
80
Pressure
LIFT LOWER
20
500 2000
Inlet
90
Lift/Lower
10
®
0 2500
10
Flow Control PSI
0
0
Valve
Ft.Lbs. x1000
Torque Gauge
0 - 2500 PSI
Figure 3-5. Typical torque wrench control manifold

October 20, 1998
n Failing to apply the correct amount of torque when using the

torque wrench to makeup connections can result in equipment
damage and injury to rig personnel.
Do not switch the Make/Break valve to BREAK until completing

the makeup sequence, which may require repeating the makeup
sequence several times.
Verify the torque pressure regulating valve setting after every

makeup sequence before releasing the makeup valve. Repeat the
makeup sequence until the torque cylinders do not stroke more
than one inch during the final sequence, repeat the sequence if
uncertain. Varco recommends that the driller operating the
pipehandler verify that the torque cylinders do not stroke more
than one inch on the last makeup cycle.
Varco also recommends checking the torque gauge on the

pipehandler while making connections to make sure the torque
wrench applies the correct amount of torque to the connection.
Stop and verify correct operation whenever the operator observes

unsteady or inconsistent hydraulic pressure readings, or finds it
difficult to adjust set points.
Varco recommends that a second individual assist the driller when

making connections with the torque wrench. The second person
can verify that the torque wrench applies the correct torque to
connections.

Changing drill string sizes
PH-85
To operate the torque wrench using drill string sizes that are different
from the size specified on your rig’s original configuration, install a
separate drill string handling kit. Refer to the following tables when
ordering a drill string handling kit for a PH-85:
Drill String Change-Over Kits

750/650 Ton PH-85
Pipehandling Desired Tool Joint Connection
Original Part Number NC 38 NC 50 5 1/2 F.H. 6 5/8 F.H. 2 7/8 F.H.
95497-A-H-N-*-* 91873-650 94731-650 94730-650 –––
95497-A-J-N-*-* 91873-650 94731-650 ––– 94729-650
95497-A-K-N-*-* 91873-651 ––– 94730-651 94729-651 97219-651
95497-B-K-N-*-* 91873-651 ––– 94730-652 94729-652
95497-A-L-N-*-* n/a n/a TBD ––– n/a
*These designators do not affect kit choice.
PH-60d
To operate the torque wrench with a 3 1/2 in. drill string, install a
separate drill string handling kit. The following lists available kits
for a PH-60d:
❏ Part No. 78652-1 – Includes stabbing guide assembly, jaw

assemblies, saver subs, installation drawing.
❏ Part No. 78652-2 – Includes stabbing guide assembly, jaw
assemblies, installation drawing.
z Part No. 78652-1 includes 3 1/2 IF saver subs, while Part No.
78652-2 does not. By purchasing the latter, the user assumes
responsibility for obtaining appropriate 6 5/8 reg. x 3 1/2 IF saver
subs separately. Specifications for these are available from the
factory or any Varco service center.

October 20, 1998
Torque values for load carrying

components
Proper makeup torque is critical to the function of drill stem
components. Table 3-3 only includes components within the
TDS. Refer to the API charts for other components.
Table 3-3. Torque values for load carrying components
Components ID Connection OD Min. torque Max. torque
Upper IBOP to
main stem/main shaft 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 50,000 ft lb 63,000 ft lb
Lower IBOP valve
to upper safety valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/4 in. 50,000 ft lb 60,000 ft lb
Saver sub to
lower IBOP valve 3 or 3 3/4 in. 6 5/8 in. API Reg. 7 3/8 in. 46,000 ft lb 60,000 ft lb
Crossover sub to
Upper IBOP valve to
main stem/main shaft 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 83,000 ft lb 91,000 ft lb
Lower IBOP valve
to upper IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 75,000 ft lb 84,000 ft lb
Saver sub to
Crossover sub to
lower IBOP valve 3 or 3 3/4 in. 7 5/8 in. API Reg. 9 in. 75,000 ft lb 91,000 ft lb

Drilling ahead
Drilling ahead with triples

Drilling ahead with triples is the common drilling mode for the
TDS. There are various sources for triples. On skidding rigs
drilling multiple well platforms, drill pipe can be left racked and
used to drill the next well.
If triples do not currently exist, there are two recommended
methods of obtaining them. One is to leave some triples racked in
the derrick when tripping back in the hole and finish the trip
with singles. Leave enough triples racked to handle anticipated bit
life.
The second method for obtaining triples is to make up triples in
the mousehole while drilling ahead or during idle rig time. For
safety reasons a pivoting mousehole is best because it can pivot to
a vertical plane to simplify making connections.
Use the following procedure to drill ahead with triples
(Figure 3-6):
1. Drill down until the saver sub is within three feet of the
rotary table.
2. Circulate bottoms up as necessary.
3. Stop the string rotation.
4. Pick up the string and set slips for a connection four feet off
the rig floor.
5. Switch the TDS motor from FORWARD to REVERSE.
6. Stop the mud pumps.
7. Close the IBOP.
8. Break out the drill pipe connection using the torque wrench
on the pipehandler.
9. Using the TDS motor, spin out of the box while hoisting the
TDS with the drawworks (follow with the drawworks, do not
lead).

October 20, 1998
Set slips on Raise block Pickup stand with Lower block to Pull slips
string elevator stab motor into
Tilt link tilt top of stand Start circulation
Stop circulation to derrickman Stab bottom of
stand onto string Spin in motor Begin drilling
Breakout and stand
connection
using pipehandler Makeup both
and drilling motor connections with
(in reverse) motor
1 2 3 4 5
Link
Makeup
Tilt
Start
Circulation
Stop
Circulation
Stab Makeup
Figure 3-6. Drilling ahead with triples

10. Stop the spin out mode.
11. Open the drill pipe elevators.
12. Retract the TDS away from the hole.
13. Hoist the TDS to the racking board level to get the next
stand.
14. Latch the backup tong on the box connection.
15. Thoroughly dope the box connection in the rotary table.
16. When the TDS is fully raised, extend the TDS.
17. Tilt the links.
18. Switch the TDS motor from REVERSE to FORWARD.
19. Derrickman latches the elevator on the next stand.
20. Hoist the pin off setback area and clear the box with the
stand.
21. Release the link tilt.
22. Stab the connection at the floor.
23. Switch the TDS to SPIN IN mode.
24. Continue to slack off approximately two feet to stab the
upper connection of the stand with the TDS.
25. Slack off to allow connection to shoulder up (lead with the
drawworks, do not follow).
26. Switch to TORQUE and hold for approximately six seconds.
The makeup torque is preset.
27. Verify full makeup to the correct value on the torque meter.
28. Switch to DRILL mode.
29. Unlatch the backup tong.
30. Open the IBOP.
31. Start the mud pumps.
32. Pick up to pull the slips.
33. Drill ahead.

October 20, 1998
Drilling ahead with singles

Typically there are two situations requiring drilling ahead with
singles. One is beginning operations on a new well where there
are no triples made up and racked. The other is when making
surveys every 30 ft. (i.e., when kicking off using a downhole mud
motor). The link tilt feature makes drilling with singles safe and
efficient by moving the elevators to the mousehole to pick up the
singles.
Use the following procedure to drill ahead with singles
(Figure 3-7):
1. Drill down the existing single, pull up to the 4 ft. level
(approximately), close the IBOP, stop mud circulation, and
set the slips.
2. Break the connection between the saver sub and the drill pipe
using the torque wrench in the pipehandler.
3. Spin out the connection using the drilling motor.
4. Lift the TDS, opening the drill pipe elevators to allow them
to pass over the box setting in the rotary table.
5. Actuate the link tilt to bring the elevator over to the single in
the mousehole and latch the elevator around the single.
6. Pull the single out of the mousehole and as the pin clears the
floor, deactivate the link tilt to allow the single to come to
well center.
7. Stab the connection at the floor and lower the TDS, allowing
the added single to enter the stabbing guide until the saver
sub pin stabs into the box of the new joint.
8. Using a backup tong to react the torque, spin up and torque
the connection using the TDS motors in the TORQUE
mode.
9. Pull the slips, start the mud pumps and drill ahead.

Set slips on Tilt links to Pickup single with Lower block to Pull slips
string mousehole elevator stab motor into
top of single Open IBOP
Stop circulation Latch drill pipe Release link tilt
elevator around Spin in motor Start circulation
Close IBOP single Stab bottom of and single
single onto string Begin drilling
Breakout Makeup both
connection connections with
using pipehandler motor in
and drilling motor torque mode
(in reverse)
1 2 3 4 5
Makeup
Open
IBOP
Close Link
IBOP Tilt
Stab Makeup
Figure 3-7. Drilling ahead with singles

October 20, 1998
Drilling ahead on a semi

Derrick clearances are critical for drilling operations with the
TDS on a floater. When making a connection, kelly drilling pulls
the bit off bottom far enough to account for vessel heave. The
54 ft. kelly must be pulled all the way up to add the next joint.
With the TDS, there is no kelly to pull up. Therefore, you must
be able to pull the bit off bottom enough to allow for vessel heave
when making a connection. The practical method for doing this
is to pull up the pipe string until the bit is sufficiently off bottom,
and then set the slips. The distance should equal the maximum
expected heave.
The TDS pipehandler can break out the drive shaft, and the TDS
motor can spin out the connection. Then hoist the TDS into the
derrick and add a new 90 ft. stand from the pipe rack in the same
manner as on a fixed rig.
Because the pin connection of the new stand is about 15 ft. above
the floor, a torque backup device is required, as well as a means to
assist stabbing. Varco provides a simple, remotely-operated Raised
Backup System (RBS) which retracts out of the way when not in
use.
Use the following procedure to drill ahead with triples on a semi
(Figure 3-8):
1. Drill the stand down until the elevator is to the floor.
2. Pull the string up sufficiently off bottom.
3. Set the slips.
4. Breakout the TDS and spinout shaft using the drilling motor.
5. Raise the TDS to the racking platform and latch the elevator
on a new stand.
6. Extend the RBS and adjust the height. Clamp the RBS tong
on the elevated box of the drill string.
7. Stab the pin of the new stand into the string using the RBS
stabbing head if so equipped, or use the lower racking arm.
8. Stab the TDS into the upper end of the stand, spin in, and
make up both connections.
9. Retract the RBS.
10. Pull the slips and drill ahead.

Drill down stand Pickup string Raise block Spin in stand Pull slips
10 to 20 ft.
Stop circulation Extend RBS Makeup both Retract RBS
Set slips and adjust height connections
Unlatch elevator with motor Start circulation
Breakout/spinout Pickup stand
with pipehandler Begin drilling
and motor Stab stand using 90 ft.
RBS to assist
1 2 3 4 5
Makeup
Start
Circulation
Stop
Circulation
Makeup
Figure 3-8. Drilling ahead with triples (floaters)

October 20, 1998
Tripping
Perform tripping operations in the conventional manner. Use the
link tilt feature to tilt the elevator to the derrickman so the
derrickman can quickly latch it around the pipe.
The hydraulic link tilt allows the elevator to also reach the
mousehole.
The air actuated link tilt has an intermediate stop which is
adjustable to set the elevator at a convenient working distance
from the monkeyboard. The intermediate stop tilts out of the way
to allow the elevator to reach the mousehole.
If a tight spot or key seat is encountered while tripping out of the
hole, spin the drilling motor into the stand at any height in the
derrick. Establish circulation and rotation immediately to work
the pipe through the tight spot.

Reaming out
The TDS permits reaming out of an open hole to prevent pipe
sticking and to reduce key seat formation, without affecting
racking functions associated with normal tripping (i.e., there are
no singles to contend with). The pipehandler torque wrench can
break out 90 ft. stands in the derrick.
Use the following procedure to ream out of the hole (Figure 3-9):
1. Hoist the block while circulating and rotating the drilling
motor until the third connection appears.
2. Stop circulation and rotation and set the slips.
3. Break out the drilling motor from the top of the stand using
the pipehandler torque wrench. Hold a backup at the floor
and spin out the drilling motor.
4. Break out the stand at floor level, and spin out using pipe
spinners.
5. Pick up the stand with the drill pipe elevator.
6. Rack the stand back.
7. Lower the block and TDS to the floor.
8. Stab the drilling motor into the box, spin up and torque it
with the drilling motor. With light slip loads, the pipehandler
torque wrench can be used to torque the connection.
9. Resume circulation and continue reaming out of the hole.

October 20, 1998
Hoist while Set slips on Hoist free stand Setback stand Lower block,
circulating and string with elevator using link tilt stab motor into
rotating string
Breakout connec-
When 3rd tion using pipehandler Spin in motor
connection and drilling motor and makeup
surfaces, stop (reverse) connection with
rotation and motor
circulation Breakout and
spinout stand Start circulation,
at floor pull slips,
hoist and rotate
1 2 3 4 5
Breakout Hoist Setback
Hoist and
Rotate
Breakout
Figure 3-9. Reaming out

Well control procedures
The TDS can stab into the string in any position in the derrick.
While drilling, the remotely controlled IBOP valve is always in
the string for immediate use as needed.
Use the following TDS well control procedure in conjunction
with standard IBOP well control procedures:
1. On indication of a kick, set the slips at the nearest connection
and stab the TDS into the string.
2. Spin up and torque the connection using the Spin/Torque
control, after setting the backup tong.
3. Remotely close the upper IBOP valve.*
4. Lower the string to the floor and reset the slips.
5. Manually close the lower IBOP valve.
6. Remove the torque wrench vertical travel stops.
7. Breakout the lower IBOP from the upper IBOP.
8. Engage the top drive motor in reverse to spin out the
connection.
9. Install the appropriate crossover sub, check valve or
circulation sub on top of the lower IBOP valve.
10. Proceed with normal well control procedures.
* Operation of the IBOP valves is the same as any standard valve.
A 7/8 in. hex wrench is included with the system to operate the
upper valves if the remote actuator should fail, or for checking
that the valve is functioning correctly.

October 20, 1998
Running casing
For casing operations, longer elevator links (180 in.) must be used
to allow clearance for the cementing head under the torque
wrench in the pipehandler.
Attach a short piece of hose to the saver sub in the pipehandler to
fill the casing while lowering. Use the remotely controlled upper
IBOP valve to start and stop the fluid flow.
If desired, run casing conventionally using the block and hook
and swinging the TDS aside. Use longer bails (180 in.) to prevent
the block dolly (if used) from contacting the TDS dolly.
Handling bottom hole assemblies

For handling bottom hole assemblies, use the swiveling drill collar
dolly (Figure 3-10) to allow the elevators to turn freely. The drill
collar dolly’s upset, which latches in the standard drill pipe
elevator, is mounted on a bearing allowing it to swivel even while
it is under load. A shoulder elevator is suspended from the
“perfection” links (or a second drill pipe elevator if lifting subs are
used.) The collars can be walked in or out with the elevator
turning on the drill collar dolly.

A
Drill Pipe
Elevator
Drill Collar
Dolly
A
100 TON
VARCO
Perfection
Links (36")
;;
;;; ;;
;;; ;;;
;;;
91 in.
Square
Shoulder
Elevator
Lifting
Sub
37 in.
Drill
8 in. Collar
View A-A
Figure 3-10. Swiveling drill collar dolly

October 20, 1998
Post jarring operations
e Jarring occurs on all drilling rigs. It is not practical to recommend

removing the top drive from the drill string during all jarring
operations. But the possibility of damage to a top drive during a
jarring operation is considerable. Consider removing the top drive
from the drill string before performing prolonged jarring. It is
imperative to exercise caution when using a top drive after a jarring
operation.
Safe operation of the TDS is the responsibility of the user and rig
crew. Use the Post Jarring Checklist (PI 93-1) and Design
Specification, Design Torque Standard (DS00008) to help ensure
safe top drive operation. Note that the checklist includes
recommended procedures. Do not limit inspections to items on the
checklist.
The checklist draws attention to specific parts on major subassemblies.
Inspection should be rigorous, looking for any wear that could cause a
safety or operational risk.
Use the Post Jarring Checklist (PI 93-1) and Design Specification,
Design Torque Standard (DS00008) after performing any jarring
operation while the top drive is in the drill string.

TDS-4S
Top Drive
Drilling
System
Maintenance
and
Troubleshooting
SM00620-4
Rev. B
March 8, 2001
4-2 TDS-4S Maintenance and Troubleshooting

Contents
Manual layout.................................................................. 4-8
Inspection ........................................................................ 4-9
TDS swing out procedure .......................................... 4-9
DC drilling motor ................................................... 4-12
Motor alignment cylinder ........................................ 4-12
Air exhaust muffler .................................................. 4-12
Derrick termination kit air filter/regulator/
lubricators ................................................................ 4-13
Pipehandler .............................................................. 4-14
Nondestructive Examination (NDE) ....................... 4-14
Visual inspection................................................ 4-14
Landing collar .............................................. 4-16
Drive stem ................................................... 4-18
Magnetic Particle Inspection (MPI) ................... 4-20
Ultrasonic Inspection ......................................... 4-21
Safety valve inspection procedures (IBOP) ... 4-21
Chapter 2 Lubrication
bonnet assembly............................................................. 4-23
Gearbox ................................................................... 4-23
Torque setting procedure ................................... 4-25
Other gearbox lubrication and
maintenance considerations ............................... 4-27
Initial oil change period ........................................... 4-27
Oil capacity.............................................................. 4-28
Lubricating the DC motor ....................................... 4-29
Lubricating the washpipe and bonnet seal ................ 4-30
Lubricating the rotating head ......................................... 4-31
Lubricating the link adapter ........................................... 4-32
Lubricating the torque wrench ....................................... 4-33
Lubricating the master bushing ID wear guide ............... 4-34
TDS-4S Maintenance and Troubleshooting 4-3

March 8, 2001
Lubricating the safety valve actuator .............................. 4-34

Lubricating the upper safety valve (IBOP) ..................... 4-35
Lubricating the guide dolly assembly ............................. 4-36
Lubricating the bail pins ................................................ 4-41
Lubricating the cooling system ....................................... 4-42
Lubrication schedule ...................................................... 4-44
Lubricant specifications ................................................. 4-45
Adjustment procedures .................................................. 4-49
Adjusting the torque wrench .................................... 4-49
Adjusting the upper safety valve (IBOP)
and safety valve actuator system ............................... 4-52
Adjusting the counterbalance system ........................ 4-52
Adjusting the motor alignment cylinder system ....... 4-54
Precharging the counterbalance system .................... 4-60
Assembly and disassembly .............................................. 4-62
Pipehandler .............................................................. 4-62
Torque wrench disassembly ............................... 4-62
Replacing the torque wrench
clamping piston seal ..................................... 4-68
glyd rings ........................................................... 4-71
glyd rings ........................................................... 4-75
link tilt air actuator ............................................ 4-77
Removing the tong dies ........................................... 4-81
Front jaw ........................................................... 4-81
Rear jaw ............................................................. 4-81
Removing the jaws ................................................... 4-82
Front jaw ........................................................... 4-82
Rear jaw ............................................................. 4-82
Upper safety valve (IBOP) ....................................... 4-82
Lower safety valve (IBOP) ....................................... 4-82
from the guide dolly....................................................... 4-83
Disassembly/assembly of the drilling motor
and motor support bonnet ....................................... 4-84
Installing the TDS motor pinion ................................... 4-87
Local blower cooling system assembly/disassembly ... 4-89
Closed loop cooling system assembly/disassembly .... 4-92
Replacing the safety wiring ............................................ 4-95
Safety wiring tips ..................................................... 4-97

Chapter 4 Troubleshooting
Troubleshooting the counterbalance .............................. 4-99
Troubleshooting the motor alignment cylinder ...... 4-100
Troubleshooting the drilling motor and guide dolly ..... 4-101
Troubleshooting the motor air brake ..................... 4-101
Troubleshooting the retract guide dolly ................. 4-101
Troubleshooting the transmission .......................... 4-102
Troubleshooting the oil pump ............................... 4-103
Troubleshooting the cooling system ....................... 4-104
Troubleshooting the pipehandler ................................. 4-106
Troubleshooting the torque wrench ....................... 4-106
Troubleshooting the safety valve actuator............... 4-108
Troubleshooting the link tilt .................................. 4-108
Troubleshooting the pipehandler at the
counterbalance manifold ........................................ 4-109
Troubleshooting the crown height indicator .......... 4-110
Six-gang air valve assembly illustration ................... 4-111
z This section contains some information regarding the GE motor.

Refer to the GE Motor Service Manual, VDR00023 (included in
VDP0001) for specific details such as:
❏ Inspection and maintenance schedule

❏ Recommended storage instructions -
drilling motors and generators
❏ Removing motors or generators from storage

March 8, 2001

Preface
Manual conventions
Safety information

damage.

personnel.


March 8, 2001
faces well center.
Manual layout

Chapter 1
Maintenance
Inspection
TDS swing out procedure

Varco top drives with swing-out guide dollies can be quickly
swung aside on their own dolly frames for inspection,
maintenance, running casing, or to allow drilling operations
requiring a kelly and rotary table. Electrical, hydraulic, and air
supplies do not have to be disconnected. Use the following
procedure to swing out the TDS only if your rig has a guide dolly
with hinge pins (refer to the engineering drawings for
information specific to your rig configuration):
1. If you have a retract system, operate the switch on the VDC
to retract the TDS.
2. Slowly lower the TDS until the elevator nears the rig floor.
3. Remove the elevator and elevator links.
4. Lower the TDS guide dolly to the stop.

March 8, 2001
z On some rigs, it may be necessary to secure the traveling block

frame to the guide dolly frame using chain and/or rope.
5. Turn off the Hydraulic Power Unit (HPU) and bleed down
hydraulic pressure by opening the needle valve on the
counterbalance manifold. (The counterbalance manifold is
located on the upper motor frame.)
6. Detach the counterbalance system cylinders from the hook or
block by unhooking the pear links from the ears on the hook
or block.
7. Disconnect the air intake hose.
8. Disconnect the mud hose from the TDS S-tube.
n Unlatching the hook from the integrated swivel bail may cause the
TDS motor assembly and/or the hook to lurch suddenly. Always
keep adequate tension on the tailing lines to prevent sudden
movement of these assemblies.
9. Unlatch the hook.

10. Attach tugger lines to the TDS motor frame, opposite the
frame hinges, to assist in swinging out the TDS motor
assembly. Use tailing lines on the motor frame to control
swing out.
11. Unfasten the two swing-out bolts, opposite the hinges,
holding the motor frame to the guide dolly.
12. Operate the air tuggers to slowly pull on the motor frame
while unhooking the traveling block from the swivel bail.
13. When the traveling block is disconnected, continue swinging
out the TDS 180° and secure the motor assembly to the
derrick with chain and/or rope.

To swing the TDS back in for operation after inspection or
maintenance, perform the following procedure:
1. Lower the guide dolly far enough to allow swinging the
TDS back into place.
2. Retract the TDS and secure it.
n While latching the hook to the integrated swivel bail, the swivel
and/or the TDS motor assembly may suddenly lurch. Always keep
adequate tension on tailing lines to prevent sudden movement of
these assemblies.
3. Attach tugger lines to the TDS motor assembly, opposite the

hinges, to aid in swinging back the TDS assembly. Use tailing
lines on the motor frame to control swing back.
4. Release the chain and/or rope securing the TDS motor
assembly to the derrick and slowly swing back the TDS motor
assembly to the guide dolly. While swinging it back, latch the
hook onto the swivel.
5. Secure the motor frame to the guide dolly with the two
swing-out bolts opposite the hinges.
6. Connect the mud hose to the S-tube.
7. Connect the air intake hose.
8. Hook the counterbalance system pear links onto the ears of
the hook or block.
9. Turn the HPU on and bleed air out of the system.

March 8, 2001
DC drilling motor
Thoroughly inspect the TDS, motor support bonnet, and guide
dolly assembly for loose bolts and fittings daily. If any safety wire
or cotter pins were removed to facilitate repairs, replace them
immediately.
z The DC motor has a complete manufacturer’s service manual for

your reference provided in the Vendor Documentation Package.
Motor alignment cylinder
e The alignment cylinder is not intended to be used to align the pin

with the box at the well bore. It is a device to counterbalance the
offset weight of the DC motor and allow the system to accommodate
external forces. It is adjustable to ensure that the mainshaft is straight
at well center–to compensate for design tolerances in the guide rails
and dolly. To work properly, the guide rails must be properly located,
and the dolly must fit within design tolerances.
Check alignment cylinder operation weekly. Also, inspect all
moving parts and check accumulator pressures on a weekly basis.
Air exhaust muffler

Varco installs air exhaust mufflers on the exhaust ports of the
multi-gang solenoid valve manifold for noise abatement. All such
mufflers reduce noise and collect contaminants that can
eventually restrict the air passage. Air passage constriction results
in back pressure on all of the solenoid valves and erratic valve
operation. It also holds pressure on the air brake.
Periodically remove the mufflers and clean or replace them.
If noise abatement is not an issue on the rig, replace the mufflers
with simple pipe elbows.

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

installation kit and recommends installing it at the fingerboard
level in the derrick. Improperly adjusted regulators can cause poor
device performance at reduced pressures, or valve and cylinder
seals and O-ring extrusion at excessive pressures.
Inspect the entire filter/regulator/lubricator monthly for damage
to the filter bowl, overall body, or inlet and outlet fittings.
Replace any damaged, corroded, or improperly functioning
components.
Adjust the pressure regulator outlet pressure to 100-120 psig
monthly. Clean and drain the filter weekly. Fill the lubricator
with petroleum-based hydraulic oil with a fluid viscosity of
100-200 SSU at 100°F (ISO 32/34).
e Do not use fluids such as Marvel Mystery Oil, motor oil, or

Dextron II in the lubricator. Swollen seals may result.

March 8, 2001
Pipehandler
Thoroughly inspect the pipehandler for loose bolts and fittings
daily. If any safety wire or cotter pins were removed during
repairs, replace them immediately.
Inspect the hinge bolts daily to make sure they are not separating
from the pipehandler. Make sure the hinge pins are not loose due
to excessive wear in the bore of the clamp clevis or a broken
retaining bolt.
n Inspect the link tilt intermediate stop and adjustment device for
overall integrity weekly. Replace the components if there is
excessive looseness of the threaded rod in the threaded hole of the
pivot arm (Figures 4-24 and 4-25). An indication of a possible
problem is if the two intermediate stops are not adjusted equally
(i.e., if the thread engagement differs between the two stops).
Failure to perform this inspection and/or component replacement
can result in injury to rig personnel.
Nondestructive Examination (NDE)

Yearly (or after approximately 3,000 operating hours), perform a
Nondestructive Examination (NDE) of all critical load path
items.
z NDE inspection includes visual examination, dye penetrant

examination, magnetic particle inspection, ultrasonic inspection,
x-ray examination, and other methods of nondestructive testing
for metallurgical integrity.
Visual inspection
Use calipers on a regular basis to measure the amount of wear on
the elevator link eyes (Figure 4-1). Compare the measurements
with the Wear Chart (Figure 4-1) to determine the current
strength of the elevator links. The capacity of the links equals the
capacity of the weakest link.

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

5 in. 2 3/4 in. 350
4 13/16 in. 2 9/16 in. 300
4 5/8 in. 2 3/8 in. 225 B
4 7/16 in. 2 3/16 in. 175
;;;
;;;
B = 4 1/2 in., 500-Ton ;;;
6 in. 3 1/2 in. 500
420 B
5 3/4 in. 3 1/4 in.
5 1/2 in. 3 in. 325
5 1/4 in. 2 3/4 in. 250
B = 6 1/4 in., 750-Ton

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

measure (with calipers) the amount of eye
wear and compare the measurements A
with the above Wear Chart to find the
current capacity. The capacity of the set of Lower
Eye
links is determined by the weakest link. (Elevator)
Figure 4-1. Visual inspection of elevator links

March 8, 2001
Landing collar
Disassemble and inspect the landing collar every six months.
Use the following procedure to disassemble the landing collar
(Figure 2-5) for inspection:
1. Disconnect the top drive from the drill string.
2. Remove the IBOPs and pipehandler.
3. Raise the solid body elevator to expose the landing collar
retainer.
4. Straighten the retainer tabs.
5. Slide the retainer ring above the split landing collar halves.
6. Drive out one roll pin.
7. Remove the landing collar halves.
8. Slide the retainer off the drive stem.
After disassembly, inspect all landing collar parts for wear,

damage, or corrosion. Check for:
❏ Grooves or other radial wear marks indicating that the bore of

the solid body elevator is rubbing on the outside diameter of
the landing collar retainer shell
❏ Radial grooves on the inside diameter of the retainer shell
❏ Missing tabs from the retainer shell
❏ Wear or corrosion induced pitting on the retainer shell shoulder
❏ Wear, corrosion, or fatigue cracks on the inside or outside
diameter of the landing collar halves
❏ Evidence of drive stem contact with the solid body elevator
❏ Evidence of inside bore wear on the solid body elevator indicating
contact with the drive stem or landing collar retainer. Wear on
the inside shoulder of the elevator should not exceed 1/8 in.
❏ Evidence of wear, corrosion, or fatigue cracks on the safety
links

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

March 8, 2001
Drive stem
Regularly inspect and measure the drive stem/main shaft for wear.
Remove the drive stem/mainshaft from service if bore wear is
greater than the dimensions shown in Figure 4-2.
Determine inspection frequency according to API Recommended
Practice 8B, Section 2 for power swivels and power subs.
Varco recommends the use of API RP 7G and API RP 8B as
guidelines for interpreting and performing inspections.
Measurement techniques are specified in API RP 7G, Section 10.
Use API Bulletin 5T1 to identify and define imperfections found
during inspections.
Large Bore
1.30 Minimum @ Landing

Collar Grooves (2.45 New)
3.75
(1.70 New) Diameter (New)
9.000
Diameter
7 5/8 API REG R.N. Pin
7.500-3 ACME-3G
Left-hand Thread
Small Bore
1.30 Minimum @ Landing
Collar Grooves (2.45 New)
3.00
(1.70 New)
Diameter (New)
9.000
Diameter
7 5/8 API REG R.N. Pin

6.250-3 ACME-2G
Left-hand Thread
Figure 4-2. Typical minimum bore wear dimensions

(Refer to engineering drawings for exact dimensions)

Use the following API recommended guidelines (Figures 4-3) to
determine the tensile load bearing capacities of the drive stem/
main shaft landing collar.
3800000
3700000
New Condition (3.00 Bore)
3600000
3500000
3400000
3300000
3200000
Load (Lbs)
3100000
New Condition
3000000
(3.82 Bore)
2900000
2800000
2700000
2600000
2500000
2400000
2300000
2200000
1.75
1.70
1.65
1.60
1.55
1.50
1.45
1.40
1.35
1.30
1.25
1.20
1.15
1.10
1.05
1.00
Remaining Wall Thickness Under Pin Thread Relief Groove

(Inches)
Figure 4-3. 750-Ton and 650-Ton drive stem/main shaft

landing collar tensile dimensions

March 8, 2001
Magnetic Particle Inspection (MPI)

Once a year, or every 3,000 operating hours, Varco recommends
performing a Magnetic Particle Inspection (MPI) of the exposed
surfaces of all load carrying components and load collar grooves
to reveal any fatigue or crack indications. Any indications found
are a potential cause for replacing the suspect component. Round
bottom pits and erosion are acceptable as long as the defect is less
than 1/16 in. deep. Larger defects or any crack indications are
cause for replacing the suspect component.
After approximately five years, or 15,000 operating hours,
depending on the severity of operating conditions, Varco
recommends performing a MPI of all load carrying components
over their entire surface (including internal bores) to reveal any
fatigue or crack indications. Any indications found are a potential
cause for replacing the suspect component. Round bottom pits
and erosion are acceptable as long as the defect is less than 1/16
in. deep. Larger defects or any crack indications are cause for
replacing the suspect component. The load carrying components
are:
❏ Drive stem/main shaft (lower portion)

❏ Landing collar
❏ Upper and lower IBOP
❏ 350-Ton BNC drill pipe elevator
❏ Link adapter
❏ Saver, crossover, and spacer subs
❏ Power subs
❏ Power swivels
❏ Elevator links
Details on MPI procedures are in the following publications:

I.A.D.C. Drilling Manual, 9th Edition
ASTM A-275 Std. Method for Magnetic Particle Inspection
of Steel Forgings
ASTM E-709 Std. Recommended Practice for
Magnetic Particle Inspection

Ultrasonic Inspection
In addition to the MPI, Varco also recommends performing an
Ultrasonic Inspection of the above components to detect any
erosion of the inside diameter. Any erosion reduces the load-
carrying capability of the part. Any subsurface irregularity can
also compromise a component’s integrity.
Details on Ultrasonic Inspection procedures are in the
publication: ASTM A-388 Std. Practice for Ultrasonic Examination
of Heavy Steel Forgings.
Safety valve inspection procedures (IBOP)
z Upper and lower IBOP valves, because of their internal grooves

and shoulders, are particularly susceptible to corrosion fatigue
cracking. These internal diameter changes act as stress risers for
bending and tensile loads. It is especially important to properly
inspect the IBOP valves on a frequent basis. Read and use the
IBOP valve inspection procedures described in the IBOP Service
Manual (SM00611).

March 8, 2001

Chapter 2
Lubrication

bonnet assembly
Gearbox
Check oil daily. With the motor off, check to see that the oil level
is at the middle of the sight glass located on the side of the main
body. Drain and refill the gearbox every 1,500 operating hours or
three months, whichever occurs first. (Refer to Oil capacity later
in this chapter.)
Properly maintaining the TDS gear shifting mechanism increases
the operational life of the top drive. Use the following procedure
to maintain proper gear lubrication:
1. Shift all top drive two speed gearboxes from one gear to the
other and back again at least once a week. This helps to
distribute lubricant and prevents contaminant buildup.
2. Remove the gear indicator lever assembly and the indicator
gearcase cover.

March 8, 2001
3. Repack the inside area with grease every six months (refer to
Figures 1-9 and 1-10 in the Description book).
4. Inspect the gears for corrosion or damage. Clean, lubricate or
replace components as required. There is a “timing mark” on
the gears to ensure correct orientation. If these marks are not
visible when removing the gears, mark the gears before
removal to ensure correct orientation when reinstalling them.
If there are problems shifting from one gear to the other, use the
following procedure to shift the gears:
1. Turn the drive stem with chain tongs to make sure the gear
mesh aligns properly. Do not turn the DC motor while
shifting gears.
2. Insert two 3/8 in. bolts in the threaded holes on the bottom
of the shafts while shifting the gears and use a bar to turn the
shaft in the proper direction. Do not shear the bolts.
Eccentric shaft rotation direction is the same as the shifter
input shaft when shifting into gear.
3. If the shift input mechanism slips when attempting to shift
gears, use a torque wrench to check the torque of the shifter
when the clutch begins to slip. If the torque is less than
65 ft lb, then use the Torque setting procedure to adjust the
clutch
e Gearbox oil must be drained before removing clutch.

The factory setting of the clutch is 45 ft lb. However, increase the
torque if there are persistent problems.
4. Remove the 3 in. inspection plugs on the rear of the gearcase
and make sure the compound gears are free to turn with the
unit in neutral. If the gears cannot turn, it indicates a larger
problem (i.e., contaminants in gears, damaged bearings, etc.).

Torque setting procedure
Use the following procedure to set the torque limit clutch to
45-50 ft lb:
1. Attach any torque indicator to the output stub (Figure 4-4).
2. Hold the body and determine the current torque setting.
3. Remove the snap ring and locking plate.
4. Use a 5/8 in. open end wrench to turn the nut clockwise to
increase torque, or to turn the nut counterclockwise to
decrease the torque.
5. Check the resulting torque and repeat the above steps if more
adjustment is necessary.
6. Replace the locking plate and snap ring.

March 8, 2001
Gear Subplate
A
Lower Gearcase
Housing Gear Changer
Gear Shaft Changer Torque Limiter (Clutch)
Detail A
Torque Limit Clutch
Figure 4-4. Torque setting procedure

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

Drain and refill the gearbox after the first 500 operating hours or
four weeks, whichever occurs first.
Remove and clean the oil pump suction strainer (or oil filter,
depending on the model and configuration) when changing
the oil.

March 8, 2001
Oil capacity
The TDS-4S holds approximately 10-20 gallons of oil, but oil
capacities vary according to the type of cooling systems, etc.
installed. Always fill the transmission to the middle of the sight
glass. Use the following procedure to fill the transmission for the
first time on a new top drive:
1. Fill the gearbox to the top of the sight glass
(approximately 10-20 gallons).
2. Operate the top drive 10-15 minutes and check the
sight glass.
3. The oil level should be near the middle of the sight glass.
If the oil level is below the middle of the sight glass, add more
oil until the level reaches the middle of the sight glass. If the
oil level is at, or above the middle of the sight glass, do not add
any additional oil to the gearcase.
After installation and initial operation of the top drive, always fill
the transmission to the middle of the sight glass.
When draining oil from the drain plug at the bottom of the
gearcase, only the 5-6 gallons of oil at the bottom of the gearcase
actually drains. Oil still remains in the rotating head cavity
(approximately 1-2 gallons), the oil lube/pump/cooler system
(approximately 1-2 gallons), and the wetted surfaces inside the
motor housing assembly (approximately 2-3 gallons). Removing
the suction hose from the cover plate below the pinion shaft
allows more oil to drain and also removes sediment that collects
there. Removing the oil drain plug from the rotating head allows
more oil to drain.

Lubricating the DC motor
The upper motor armature bearings have grease points located on
the brake adapter plate attached to the top of the motor. The
lower armature bearing grease point on the G.E. motor is at the
end of a small diameter tube projecting toward the back of the
tool.
The grease points all have plugs or relief fittings installed during
operation. Install grease fittings to lubricate and then remove the
fittings and replace the plugs for operation. Lubricate the pinion
(transmission) end bearing every 750 operating hours, or three
months, with two ounce by weight Shell Cyprina RA™.
Lubricate the commutator (brake) end bearing every 1,500
operating hours, or six months, with two ounce by weight Shell
Cyprina RA™.
e Excessive lubrication of electric motors can cause motor failure due to

shorting or heat buildup from grease coming in contact with the field
windings.

March 8, 2001
Lubricating the washpipe and

bonnet seal
Apply grease daily to the washpipe grease fitting and the two
bonnet seal fittings (located below the washpipe grease fitting)
(Figure 4-5).
Grease
Fittings
Wash Pipe
Assembly
Bonnet
Figure 4-5. Lubricating the washpipe and bonnet seal

Lubricating the rotating head
Apply grease daily at the fittings (Figures 4-6 and 4-7). Inspect for
seal leakage weekly around the lower bearing retainer.
Grease
Fittings
Grease
Fitting
Grease
Fittings
Figure 4-6. Lubricating the standard rotating head
Grease Fitting
Grease Fittings
Figure 4-7. Lubricating the powered rotating head

March 8, 2001
Lubricating the link adapter

Apply grease to the link adapter fittings weekly as shown
in Figure 4-8.
2 Grease Fittings on front,

2 Grease Fittings opposite.
(4 places total)
Figure 4-8. Lubricating the link adapter

Lubricating the torque wrench
Apply grease daily to the torque wrench fittings (Figure 4-9).
Inspect the stabbing guide for excessive wear or cracks. Replace as
necessary.
Grease Fitting
(6 on IBOP Actuator
Rollers, Cylinder Pins
and Arm Pins)
Grease Fitting
(6 on Optional Link Stop
and Cylinder Assembly)
Grease Fitting
(1 each side of Torque
Tube on Clevis Pin)
Grease Fitting
(8 on Bottom of Clamp)
Figure 4-9. Lubricating the PH-85 torque wrench

March 8, 2001
Lubricating the master bushing

ID wear guide
The master bushing ID wear guide has four fittings (Figure 4-10).
Lubricate weekly. Inspect the guide ring periodically for wear or
damage and replace it as necessary.
Master Bushing
Wear Guide
Grease Fittings (4)
Figure 4-10. Lubricating the master ID bushing wear guide
Lubricating the safety valve actuator

Apply grease daily to the fitting in the crank assemblies (Figure 4-
11). Check for worn components and operate the valve to verify
correct adjustment weekly.

Lubricating the upper safety valve (IBOP)
Lubricate the upper IBOP valve weekly at the lubrication fittings
located directly below the actuator cranks in the recessed counter
bores (Figure 4-11). Refer to the IBOP Service Manual for
complete IBOP lubrication instructions.
Open
Position
Actuator Shell Grease Fitting
Crank Arm
Grease Port
Actuator Arm
Groove
Upper IBOP
Valve
Figure 4-11. Lubricating the IBOP

March 8, 2001
Lubricating the guide dolly assembly

Lubricate the 20 guide rollers every trip at the four manifolds
(5 fittings each) located on each corner of the guide dolly (Figure
4-12). If your rig has a retract system, refer to the Retract Guide
Dolly supplement. Check guide rollers weekly for cracks or
excessive axial or radial play and replace as necessary. Lubricate
the hinges (one place on each hinge) monthly.
It is possible to over-grease (too much pressure, not volume) the
guide rollers. This can push the plugs out. Visually inspect all of
the guide rollers for evidence of grease extruding from the end(s)
of the shaft. If you discover over-greasing, perform the following
procedure:
1. Remove and disassemble the roller assembly.
2. Thoroughly clean and inspect all parts.
3. If the component parts are still serviceable, drill and tap the
shaft end(s) for 1/8 in. NPT threads and install internal
wrenching pipe plugs after thoroughly cleaning metal chips
from the grease ports in the roller shaft.
4. Pre-grease roller bearings before reassembling and installing
the rollers and shaft.
5. Re-grease roller bearings through grease lines to make sure
lubricant is pumping through the roller bearings. Some grease
should extrude between the rollers and roller shaft.
6. Replace unserviceable assemblies.
7. Improve plug retention on roller assemblies with intact sheet
metal plugs by staking the edges of the port(s). To do this:
a. Remove the roller or roller bracket assembly to improve
accessibility.
b. Use a hammer and chisel to stake the port edges.

A preferred method is to rework the roller assembly for drill and
tap operation, but the staking method is also effective.
At each bottom corner of the motor frame are the two grease
points for the motor trunnions (Figure 4-13). Lubricate these
weekly.
Lubricate the washpipe packing daily with the mud pump off.
Daily, with the hydraulic power on, check the filter gauge on the
pressure filter to determine the condition of the filter element.
Replace the element when a bypass condition is indicated.
e Do not weld or torch cut on or near the motor frame without

removing hydraulic accumulators.

March 8, 2001
Grease
Fitting
(20) Grease Fittings
(TDS Removed for clarity)

Non-Swing
Guide Dolly
Grease Fittings
Figure 4-12. Lubricating the non-swing guide dolly assembly

Grease Fittings
Grease
Fitting
(20)
Swing
Guide Dolly
Grease
Fitting
Grease
Fitting
Grease Fittings
Figure 4-13. Lubricating the swing guide dolly assembly

March 8, 2001
Grease
Fitting Grease Fittings
(28)
Retract Guide Dolly
(TDS Removed for clarity)
Grease Fittings
Figure 4-14. Lubricating the retract guide dolly assembly

Lubricating the bail pins
Lubricate the bail pins weekly, at the same time the dolly
rollers are lubricated, at the two fittings, one on each bail pin
(Figure 4-15).
Bail
Bail Pin Bail Pin
Grease Fitting Grease Fitting
Figure 4-15. Lubricating the bail pins

March 8, 2001
Lubricating the cooling system

Lubricate AC blower motors every three months (Figure 4-16).
On rigs with closed loop cooling systems (Figure 4-17) also check
the heat exchangers for water leakage weekly, and remove the
access covers and operate the blower to remove dust buildup every
500 operating hours.
Explosion Proof AC Blower Motor
Grease Fitting
Grease Fitting
Motor Cooling Blower
Transmission Cooler
Figure 4-16. Lubricating the local cooling system

Explosion Proof AC Blower Motor
Grease Fitting Grease Fitting
Motor Cooling Blower Motor Cooling Blower
Heat Exchanger Heat Exchanger
Figure 4-17. Lubricating the closed loop cooling system

March 8, 2001
Lubrication schedule
Frequency Location Lubricant code* Number of points
Daily Bonnet seal 1 2
Daily Torque wrench (PH-85) 1 6
Daily Gearbox oil (check level) 2 1
Daily Rotating head 1 5
Daily Safety valve actuator cranks 1 2
Daily Hydraulic pressure filter † – –
Daily Wash pipe assembly 1 1
Each trip BNC drill pipe elevator 1 7
Each trip Guide dolly rollers (Retract ‡) 1 20
Weekly Gearbox (shift gears) - -
Weekly Dolly motor trunnions 1 2
Weekly Air filter/regulator/lubricator † – –
Weekly IBOP actuator arms 1 6
Weekly Link adapter (650-Ton) 1 4
Weekly Elevator support 1 7
Weekly Master bushing wear guide 1 4
Weekly Link tilt (check condition)
Weekly Bail pins 1 2
750 hrs/90 days GE drilling motor pinion bearing 3
1,500 hrs/6 mos. GE drilling motor commutator bearing 3
Monthly Motor frame/dolly hinges (Retract ‡) 1 4
Monthly Cooling system cleaning – –
3 months AC blower motor 1 2
3 months Change gearbox oil 2 1
3 months Gear oil filter/suction strainer † – 1
* See Table 4-1, Recommended lubricants
† Check condition and replace as necessary
‡ Refer to Retract Guide Dolly supplement
e Use only 10-wt. hydraulic oil or non-detergent motor oil as a

lubricant in the air control system. Using any other type of oil or
synthetic additive causes the seals in the air valves to swell and cease
to function.

Lubricant specifications
TDS-4S transmissions operate under a combination of heavy and
shock loads. Under these conditions oil tends to extrude out of
the gear mesh. Keeping an effective film of oil on the gear mesh
requires oil with an AGMA “extra pressure” rating, and a
minimum viscosity of 100 SUS at operating temperature.
Varco top drives also operate under a wide variety of
temperatures. Select lubrication for the TDS based on the
minimum ambient temperature to be expected before the next oil
change. Under all but the most severe operating conditions,
Varco recommends changing the oil every three months.
Introducing an oil viscosity greater than required by the ambient
temperature can:
❏ Damage the gearbox due to reduced oil flow

❏ Damage the oil pump because of excessive load
All oils change viscosity with temperature and EP oil is no
exception. The TDS transmission lubrication system is limited to
pumping oils of a maximum of 9,000 SUS viscosity.
Varco recommends measuring the oil temperature with a contact
thermometer. Measure on the pump discharge fitting on the TDS.
The following tables will aid in your lubricant selection and keep
your TDS-4S transmission operating properly:
Minimum ambient temperature
°F °C Oil type required Varco P/N
Below 20° -6° See note below See note below
20° to 60° -6 to 16° 2EP, ISO 68 56004-1
45° to 85° 7° to 30° 4EP, ISO 150 56004-BSC
Above 70° 21° 6EP, ISO 320 56004-2
z For minimum temperatures below 20°F, the TDS must be

warmed up by rotating at a very light load (less than 200 Amps)
and at very slow speeds (less than 50 rpm) until the oil
temperature climbs above 20°F.

March 8, 2001
If the oil temperature falls below 20°F, Varco recommends

running the TDS at very light loads (less than 100 Amps) until
the oil is above 20°F. If drilling conditions dictate oil
temperatures below 20°F, consult Varco engineering.
If the oil temperature rises above 200°F, Varco recommends
shutting down or reducing drilling loads to stabilize the oil
temperature below 200°F If drilling conditions dictate oil
temperatures above 200°F, consult Varco engineering.
Table 4-1. Recommended lubricants
Lube Code and Description
1 2
General Purpose Grease Gear Oil
Ambient Above Below Above 20° to 60°F

temperature -4°F -4°F 70°F 45° to 85°F
(7° to 30°C) (-6° to 16°C)
range (-20°C) (-20°C) (21°C)
Castrol MP grease - Alpha LS-320 Alpha -150 Alpha LS-68
Chevron Avi-Motive Avi-Motive W NL Gear 320 NL Gear 150 NL Gear 68
Exxon Lidok EP2 Lidok EP1 Spartan EP320 Spartan EP150 Spartan EP68
Gulf Gulf Crown EP32 Gulf Crown EP31 EP Lube HD320 EP Lube HD150 EP Lube HD68
Mobil Mobilux EP2 Mobilux EP1 MobilGear 632 MobilGear 629 MobilGear 626
Shell Alvania EP2 Alvania EP1 Omala 320 Omala 150 Omala 68
Statoil Uniway EP2N Uniway EP1N Loadway EP320 Loadway EP150 Statoil
Texaco Multifak EP2 Multifak EP1 Meropa 320 Meropa 150 Meropa 68
Total Multis EP2 Multis EP1 Carter EP 320 Carter EP 150 Carter EP 68
Union Unoba EP2 Unoba EP1 Extra Duty NL6EP Extra Duty NL4EP Extra Duty NL2EP
NGLI 2 1 - - -
AGMA - - 6EP 4EP 2EP
ISO Viscosity - - 320 150 68

Grade

Table 4-1. Recommended lubricants (continued)
Lube Code and Description
3 4 5
Motor Grease Hydraulic Oil Bio-degradable
Ambient All 14° to 185°F 5° to 167°F

temperature temperatures (-10° to 85°C) (-15° to 75°C)
range
Castrol N/R Hyspin AWS-46 Hyspin AWS-32
Chevron Black Pearl AW Hyd oil 46 AW Hyd oil 32
Exxon N/R Nuto H46 Nuto H32
Gulf N/R Harmony 46AW Harmony 32AW
Mobil N/R DTE 25 DTE 24
Shell N/R Tellus 46 Tellus 32
Statoil N/R Hydraway HMA 46 Hydraway HMA 32
Texaco N/R Rando oil HD46 Rando oil HD32
Total N/R Azolla ZS 46 Azolla ZS 32
Union N/R Unax AW46 Unax AW32
NGLI 2 - -
AGMA - - -
ISO Viscosity - 46 32
Grade

March 8, 2001

Chapter 3
Maintenance
Adjustment procedures
Adjusting the torque wrench

Use the following procedure to adjust the pipehandler torque
wrench:
e The pipehandler torque wrench is properly adjusted and tested in the

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

locknut around the valve stem and use a 5/32 in. hex wrench to
adjust the valve. After obtaining desired setting tighten locknut
around valve stem.

March 8, 2001
2. With the HPU off, screw the RECYCLE, CLAMP, and

TORQUE sequence valves on the torque wrench manifold
fully in (Figure 4-18).
3. Fully back out the Pressure Reducing Valve (PRV), then screw
in one turn.
4. Turn the LIFT/LOWER flow control valve fully in, and then
back it out three turns.
5. Turn on the HPU.
6. If the torque cylinders are in their full clockwise position, set
the Make/Break valve to MAKE. If they are in their full
counterclockwise position, set Make/Break valve to BREAK.
Note that torque cylinders should not move if the recycle
sequence valve is fully in.
7. Slowly back out the RECYCLE sequence valve until torque
cylinders just start to move, then screw out an additional
full turn.
Make/Break
Valve
Recycle Clamp Torque

Sequence Sequence Sequence
Valve Valve Valve
Torque Wrench
Manifold
BREAK MAKE
Hydraulic
Pressure
Return
RECYCLE CLAMP TORQUE

PRV 50 60
40
70
1000 1500
30
Hydraulic
80
Pressure
LIFT LOWER
20
500 2000
Inlet
90
Lift/Lower
10
0 2500
10
Flow Control PSI

0
0
Valve
Ft.Lbs. x1000
Torque Gauge
0 - 2500 PSI
Figure 4-18. Torque wrench control manifold

8. Move the Make/Break valve to BREAK. Set the PRV
to 750 psi.
9. Switch the lever between MAKE and BREAK to adjust the
RECYCLE sequence valve until full rotation in each direction
takes six to eight seconds. Tighten the locknut around the
RECYCLE sequence valve adjustment screw.
10. Set the Make/Break valve to MAKE.
11. Depress and hold the torque wrench operating button on the
VDC. The torque wrench should lift and the clamp jaws
should remain retracted.
12. Slowly back out the CLAMP sequence valve until the clamp
jaws just begin to clamp onto the tool joint. Screw out an
additional half turn. Lock the CLAMP sequence valve
adjustment screw in position by tightening the locknut.
13. Back out the TORQUE sequence valve until the torque
cylinders just begin to stroke, then back out an additional half
turn. Tighten the locknut around the TORQUE sequence
valve adjustment screw.
14. Release the torque wrench operating button on the VDC.
The torque wrench should start to unclamp and drop, then
the torque cylinders should recycle.
15. If the torque cylinders recycle before the clamp cylinders
retract, screw in the RECYCLE sequence valve until the
torque cylinders do not move before clamp cylinders have
fully retracted. Tighten the RECYCLE sequence valve
adjustment screw locknut.
16. Cycle the torque wrench as many times as required to makeup
the connection.
17. Set the Make/Break valve to BREAK.
18. Verify that the torque wrench correctly breaks out the drill
pipe from the saver sub, without breaking out the saver sub or
lower IBOP.
19. The torque wrench is ready for operation.

March 8, 2001
Adjusting the upper safety valve

(IBOP) and safety valve actuator
system
Refer to the IBOP Service Manual for upper IBOP and safety
valve actuator system adjustment procedures.
Adjusting the counterbalance

system
Leave the HPU on during the entire adjustment procedure, and
disconnect the TDS from the drill string near the bottom of the
rails, but well off the stops.
1. Remove the caps and loosen the lock nuts on the needle valve
and PRV located on the counterbalance manifold (Figure 4-
19). It is not necessary to remove the front guard for access to
the manifold. A small amount of oil will leak around the
adjusting stems after removing the caps.
2. Open the needle valve and let the stem circulate for two
minutes. Crack both upper cylinder fittings and bleed air
from system. Tighten the fittings. Close the needle valve.
3. Using a hex wrench, screw in the PRV until the cylinder
retracts, raising the TDS.
4. Slowly back out the PRV. The pressure decreases and the
cylinder rods begin extending. When the integrated swivel
bail contacts the hook, note the pressure on the gauge. Allow
the pressure to decrease an additional 25 psi and tighten the
locknut. Replace the caps on the valve adjustment stem.

Needle Valve
(on opposite side)
Upper Motor Frame

Crossmember
Pressure Reducing Pressure

Valve Gauge
Figure 4-19. Counterbalance manifold

March 8, 2001
Adjusting the motor alignment

cylinder system
Once the alignment cylinder is installed, use the following
procedure to properly adjust the motor alignment before
operating TDS systems that have a separate alignment cylinder
accumulator and valve manifold.
1. With the HPU turned off, bleed down the alignment cylinder
accumulator by opening the needle valve located at the
alignment cylinder valve manifold (Figures 4-20 and 4-21).
2. Remove the split shipping brace from the motor alignment
cylinder (Figure 4-22).
3. Turn on the HPU and allow the system to circulate for
approximately two minutes.
4. Close the needle valve.
5. Open the two flow control valves located at the alignment
cylinder supply return lines 1-1/2 turns off their seats.

Alignment Cylinder
Lug (ref)
Pressure Reducing
Valve
Needle Valve
Motor Frame (ref)
Alignment
Cylinder
Manifold
Accumulator
Bracket
Gas Valve
Figure 4-20. Typical motor alignment cylinder valve manifold

March 8, 2001
Prefill Valve Assembly
Directional Control Valve

(Operation Switch)
Pressure Reducing Valve

(PRV)
Needle Valve
Motor Frame (ref)
Alignment Cylinder
Valve Manifold
Bracket
Gas Valve
Accumulator
Figure 4-21. Motor alignment cylinder valve manifold

Motor Alignment
Cylinder
Shipping
Brace
Motor
Frame Dolly (Ref)

March 8, 2001
z The pressure setting is adjusted by screwing the PRV in or out

with a hex wrench (Figure 4-19). Screwing in the valve increases
pressure and moves the saver sub toward the rails. Backing out the
PRV reduces pressure and moves the saver sub away from the rails
(see additional notes at the end of this procedure).
6. Verify the correct pressure setting using the following
procedure:
a. With the HPU on, back down the pressure using the PRV
until the saver sub begins to pivot away from the rails.
Record this pressure.
b. Slowly increase the pressure until the saver sub no longer
moves closer to the rails as pressure increases. At this time,
the cylinder should be in a “dead band” area.
c. Slowly increase the pressure until the saver sub begins to
move toward the rails again. Record the pressure reading
when this occurs.
d. To determine the correct pressure setting, add the average
pressure readings from steps a and c above and divide by two.
The resulting pressure “dead band” provides equal pre-load
in each direction – both toward and away from the rails.
e. Record the pressure setting for future reference.
7. Set a joint of drill pipe in the slips.
8. Bring the top drive down as if stabbing the saver sub into the
box. The pin and the box should be in alignment so that the
OD of the pin clears the shoulder of the box. If adjustment is
necessary, use the following procedure:
a. Measure how far and in what direction (toward or away
from the rails) the pin must move to line up with drill
pipe box.
b. Turn off the HPU and bleed down the alignment cylinder
accumulator. This allows the motor alignment cylinder to
relax and the motor to rotate on its trunnions, until the
swivel contacts the motor frame.
c. Loosen the lock tab and jam nut on the cylinder clevis.

d. Use a wrench on the cylinder rod flats to screw the rod
into or out of the clevis, in the same direction the saver
sub pin is to be moved. A 1/4 in. of pin movement results
from a 3/4 turn of the rod. The alignment cylinder rod
extension should be 2 3/8 ± 1/8 in. gland to rod threads
when the system is properly aligned.
e. Secure the jam nut and lock tab.
f. The nominal position of the two flow control valves is
1-1/2 turns off their seats. Should heavy drill pipe
vibration be encountered, first attempt to control it with
non-rotating stabilizers in the casing close to the surface.
If motor movement becomes excessive due to continued
vibration (more than 1/2 in. of cylinder stroke), the flow
control valves may be closed to 3/4 turn off their seats.
g. Tighten the lock nuts and replace the caps on all valve stems.
z If the alignment cylinder is removed for service, install the

alignment cylinder replacement brace to support the motor
housing assembly while continuing to operate the TDS. After
reinstalling the alignment cylinder, use the three bleed holes
(located along top of cylinder barrel) to remove air trapped in the
cylinder.
Rail spacing and setback from the centerline of the well must be
held within recommended tolerances in order to maintain vertical
alignment of the TDS.

March 8, 2001
Precharging the
counterbalance system
Please read these instructions completely before precharging,
making note of the special cautions at the end of the section.
1. Use an inert gas such as nitrogen for precharging
accumulators. If oil-pumped is not available, use dry, water-
pumped nitrogen gas.
2. Before precharging, make certain:
a. The accumulator end caps are screwed flush into the
accumulator body.
b. The gas valve is screwed in tight.
c. No oil remains trapped in the top end of the accumulator.
3. Remove the gas valve protector and the gas valve cap.
4. Attach the charging hose to the nitrogen bottle and to the gas
valve using the following procedure:
a. Use thread sealing and lubricating compound on the pipe
threads of the gauge.
b. Back the gas chuck stem completely out of the way before
attaching the assembly to the accumulator gas valve.
c. Use a wrench to tighten the gas chuck swivel nut onto the
gas valve. Close the bleeder valve.
d. Turn the gas chuck stem all of the way down, depressing
the core in the accumulator gas valve.
e. Only crack open the nitrogen bottle valve to slowly fill the
accumulator. Shut it off when the gauge indicates 900 psi.
f. If the 900 psi precharge pressure is exceeded, make sure
the nitrogen bottle valve is closed, then open the bleeder
valve (opposite the gas valve below the gauge) slightly, but
only momentarily, to reduce pressure.
g. Before loosening the swivel nut, turn the gas chuck stem
out all of the way, then open the bleeder valve.
h. Prevent the gas valve from turning, loosen swivel nut, and
remove the assembly.
5. When precharging is complete, replace the cap on the gas
valve and install the gas valve protector.

e Do not loop or twist hose as it stiffens when gas pressure is released
from nitrogen bottles.
Never loosen the swivel nut attached to the gas valve in the
accumulator without first backing the gas chuck stem all of the way
out.
Do not reduce accumulator precharge by depressing valve core (high
pressure may rupture rubber valve seat). Instead, slowly turn gas valve
out until gas begins to escape through bleed hole drilled through
threads of valve. This hole is a safety feature, it warns of stored
pressure whenever gas valve is being removed. Install new gas valve
O-ring each time gas valve is removed.

March 8, 2001
Assembly and disassembly
Pipehandler
Torque wrench disassembly

For PH-85, see Figures 4-23, 4-24, 4-25, and 4-26.
For PH-60d, see Figure 4-27.
1. Remove the guard.
2. Disconnect the hard plumbing from the quick disconnects
near the left torque cylinder.
3. Remove the bolts holding the frame onto the cast body and
lift off.
4. Remove the pins holding the torque tube in place and remove.
5. Disconnect and label the hoses from the torque cylinders and
remove the cylinders.
6. Disconnect and label the remaining plumbing, and remove
the Make/Break manifold assembly.
7. Remove the jaws.
8. Remove the stabbing guide.
9. Remove the retaining bolts, hinge pins and outer body.
10. Remove the cylinder ring from the clamping piston bore.
11. Pressurize the blind end of the clamping cylinder to remove
the gland and piston.
e Use care in this operation. High pressure air can be explosive.

Torque Tube
V
a
r
c
o
Torque Cylinders
Figure 4-23. PH-85 torque wrench assembly/disassembly

March 8, 2001
Clamping Jaws
Body
Clamp Cylinder Body
Clamp Cylinder Pistons
Stabbing Guide

Mounting Shaft
Frame
Safety Valve Vertical

Actuating Positioning
Cylinder Cylinder
(2)
Hanging
Height
Adjustment
Guard

March 8, 2001

(optional link retractor)

Frame
Mounting
Shaft
Safety Valve
Actuating Vertical
Cylinders (2) Positing
Cylinder
Safety Valve
Actuating
Arm (2) Torque
Tube
Stabilizer
Stop Tube
Hanging Height Torque Guard

Adjustment Shim Tube
Body
Torque
Cylinder (2)
Clamp Cylinder Body

Stabbing
Guide
Clamping Clamping
Jaws (2) Cylinder
Piston
Control
Manifold
Figure 27. PH-60d torque wrench assembly/disassembly

March 8, 2001
Reassembly is accomplished in the reverse order of the above

procedure. Pay close attention to the following points:
1. Replace all seals.
2. Take great care when installing the clamping piston and
gland. If they are not closely aligned with the bore, they may
become jammed and could be extremely difficult to remove.
3. Use the following torque values:
Cylinder rod end to cylinder rod* 944 ft lb
Frame to clamp cylinder body 250 ft lb
Stabbing guide to body 250 ft lb
Die retainer screws 380 ft lb
Body hinge pin retainer screws 150 ft lb
Stabbing guide spring retainer screws 75 ft lb
Jaw retaining screws 110 ft lb
*The torque cylinder rod ends are threaded into the rods with
locktite and cross pinned.
Replacing the torque wrench clamping piston seal

The following procedures require that the torque wrench be
removed from the pipehandler.
Replacing the front and rear piston seals

Parts required front and rear piston seal replacement:
Qty. P/N Description
3 72219 Piston seal
2 72220 Rod seal
2 72221 Rod wiper
Disassembly
1. Remove the slotted hex nut and cotter pin attaching the two
halves of the stabbing guide together at the front and swing
the guides out to each side.
2. Vent the clamping cylinder as follows: disconnect the
hydraulic lines to the clamp port and front unclamp port on
the clamp body cylinder at the torque wrench manifold clamp
and unclamp ports.

3. Remove the jaw pins from the rear clamping jaw and remove
the jaw.
4. Remove the two screws holding the jaw spacer to the front
clamp cylinder piston and remove the spacer and jaw spacer.
5. Remove the two screws holding the clamp clevis to the rear
clamp cylinder piston.
6. Remove the pins holding the clamp body to the clamp clevis
and remove the clamp clevis. Be sure to remove the spacer
from the piston rod slot.
7. Push in the cylinder gland from the rear cylinder head
retainer ring and remove the ring with a screwdriver.
8. Attach the sliding hammer to the rear piston rod and carefully
pull the piston until the cylinder gland can be removed.
9. Continue to pull until the piston comes out.
10. Using a piece of wood or brass bar, tap the front clamp piston
from the front and remove it from the rear.
11. Remove and discard the piston seals, rod seals, and rod
wipers.
12. Remove the front piston rod seal and rod wiper from the
clamp cylinder body and discard.
13. Inspect the clamp cylinder bore thoroughly for dirt, burrs,
nicks, gouges, and pitting. Repair and clean as necessary.
Assembly
1. Insert a new front rod seal and rod wiper in the clamp
cylinder body and lubricate with clean hydraulic fluid.
2. Install a new piston seal in the front piston groove and
lubricate with hydraulic fluid.
3. Insert the front piston into the clamp cylinder body with the
two jaw spacer screw holes orientated vertically.
4. Gently and evenly tap the piston into place until the rod
appears beyond the front cylinder bore.

March 8, 2001
5. Install a new piston seal in the rear piston groove and

lubricate with hydraulic fluid.
6. Insert the rear piston into the clamp cylinder body with the
two screws holes on the rod oriented to the horizontal
position.
7. Gently tap piston into place until there is enough space
between the piston face and retaining ring groove to insert
cylinder gland and retainer ring.
8. Install the rod seal and rod wiper in the inside grooves of the
cylinder gland.
9. Install the piston seal in the outside groove.
10. Lubricate all seals with hydraulic fluid.
11. Insert cylinder gland into the bore rod and piston seals first.
Push the gland past retainer groove and install the retainer
ring.
12. Insert the spacer and attach the clamp clevis to the rear
cylinder rod with the two hex head cap screws and flat
washers. Tighten firmly and lockwire.
13. Adjust orientation of the clamp clevis and attach to the clamp
body using the two clevis pins and cotter pins.
14. Attach the rear clamping jaw spacer to the front piston rod
using the spacer and two hex head cap screws and flat
washers. Tighten firmly and lockwire.
15. Attach the clamping jaw with the two jaw pins.
16 Swing the stabbing guide back into position and attach with
the slotted nut and cotter pin.
17. Reconnect the hydraulic lines from the clamp body cylinder
clamp port and front unclamp port at the torque wrench
manifold clamp and unclamp ports.
18. Reinstall and adjust the torque wrench
(refer to Adjusting the torque wrench earlier in this chapter).

glyd rings
z Rotary glyd ring replacement is indicated when hydraulic oil is

detected in the pipehandler air supply. An indication of oil
contaminating the air supply would be an accumulation of oil in
the link tilt air actuator (bag).
The following disassembly and assembly procedures assume that
the TDS is swung out for maintenance in accordance with the
TDS swing out procedures (refer to TDS swing out procedure in
Chapter 1 of this book). Refer to Figures 4-28 and 4-29, when
performing the following procedures.
Cam Follower
Locking Lever
Auto-Return
Cylinder
Torque Arrestor
Location

(Lug not shown)
Figure 4-28. 650-Ton rotating head assembly

March 8, 2001
Disassembly
1. Order eight replacement glyd rings, two gearcase seals, one
flange gasket, and one excluder cap gasket from Varco.
Contact the nearest Varco Service Center for details about
building an appropriate stand for working on the rotating
head when removed from the TDS for service or
maintenance.
2. Disconnect the hydraulic and air hoses from the rotating head
rotating block to the various pipehandler components.
3. Support the torque wrench.
4. Disconnect the IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating block
clevis, and remove the torque wrench.
6. Support the link tilt and link adapter assembly while
removing the pins attaching the torque arrestors to the
rotating block.
7. Remove the torque arrestors, link tilt and link adapter.
8. Place the rotating head stand, built prior to disassembly,
under the TDS and lower the TDS until the rotating head
rests on the stand.
9. Remove the flange nuts and lift the block, leaving the rotating
head on the stand.
10. Remove the quick disconnect fittings from the rotating block
hydraulic lines and drain the hydraulic fluid from the system.
11. Remove the cotter pin from the return cylinder clevis pin.
12. Remove the hex-slotted nut and remove the clevis pin.
13. Push the cam follower away from the rotating block cam.
14. Remove the safety wire from the ten hex-head screws
attaching the rotating block to the stationary flange.
15. Support the rotating block and remove the ten screws.
16. Remove the rotating block and glyd rings.
17. Remove the excluder cap and gasket.
18. Remove the glyd rings from the rotating block and discard.
19. Remove excluder cap gasket and replace with new gasket.

Cam Assembly
Locking Handle
Return Cylinder Return

Cylinder
Clevis Pin
Return
Cylinder
Rod End Detail
Hex Nut
;;;;
Cotter Pin
Cam
;;;;;;
;;;;;;
Cylinder Clevis
;;;;;;
Excluder
Cap
;;;;;;
C;;;;;;
Retainer Ring
Detail
;;;;;;
;;;;;;
Glyd Ring (8)
Ball Bearing
;;;;;; Excluder Cap
Gasket
Cam
Ball Bearing
C
Stationary Flange
Bull Gear
Lip Seal
Figure 4-29. Replacing the 650-Ton rotating head glyd rings

March 8, 2001
Assembly
1. Lubricate the eight new glyd rings with hydraulic fluid and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the
rotating block.
3. Using a tugger or other support, carefully mate the rotating
block to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the quick disconnect hydraulic fittings on the
rotating block.
7. Attach the return cylinder rod to the clevis with the clevis pin
and install the slotted hex-head nut and cotter pin.
8. Reinstall the pipehandler components per the procedures
detailed in the Installation and Commissioning book.

glyd rings
Refer to the assembly drawings when performing the following
procedures.
Disassembly
1. Order eleven replacement glyd rings, two gearcase seals, one
flange gasket, and one excluder cap gasket from Varco.
Contact the nearest Varco Service Center for details about
building an appropriate stand for working on the rotating
head when removed from the TDS for service or
maintenance.
2. Disconnect the hydraulic and air hoses from the rotating head
rotating block to the various pipehandler components.
3. Support the torque wrench.
4. Disconnect the IBOP actuator arms and hoses.
5. Remove the pin attaching the hanger to the rotating block
clevis, and remove the torque wrench.
6. Support the link tilt and link adapter assembly while
removing the pins attaching the torque arrestors to the
rotating block.
7. Remove the torque arrestors, link tilt, and link adapter.
8. Place the rotating head stand, built prior to disassembly,
under the TDS and lower the TDS until the rotating head
rests on the stand.
9. Remove the flange nuts and lift the block, leaving the rotating
head on the stand.
10. Remove the quick disconnect fittings from the rotating block
hydraulic lines and drain the hydraulic fluid from the system.
11. Remove the cotter pin from the return cylinder clevis pin.
12. Remove the hex-slotted nut and remove the clevis pin.
13. Remove the hydraulic motor assembly.
14. Remove the safety wire from the ten hex-head screws
attaching the rotating block to the stationary flange.

March 8, 2001
15. Support the rotating block and remove the ten screws.
16. Remove the rotating block and glyd rings.
17. Remove the excluder cap and gasket.
18. Remove the glyd rings from the rotating block and discard.
19. Remove excluder cap gasket and replace with new gasket.
Assembly
1. Lubricate the eleven new glyd rings with hydraulic fluid and
insert them into the glyd ring grooves inside the rotating
block.
2. Place the excluder cap and gasket on the bottom of the
rotating block.
3. Using a tugger or other support, carefully mate the rotating
block to the stationary flange.
4. Reinstall the ten hex-head screws and torque to 250 ft lb.
5. Safety wire the screws per standard safety wire procedures.
6. Reinstall the QD hydraulic fittings on the rotating block.
7. Reinstall the hydraulic motor assembly.
8. Reinstall the pipehandler components per the procedures
detailed in the Installation and Commissioning book.

link tilt air actuator
The link tilt mechanism has two air actuators. Use the following
procedure to replace one air actuator (Figures 4-30 and 4-31).
Parts required: One air actuator (P/N 82353)
18 Button head cap screws (P/N 50186-10-01)
Disassembly
1. Disconnect the air hose from the rotating head rotating block
to the link tilt assembly.
2. Support the link tilt and remove the two upper and two lower
screws attaching the link tilt to the link adapter.
3. Lower the link tilt to the floor with the air actuator to be
replaced facing up.
4. Remove the cotter key and pin from one end of chain
connecting the two sealing plates.
5. Remove the safety wire from the four hex-head cap screws
holding the air actuator sealing plate to the link tilt base or
lever and remove the screws.
6. Lift the lever or base off the air actuator sealing plate, and
rotate it 180° on the link tilt pivot pin and lay down.
7. Remove the nuts and washers holding the sealing plate to the
air actuator and remove the plate.
8. Using a pry bar or screwdriver, pry the air actuator away from
the screws, attach the actuator to the hanger plate and remove
the screws using a hex wrench.
9. Remove and discard the air actuator.
10. Remove any burrs or gouges on sealing surfaces of the hanger
and sealing plates.

March 8, 2001
Lever Weldment
Pivot Pin
Sealing Plate (2)
Pressure
Air Actuator Regulator
Nuts, Lock
Washers (18) Base
Sealing Plate
Bolt (4)
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Buttonhead
Capscrew (18)
Stop Pivot Arm
Elevator Link (Ref)
Stop Release
Loop
Figure 4-30. Standard reach link tilt assembly/disassembly

Lever Weldment
Pivot Pin
Sealing Plate (2)
Nuts, Lock Pressure

Washers (18) Regulator
Hanger Plate
Sealing Air Actuator (2)

Plate Base
Bolt (4)
Quick
Exhaust
Valve
Lever
Intermediate
Stop (2)
Connecting Chain
Stop Pivot Arm
Elevator Link (Ref) Stop Release

Loop
Figure 4-31. Extended reach link tilt assembly/disassembly

March 8, 2001
Assembly
1. Place a new actuator on the hanger plate.
2. Attach the air actuator to the hanger plate with the 18
buttonhead cap screws. Coat the screw threads with locktite
before installation.
e The air actuator has aluminum neck bead rings on both sealing
surfaces. These beads must be compressed equally to ensure a good air
seal. This requires more than one tightening pass to accomplish.
Over-torquing may cause hex sockets to strip.
4. Torque the cap screws to the hanger plate at 80 ft lb.
5. Insert the 18 bolts into the neck ring of the air actuator.
6. Reinstall the air actuator sealing plate, coat the bolt threads
with locktite and fasten with the lockwashers and nuts
provided.
7. Torque the nuts to the sealing plate at 80 ft lb.
(See Caution above.)
8. Lift and rotate the link tilt lever or base to line up with the air
actuator sealing plate. Attach with the four hex-head cap
screws and torque to 250 ft lb.
9. Safety wire the four screws.
10. Reconnect the chain between the two sealing plates.
11. Reinstall and adjust the link tilt per the Installation and
Commissioning book.

Removing the tong dies
Front jaw
1. Remove the cotter pin from the retaining bolts
and slotted nut.
2. Remove the nuts securing the die retainer to the jaw.
3. Remove the die retainer from the jaw.
4. Remove the tong dies from the jaw.
Rear jaw
1. On the rear jaw, remove the cotter pins from the retaining
bolts and slotted nuts.
2. Support the retaining bolt while removing the slotted nut.
3. Remove the retaining bolt from the piston jaw.
4. Support the remaining retaining bolt while removing the
slotted nut and upper die retainer.
5. Remove the retaining bolt and lower die retainer.
6. Remove the tong dies from the jaw.

March 8, 2001
Removing the jaws
Front jaw
1. Loosen the socket head cap screws securing the jaw assembly
to the torque wrench body.
2. Support the jaw and remove the socket-head cap screws and
washers from the jaw assembly and the torque wrench body.
3. Remove the front jaw assembly from the torque wrench body.
Rear jaw
1. Loosen the socket head cap screws securing the jaw assembly
to the piston.
2. Support the jaw assembly and remove the socket-head cap
screws and washers from the jaw assembly and piston.
3. Remove the rear jaw assembly from the piston.
Upper safety valve (IBOP)

Refer to the IBOP Service Manual for IBOP valve assembly and
disassembly procedures.
Lower safety valve (IBOP)

Refer to the IBOP Service Manual for IBOP valve assembly and
disassembly procedures.

from the guide dolly
You can perform some service procedures on top drives (i.e. upper
drive stem bearing and seal, air brake or locally mounted cooling
system) without removing the drilling motor assembly from the
dolly. If service is required on the lower end (i.e. gear set, lower
bearings or seals), the drilling motor must be removed from the dolly.
1. Set the TDS down horizontally on a good flat surface.
2. Make sure none of the components protrude past the guide
dolly roller brackets before setting the TDS down. If so, block
up the guide dolly accordingly.
3. Disconnect all wiring and hoses between transmission and
guide dolly frame.
4. Remove any cooling ducts (heat exchanger, spark arrestor,
etc.) that interfere with removing the transmission from guide
dolly frame.
5. Use a suitable sling to support the weight of the TDS and
motor support bonnet (approximately 10,000 lb).
6. Take up the slack and remove the trunnion blocks that hold
the transmission to the guide dolly frame.
7. Hoist the transmission out of the guide dolly frame.
8. Set the TDS and motor support bonnet down on wooden
chocks, being careful not to damage components.
9. Disconnect the wiring between the motor and motor support
bonnet.
10. Make sure the transmission is in neutral.
11. Remove the dowel pins in the motor feet.
12. Remove the four large motor bolts.
13. Lift the transmission off of the motor, angling the upper end
slightly to clear the motor support bonnet, and sliding the
housing off of the motor toward the gearcase
14. Remove the blower and brake assemblies.
15. Reverse this procedure for reassembly.

March 8, 2001
Disassembly/assembly of the
drilling motor and motor support
bonnet
1. Remove the upper bearing cover and grease seal
(Figure 4-32).
2. Pressurize the air brake to hold the drive mechanism in place.
3. Remove cotter pins, slotted nuts and the rotating head.
4. Remove the lower gearcase, carefully avoiding damage to the
lower gearcase locator dowel pins.
5. Carefully remove the bull gear, avoiding damage to the
bearing surfaces or wear sleeves. Do not remove the gear from
the shaft unless you are replacing it.
6. Remove the pinion seal and retaining ring.
7. Remove the main body.
8. On the opposite end of the motor, remove the magnetic
pickup and brake cover.
9. Remove the brake for service.

Main Body
Air Brake
Low DC
Gear Drilling
Assembly Motor
Bull Gear
High
Gear
Assembly
Pinion Gear
Manual
Shifter
Input Geneva
Mechanism
HI Motor
Shaft
Oil Level Pinion Seal
LO Sight Glass
Lower Gear
Case
Motor Gear
Alignment Selection
Cylinder Indicator
Figure 4-32. Drilling motor and motor support bonnet assembly/disassembly

March 8, 2001
Refer to the GE Electric Motor Manual for procedures to remove

the pinion or hub on the armature shaft, or to service the motor
itself.
Once the unit has been disassembled, inspect the following
assemblies for any wear or damage that may be critical:
1. Gear set: Check the teeth and splines for chips or heavy wear.
The wear pattern should be even and symmetrical. If not,
replace it. Expect some small surface pitting. It is not cause
for replacing the gear set.
2. Bearings: Clean thoroughly in solvent, then rotate and listen
for any roughness during rotation.
3. Main shaft: Check splines and tool joints for wear. Replace
the shaft if spline wear exceeds 0.090 in.
4. Main shaft: Check fit to bull gear, wear sleeve surfaces, and
retaining threads.
5. Seals: Always replace seals and gaskets when removed.
6. Main shaft housing: The bore for the upper bearing and the
pilot diameter for the lower gearcase are critical. Clean up any
nicks or gouges prior to reassembly.
7. Air brake: Check the brake for air leakage and the pads for
wear.
8. Wear sleeves: These should be free of any imperfections on
the sealing surface.
9. Blower: Clean any accumulation of dust from the ducting,
then operate the unit and correct any interference between
the impeller and housing.
10. Air valve assembly: If any air-operated systems are
malfunctioning, remove the appropriate valve and repair or
replace.
Reassemble the drilling motor and motor support bonnet by
reversing the steps in the disassembly procedure. Replace all
grease seals and O-rings, and refer to the following torque chart
for bolt tightening guidelines.

Torque Chart
Motor support/bonnet to main body 1100 ft lb
Main body to motor support/bonnet 1100 ft lb
Bull gear to hub 580 ft lb
Lower gearcase to main body 250 ft lb
Rotating head to lower gearcase 250 ft lb
Brake adapter ring to motor 250 ft lb
Brake to brake adapter plate 50 ft lb
Brake drum to hub 250 ft lb
Brake cover to brake 50 ft lb
Installing the TDS motor pinion
n Installing a pinion gear can be dangerous to personnel installing

it as well as anyone witnessing the procedure. Exercise caution at
all times.
Use the following procedure to install a TDS motor pinion:

1. Clean the motor shaft by hand and cover with a thin layer of
Engineer’s Blue.
2. Firmly install the pinion on the motor shaft by hand. Mark
reference lines on the pinion and the shaft to ensure identical
angular orientation each time.
3. There must be a minimum of 75% surface contact between
the pinion and motor shaft. Dress the motor shaft/pinion
very lightly with a fine emery cloth and repeat the “blueing”
procedure if necessary until there is at least 75% surface
contact between the pinion and motor shaft.
4. After thoroughly cleaning all blueing, oil, and/or grease from
the pinion bore and shaft, trial mount the cold pinion gear on
the motor shaft, lining up the reference marks.

March 8, 2001
5. Make sure the fixture is clean and the “horse shoe” face and
bar are parallel.
6. Place the fixture on the motor shaft with the “horse shoe” end
against the inner face of the gear and the bar against the outer
face of the gear, sandwiching the pinion gear in the fixture.
7. Adjust the adjusting screw to butt against the end of the
motor shaft.
8. Attach a calibrated dial indicator gauge to the fixture and set
to zero.
9. Back off the adjusting screw until the gauge reads 0.072-
0.074 in. Then lock the screw in place with a locknut.
10. Remove the fixture from the pinion gear assembly.
e Do not put the fixture in the oven.

11. Heat the pinion gear to 360-385°F (182-196°C) for three
hours in an oven. After heating for three hours, remove the
pinion gear assembly and immediately attach the fixture.
12. Place the pinion gear assembly and fixture on the motor shaft,
lining up the reference marks.
13. Gently tap the pinion gear assembly and fixture into place
until the adjusting screw butts against the motor shaft.
14. Wait 2-3 minutes and back off the nuts holding the fixture in
place. There may be some noise as the pinion gear cools.
15. The pinion creeps up the shaft as it cools to the required
position of 0.085 ± 0.005 in. advancement.
16. When the pinion is fully cooled, fit the fixture and check final
advancement.
17. Complete the required documentation recording pinion
advancement.

Local blower cooling system
assembly/disassembly
Use the following procedure to remove the blower motor in the
local blower cooling system (Figure 4-33):
1. Remove the electrical wires from the blower motor.
2. Remove the eight bolts on each side connecting the ducts to
the blower housing ducts.
3. Remove the four bolts on each side connecting the duct
housing to the blower inlet ducts.
4. Remove the four bolts connecting the blower mount to the
brake cover.
5. Hoist the blower assembly off of the TDS and place on a
clean work space on the derrick floor.
6. Remove the blower inlet ducts on both sides of the blower
motor.
7. Remove the taper lock bushings from both blower impellers.
8. Remove both blower impellers.
9. Remove the bolts connecting the blower housing assemblies
on both sides to the blower mount.
10. Remove the shaft seal assemblies from both sides.
11. Remove the blower housing and inner plate assemblies as
units from both sides. Do not separate the blower housing
assemblies from the inner plates.
12. Unbolt the four bolts connecting the blower motor feet to the
blower mount.
13. Lift the motor out.

March 8, 2001
Axial Fan
20 hp Transmission
Blower Motor Cooler
Locking Key
Oil Fittings (2)

Blower Housing
Gasket
Mounting
Brackets (2)
Blower Impeller
Taper Lock
Bushing
Gasket
Flex Duct
Connection
Point
Mounting Plate
Blower Duct to
AC Drilling Motor
Spark Arrestor
Figure 4-33. Typical local blower cooling system assembly/disassembly

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

March 8, 2001
Closed loop cooling system

assembly/disassembly
Use the following procedure to remove the blower motor in the
local blower cooling system (Figure 4-34):
1. Remove the electrical wires from the blower motor.
2. Remove the eight bolts on each side connecting the ducts to
the blower housing ducts.
3. Remove the four bolts on each side connecting the duct
housing to the blower inlet ducts.
4. Remove the four bolts connecting the blower mount to the
brake cover.
5. Hoist the blower assembly off of the TDS and place on a
clean work space on the derrick floor.
6. Remove the blower inlet ducts on both sides of the blower
motor.
7. Remove the taper lock bushings from both blower impellers.
8. Remove both blower impellers.
9. Remove the bolts connecting the blower housing assemblies
on both sides to the blower mount.
10. Remove the shaft seal assemblies from both sides.
11. Remove the blower housing and inner plate assemblies as
units from both sides. Do not separate the blower housing
assemblies from the inner plates.
12. Unbolt the four bolts connecting the blower motor feet to the
blower mount.
13. Lift the motor out.

Dual Shaft
20 hp AC
Blower Motor
Blower Mount/
Brake Cover
Blower
Housing (2)
Impeller (2)
8 in. Flex
Connection (2)
Blower Inlet (2)
Water
Connections
DC to Motor
Exhaust Port on
Upper Gear Case
Inspection
Cover
GE
Drilling Motor
Heat Exchanger (2)
Figure 4-34. Typical closed loop cooling system assembly/disassembly

March 8, 2001
Use the following procedure to install a new motor in the local

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

Replacing the safety wiring
Use the following procedures to safety wire screws, nuts, bolts, or
other fasteners where applicable.
n Torque fasteners before safety wiring any screw, nut, plug, or

other fastener. Never overtorque or loosen a torqued fastener to
align safety wire holes.
Use the size and type of safety wire required in the applicable
specifications and drawings. Whenever possible, use double-twist
safety wiring.
n Limit single-twist wiring to the following: small screws located in

closely spaced, closed geometrical patterns (e.g., triangles, squares,
rectangles, or circles), parts in electrical systems, or parts that are
difficult to reach.
n Do not reuse safety wire.
To install safety wire:

1. Open the jaws of the safety twist pliers.
2. Squeeze the handles of the pliers together and unlock the
round, perforated slider in the center of the pliers from the
hook lock.
3. Grip both safety wires in the jaw. Squeeze the handles
together with one hand and pull the slider toward the rear of
the pliers with the other hand to lock the pliers.
4. Twist the safety wire by pulling the aluminum knob and twist
the rod out from the pliers. Let the pliers spin free.
5. Return the knob and twist the rod by holding the pliers
steady with one hand and pushing against the end of the
knob the with other hand (step 4 in Figure 4-35).
6. Repeat the previous twisting cycle.

March 8, 2001
7. After threading the safety wire through the hole in the

fastener, pull the wire straight through without nicking the
wire. Twist four to five complete revolutions per inch of wire.
8. Make a pigtail of approximately 1 in. (25 mm) length (four
twists minimum) at the end of the wiring and bend back or
under to prevent it from becoming a snag.
1
2
3 4
Figure 4-35. Safety wiring procedures

Safety wiring tips
❏ Pull the safety wire firmly, but do not stretch it or let kinks
develop. Make twists tight, even, and as taut as possible
without weakening the wire by overtwisting (Figure 4-36).
n Do not nick the wire with the edge of the hole in the fastener.
Position the safety wire so the pull exerted by the wire tightens the
nut. For best results, let the wire leave the fastener in a clockwise
direction
❏ Twist the safety wire so the loop around the bolt or head has
sufficient tension to keep it from slipping up and over the
bolt head, with resulting slack in the safety wiring.
n When securing castellated nuts with safety wire, tighten the nut to
the low side of the selected torque range, unless otherwise specified.
If necessary, continue tightening within specified torque limits
until a slot aligns with the hole.
❏ The number of nuts, bolts or screws that can be safety-wired

together depends on the application. As a guide, when safety-
wiring widely spaced bolts by the double-twist method, a
group of three, or a 24 in. (610 mm) length of safety wire is
usually the maximum.
Figure 4-36. Safety wiring examples

March 8, 2001

Chapter 4
Troubleshooting
Troubleshooting the counterbalance
Symptom Probable cause Remedy

System does not hold Needle valve is not closed. See adjustment procedure and check
pressure. needle valve.
Cylinder rod seals leak. Replace seals.
Fittings or hoses leak. Tighten or replace as required.

Dirty or defective PRV valve. See adjustment procedure.
Clean or replace.
Dirty or stuck check valve. Clean or replace.
Counterbalance control valve Return valve to drilling position.
in rig down position.
Cylinder rods remain Pressure setting too high. Adjust per adjustment procedure.
retracted (closed).
e When activating or reactivating the counterbalance system, never start

an empty system with the needle valve closed. Always start the Hydraulic
Power Unit (HPU) first, run for 3-5 minutes, then slowly close needle
valve with HPU running. If an empty system is started up with needle
valve closed there is a good potential for damaging counterbalance
cylinder seals.

March 8, 2001
Troubleshooting the motor

alignment cylinder

Alignment cylinder Transmission trunnion pins Free trunnion pins as needed and
fails to move will not pivot in dolly lubricate area regularly.
transmission at support brackets, from lack
trunnion pivot points of lubrication.
with recommended
pressure setting.
Counterbalance Possible problem with Check Troubleshooting the
system works system hydraulic counterbalance section of this book.
erratically or does not components.
work at all.
Loss of nitrogen precharge in Recharge accumulators as per the
accumulators located in procedure in the Troubleshooting the
motor dolly upright frame. counterbalance section of this book.
System does not hold Needle valve is not closed. See the adjustment procedure.
pressure.
Cylinder rod seals leak. Replace seals.
Fittings or hoses leak. Tighten or replace as required.
Dirty or defective PRV valve. Clean or replace.
Saver sub on TDS Alignment cylinder pressure See the adjustment procedure.
does not align with too high or too low.
drill pipe.
Alignment cylinder rod Adjust according to procedure.
adjustment too long or short.
Rails not properly aligned Check to make sure that rotary is in
with centerline of well. center of floor and then check
alignment of rails in relation to
rotary.
Excessive motor Alignment cylinder fluid See the adjustment procedure.
movement. flow not adequately Normal adjustment is 1 1/2 turns
throttled. from full closed position on flow
control valves. If there is excessive
movement close to 3/4 turn from
full closed position.

Troubleshooting the drilling motor
and guide dolly
Troubleshooting the motor air brake

Brake does not hold. Insufficient air supply. Check air supply pressure,
90 psi minimum required.
Solenoid valve not shifting. Check electrical continuity.
Check lubricator on air supply.
Check mechanical operation of
solenoid valve.
Brake drum contaminated Inspect and replace if necessary.
with grease or pads worn or
burnt.
Brake does not Solenoid valve sticking. Lubricate, repair with repair kit or
release. replace valve.
Check air supply lubricator.
Quick exhaust valve not Clean or replace.
functioning properly.
Troubleshooting the
retract guide dolly

Guide dolly retracts Flow control valves on the Set the flow controls to attain
too slow or too fast. guide dolly are not properly desired retract speed.
set.

March 8, 2001
Troubleshooting the transmission

Oil leaking from Lower gear case seals are dry Apply grease to seal.
lower seal. or damaged. Grease fitting daily.
If problem persists replace gearcase
seals and bearing.
Oil leaking from shaft Oil level too high. Adjust oil level per recommended
housing breather. specification.
Incorrect lubricant used. Check recommended lubricants
chart and replace as needed.
Oil is foaming. Replace oil.
Gearbox temperature Oil level too low or too high. Adjust oil level to recommended
is excessive. level in sight glass.
chart and replace as needed.
Clogged oil suction screen. Remove suction screen from oil
pump. Check discharge or pressure
hoses at outlets to confirm
circulation.
Clogged or dirty heat Check heat exchangers for air flow
exchangers on unit equipped or water flow to ensure adequate
with such. heat transfer and dissipation.

Troubleshooting the oil pump

OIL PUMP LOSS Motor is not running. Check electrical components to
alarm is on. ensure power is available to motor.
Repair or replace as needed.
Incorrect motor rotation. Verify proper rotation and correct
if necessary.
Dirty or clogged oil pump Remove and clean suction screen
suction screen. making sure to properly seal screen
cover when installing.
Oil pump cavitating- Check all connections and suction
evidence of air bubbles in screen cover plate to ensure there are
discharge lines. no air leaks on suction side of oil
pump. Repair as needed.
Defective or improperly Check switch operation.
adjusted pressure switch. Repair or replace as needed.
Failure of oil pump drive Inspect, repair or replace as needed.
coupling.
Faulty or worn oil pump. Check relief valve on back of pump.
Install test gauge in discharge line
and adjust to 10 psi.
If unable to make oil pump work
after checking all of the above, repair
or replace as needed.
chart to make sure proper viscosity
of oil is used. Replace as needed.

March 8, 2001
Troubleshooting the cooling system

Mechanical noise in Loose impeller. Reinstall impeller and hub and
blower. locktite screws.
Faulty motor bearings. Repair or replace as needed.
Blower runs Faulty or loose wiring. Locate and repair as needed.
intermittently.
Faulty motor starter. Check for dirt or trash between
starter coil. Repair or replace as
needed.
Excessive air loss in Worn or defective seal or Replace as needed.
blower motor shaft wear sleeve.
area.
Loose or vibrating blower Correct blower mounting problem
motor, wearing seals or faulty motor bearing and replace
excessively. blower shaft seals.
DC MOTOR Incorrect blower rotation. Verify blower rotation. Correct as
OVERHEATING, needed.
OVERTEMP alarm
stays on with blower
running.
Dirty or clogged spark Remove spark arrestors from motor
arrestors (local or remote and clean screens if screens are
cooling systems). damaged with holes. Replace as
needed.
Clogged water or air passages Remove and clean passages as
in water cooled exchangers needed.
(closed loop cooling).

Troubleshooting the cooling system (cont.)

DC MOTOR Continuous drilling Amps Check service manual for continuous
OVERHEATING, over recommended levels. Amp motor rating and adjust
OVERTEMP alarm drilling program accordingly.
stays on with blower
running.
Motor being stalled for over DC motor should never be stalled
recommended periods of for more than 5 seconds with over
time. 300 Amps applied.
e Serious damage could occur to the

motor if this is done.
Faulty temperature switch or Repair or replace as needed.
probe.
z Do not readjust or raise heat range

setting.
Improper cooling water flow See the Installation and
or incoming water temp too Commissioning book for
high (closed loop cooling). recommended or required flow rates
and water temp.
Restricted air flow (local or Check and clean spark arrestors as
remote cooling). needed.
Check air intake on blower to ensure
there are no restrictions.
Verify proper blower rotation.
WATER Moisture in air inside DC Check for leaks in heat exchanger.
DETECTOR motor. Check air purge line filters. Ensure
alarm is on dry air is going into motor.
(closed loop system).
Dirty or faulty water Clean or replace as needed.
detector.

March 8, 2001
Troubleshooting the pipehandler
Troubleshooting the torque wrench

Tool does not cycle Valves in manifold out of Readjust.
properly. adjustment.
Supply and return hoses are Reconnect hoses correctly.
crossed.
Improperly connected Quick Check QDs to make sure they are
Disconnects (QDs). properly plugged together and
flowing in both directions.
Needle valve in counter- Close needle valve (always with
balance manifold is open. HPU running).
Defective cartridge valve or Inspect valves for damaged seals or
PRV valve. stuck spools. Replace if necessary.
Improper component or Valve cartridge replaced with wrong
component installation. type.
z When changing the Make/Break

valve, make sure the valve is properly
oriented when installed.
Die retainer and die Improper saver sub length or Saver sub length too long. Sub
retainer bolts machining. should also have proper chamfer on
damaged while both shoulders.
breaking.
Torque wrench does Oil bypass in pipehandler Listen for oil bypassing in
not lift. hydraulic components. pipehandler cylinders or manifold.
Locate and repair bypass as
necessary.

Troubleshooting the torque wrench (cont.)

Tool goes up, clamps, Air pilot valve on counter- Remove air supply line to verify air
and cycles, but balance manifold stuck or supply when solenoid valve is
remains clamped on inoperative. activated.
pipe when switch is
released.
Pilot valve dirty. If air supply is available remove end
cap on pilot valve, clean and
lubricate.
Improperly connected quick If air pilot valve is operable, hook
disconnects. both pipehandler hoses together and
verify flow in both directions by
activating switch with hydraulics on.
If there is flow in only one direction,
check QDs.
If QDs are properly connected,
check hydraulic pilot valve for stuck
spool.
Hydraulic valve not shifting. Repair or replace.
Saver sub breaks out Saver sub not made up Make up saver sub per procedure
instead of tool joint. properly. described in the IBOP Service
Manual, increase previous torque
makeup by 10% to maximum
torque recommended in the IBOP
Service Manual (for original Varco
OEM subs).
Tong dies break or Valves in manifold out of Readjust per procedure.
score drill pipe. adjustment.
Tong dies worn. Replace tong dies.
Connection overtorqued. If saver sub is made up to
recommended torque and continues
to break out instead of drill pipe
connection, break out using rig
tongs.
If saver sub or drill pipe will not
break out using pipehandler, remove
pipehandler and break out with rig
tongs at floor.

March 8, 2001
Troubleshooting the
safety valve actuator

Safety valve leaks. Internal parts worn out. Check for washouts or defective
parts. Repair as needed.
Actuator out of adjustment. Check electrical continuity.
Check spool mechanical operation.
Lubricate if needed.
Check actuator cylinder adjustment
(see procedure).
Excessive vibration or Actuator support roller Check actuator shell adjustment and
wobble while rotating. brackets bent or out of crank assembly operation.
adjustment.
Worn cam rollers. Repair or replace rollers and roller
brackets, shimming as needed to
maintain smooth operation.
Troubleshooting the link tilt

Does not tilt. Solenoid valve not shifting. Check electrical continuity.
Check spool mechanical operation
and lubricate as needed.
Does not reach Improperly adjusted. Readjust drag link, shorten if
mousehole. necessary.
Retracts slowly, does Pressure setting on float Adjust pressure setting.
not make it back to valve too low.
well center.
Passive stop not in right Adjust jam not on passive stop to
spot. position elevators over well center.
Retracts past well Pressure setting on float Adjust pressure setting.
center in float mode. valve too high.
Passive stop not in right Adjust jam not on passive stop to
spot. position elevators over well center.

Troubleshooting the pipehandler at
the counterbalance manifold

Pipehandler goes up and Improperly connected Check all QDs to make sure that they are
clamps when the HPU is QDs. properly connected, also making sure that
turned on without each half is intact and not coming apart and
pressing switch. restricting fluid.
Solenoid valve stuck or Disconnect air line from solenoid to air pilot
inoperative. valve. If there is a constant air flow, the
solenoid valve is stuck in the open position.
Remove the solenoid and valve. Clean as
needed. Repair or replace valve as needed.
Check oil lubricator to make sure valves are
being lubricated.
Air pilot valve sticking. If there is no constant air flow from air line,
remove end cover on air pilot valve and
check spool to see if it is operating freely.
Clean as needed and lubricate. Repair or
replace valve as needed.
IBOP valve actuator Faulty or loose wiring. Check electrical continuity to switches and
remains either in closed or solenoids.
open position.
No air supply or air Check air supply. There must be 90 psi
supply incorrect. minimum pressure.
Crank assembly, actuator Check crank assembly, actuator arms and
arms or cylinders cylinders. Repair as needed.
sticking.
Solenoid valves stuck in Check solenoid valves to see if they are not
the open position or in stuck in the open position or in center
center position. position. Repair or replace valve as needed.
IBOP valve does not fully Actuator cylinder out of Check actuator cylinder adjustment and
open or close. adjustment. adjust as needed.
Cam follower rollers Check cam follower rollers on crank
sticking. assembly and arms.
Crank assembly retainer Check crank assembly retainer bolts to
bolts loose. assure tightness.
z Crank assembly retainer bolts should be

checked weekly to make sure they remain
tight.

March 8, 2001
Troubleshooting the
crown height indicator

Green power indicator No AC power being applied. Check Expo purge system and
does not illuminate. input AC power.
Internal AC breaker tripped. Check internal circuit breaker on control
electronic module for tripped condition.
Failure of DC power supply. Check AC power LED on control electronic
module. Replace electronic control module
necessary.
Depressing the PUSH TO Malfunction of control Replace electronic control module.
TEST indicator does not electronics.
cause position indicators to
flash or illuminate.
Yellow indicator is Misadjusted lower sensor Check proximity switch alignment.
constantly illuminated proximity switch.
while traveling assembly is
below ten feet.
Defective lower sensor Check mechanical operation of sensor
bracket assembly. bracket assembly.
Defective sensor cable Perform cable continuity tests.
between sensor junction box
and control electronics.
Defective proximity switch. Replace proximity switch.
Malfunction of electronics Replace electronic control module.

control module.
Yellow and red indicator Misadjusted lower sensor Check proximity switch alignment.
constantly flash while proximity switch.
traveling assembly is below
ten feet.
Defective sensor cable Perform cable continuity tests.
between the sensor junction
box and control electronics.
Defective upper sensor Check the mechanical operation of the upper
bracket assemblies. sensor bracket assembly.
Defective upper proximity Check voltages from upper proximity switch
switches. by measuring voltage between TB3 and TB2
for upper sensor at the sensor junction box.
A measurement of less than 2.0 VDC indicates
a working sensor when metal is detected.
Replace proximity switches as required.
Malfunction of electronics Replace electronic control module.
control module.

Six-gang air valve assembly
illustration
Air Elevator
Torque Wrench
Brake
IBOP Open
Link Tilt
IBOP Close

March 8, 2001

TDS-4S
Top Drive
Drilling
System
Control System
SM00620-5
March 8, 2001
5-2 TDS-4S Control System

Contents
TDS-4S Control System
checkout procedures ........................................................ 5-7
TDS-4S Control System 5-3

March 8, 2001

TDS-4S
Control System
General description
The Top Drive Drilling System (TDS) typically operates from the
same SCR as the rotary table. A panel, located in a Central
Electronics Enclosure (CEE), switches power from one to the
other. The CEE typically contains the following components:
❏ DC contactors
❏ A programmable logic controller (PLC)
❏ Auxiliary AC components
❏ Rig instrumentation interfaces for recording
TDS torque and speed

March 8, 2001
In dedicated top drive SCR configurations, the SCR runs the top
drive only.
The panel can feature a purge control system so it can be located
in hazardous areas. If the panel is located in the SCR room, a
purge system is not required.
The panel is designed to be compatible with all presently installed
SCR systems and is configured at installation for the specific SCR
used on a rig. Logic and alarm functions are connected to the
TDS via PLC programming so the TDS can operate existing rig
systems. Also, TDS interlocks and limits, such as spin-up and
makeup speeds, are programmed into the PLC and are the same
for all installations.

checkout procedures
The Varco Top Drive Drilling Control System (TDCS) is
straightforward in its operation and relatively easy to service.
Refer to the following documentation for maintenance,
troubleshooting and checkout information:
❏ Periodic control system maintenance schedule

(See Table 1 below.)
❏ Rig checklist
❏ PLC manual
❏ Card rack terminal specifications
Table 1. Periodic control system maintenance schedule
Location Procedure Frequency

Indicator lamps Test using the lamp test switch Each time the
on the driller’s console. TDS is assigned.
Heater Check operation with an Ohm meter. Monthly
High voltage connections Check for discolored or brittle insulation. Monthly
Check retaining bolt torque Monthly
(needs to be 25 ft lb).
Component mounting Check fastener tightness, especially in Monthly
vibration-prone areas.
Blower mounting current Check and record current. Monthly
(A drop in the current may indicate
restriction or blockage of the air intake.)
Drilling motor field current Verify and record. Weekly
Seals and gaskets Check for integrity. Monthly
Apply a light film of silicone lubricant Every 3 months
to the transfer panel door.

March 8, 2001

Service Manual Top Drive System: TDS-4S

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TDS-4S

Top Drive System

Chapter 2 Major component description

TDS-4S Contents iii

Link tilt mechanisms ................................................ 1-45

Chapter 1 Operating procedures

TDS-4S Contents vii

Lubricating the safety valve actuator .............................. 4-34

viii TDS-4S Contents

Book 4 – TDS-4S Control System

1-2 TDS-4S Description

Chapter 2 Major component description

TDS-4S Description 1-3

TDS Control System (TDCS) ....................................... 1-53

1-4 TDS-4S Description

z Indicates advisories for operational or servicing procedures

e Indicates advisories involving a risk of equipment damage.

n Indicates advisories involving a definite risk of injury to rig

Avoid personnel injury and equipment damage by reading this

TDS-4S Description 1-5

1-6 TDS-4S Description

TDS-4S Description 1-7

Figure 1-1. Typical TDS-4S overall view

1-8 TDS-4S Description

Integrated Swivel Bail

;;;;;;; ;;;;;;; Upper Gearcase

Figure 1-2. TDS-4S motor and swivel housing assembly

TDS-4S Description 1-9

The integrated drive stem functions as the main output shaft

1-10 TDS-4S Description

350-Ton 108 in. Link (2)

Figure 1-3. Typical 650-Ton, PH-85 pipehandler assembly

TDS-4S Description 1-11

Torque Arrestor (4)

Pneumatic Link Tilt

Lower IBOP Valve

Figure 1-4. 650-Ton, PH-60d pipehandler assembly

1-12 TDS-4S Description

Actuator Arm (2) Safety Valve

Figure 1-5. Safety valves (IBOPs) and actuator assembly

TDS-4S Description 1-13

1-14 TDS-4S Description

TDS-4S Description 1-15

Manually or Remotely Operated

Figure 1-7. 650-Ton, PH-85 pipehandler in relation to other TDS assemblies

1-16 TDS-4S Description

Manually or Remotely Operated

Figure 1-8. 650-Ton, PH-60d pipehandler in relation to other TDS assemblies

TDS-4S Description 1-17

1-18 TDS-4S Description

Motor housing assembly

❏ Drilling motor and brake

TDS-4S Description 1-19

Two speed transmission

❏ Bull gears – 96 tooth, 2.0 diametral pitch

1-20 TDS-4S Description

High Gear Low Gear

Geneva Shifter Input

Figure 1-9. Transmission/geneva mechanism

TDS-4S Description 1-21

Lubrication to the bearings and gear meshes is force fed by an

Integrated swivel bail and swivel

1-22 TDS-4S Description