Top Drive

Maintenance and Operation

Rig Crew Training

More than ever before

THE CAN-RIG MISSION
STATEMENT!

HELPING OUR
CUSTOMERS ACHIEVE
SUPERIOR RESULTS.
 INTRODUCTION
The Top Drive has multiple items that need to be
inspected and maintained to prevent down time
on repairs and to protect the safety of the rig
personnel. You should use a routine maintenance
program and safety program for the best results
in your top drives performance. In this power
point we will discuss the critical safety programs
and maintance required in order to be successful
in drilling operations!
 Critical Safety Programs
LOTO
Understanding of the principles of Lock-out Tag-out and how to
apply to Canrig Equipment
Fall Protection
Understanding of fall protection equipment and when it is needed
Personal Protective Equipment
Understanding of what PPE should be worn
Job Safety Analysis
Understanding how to review hazards of each job and mitigate risk
Safety Observation Programs
Understanding how to communicate Safety issues and how to
communicate with peers about unsafe behaviors and hazards in the
workplace
 THE TRAINERS GOAL
TO HELP THE RIG
PERSONELL IMPLOMENT
AND TRAIN ON A ROUTINE
TOP DRIVE MAINTENANCE
PROGRAM BY REVIEWING
THE MAIN COMPONETS ON
THE EQUITMENT WITH ALL
PERSONELL OVER THE
DAILY, WEEKLY AND
MONTHLY MAINTANCE.
TO UNDERSTAND THE
OPERATIONS OF THE TOP
DRIVE DURING NORMAL
AND CRITICAL
OPERATIONS.
 HOW TO CONTACT CANRIG
CANRIG CAN BE REACHED BY CONTACTING:
24/7 RIG LINE 1-866-433-4345
OR FOR INTERNATIONAL
281-774-5649
OR BY EMAIL AT
RIGLINEsupport@canrig.com

FOLLOW THE PROMPTS TO GET THE BEST

REPRESENATIVE FOR YOUR EQUIPTMENT AND
CONCERNS
 COURSE OBJECTIVES

Understanding of Top Drive Maintenance

Top Drive Daily Inspection Form
Dropped Object Identification
Hydraulic Pump Unit
Top Drive Operation
Panel View Operations
 TOP DRIVE
MAINTENANCE
 TOOLS REQUIRED
A GREASE GUN
TUBES OF GREASE
A BOATSWAIN
CHAIR
MAN RIDER OR
HOIST
ALL APPROVED
LIFTING
EQUITMENT
TEATHER TOOL KIT
RAGS
 OTHER RECOMENDATIONS
LOTO
JSA
COMMUNICATION
WITH DRILLER
WELL CONTROL
MONITORING
CONFIDENT
PERSONEL FOR
HOIST OPERATOR
RIG MANAGER
PRESENT
 MAINTENANCE
Grease the Wash
pipe Packing Every
12 hours when
Drilling, Grease to
excess of 10 pumps
with a grease gun
Visually inspect for
leaks and wear
Do NOT run Mud
Pump while doing a
serivce
MAINTENANCE

Grease Link Tilt

Cylinder Bushings
Once Per Day.
4 fittings, grease at
least 10 strokes per
fitting if dry or until
grease is seen in the
bushing / bearing
 Top Drive Maintenance
The Link Tilt bushing at the upper end near the rotary manifold
has a safety keeper on both sides
Swing Armat the ens of the castle nut. Verify the
Console
condition of the keeper when greasing the bushings. Note the safety cable on
the pins near the clamps. Verify as well!
MAINTENANCE
Check Indicator on
Hydraulic Filter
Once Per Day.
Look for leaks and
wear
GREEN- GOOD
YELLOW- MEDIUM
RED- REPLACE
MAINTENANCE
Check Indicator on
Lube Oil filter Once
Per Day
GREEN- GOOD
YELLOW- MEDIUM
RED- REPLACE
MAINTENANCE
Check gear oil level on
the Top Drive at the at
the window. Daily.
Use a 75W90 Synthetic
for best results
Look through the view
port to inspect for any
damage or wear to the
pinion and bull gears.
Inspect area for leaks.
OIL LEVEL CHART
MAINTENANCE
Fill Location for
Gear Oil
Recommend to use a
funnel with screen to
prevent any
unwanted items
from entering the
gear case.
Also using a funnel
will control spills
MAINTENANCE
Examine Brake Pads for
wear weekly
Test Brake by turning on
brake first then applying the
traction motor (Drill RPM)
Use the drill torque limit to
apply amount. Up to 20k or
30k once reached zero out
limit and release brake.
Good working brakes on a
500 ton should hold 50k
MAINTENANCE
Check Fluid in
Brake Actuators
Daily.
Use same type of
hydraulic oil used in
HPU.
 MAINTENANCE
BRAKE ASSEMBLY MAINTENANCE cont.
Ensure that the brake valves are set in their correct positions, as shown. The
picture below shows the valves in the closed, or operating position.
Swing Arm Console

Operation - Closed

The picture below shows the valves in the open, or maintenance position.

Maintenance Open
Auto Brake Bleeding
 Auto Brake Bleeding

1. Clean area around reservoir covers

2. Remove covers.
3. Fill reservoirs to indicated FULL level. Use only mineral base oil
(hydraulic oil) in the brake reservoirs. Do not use brake fluid.
4. Replace reservoir cover(s) but leave loose. If the cover is
tightened the reservoir could be damaged during bleeding.
5. Open ball valve(s) (1 per reservoir) on reservoir return lines.
6. Put the Top Drive selector switch in the AUX position and start
the HPU.
7. Cycle the brakes several times by operating the Brake switch at
the Top Drive Console.
8. Close the ball valve(s) on the reservoir return line.
9. Top off reservoirs and replace covers tightly. Ensure there is no
air visible in the system.
MAINTENANCE
Grease Link Support
Weekly.
8 fittings, 4 each
side.
10 pumps per fitting
Visually inspect area
for damage.
Watch you PINCH
POINTS
MAINTENANCE
Grease Main Back Up
Wrench Tube Weekly.
5 fittings, 10 strokes per
fitting.

Visually Inspect the

Guide Plates.
MAINTENANCE
Grease Back Up
Wrench Gripper
Cylinder Weekly
2 fittings, at least 10
strokes per fitting.
Clean area of MUD
and GRIME
MAINTENANCE

The picture shows the

cylinder rod that the die
block attached too. The Die
Block needs to be removed.
They are located on end of
the cylinder rod, under the
die block. The die block must
be removed to access the 2
grease zert. Coat with Anti-
seize to prevent the die block
from sticking to the rod. Also
notice the sleeve for the pin
and coat with anti seize.
MAINTENANCE
This tool may need to
be installed under the
bottom Nut of the Wash
pipe to raise the quill up
high enough to get
access to the Die Block.
To install you need to
set the Top Drive down
on the stump too take up
the slack of the floating
Quill.
MAINTENANCE
Check Gear Case
Breather for any
debris around it.
Blockage of the gear
case Breather can
lead to top drive seal
failure.
 Top Drive Maintenance
Hyd System GAUGE AND PRESSURE INDICATORS
Pressure
Arm
Swing The Hydraulic
Console system pressure. This pressure
should be 2300 PSI when the HPU is on or the top
drive is running. If this pressure is low, it could be
caused by a leak in the system, or the link
counterbalance valve on the valve stack is not
Hyd System adjusted properly.
Return Hydraulic return pressure. This pressure should be
less than < 30 PSI when the HPU is on or the top
drive is running. If this pressure is too high, it could
be caused by a leak in the system allowing hyd
fluid to bypass a valve. High pressure in this part of
Lube Oil the system can cause erratic hyd valve operation
Pressure across the entire valve manifold.
 Top Drive Maintenance
GAUGE AND PRESSURE INDICATORS
Lube oil pressure. This pressure should be 20-100 PSI when the top
Swing Arm Console
drive is running. Near the lube oil pressure gauge is a lube oil
sampling port. This allows you to acquire a lube oil sample for
testing. It is recommended to allow a small amount of oil to flow
freely before acquiring the sample to allow the oil in the sampling
port hose to be discarded. The top drive should still be warm after
running when the sample is taken.
At the bottom right of the picture above, note that there is a lube oil
filter and a differential pressure gauge. On some models, there may
be a temperature gauge instead of the differential pressure gauge.

CAUTION: Hot oil hazard. Wear protective gloves when taking

sample. Minimize spilling of fluid. Use oil absorbent pads if needed.
 Top Drive Maintenance
GAUGE AND PRESSURE INDICATORS cont.
Swing Arm Console
The purpose of the differential pressure gauge is to indicate
when the filter needs to be changed. Always change the lube
filter element at every oil change-consult the filter change
recommendations of the manual for your specific top drive
model. Always check the differential pressure gauge, as it
may indicate that the filter needs to be changed sooner, such
as under harsh operating conditions, or when using corrosive
or briny mud fluids. The manual for your specific top drive
should indicate the specific oil type and oil operating
temperature. The picture below also shows the lube oil filter
and differential pressure gauge.
MAINTENANCE

FILTER

DIFFERNTIAL GUAGE
Typically runs @ 2-7
psi
Change filter @ 10+
 MAINTENANCE
Check the Lube Cooler weekly for leaks or plugged screens.
Screens or cooler fins plugged by dirt, oil, leaves, etc. will
Swing Arm Console
seriously affect the cooling efficiency of the Lube Cooler and
result in overheating. See Lube Cooler in the picture below.
 MAINTENANCE

Handler Rotate Gear Box

The handler rotate gearbox is
not oiled by the lube oil system,
FILL and requires its own specific oil
as recommended in your top
drive maintenance manual.
The oil level should be checked
DRAIN monthly, and the oil should be
changed every 6 months.
USE ISO 68 GEAR OIL
MAINTENANCE
Torque Boost (TB)
The Torque Boost gear
box is not oiled by the
lube oil system, and
requires its own specific
oil.
The oil level should be
checked monthly, and the
oil should be changed
every 6 months.
USE ISO 68 GEAR OIL
MAINTENANCE
Grease Lube Oil
Pump monthly. One
fitting.
One pump of grease.
Verify the safety
cable is attached!
Do Not OVER
GREASE
Handler lock 500
Inspect the area for
damage.
Inspect for leaks.
Stay clear of pinch
points.
Ensure that it is
locked at all times
when drilling and
torqueing.
MAINTENANCE
Clean the lube oil Y
strainer once a week.
Check for
contaminants.
Close valve prior to
removal
MAINTENANCE
Grease LWCV
Actuator Weekly.
6 fittings.
Grease the two
fittings on the
bearing only at rig
down or monthly.
Excessive grease
will cause them to
overheat
 Top Drive Maintenance

Installation ofSwing
tool Arm
joint clamp:
Console
Install tool joint clamps as shown below and ensure there is an even gap
on both sides when tightening Allen head bolts. While installing clamps
have another crew member tap on the outside of the clamp with an
appropriate device where the dies bite against the pipe to ensure tool
joint clamps make a good bite into the sub. Torque the bolts to the
proper amount.

100 ft/lbs Torque

 Top Drive Maintenance

Swing Arm Console

Counterbalance Bleeding Procedure:
Put the HPU switch on the HMI to the OFF position. Lockout the CIP.
After the hydraulic pressure reaches zero remove the cover on the test port (K )
and install a hydraulic test hose to the test port on the lower end of the Rotary
Manifold.
Note: When the test hose is fully engaged into the test port the hydraulic fluid will start to flow. A container
and absorption pads are needed.
The Counterbalance will travel down until it engages the lower section of the
Rotary Manifold.
Note: Extreme caution must be used and at no time should any items be placed on the lower section of the
Rotary Manifold. Severe damage and injury can occur when the Counterbalance engages the Rotary
Manifold.
After the Counterbalance has rested on the Rotary Manifold the Bales can be
removed from the Top Drive.
After the job is complete, remove the test hose and install the dust cover onto the
port.
Note: Insure that there are not any tools or items of any kind left on the top of the Counter balance. When
the hydraulic system is engaged the Counterbalance will move upward at a rapid rate of speed.
 Top Drive Maintenance
DRAIN PORTS ON TOP DRIVE
The pictures shown below indicate drain ports for the lube oil system on the
Swing
top drive. They are located onArm Console
the rotary manifold. The picture on the left is
of a 500 ton model, and the picture on the right is of a 275 ton model. Note
that although the drain ports of both models are located on the rotary
manifold, they are on opposite sides, and are marked DRAIN.

 Top Drive Maintenance
DRAIN PORTS ON TOP DRIVE cont.
The picture below shows a close-up of the drain port.
Swing Arm Console

The importance of this drain port can not be stressed enough. This is the lowest point in the lube oil
system. The oil that collects here is not re-circulated into the lube oil system. As a result, metals, mud
fluids, and other heavy contaminants easily collect here. This makes the drain ports on the rotary
manifold an excellent source for the oil sample. The top drive should still be warm after running when
the sample is taken. CAUTION: Hot oil hazard. Wear protective gloves when taking sample. Minimize
spilling of fluid. Use oil absorbent pads if needed. The oil from the drain ports will flow slowly, as the
oil will be thick and could possibly be in a sludge-like state. Using a thin wire, poke the wire up inside
the drain port hole to loosen the sludge and allow the oil to flow more freely. Upon opening the drain
port, collect all of the oil as it pours slowly into the sample bottle.
TOP DRIVE TRACK
Grease the Track when
rigging up as the track
unfolds or if on site for
a long length of time
you should consider a
maintance program and
a visual inspection of
the track and Hanger
Assembly
 MAINTENACE
Service and Maintenance Location Drawing Off-Drillers Side View

Swing Arm Console

 MAINTENANCE
Service and Maintenance Location Drawing Drillers Side View

Swing Arm Console

 MAINTENANCE
Service and Maintenance Location V-Door Side View

Swing Arm Console

 TOP DRIVE DAILY
INSPECTION FORM
 Top Drive Maintenance
CAP SCREW TORQUE VALUES
All cap screws and bolts used on a Canrig Top Drive meet or exceed the
SAE Gr.8 specifications. These must be torqued to the values shown on
the assembly drawings
SwingorArmto theConsole
value charted below. In addition, the
following guidelines should be followed when reinstalling cap screws or
bolts:
All cap screws or fasteners permanently installed must be coated with
Loctite 242 Thread locker or the equivalent after insuring that the cap
screw threads and mating thread are free of all dirt, oil and grease. This
is a medium strength thread locker that prevents rusting of all threads
and prevents loosening due to vibration. This thread locker can be
sheared using normal hand tools.
All cap screws or fasteners that require periodic loosening to facilitate
adjustment of components (tool joint clams, link tilt clamps, guide rails,
etc.) should be coated with anti-seize thread compound 767 or the
equivalent. When using cap screws with locknuts, use only Grade C
Stover locknuts or equivalent. These can be identified visually by eight
raised dots. These are re-usable, but new nuts are recommended after
repeated removal and installation.
CAP SCREW TORQUE CHART
HYDRALIC
PUMP UNIT
 TOP DRIVE STAND ALONE
HPU
CAN RIG OFFERS A STAND ALONE HPU THAT COMES EQUIPT
WITH 2 PUMPS AND A WORKING PRESSURE OF 2350PSI
THEY PROVIDE 13 GPM(FLOW) PER PUMP AND ARE
STANDANDARD WITH 20HP MOTORS. WE ALSO OFFER THEM IN
460V OR 600V.
THEY HAVE A SELF CONTAINED 60 GAL RESAVOIR.
THE UNITS ALSO OFFER FEATURES SUCH AS
1. SAFETY PRESSURE RELIEF
2. SYTEM PRESSURE GUAGE
3. BACK PRESSURE CHECK VALVES
4. TANK FILL FILTRATION SYSTEM
5. SUCTION STRAINERS
AND MUCH MORE
 Hydraulic Power Unit (HPU)

The HPU is usually located on the TDSU Top Drive Support Unit
Some installations may be in other locations or may use the Rig
Hydraulics
 HPU

Check HPU level daily.

Do not overfill as it will
release into the
WHEN HPU IS
OFF THE FLUID atmosphere.
WILL RISE IN Use section 4 of the
TANK. AKA
(DRAIN FROM Top Drive manual to see
SERVICE hydraulic oil temp chart
LOOP) KEEP and grade oil
LEVEL LOW
ENOUGH TO recommendations
ALLOW DRAIN!
HPU
Examine area for
leaks
Check the Indicator
on the Low Pressure
Filter.
Check Indicator on
Pressure Filter Daily
GREEN- GOOD
YELLOW- MEDIUM
RED BAD
HPU
This handle is used to
fill the tank with the free
hose in a barrel of oil
and the motor running.

Check the Y - strainer

for metal particles.
HPU
Check Hydraulic Oil
Pressure Daily at
HPU pressure gauge.
Should be a
minimum of at least
2300 PSI.
Use the Panel View
to verify the RTD
reading and pump
gauge are accurate.
 TOP DRIVE
OPERATIONS
TOP DRIVE CONSOLE
LOCK OUT - E-STOP
TOP DRIVE LOCKOUT SWITCH
(PB 1)
DEPRESSED Shuts off all electrical power to the top drive
and disables all Top Drive functions.

RELEASED Normal Top Drive operation.

EMERGENCY STOP SWITCH

(PB 2)
DEPRESSED Shuts off all electrical power to the top drive
and disables all Top Drive functions by:
tripping the VFD (Variable
Frequency Drive)breaker on Canrig
supplied VFD units
tripping the feeder breaker at the CIP panel or
Transfer panel.
PULLED - Normal Top Drive operation.
OUT
 OFF - AUX - ENABLE
OFF - AUX - ENABLE (SW 1)
OFF Disables operation of the Top Drive.
AUX Power is supplied to the Top Drive for auxiliary functions but no
power is available to the Top Drive motor.
There is a 5 second alarm test sequence when AUX is first
selected.
Used for tripping operations.
ENABLE The VFD is enabled
Auxiliary functions.
5 second alarm test sequence.
The Top Drive blower will start when the motor temperature
reaches 30 C. If the internal motor temperature drops below
20 C, the blower will shut off.
The Top Drive lube pump will start.
The Top Drive lube cooler will start after a 30 minute delay.
The TOP DRIVE ENABLE light will be lit
The TOP DRIVE ENABLE light will flash under the following
conditions if VFD not properly enabled.

The Top Drive will automatically shut down under the following conditions:
Low air flow detected while the Top Drive is in ENABLE and
the motor temperature exceeds 30 C.
Loss of the Top Drive Lube Pump Running status.
If the drilling motor temperature reaches 356 F (180 C). The
throttle can be zeroed and the top drive restarted ONE TIME.
If the high temp continues for 10 minutes the top drive will
shut down and cannot be restarted until the temperature
reaches 310 F (155 C).
TOP DRIVE MODE FUNCTIONS

TORQUE TORQUE
FORWARD REVERSE

SPIN DRILL SPIN

FORWARD FORWARD REVERSE

SPIN DRILL SPIN

FORWARD REVERSE REVERSE
(Maintain) (Maintain) (Maintain)
 TOP DRIVE JOYSTICK
TOP DRIVE MODE JOYSTICK (JS 1)
DRILL The speed is controlled with the hand throttle wheel (TH1).
Forward The torque is limited by the DRILLING TORQUE LIMIT which is displayed in units of ft-lb on the
& DRILL TORQUE LIMIT meter (M3) and can be adjusted with the DRILLING TORQUE LIMIT
Reverse dial (TH2).
The maximum continuous torque is limited by the Torque - Speed Limitations shown on the torque
curves in section 2 of the manual.
SPIN The speed is preset at approximately 30 RPM.
Forward The torque is limited to 3 000 ft-lb (4 000 Nm).
& Note that there are two spin joystick positions for each direction. One is maintained and the other will
Reverse spring return to neutral.
TORQUE The maximum torque is limited by the MAKE-UP TORQUE LIMIT which is displayed in units of
Forward** ft-lb on the MAKE-UP TORQUE LIMIT meter (M4) and can be adjusted with the MAKE-UP
TORQUE LIMIT dial (TH3).
The torque will ramp up to the MAKE-UP TORQUE LIMIT, hold for 1.5 seconds and ramp down.
Currents above the continuous rating will be time limited by the PLC to 5-85 seconds depending on
the current level.
TORQUE The maximum Break Out torque is limited to the maximum electric motor torque plus the maximum
Reverse Torque Boost Break Out torque of 37 500 ft-lb (50 800 Nm).
Currents above the continuous rating will be time limited by the PLC.
DRILL THROTTLE

TOP DRIVE DRILL THROTTLE

HANDWHEEL (TH1)

Active only in DRILL mode.

De-activated in SPIN and TORQUE modes.
De-activated if the Torque Boost is ENGAGED.

CLOCKWISE Increases the Top Drive rotary speed.

COUNTER- Decreases the Top Drive rotary speed.
CLOCKWIS
E
DRILLING TORQUE
MAKE-UP TORQUE
DRILLING TORQUE LIMIT DIAL (TH 2)
Adjusts the torque limit of the Top Drive in DRILL mode.
Turn the dial clockwise to increase the torque limit.
The drilling torque limit is displayed on the DRILLING TORQUE LIMIT
meter (M4).

MAKE-UP TORQUE LIMIT DIAL (TH 3)

Adjusts the Make-Up Torque Limit of the Top Drive in TORQUE mode.
Turn the dial clockwise to increase the torque limit.
The Make-Up Torque Limit is displayed on the MAKE-UP TORQUE LIMIT
meter (M4).
If the Torque Boost and electric motor are used together, set the
Make-Up Torque Limit at the desired torque minus 24 000 ft-lb (32
500 Nm).**
HPU SWITCH

HYDRAULIC POWER UNIT SWITCH (SW 3)

The Hydraulic Power Unit (HPU) supplies hydraulic pressure to the

auxiliary functions.
The unit has two pumps; only one runs at any given time.
The pumps can run continuously or can be turned off if no auxiliary
functions are being used.
HPU 1 HPU No. 1 will start.
The HYDRAULIC UNIT indicator light will be on if the
HPU is running properly.
The HYDRAULIC UNIT indicator light and the HPU
FAULT lamp will flash if an HPU fault is detected:
Motor not running.
Low hydraulic oil level.
High hydraulic oil temperature.
UWCV actuation or BUW Gripper opening prevented
by the HPU not running.

OFF Both units will stop.

HPU 2 Same as HPU 1 above except HPU 2.
TOP DRIVE BRAKE

TOP DRIVE BRAKE SWITCH (SW 4)

The brake should NOT be used for dynamic braking. It
can be used for static operation only.
The brake is a hydraulic caliper disc type mounted on the top of the
motor.
OFF The Top Drive can rotate freely.
ON The Top Drive brake is applied.
The BRAKE indicator light will turn on.
The Hydraulic Power Unit must be running for
brake operation, e.g. for directional drilling.
If the brake is turned on for more that 2 seconds
while the throttle is ON, the horn will sound and the
BRAKE indicator light will flash.
The brake will not apply if in SPIN or TORQUE
mode. The horn will sound and the BRAKE
indicator light will flash.
 LWCV

LOWER WELL CONTROL VALVE SWITCH (SW 6)

(* Optional)
This air or hydraulic actuated valve is mounted on the quill, below
the Top Drive.
OPEN The valve will open, regardless of the mud pump
status.
AUTO The valve closes automatically whenever the mud
(Optional) pump(s) are stopped and the standpipe pressure is
less than 250 psi (1725 KPa).
The valve opens automatically whenever the
mud pump(s) are started.
CLOSE The valve will close, regardless of the mud pump
status.
The LWCV CLOSED indicator light will turn on.
 TORQUE BOOST
TORQUE BOOST SWITCH (SW 8)
The Torque Boost is a high-torque, low speed hydraulic drive for connection make-up or break
out.
The Torque Boost clutch is automatically engaged when the Make-Up or Break Out function
is selected.
The Torque Boost clutch is automatically disengaged when the Make-Up or Break Out function
is released, then every 10 minutes thereafter to ensure that it does not inadvertently creep
engaged.
The Torque Boost will not engage if:
the Throttle is not at zero
the Top Drive is turning
the Back-Up Wrench Gripper is closed and the Handler is not locked
MAKE-UP The Top Drive quill will hydraulically rotate forward with a maximum
torque of 24 000 ft-lb (32 500 Nm).
Select TORQUE FORWARD mode (using JS1) to provide additional
electric motor torque.
OFF Torque Boost rotation will stop. The Torque Boost clutch will
disengage.
BREAK OUT The Top Drive quill will hydraulically rotate in reverse with a
maximum torque of 37 500 ft-lb (50 800 Nm).
Select TORQUE REVERSE mode (using JS1) to provide additional
electric motor torque.

IMPORTANT: When using the Torque Boost and electric

motor together, the Torque Boost torque
must be applied first. The Torque Boost
clutch cannot engage while the Top Drive is
turning.
 BUW GRIPPER
BACK-UP WRENCH (BUW) JOYSTICK
(JS 2)
UP Raise the BUW Gripper assembly.
DOWN Lower the BUW Gripper assembly.
OPEN Open the BUW Gripper to allow normal
(Neutral) Top Drive rotation.
Maintain the BUW gripper at its current
height.
NORMAL Close the BUW Gripper on the tubular.
CLOSE This position is spring returned.
If the handler is locked and the top drive
is not rotating, the BUW Gripper will
hold the tubular for make-up or break
out operations.
The BACK-UP WRENCH CLOSED
indicator light will flash when the Gripper
UP is closed. This is a warning to avoid
hoisting with the BUW Gripper closed.

IMPORTANT: Electric motor torque nor Torque Boost

torque are permitted if the BUW
NORMAL Gripper is closed and the Handler is
CLOSE OPEN unlocked. In that condition the bails
could swing unexpectedly causing
severe damage, injury, or death.

DOWN
 LINK TILT JOYSTICK
LINK TILT JOYSTICK (JS 3)
EXTEND Extends the Link Tilt hydraulic cylinder rods. This will push the bails
(UP) toward the latch side of the elevators.
RETRACT Retracts the Link Tilt hydraulic cylinder rods. This will pull the bails
(DOWN) toward the hinge side of the elevators.
MAINTAIN If neither EXTEND nor RETRACT are selected, the Link Tilt will
(CENTER) remain in its current position.
FLOAT If neither EXTEND nor RETRACT are selected the Link Tilt will float as
(RIGHT) influenced by gravity or may be moved by hand.

EXTEND EXTEND
FLOAT

FLOAT
NEUTRAL (Maintain)

RETRACT RETRACT
FLOAT
 HANDLER ROTATE JOYSTICK
HANDLER JOYSTICK (JS 4)
UNLOCK Disengages the lock dog from the handler rotate gear.
UNLOCK The lock dog disengages and the entire pipe handler assembly rotates
FORWARD in a clockwise direction.
UNLOCK The lock dog disengages and the entire pipe handler assembly rotates
REVERSE in a counter-clockwise direction.
LOCK Engages the lock dog in the current position.
LOCK It may be necessary to rotate the pipe handler in a clockwise direction in
FORWARD order to line up the lock dog with the teeth of the handler rotate gear.
When they align, the handler will lock into place.
LOCK It may be necessary to rotate the pipe handler in a counter- clockwise
REVERSE direction in order to line up the lock dog with the teeth of the handler
rotate gear. When they align, the handler will lock into place.

UNLOCK UNLOCK
FORWARD UNLOCK REVERSE

LOCK LOCK
FORWARD LOCK REVERSE
HANDLER LOCK BYPASS
HANDLER LOCK BYPASS SWITCH (PB 3)
PUSH Starts a timer which creates a 30 second window
where Make-Up or Break Out torque is permitted
even if the system cannot determine that the handler is
positively locked. Normally this feature would only
be used in the event of a handler lock sensor failure.
The HANDLER LOCK FAULT indicator light will
turn on for 30 seconds.
RELEASED Normal handler lock operation (after 30 second bypass
time.)
HANDLER LOCK FAULT LIGHT (on PB 3)
OFF Handler is locked.
Handler is being held unlocked
with the Handler Lock joystick.
ON Handler Lock Bypass is in progress 3 second Horn
which creates a 30 second window Burst every
for applying torque without handler 15 sec
lock confirmation.
FAST FLASH Handler is not locked and the 3 second Horn
Handler Lock joystick is in the Burst every
LOCK position. 15 sec
PANEL VIEW
 USING THE PANEL VIEW
THE PANNEL VIEW CAN BE USED FOR MULTIPLE TASKS.
THE MOST IMPORTANT WILL BE THE ROCK IT SCREEN,
THE ANALOG SCREEN, THE DRILLING SCREEN AND THE
ALARM SCREEN.
HOWEVER THE OTHERS ARE IMPORTANT BUT WILL BE
USED FOR MORE TROUBLESHOOTING ON THE
TECHNICAL LEVEL THAN THE DAILY OPERATIONS.
WELCOME SCREEN

TOUCH THE TOP LEFT CORNER TO BRING

UP THE PV OVERVIEW SCREEN
OVERVIEW SCREEN
 DRILLING SCREEN

THE DRILLING SCREEN WILL SHOW YOU TORQUE

AND RPM AS WELL AS ACTIVE STATE OF THE
CONTROL. (AUX, ENABLE, AND HPU STATUS)
 AUX SCREEN

The AUXILIARY MODE screen is automatically displayed

whenever the OFF AUX ENABLE
switch on the CONTROL CONSOLE is in the AUX position.
 ANALOG SCREEN
ANALOG SHOWS YOU ALL THE TEMPS. AND PRESSURES OF THE
TOP DRIVE AT CURRENT STATE AS WELL AS HPU IF
APPLICABLE.
ALARM SCREEN
 ALARM BANNER

THE ALARM BANNER is a display that pops up over the current

screen and disables the covered objects. The ALARM BANNER
contains a message description of the alarm condition and the
ACKNOWLEDGED ALARM button. When the alarm in the
banner is acknowledged or cleared, the next alarm is displayed
or the banner disappears when all alarms have been
acknowledged. The ALARM BANNER can hold only one
message, displayed in chronological order.
ALARMS YOU MIGHT SEE
 CIP I/0 SCREEN

The CIP I/O SCREEN displays the current status of all CIP digital
inputs and outputs. The numbered fields turn RED to indicate the
input or output is on, or GRAY to indicate that the input or output is
off.
 TOP DRIVE I/0 SCREEN

The TOP DRIVE I/O SCREEN displays the current

status of all Flex I/O digital inputs and outputs. The
numbered fields turn RED to indicate that the input or
output is on, or GRAY to indicate that it is off.
CONSOLE I/O SCREEN
DRIVE I/0 SCREEN
MAINTANCE SCREEN
DROPPED OBJECT
IDENTIFICATION
 DROPPED OBJECTS
Top Drive System Dropped Object Identification
The information contained in this book is intended to identify areas where routine
inspections should take place. These inspections are not intended to replace good maintenance
practices. The frequency of these inspections will depend upon working conditions and should be
identified by the owner/operator.

These inspections should be done:

After periods of rough drilling.
After jarring.
After accidental contact with other equipment.

In performing these inspections, proper safety precautions must be observed.

All bolts and cap screws should be torqued as identified in the Parts & Maintenance
Manual. Any components disassembled for repair or replacement should be assembled to the
original manufacturers specifications. This includes the use of Loctite and lubricants. All cap
screws shall be safety wired when required.
 DROPPED OBJECTS
Perform a visual inspection of the entire top drive looking for any signs of damage. Check all wired bolts for damaged or broken
wires. If broken wires are detected, check the affected bolts for proper torque and rewire. Check all external bolts that are not wired. Ensure that all safety
cables are properly and securely attached. Some areas to inspect are:

_______ Mud line flange bolts

_______ Blower motor bolts
_______ Blower inlet cover
_______ Blower mounts
_______ Oil breather cap
_______ Brake Cover
_______ Upper Links and Pins
_______ Motor Inspection Covers
_______ Oil Cooler
_______ Valve Bank Cover
_______ J-Box Mounts
_______ Guard Covers
_______ Guard Mounting Bolts
_______ Guide Runner adjusting bolts
_______ Housing/frame bolts
_______ Lube Pump motor and brackets
_______ Guard Deflector
_______ Link Tilt Cylinder Retainer
_______ Link Tilt Mount
_______ Spark Arrestor Screen
_______ Elevator Alarm Target
_______ BUW Mounts
_______ BUW Positioning Cylinder clevis and pin
_______ BUW Gripper Cylinder
_______ BUW slide and guide
_______ BUW Die Blocks
 DROPPED OBJECTS
BLOWER
BRAKE
MOTOR
COVER

MOTOR
COVER

MUD LINE
FLAGES BREATHER

LINKS
AND
PINS

J- BOX
DROPPED OBJECTS
Upper Links
and Pins

Blower Inlet
Cover

Blower
Mounting
Frame
 DROPPED OBJECTS

Valve Bank Cover

Mud Flanges

J box mounts
 DROPPED OBJECTS

J box

Guards
and Bolts
 DROPPED OBJECTS

Housing to
Frame Lube Pump
Bolts Assembly

Guard Bolts
DROPPED OBJECTS

Housing to
Frame Bolts
 DROPPED OBJECTS
Guard Bolts

Lube Pump
Deflector Mounts
Guard

Deflector
Guard
 DROPPED OBJECTS
Link Tilt
Retainer

Link Tilt Mounts

 DROPPED OBJECTS

Spark
Link Tilt Arrestor
Cylinder Screen
Retainer

Guard
Deflector
DROPPED OBJECTS

Guide Runner
Adjustments

Elevator
Alarm Targets

BUW Mounts
DROPPED OBJECTS

BUW
Mounts
 DROPPED OBJECTS

BUW BUW Slides

Positioning
Cylinder

BUW
Stabbing
BUW Gripper Guide
Cylinder
 OPEN FOR DISCUSION

Next we will review the Rock It

operations!
Wash Pipe removal/ Install procedures for
the Can-Rig wash pipe 3 and 4
Hands on with Rock It at Rig Up Yard
along with a walk though of the top drive
maintenance locations!